Hatz 4H50TIC Operator's Manual

OPERATOR’S MANUAL Diesel engine 0000 436 004 00 - 07.2014 - 0.1 Printed in Germany EN Motorenfabrik Hatz GmbH & Co. KG Ernst-Hatz-Str. 16 94099 Ruhstorf a.d. Rott Deutschland Tel. +49 8531 319-0 Fax +49 8531 319-418 [email protected] www.hatz-diesel.com CREATING POWER SOLUTIONS.

1 Notices ............................................................................................................. 5 2 General information ........................................................................................ 6 3 Safety ............................................................................................................... 7 3.1 General information .......................................................................................... 7 3.1.1 Intended use and foreseeable misuse .............................................................. 7 3.1.2 Machine user or machine manufacturer obligations ......................................... 8 3.1.3 Representation of safety notes ......................................................................... 9 3.1.4 Meaning of safety symbols ............................................................................... 10 3.2 Safety notes ...................................................................................................... 11 3.2.1 Operational safety ............................................................................................. 11 3.2.2 Machine-specific safety instructions for operation ............................................ 14 3.2.3 Machine-specific safety instructions for maintenance work .............................. 15 3.2.4 Electrical equipment .......................................................................................... 18 3.3 Labels ............................................................................................................... 19 4 Technical data ................................................................................................. 20 4.1 Engine information and filling quantities ........................................................... 20 4.2 Engine type plate .............................................................................................. 21 4.3 Engine oil .......................................................................................................... 22 4.4 Coolant .............................................................................................................. 23 4.5 Fuel ................................................................................................................... 26 5 Engine design ................................................................................................. 28 5.1 Overview ........................................................................................................... 28 6 Transport, assembly and commissioning .................................................... 31 6.1 Transport - Engine with 2 lifting eyes ................................................................ 31 6.2 Assembly instructions ....................................................................................... 32 6.3 Preparations for commissioning ........................................................................ 33 6.4 Filling engine oil ................................................................................................ 33 6.5 Filling the cooling system .................................................................................. 35 7 Operation and use .......................................................................................... 38 7.1 Safety notes ...................................................................................................... 38 7.2 Performing tests ................................................................................................ 38 7.3 Starting the engine ............................................................................................ 39 7.4 Starting the engine for the first time/after a filter change .................................. 42 7.5 Switching off the engine .................................................................................... 45 7.6 Checking the oil level and adding oil if necessary ............................................ 47 7.7 Refueling ........................................................................................................... 49 8 Maintenance .................................................................................................... 51 8.1 General maintenance instructions .................................................................... 51 8.2 Maintenance work ............................................................................................. 52 4H50TIC Table of contents HATZ Operator's Manual 3

8.2.2 Checking the intake area of the combustion air ................................................ 54 8.2.3 Checking the radiator fins for dirt accumulation ................................................ 55 8.2.4 Checking the cooling system ............................................................................ 57 8.2.5 Changing the engine oil and oil filter ................................................................. 59 8.2.6 Cleaning the radiator fins .................................................................................. 64 8.2.7 Tensioning the poly v belt ................................................................................. 67 8.2.8 Replacing the poly v belts ................................................................................. 69 8.2.9 Changing the oil separator of the crankcase ventilation ................................... 71 8.2.10 Checking the screw connections ...................................................................... 72 8.2.11 Draining the water separator ............................................................................. 73 8.2.12 Changing the fuel prefilter ................................................................................. 74 8.2.13 Changing the fuel fine filter ............................................................................... 77 8.2.14 Servicing the air filter (optional) ........................................................................ 80 8.2.15 Changing coolant .............................................................................................. 82 9 Faults ............................................................................................................... 86 9.1 Fault table ......................................................................................................... 86 10 Storage and disposal ...................................................................................... 95 10.1 Storing the machine .......................................................................................... 95 10.2 Disposing of the machine .................................................................................. 95 11 Installation declaration ................................................................................... 97 Table of contents 4H50TIC 4 Operator's Manual HATZ

Fax +49 (0)8531 319-418 [email protected] www.hatz-diesel.com All rights reserved! Copyright The copyright for this Operator's Manual rests entirely with Motorenfabrik HATZ, Ruhstorf. This Operator's Manual may only be copied or distributed if written approval has been received. This also applies to the copying or distribution of ex- cerpts of the Operator's Manual. The same conditions apply to distribution of the Operator's Manual to third parties in digital form. Original Operator's Manual This Operator's Manual was translated into multiple languages. The German version is the original Operator's Manual. All other language versions are translations of the original Operator's Manual. 4H50TIC Notices HATZ Operator's Manual 5

This Operator's Manual was created with due care. It is exclusively intended to offer a technical description of the machine and to provide instructions on commissioning, operating and maintaining the machine. When operating the machine, the applicable standards and legal regulations as well as any in- house regulations apply. Before commissioning, during operation and before maintenance work is be- gun on the machine, read the Operator's Manual carefully and keep it close by for ready access. Machine This Operator's Manual describes the following machine. Machine name HATZ diesel engine Type number 4H50TIC Customer service Have service work performed by qualified technicians only. We recommend that you work with one of the more than 500 HATZ service stations.Trained specialists there will repair your machine with Hatz original spare parts and with HATZ tools. The global HATZ service network is at your disposal to ad- vise you and supply you with spare parts. For the address of the Hatz serv- ice station nearest you, please see the directory enclosed or visit the inter- net at: www.hatz-diesel.com Problems may occur if unsuitable spare parts are installed. We cannot ac- cept responsibility for damage and secondary damage that result from this. We therefore recommend the use of Hatz original spare parts. These parts are manufactured according to strict Hatz specifications and achieve maxi- mum operational reliability through their perfect fit and functionality. The or- der number can be found in the enclosed spare parts list or on the internet at: www.hatz-diesel.com Exclusion of liability The manufacturer cannot be held responsible for personal injury, damage to property, or damage to the machine itself caused by improper use, foreseea- ble misuse, or failure to follow or adequately follow the safety measures and procedures described in this Operator's Manual. This also applies to changes made to the machine and use of unsuitable spare parts. Modifications, which serve the technical improvements, are reserved. General information 4H50TIC 6 Operator's Manual HATZ

chine. To prevent accidents and damage to the machine, it is imperative that these safety instructions are followed. Read this chapter carefully before beginning work. 3.1.1 Intended use and foreseeable misuse Intended use The machine described in this Operator's Manual fulfills the following func- tions: ▪Diesel engine intended for installation in a machine or for assembly with other machines to form a machine. See chapter 11 Installation declaration, page 97. This engine is intended exclusively for the purpose specified and tested by the manufacturer of the machine into which the engine is installed. Any other use is not intended and therefore not permitted. Violations com- promise the safety of the personnel working with the machine. Responsibility is not accepted by Motorenfabrik HATZ for damage resulting from this situa- tion. The operational safety of the machine is only guaranteed if it is used as in- tended. Use according to the intended purpose also includes observance of the in- structions in this Operator's Manual. Foreseeable misuse The following is considered to be foreseeable misuse: ▪Any use that varies from or extends beyond the uses specified above. ▪Failure to comply with the instructions in this Operator's Manual. ▪Failure to comply with the safety instructions. ▪Failure to immediately eliminate malfunctions that impact safety before continuing work with the machine (working with the machine when it is not in perfect condition, either functionally or in terms of safety). ▪Failure to perform the necessary inspection and maintenance work. ▪Any unauthorized modification of or removal of safety equipment. ▪Use of spare parts and accessories that are unsuitable or have not been approved by HATZ. ▪Operation in flammable or hazardous environments. ▪Operation in closed-off or poorly ventilated rooms. 4H50TIC Safety HATZ Operator's Manual 7

in closed rooms without additional measures to handle supply air, extract air, and exhaust gas. ▪Improper operation at variance with DIN 6271 and DIN ISO 8528 (climate, load, safety). Residual risks Residual risks result during daily use and in association with maintenance work. These residual risks will be pointed out in chapter 3.2.2 Machine-specific safety instructions for operation, page 14 and in chapter 3.2.3 Machine- specific safety instructions for maintenance work, page 15 as well as in the further contents of the manual, directly in front of the descriptions or operat- ing instructions concerned. 3.1.2 Machine user or machine manufacturer obligations Machine manufacturer obligations If you have an engine that is not yet installed in a machine, it is imperative that you follow the Assembly Instructions for HATZ Diesel Engines be- fore installing the engine. These assembly instructions contain important in- formation on how to safely install the engine and are available at your near- est HATZ service station. It is prohibited to start the engine before it is fully installed. In addition, please note that it is prohibited to start up the machine before it has been determined that the machine into which this engine is installed ful- fills all safety-related requirements and legal regulations. User obligations The user is obligated to only operate the machine while it is in perfect condi- tion. The user must check the condition of the machine before using it and ensure that any defects are eliminated before it is taken into service. Run- ning the machine while identified defects exist is not permitted. The user must also ensure that the information contained in the Operator's Manual has been read and understood. Obligations of the operating and maintenance personnel Personnel assigned with operating and maintaining the machine must have read and understood the Operator's Manual or must possess the qualifica- tions necessary for working with this equipment, acquired in training/instruc- tional courses. No one may work with the machine without the necessary qualifications, even if for just a brief period. The operating personnel must not be under the influence of drugs, medica- tion or alcohol. All work performed on the machine must be in compliance with the informa- tion provided in the Operator's Manual. Safety 4H50TIC 8 Operator's Manual HATZ

This Operator's Manual is an integral component of the machine (also when being sold). It must be stored in the direct vicinity of the machine and be ac- cessible to personnel at all times. 3.1.3 Representation of safety notes Overview This machine has been designed and built according to state-of-the-art tech- nology and the recognized safety standards. Despite these precautions, risks exist when operating the machine and during maintenance work. These risks are identified in this manual by means of safety notes. The safety notes precede the related description or operating step. Structure of the safety notes The safety notes consist of: ▪Warning symbol ▪Signal word ▪Description of danger ▪Possible consequences ▪Preventative measures General danger symbol The general danger symbol is used to identify the danger of personal injury. Signal words Signal words identify the magnitude of the risk and the seriousness of the possible injuries: Danger symbol/ signal word Meaning DANGER This signal word is used to indicate imminently dangerous situations which, if not avoided, will lead to serious injury or death. WARNING This signal word is used to indicate potentially dangerous situations which, if not avoided, may lead to serious injury or death. CAUTION This signal word is used to indicate potentially dangerous situations which, if not avoided, may lead to minor or moderate injury. 4H50TIC Safety HATZ Operator's Manual 9

used to indicate the risk of property damage. NOTICE This signal word indicates additional useful infor- mation, such as operating tips and cross referen- ces. 3.1.4 Meaning of safety symbols Explanation of symbols The following table describes the meanings of the safety symbols used in this Operator's Manual. Symbol Meaning Smoking, fire and open flames are prohibited. Warning of personal injury! Warning of hot surfaces! Warning of flammable substances! Warning of explosive substances! Warning of toxic engine exhaust! Warning of corrosive substances! Safety 4H50TIC 10 Operator's Manual HATZ

Warning of environmental damage! Comply with the Operator's Manual or additional documenta- tion from other manufacturers or the user. i Additional information that is useful to the reader. 3.2 Safety notes 3.2.1 Operational safety Introduction This chapter contains all of the important safety instructions for personal pro- tection and for safe and reliable operation. Additional, task-related safety in- structions can be found at the beginning of each chapter. DANGER Danger to life, danger of injury, or danger of property dam- age due to failure to comply with the Operator's Manual and the safety instructions contained therein. ▪ As the user of the machine, you must ensure that all people working on the machine are familiar with the contents of this Operator's Manual. ▪ Before working on the machine, read this Operator's Manual carefully, paying special attention to the safety notes. ▪ Fulfill all required safety conditions before working on the machine. ▪ Follow all general safety instructions as well as the specific task-related safety instructions contained in the individual chapters. 4H50TIC Safety HATZ Operator's Manual 11

▪Only operate the machine for the purposes described in the chapter 3.1.1 Intended use and foreseeable misuse, page 7. Compliance with other regulations ▪Adhere to the applicable accident prevention regulations of the trade asso- ciations. ▪Comply with the regulations concerning the minimum safety and health re- quirements for the use of work equipment by workers at work. ▪In addition, local safety, accident prevention and environmental regula- tions also apply when operating the machine. Personal protective equipment During operation and maintenance of the machine, personal protective equipment must be available and must be used if necessary. The required personal protective equipment is specified in the description of the operating steps. Personal protective equipment Pictogram Function Safety shoes Safety shoes offer protection against: ▪Slipping ▪Falling objects Hearing protection Hearing protection offers protec- tion against ear injuries due to excessive and constant noise. Safety gloves Safety gloves protect the hands against injury, e.g. from battery acid. Safety goggles (with side protection) Safety goggles protect the eyes from flying objects (e.g. dust particles, spraying liquids, spraying acid). Working clothes Wear close-fitting clothing. How- ever, it must not restrict the wearer's freedom of movement. Safety 4H50TIC 12 Operator's Manual HATZ

The warning labels and information signs on the machine must be followed (see the chapter "Labels" 3.3 Labels, page 19). The warning labels and information signs must be kept legible and must be replaced if necessary. For this purpose, contact your nearest HATZ service station. Maintenance work Maintenance work that goes beyond the scope described in this manual must only be performed by qualified technicians (see the chapter 2 General information, page 6). Independent maintenance work and constructional changes to the machine, especially to the safety equipment, are not permitted. Safety equipment Safety equipment must not be modified and must not be rendered ineffective during normal operation. General safety instructions DANGER Danger to life and danger of injury due to failure to follow the warnings on the machine and in the Operator's Manual. ▪ Heed the warnings on the machine and in the Operator's Manual. WARNING Danger of injury and danger of incorrect operation due to inadequate personnel qualifications. ▪ The personnel must have read and understood this Opera- tor's Manual or must possess the qualifications necessary for working with this equipment, acquired in training/instruc- tional courses. ▪ Only qualified personnel are permitted to operate and main- tain this machine. ▪ Failure to comply will cause the warranty to become void. 4H50TIC Safety HATZ Operator's Manual 13

structions and from performing unauthorized tasks on the machine. ▪ Follow all instructions. ▪ Do not perform activities for which no qualification is availa- ble. Contact properly trained personnel if necessary. CAUTION Danger of injury from overloading the body. Lifting the machine to transport it or to move it to another loca- tion can lead to injuries (of the back, for example). ▪ Only lift the machine with a hoist (see the chapter 6.1 Trans- port - Engine with 2 lifting eyes, page 31). 3.2.2 Machine-specific safety instructions for operation Introduction The machine can pose residual risks during operation. To eliminate these risks, all persons working on the machine must follow the general and ma- chine-specific safety instructions. If you have an engine that is not yet installed in a machine, it is imperative that you follow the Assembly Instructions for HATZ Diesel Engines be- fore installing the engine. These assembly instructions contain important information on safe installa- tion. If the engine is installed in a machine or assembled with other machines to form a machine, it is prohibited to start the engine before it has been deter- mined that the newly created machine fulfills all safety-related requirements and applicable legal regulations. Safe operation ▪Before switching on the machine, ensure that no one can be injured when the machine is started up. ▪During machine operation, ensure that unauthorized persons do not have access to the area in which the machine has an impact. ▪Parts of the exhaust gas system and the surface of the engine become hot during operation. Risk of injury from touching hot parts! Let the engine cool before maintenance. ▪Do not refuel during operation. Safety 4H50TIC 14 Operator's Manual HATZ

▪Switch off the machine and do not take into service again until all faults have been eliminated. Safety instructions for operation DANGER Danger to life from inhaling exhaust gases. Toxic engine exhaust gases can lead to loss of consciousness and even death in closed-off and poorly ventilated rooms. ▪ Never operate the machine in closed-off or poorly ventilated rooms. ▪ Do not breathe in the exhaust gases. DANGER Fire hazard from fuel. Leaked or spilled fuel can ignite on hot engine parts and cause serious burn injuries. ▪ Only refuel when the engine is switched off. ▪ Never refuel in the vicinity of open flames or sparks that can cause ignition. ▪ Do not smoke. ▪ Do not spill fuel. 3.2.3 Machine-specific safety instructions for maintenance work Introduction The machine can pose residual risks during maintenance. To eliminate these risks, all persons working on the machine must follow the general and machine-specific safety instructions. Maintenance intervals ▪Strictly adhere to the maintenance intervals. ▪Check the safety equipment regularly to ensure it is in good condition and functioning properly. ▪Check connections, cables and fasteners regularly to ensure they are in good condition. 4H50TIC Safety HATZ Operator's Manual 15

must only be performed by qualified technicians. We recommend that you work with one of the more than 500 HATZ service stations. Replacing parts ▪When replacing defective components, we recommend that you use gen- uine HATZ original spare parts (see the chapter 2 General information, page 6). ▪When disposing of parts that can no longer be used, do so in accordance with local environmental regulations or send them to a recycling center. Measures following maintenance and troubleshooting ▪Securely reconnect loose electrical connections; check that the electrical components and equipment are functioning properly. ▪Check the entire machine for foreign bodies; remove any foreign bodies. Safety instructions for maintenance work DANGER Danger of explosion from flammable cleaning agents. Cleaning with benzene is an explosion hazard. It is highly flam- mable, can become electrostatically charged and can generate an explosive gas-air mixture. ▪ Use halogen-free, cold cleaners with a high flashpoint for cleaning. DANGER Fire hazard from spontaneous combustion. Cleaning materials soaked with cold cleaner may produce heat together with atmospheric oxygen and combust spontaneously. ▪ Collect cleaning materials soaked with cold cleaner only in fire-proof, tightly sealed containers. ▪ Do not dispose of cold cleaner residues and used cleaning materials with domestic waste, rather only in accordance with manufacturer instructions. ▪ Comply with the instructions for preventing fire on the safety data sheet for the cold cleaner. Safety 4H50TIC 16 Operator's Manual HATZ

Eye injuries may occur when cleaning with compressed air. ▪ Wear safety goggles. CAUTION Danger of injury if maintenance instructions are not fol- lowed. ▪ Only perform maintenance when the engine is switched off. ▪ For engines with an electric starter: Disconnect the negative battery terminal. Protect the starting key against unauthorized access. CAUTION Danger of burns. There is a danger of burns when working on a hot engine. ▪ Let the engine cool before maintenance. 4H50TIC Safety HATZ Operator's Manual 17

Safety notes DANGER Danger to life, danger of injury or danger of property dam- age due to incorrect use of batteries. ▪ Do not place tools on the battery. ▪ Before performing work on the electrical equipment, always disconnect the negative terminal of the battery. ▪ Never swap the positive (+) and negative (–) battery termi- nals. ▪ When installing the battery, first connect the positive cable and then the negative cable. ▪ When removing the battery, first disconnect the negative cable and then the positive cable. ▪ It is imperative that you prevent short circuits and mass con- tact of current-carrying cables. ▪ If faults occur, check the cable connections for good con- tact. DANGER Danger of explosion from flammable substances. There is a danger of explosion from flammable gases. ▪ Keep batteries away from open flames and incendiary sparks. ▪ Do not smoke when working with batteries. CAUTION Danger of chemical burns Chemical burns can occur when using batteries for the electrical operation. ▪ Protect your eyes, skin, and clothing from corrosive battery acid. ▪ Immediately rinse areas affected by splashed acid with clear water and consult a physician if necessary. Safety 4H50TIC 18 Operator's Manual HATZ

chine if it is equipped with electrical equipment. Additional wiring diagrams can be requested when needed. ▪ We cannot be held liable for electrical equipment that is not designed according to HATZ wiring diagrams. ▪Promptly replace faulty indicator lamps. ▪Do not pull out the starting key during operation. ▪Do not disconnect the battery while the machine is running. Resulting volt- age peaks could destroy the electronic components. ▪When cleaning, do no spray the electrical equipment components with a water jet or high pressure cleaner. ▪When performing welding work on the machine, disconnect the battery and place the ground clamp of the welding equipment as close as possible to the welding area. Disconnect the plug-in connection to the voltage regu- lator. 3.3 Labels Warning labels and information signs on the engine Label Meaning BIO DIESEL 052 356 02 Refuel with diesel fuel only. For the specification, see the chapter 4.5 Fuel, page 26 Do not use bio diesel. 0000 053 657 02 The engine may only be operated with fuel that is "EXTREMELY LOW IN SULFUR OR SULFUR-FREE". The fuel label is located close to the fuel cap. If there is no fuel tank in- stalled on the engine, the label must be applied permanently close to the fuel filler opening. 4H50TIC Safety HATZ Operator's Manual 19

Type 4H50TIC Type Liquid-cooled four stroke diesel engine Combustion system Direct injection, turbocharger with charge air cool- ing, cooled exhaust-gas recirculation Injection system Bosch common rail Number of cylinders 4 Bore/stroke mm 84 / 88 Displacement cm3 1,952 Engine oil capacity Approx. ltr. 7.0 1) Difference between the "max." and "min." marks Approx. ltr. 1.0 1) Engine oil consumption (after running-in period) Max. 0.5 % of fuel consumption, pertaining to full load Engine oil pressure 2.5 bar to 4.5 bar Coolant quantity Approx. ltr. 12.5 (HATZ standard radiator with external expan- sion tank) 13.2 (HATZ OpenPowerUnit radiator with integrat- ed expansion tank) Sense of rotation When viewing flywheel: left Tappet clearance Automatic valve lash adjustment with hydraulic valve tappets Max. perm. inclination during continuous opera- tion in every direction 30° 2) (with HATZ standard radiator) 20° 2) (with HATZ OpenPowerUnit radiator) Weight (without operating fluids) Approx. kg 226 (with HATZ standard radiator and catalytic converter) 260 (with HATZ OpenPowerUnit radiator and cata- lytic converter) Battery capacity Max. 12 V – 110 Ah / 450 A according to DIN 24 V – 66 Ah / 300 A according to DIN Technical data 4H50TIC 20 Operator's Manual HATZ

decisive in any case (see the chapter 7.6 Checking the oil level and adding oil if necessary, page 47). 2) Exceeding these limit values can cause engine damage. 4.2 Engine type plate 120R-xxxxxx*xx 24R-xxxxxx EMISSION CONTROL INFORMATION MOTORENFABRIK HATZ KG ¬ D-94099 RUHSTORF GMBH +CO Model: 4H50TIC – 162J S/N: 1361014000001 Build: 03/2014 Power: 36.4kW @ 1800 RPM Constant Displ: 1.95L Eng.Fam: FHZXL1.95C50 Emission Control System: DDI, DOC, EGR, ECM, TC, CAC Power Category: 19≤kW<37 ULTRA LOW SULFUR DIESEL FUEL ONLY. THIS ENGINE COMPLIES WITH U.S. EPA AND CALIFORNIA REGULATIONS FOR THE MY2015 YEAR NONROAD DIESEL ENGINES. Use in Constant-Speed Applications only. EU-Type: e1*97/68KA*2012/46*0801*00 (IIIA) www.hatz-diesel.com 187_44_C_3B 120R xxxxxx*xx 24R xxxxxx E1 8 9 The engine type plate is located on the crankcase and contains the following engine information: 1 Model designation of the engine 2 Engine serial number 3 Serial rating (kW) at nominal speed (rpm) 4 Displacement (liters) 5 Information for US emission certification (EPA/CARB) 6 EU type approval 7 EU country of origin (Germany) 8 Model year (month/year) 9 Bar code (engine serial number) The following data must always be specified for requests and spare part or- ders 1 Model designation 2 Engine serial number 4H50TIC Technical data HATZ Operator's Manual 21

ble: Engines with catalytic converter or with catalytic converter and partic- ulate filter ▪ACEA E6 "Low SAPS" (preferred) ▪ACEA E9 ▪ACEA C3 / C4 (HTHS ≥ 3.5 mPas) ▪API CJ-4 CAUTION Damage to the catalytic converter and/or particulate filter from using unsuitable engine oil. Unsuitable engine oil diminishes the functionality and service life of the catalytic converter and/or particulate filter. Only use engine oil that fulfills the specifications stipulated above. In principle, engine oils with low ash (low SAPS) are rec- ommended. Engines without catalytic converter and without particulate filter ▪ACEA E6, E7 or E9 ▪ACEA C1, C2, C3 or C4 ▪API CJ-4 or CI-4 Oil viscosity Technical data 4H50TIC 22 Operator's Manual HATZ

which the engine will be operated. CAUTION Engine damage from unsuitable engine oil. Unsuitable engine oil considerably reduces engine service life. Only use engine oil that fulfills the specifications stipulated above. 4.4 Coolant Introduction Liquid-cooled engines require a coolant specified by HATZ for engine cool- ing. Coolant is prepared in accordance with manufacturer's instructions, please comply with the information on the packaging label. Radiator protection fluids give effective protection against corrosion and freezing. Additionally, the coolant boiling point is significantly raised and de- posits of lime in the cooling system are reduced. Safety notes CAUTION Danger of damage to health Radiator protection fluids are harmful to health. ▪ Avoid contact to eyes and skin. ▪ Store only in the sealed original container and in a place in- accessible for unauthorized persons. ▪ Comply with manufacturer's instructions. CAUTION Danger of environmental damage from spilled coolant. Coolant is water-polluting. ▪ Do no allow it to enter the ground water, water bodies, or sewage system. ▪ Collect coolant and dispose of it in an environmentally com- patible manner. 4H50TIC Technical data HATZ Operator's Manual 23

Use of a radiator protection fluid not approved by HATZ may cause engine damage. ▪ If you have any questions, please contact your nearest HATZ service station before commissioning the engine. CAUTION Danger of engine damage by mixing radiator protection flu- ids from different manufacturers. The effectiveness may be degraded when different radiator pro- tection fluids are mixed. The consequence may be damage to the water pump, radiator, hoses, and gaskets. ▪ Before changing the product, flush the entire cooling system (see the chapter 8.2.15 Changing coolant, page 82). Approved radiator protection fluids The following radiator protection fluids are approved by HATZ: Manufacturer Product name ARAL Aral Antifreeze Silikatfrei (silicate-free) Arteco Havoline XLC (OF02), Havoline XLC+B Auto-Teile-Ring Cartechnic Antifreeze CT 12 plus BASF Glysantin® G30®, Glysantin® G40® Belgin Madeni Yaglar Tic LUBEX ANTIFREEZE G-12 PLUS BP BP Procool Bucher MOTOREX COOLANT M4.0 BVG Blume Mofin Antifreeze M40 Extra Castrol Radicool SF, Radicool Si OAT CCI LLC C521, LLC L415 CHEMIA- BOMAR Glidex Extra Premium Chevron Caltex Extended Life Coolant, Havoline XLC Concentrate, Ursa ELC NF Concentrate CLASSIC CLASSIC KOLDA UE G30, CLASSIC KOLDA UE G40 Technical data 4H50TIC 24 Operator's Manual HATZ

tion fluid silicate-free, radiator protection fluid D-40 SU- PER Exxon Mobil Delvac ELC Coolant Fuchs MAINTAIN FRICOFIN G 12 PLUS, MAINTAIN FRICOFIN LL, MAINTAIN FRICOFIN DP Gazpromneft- Lubricants G-ENERGY ANTIFREEZE SNF Krafft K-140 Energy - Plus Kuttenkeuler Kuttenkeuler Antifreeze K 12 Plus LUKOIL OMV coolant SF, OMV coolant SOT Mitan Alpine C40, Alpine C12+ MOL-LUB EVOX Premium Concentrate Müller Minera- löle Startol Top G 12 Plus Neste Markki- nointi Neste Superjäähdytinneste XLC OAO Techno- form Cool Stream Premium Old World In- dustries Final Charge Global Coolant Petrol Ofisi Anonim Sirketi PO EXTENDED LIFE coolant Tedex Tedex Antifreeze OT LL Total Total Glacelf Auto Supra Valvoline Zerex G 30, Zerex G 40-91 NOTICE i Prior approval from HATZ is needed when none of these radia- tor protection fluids is available or an own-product radiator pro- tection fluid is to be used. 4H50TIC Technical data HATZ Operator's Manual 25

CAUTION Danger of engine damage from incorrect radiator protection fluid concentration. A too low radiator protection fluid concentration increases the risk of corrosion and also the risk of the cooling system freezing. A radiator protection fluid proportion of over 50 vol% degrades the cooling action and also the protection against frost is re- duced. Therefore, serious engine damage may result from ex- ceeding or dropping below the radiator protection fluid concen- tration. ▪The radiator protection fluid must be prepared according to manufacturer's instructions before pouring it into the cooling circuit. Comply with the infor- mation on the packaging label. ▪If the radiator protection fluid has to be mixed with water, use only clean water that is not too hard. Tap water with as low as possible content of salt, minerals, and suspended matter is ideal. Distilled water is equally ide- al. The coolant mixture ratio is not to be below or exceed the following concen- tration: Radiator protection fluid Water Frost-resistant to ap- prox. min. 40 vol% 60 vol% -27 °C max. 50 vol% 50 vol% -38 °C NOTICE i As the corrosion and antifreeze concentration reduces with time, carry out an annual check with a commercially available anti- freeze tester. If the concentration is too low, change the coolant independent of the service interval (see the chapter 8.2.15 Changing coolant, page 82). 4.5 Fuel Fuel type All types of diesel fuel that meet the minimum requirements of the following specifications are suitable: ▪Europe: EN 590 ▪UK: BS2869 A1/A2 ▪USA: ASTM D 975-09a 1-D or 2-D (engines without catalytic converter and without particulate filter) ASTM D 975-09a 1-D S15 or 2-D S15 Technical data 4H50TIC 26 Operator's Manual HATZ

CAUTION Danger of engine damage from low quality fuel. The use of fuel that does not meet the specifications can lead to engine damage. ▪ Only use fuel that is very low in sulfur or that contains no sulfur at all. ▪ The use of fuel that does not meet specifications requires approval by Motorenfabrik HATZ (main plant). 4H50TIC Technical data HATZ Operator's Manual 27

5 Engine design 5.1 Overview Intake side 4 3 2 5 5 6 7 8 9 10 11 12 13 14 15 16 17 1 Engine design 4H50TIC 28 Operator's Manual HATZ

2 Rain cap 3 Air filter (optional) 4 Dust discharge valve 5 Lifting eyes 6 Fan 7 Oil filter 8 Fuel fine filter 9 Side oil drain screw 10 Starter (low mounting position) 11 Electric fuel pump 12 Drain plug on fuel prefilter 13 Fuel prefilter 14 Engine type plate 15 Dipstick 16 Oil filler plug, bottom 17 Crankcase ventilation 4H50TIC Engine design HATZ Operator's Manual 29

2 Oil filler plug, top 3 Turbocharger 4 Oxidation catalytic converter 5 Exhaust outlet 6 Starter (high mounting position) 7 Oil drain screw, front 8 Poly v belt 9 Cooler Engine design 4H50TIC 30 Operator's Manual HATZ

6.1 Transport - Engine with 2 lifting eyes Safety notes WARNING Danger of injury from improper lifting and transport. Danger of crushing from falling or tipping of the engine. ▪ Only use the lifting eye already mounted on the machine for lifting. ▪ Only use a suitable hoist with a sufficient carrying capacity. ▪ Do not remain under suspended loads. CAUTION Only use lifting lugs for transporting the engine. Do not use for lifting the entire machine. CAUTION Danger of injury from overloading the body. Lifting the machine to transport it or to move it to another loca- tion can lead to injuries (of the back, for example). ▪ Only lift the machine with a hoist. NOTICE Danger of environmental damage from leaking fluid. If the machine is tilted, engine oil and fuel can run out. ▪ Only transport the machine in an upright position. 4H50TIC Transport, assembly and commissioning HATZ Operator's Manual 31

Ensure that the load on the lifting eyes is always vertical. ▪The lifting eyes deform when they are overloaded. If this happens, the lift- ing eyes must be replaced and if necessary additional lifting points must be used. ▪When transporting the machine, follow the safety instructions. ▪When transporting, follow the applicable safety and accident prevention regulations of the trade associations. ▪After delivery, check the machine for completeness and transport damage. ▪Only transport the machine when it is switched off and has cooled down. ▪If you have questions on transporting the machine, please contact your nearest HATZ service station. For contact data, see the chapter 1 Im- pressum, page 5 or www.hatz-diesel.com. 6.2 Assembly instructions Assembly notes HATZ diesel engines are efficient, robust and long-lived. Therefore, they are usually installed in machines that are used for commercial purposes. The machine manufacturer must follow the applicable regulations regarding machine safety – the engine is a part of a machine. Depending on the use and installation of the engine, it may be necessary for the machine manufacturer and machine user to install safety equipment to prevent inappropriate use. Note the following: Transport, assembly and commissioning 4H50TIC 32 Operator's Manual HATZ

ing operation and should not be touched until they cool down after the en- gine is switched off. ▪Incorrect cable connections and incorrect operation of the electrical equip- ment can lead to sparking and must be avoided. ▪After the engine is installed in the machine, rotating parts must be protect- ed against contact. HATZ safety equipment is available for the belt drive of the cooling fan and alternator. ▪Comply with all notice and warning labels on the engine and keep them in a legible condition. If a label should become detached or be difficult to read, it must be replaced promptly. For this purpose, contact your nearest HATZ service station. ▪Any improper modification of the engine results in a loss of liability cover- age for resulting damage. Only regular maintenance, as specified in this Operator's Manual, will main- tain the operating readiness of the engine. The assembly instructions contain important information on how to safely as- semble the engine. They are available from any Hatz service station. If you have any questions, please contact your nearest HATZ service sta- tion before commissioning the engine. 6.3 Preparations for commissioning ▪Check the delivered parts for completeness, damage, and other noticeable issues. ▪Ensure that the setup location is adequately ventilated. DANGER Danger to life from inhaling exhaust gases. Toxic engine exhaust gases can lead to loss of consciousness and even death in closed-off and poorly ventilated rooms. ▪ Never operate the machine in closed-off or poorly ventilated rooms. ▪ Do not breathe in the exhaust gases. 6.4 Filling engine oil Engines are normally delivered without an engine oil filling. 4H50TIC Transport, assembly and commissioning HATZ Operator's Manual 33

▪ Operating the engine with an oil level below the min. mark or above the max. mark can lead to engine damage. ▪ When checking the oil level, the engine must be horizontal and have been switched off for a few minutes. Overview 1 Dipstick 2 Oil filler plug, top 3 Oil refilling container 4 Oil filler plug, bottom Procedure Step Activity 1 Pull out the dipstick (1) and clean it. Transport, assembly and commissioning 4H50TIC 34 Operator's Manual HATZ

3 Fill engine oil. For the specification, viscosity and filling quantity, see the chapter 4.3 Engine oil, page 22. 4 Reinsert the dipstick. 5 Pull out the dipstick and check the oil level. 6 If required, top up engine oil to the max. mark. 7 Reinsert the dipstick. 8 Screw in the oil filler plug. 6.5 Filling the cooling system Safety notes CAUTION Danger of burns. There is a danger of burns when working on a hot cooling sys- tem. The cooling system is pressurized. ▪ Let the engine cool. ▪ Wear safety gloves. CAUTION Danger of later engine damage. ▪ Operating the engine with a coolant level below the MIN. mark can lead to engine damage. ▪ When checking the coolant level, the engine must be hori- zontal and be switched off. 4H50TIC Transport, assembly and commissioning HATZ Operator's Manual 35

2 Sealing cap 3 MAX - Maximum coolant level 4 MIN - Minimum coolant level Procedure Step Activity 1 Open the sealing cap (2). 2 For the HATZ standard radiator: Top up coolant to the MAX mark on the expansion tank. For the HATZ OpenPowerUnit radiator: Top up coolant to the edge of the pipe cut-out. Preparation of the coolant, see the chapter 4.4 Coolant, page 23. 3 Tighten the sealing cap (2) by hand all the way. 4 Start the engine (see the chapter 7 Operation and use, page 38). 5 Warm up the engine until the coolant has reached a tempera- ture of approx. 85°C. Above this temperature the coolant is pumped through the entire cooling system and forces out re- maining air bubbles. 6 Switch off the engine and let it cool down completely (see the chapter 7 Operation and use, page 38). 7 Check the coolant level again. The coolant must be seen be- tween the MIN and MAX mark; for a warm engine the level can also be slightly above the MAX mark. Transport, assembly and commissioning 4H50TIC 36 Operator's Manual HATZ

necessary (see the chapter 8.2.4 Checking the cooling system, page 57). 4H50TIC Transport, assembly and commissioning HATZ Operator's Manual 37

7.1 Safety notes NOTICE Comply with the safety chapter! Follow the basic safety instructions in the chapter 3 Safety, page 7. WARNING Danger of injury from damage and defects on the machine. ▪ Do not take the machine into service if damage has been lo- calized and identified. ▪ Replace faulty components. WARNING Danger of injury from the failure to follow the operating in- structions and from performing unauthorized tasks on the machine. ▪ Define the responsibilities of the personnel taking the ma- chine into service. ▪ Replace faulty machine parts immediately. ▪ Check the installation conditions when the machine is first taken into service and after the machine has been inactive for a lengthy period. CAUTION Danger of engine damage from low load operation. Operating the engine at no load or at very low load for an ex- tended period can impair the running characteristics of the en- gine. ▪ Make sure that the engine load is at least 15 %. ▪ Before switching off the engine following low load operation, briefly operate it at a considerably higher load. 7.2 Performing tests Before starting Before starting the engine, several tests need to be performed to ensure the machine is working properly. Operation and use 4H50TIC 38 Operator's Manual HATZ

2 The installation location is adequately ventilated. 3 There is a sufficient amount of fuel in the fuel tank (see the chap- ter 7.7 Refueling, page 49). 4 There is a sufficient amount of engine oil in the engine housing (see the chapter 7.6 Checking the oil level and adding oil if nec- essary, page 47). 5 There is a sufficient amount of coolant in the expansion tank (see the chapter 8.2.4 Checking the cooling system, page 57). 6 Radiator and radiator hoses are free from leaks (see the chapter 8.2.4 Checking the cooling system, page 57). 7 No persons are located in the danger zone of the engine or ma- chine. 8 All safety equipment is in place. 7.3 Starting the engine Safety notes DANGER Danger to life from inhaling exhaust gases. Toxic engine exhaust gases can lead to loss of consciousness and even death in closed-off and poorly ventilated rooms. ▪ Never operate the machine in closed-off or poorly ventilated rooms. ▪ Do not breathe in the exhaust gases. CAUTION Danger of engine damage from the use of starting fluid. ▪ The use of engine damage from the use of starting fluid can lead to uncontrolled ignition. ▪ Engine damage from uncontrolled ignitions. ▪ Never use starting fluid. 4H50TIC Operation and use HATZ Operator's Manual 39

plete machine. Overview — HATZ instrument boxes 4 II I 6 7 8 9 10 11 5 0 1 3 2 Pos. Designation 1 Error diagnosis display 2 Service interval indicator 3 Button for error interrogation 4 Protective cap 5 Starting key 6 Pre glow display 7 Air filter service required 8 Engine temperature display 9 Oil pressure display 10 Charge control 11 Operating display Ignition lock 0 Off I Operation II Starting Operation and use 4H50TIC 40 Operator's Manual HATZ

matically to protect the starter. If the engine is still not run- ning after that, turn the starting key back to position "0" and eliminate the cause (see the chapter 9.1 Fault table, page 86). ▪ Turn the starting key to position "0" every time you want to start the engine. ▪ The anti repeat device in the ignition lock makes it impossi- ble for the starter to engage while the engine is running and become damaged. Step Activity 1 Remove the protective cap (4) from the ignition lock. 2 Insert the starting key all the way and turn to position "I". Depending on the model, the following indicators light up: ▪Charge control (10) ▪Oil pressure display (9) ▪Pre glow display (6) NOTE: If the optional engine temperature display (8) lights up, the coolant temperature is impermissibly high. Do not start the engine; eliminate the cause. When the optional pre glow display (6) goes out, continue with step 3. 3 Turn the starting key to position "II". 4 As soon as the engine is running, release the starting key. ▪The starting key springs back to position "I" and remains in this position during operation. ▪The charge control (10) and oil pressure display (9) go out. ▪The operating display (11) lights up. NOTICE i ▪ In case of irregularities, switch off the engine immediately. ▪ Identify the fault and eliminate it. ▪ For details of troubleshooting, see the chapter 9.1 Fault ta- ble, page 86. 4H50TIC Operation and use HATZ Operator's Manual 41

Safety notes DANGER Danger to life from inhaling exhaust gases. Toxic engine exhaust gases can lead to loss of consciousness and even death in closed-off and poorly ventilated rooms. ▪ Never operate the machine in closed-off or poorly ventilated rooms. ▪ Do not breathe in the exhaust gases. CAUTION Danger of engine damage from the use of starting fluid. ▪ The use of engine damage from the use of starting fluid can lead to uncontrolled ignition. ▪ Engine damage from uncontrolled ignitions. ▪ Never use starting fluid. NOTICE See also starting instructions in the documentation for the com- plete machine. Overview — HATZ instrument boxes 4 II I 6 7 8 9 10 11 5 0 1 3 2 Operation and use 4H50TIC 42 Operator's Manual HATZ

2 Service interval indicator 3 Button for error interrogation 4 Protective cap 5 Starting key 6 Pre glow display 7 Air filter service required 8 Engine temperature display 9 Oil pressure display 10 Charge control 11 Operating display Ignition lock 0 Off I Operation II Starting Procedure NOTICE i ▪ After approx. 20 seconds the start procedure cuts off auto- matically to protect the starter. If the engine is still not run- ning after that, turn the starting key back to position "0" and eliminate the cause (see the chapter 9.1 Fault table, page 86). ▪ Turn the starting key to position "0" every time you want to start the engine. ▪ The anti repeat device in the ignition lock makes it impossi- ble for the starter to engage while the engine is running and become damaged. Step Activity 1 Remove the protective cap (4) from the ignition lock. 4H50TIC Operation and use HATZ Operator's Manual 43

Depending on the model, the following indicators light up: ▪Charge control (10) ▪Oil pressure display (9) ▪Pre glow display (6) NOTE: If the optional engine temperature display (8) lights up, the coolant temperature is impermissibly high. Do not start the engine; eliminate the cause. When the optional pre glow display (6) goes out, continue with step 3. 3 Leave the starting key at position "I" until you hear the fuel feed pump switches off (approx. 30 seconds). 4 Turn the starting key to position "II". The start procedure takes longer than normal as air is still in the fuel system. 5 As soon as the engine is running, release the starting key. ▪The starting key springs back to position "I" and remains in this position during operation. ▪The charge control (10) and oil pressure display (9) go out. ▪The operating display (11) lights up. NOTE: There is air in the fuel system when starting the engine for the first time/after a filter change. The engine therefore starts in the emergency program (reduced power and speed). 6 Run the engine for approx. 2 minutes in the emergency program to make sure there is no more air in the fuel system. 7 Switch off the engine and leave it switched off for at least 2 mi- nutes. At the next start the engine again runs in the normal pro- gram. NOTICE i ▪ In case of irregularities, switch off the engine immediately. ▪ Identify the fault and eliminate it. ▪ For details of troubleshooting, see the chapter 9.1 Fault ta- ble, page 86. Operation and use 4H50TIC 44 Operator's Manual HATZ

Safety notes CAUTION Danger of injury from unauthorized access. There is a danger of injury if unauthorized persons handle the machine. ▪ Protect the starting key against unauthorized access during breaks in operation or after completing work. CAUTION Protect the ignition lock against dirt and moisture. ▪ With the starting key pulled out, seal the ignition lock with the protective cap. NOTICE i Danger of overheating and full battery discharge. ▪ To prevent damage due to overheating, cool down the en- gine before switching it off by running it for approx. 5 mi- nutes at a reduced speed and load. ▪ When the machine is switched off, always turn the starting key to position "0" or else the battery may become fully dis- charged. NOTICE See also instructions in the documentation for the complete ma- chine. 4H50TIC Operation and use HATZ Operator's Manual 45

2 I 0 2 1 Pos. Designation 1 Starting key 2 Protective cap Ignition lock 0 Off I Operation Procedure Step Activity 1 Turn the starting key (1) to position "0". The engine switches off. All indicator lamps go out. 2 Remove the starting key. 3 Seal the ignition lock with the protective cap (2). Operation and use 4H50TIC 46 Operator's Manual HATZ

Safety notes CAUTION Danger of burns. There is a danger of burns when working on a hot engine. ▪ Wear safety gloves. CAUTION Danger of later engine damage. ▪ Operating the engine with an oil level below the min. mark or above the max. mark can lead to engine damage. ▪ When checking the oil level, the engine must be horizontal and have been switched off for a few minutes. 4H50TIC Operation and use HATZ Operator's Manual 47

3 Oil refilling container 4 Oil filler plug, bottom Procedure — Checking oil level/adding oil Step Activity 1 Switch off the engine and wait several minutes for the engine oil to collect in the crank housing. Engine must be level. 2 Remove contamination on the engine in the area of the dipstick (1). 3 Pull out the dipstick and clean it. 4 Reinsert the dipstick. 5 Pull out the dipstick and check the oil level. Operation and use 4H50TIC 48 Operator's Manual HATZ

max. mark. For the specification and viscosity, see the chapter 4.3 Engine oil, page 22. 7 Reinsert the dipstick. 7.7 Refueling This diesel engine is intended for installation in a machine or for assembly with other machines to form a machine and does not have its own fuel tank. Follow the instructions from the manufacturer and comply with the following safety information. NOTICE i If possible, never run the fuel tank empty, otherwise air can en- ter the fuel system and the engine switches to the emergency program. There is also the risk that damage is caused in the fuel high-pressure section. If the fuel tank is nevertheless run empty, the procedure descri- bed under "7.4 Starting the engine for the first time/after a filter change, page 42" must be adhered to. Safety notes DANGER Fire hazard from fuel. Leaked or spilled fuel can ignite on hot engine parts and cause serious burn injuries. ▪ Only refuel when the engine is switched off. ▪ Never refuel in the vicinity of open flames or sparks that can cause ignition. ▪ Do not smoke. ▪ Do not spill fuel. CAUTION Danger of environmental damage from spilled fuel. Do not overfill the fuel tank and do not spill fuel. ▪ Collect emerging fuel and dispose of it in an environmentally compatible manner. 4H50TIC Operation and use HATZ Operator's Manual 49

The use of fuel that does not meet the specifications can lead to engine damage. ▪ Only use the fuel specified in the chapter 4.5 Fuel, page 26. ▪ The use of fuel that does not meet specifications requires approval by Motorenfabrik HATZ (main plant). Operation and use 4H50TIC 50 Operator's Manual HATZ

Safety notes WARNING Danger of injury from the failure to follow the operating in- structions and from performing unauthorized tasks on the machine. ▪ Follow all instructions. ▪ Do not perform activities for which no qualification is availa- ble. Contact properly trained personnel if necessary. NOTICE Comply with the safety chapter! Follow the basic safety instructions in the chapter 3 Safety, page 7. ▪Maintenance tasks may only be performed by trained personnel. ▪Accident prevention measures must be in accordance with the local acci- dent prevention regulations. ▪Perform setting and maintenance work at the specified intervals. ▪Replace faulty machine parts as soon as possible. ▪Always use personal protective equipment. ▪Only use fully functional tools. ▪Problems may occur if unsuitable spare parts are installed. We cannot ac- cept responsibility for damage and secondary damage that result from this. We therefore recommend the use of Hatz original spare parts. ▪Closely adhere to the maintenance conditions prescribed in this Operator's Manual. ▪Only make changes on the machine in agreement with the manufacturer. ▪Only perform maintenance when the engine is switched off. ▪Adhere to legal regulations when handling and disposing of used oil, fil- ters, coolants, and cleaning agents. ▪Protect the starting key against unauthorized access. ▪Disconnect the negative battery terminal before carrying out maintenance work. ▪After completing maintenance work, check that all tools, bolts, aids and other objects are removed from the machine and that all safety equipment has been replaced. 4H50TIC Maintenance HATZ Operator's Manual 51

the engine or machine. Performance of maintenance work The entire machine is designed to be maintenance friendly. Parts that re- quire maintenance are easily accessible. ▪Perform maintenance work faithfully at the specified intervals to prevent premature wear of the machine. ▪Follow the notice and warning labels on the machine. ▪Always retighten screw connections loosened during maintenance work. ▪After the necessary maintenance and repair work is completed, perform a function test (test run). ▪For maintenance work that is not listed and described in the maintenance documentation, please contact your nearest HATZ service station. 8.2 Maintenance work Safety note CAUTION Danger of injury if maintenance instructions are not fol- lowed. ▪ Only perform maintenance when the engine is switched off. ▪ Protect the starting key against unauthorized access. ▪ Disconnect the negative terminal of the battery. ▪ After the maintenance work is completed, ensure that all tools have been removed from the machine. 8.2.1 Maintenance plan Symbol Maintenance in- terval Maintenance activity/Check Chapter Every 8-15 oper- ating hours or ev- ery day before starting Check the oil level. 7.6 Checking the oil level and add- ing oil if necessa- ry, page 47 Check the intake area of the combustion air. 8.2.2 Checking the intake area of the combustion air, page 54 Maintenance 4H50TIC 52 Operator's Manual HATZ

accumulation. 8.2.3 Checking the radiator fins for dirt accumula- tion, page 55 Checking the cooling system 8.2.4 Checking the cooling sys- tem, page 57 500h Every 500 operat- ing hours or every 2 years Change the engine oil and oil filter1) 8.2.5 Changing the engine oil and oil filter, page 59 Change the fuel prefilter1) 8.2.12 Changing the fuel prefilter, page 74 Change the fuel fine filter1) 8.2.13 Changing the fuel fine filter, page 77 Check the poly v belt1) 8.2.7 Tensioning the poly v belt, page 67 Change the oil separator of the crankcase ventilation1) 8.2.9 Changing the oil separator of the crankcase ventilation, page 71 Check the screw connections1) 8.2.10 Checking the screw con- nections, page 72 Clean the radiator fins1) 8.2.6 Cleaning the radiator fins, page 64 Every 500 operat- ing hours or when indicated, at least every 2 years Change the air filter cartridges 8.2.14 Servicing the air filter (op- tional), page 80 When indicated Drain the water separator1) 8.2.11 Draining the water separa- tor, page 73 4H50TIC Maintenance HATZ Operator's Manual 53

ery 3000 operat- ing hours at the latest Replacing the poly v belts 8.2.8 Replacing the poly v belts, page 69 Every 4000 oper- ating hours Clean the entire EGR section (EGR precooler, EGR valve, EGR main cooler as well as EGR mixing nozzle) (To be carried out by a trained specialist) 1) Service according to service interval or after 2 years depending on which criteria is first. In new and generally overhauled engines, after 50 operating hours: ▪Change the engine oil and oil filter. See the chapter 8.2.5 Changing the engine oil and oil filter, page 59. ▪Check the screw connections (do not retighten the screws for attaching the cylinder head). See the chapter 8.2.10 Checking the screw connec- tions, page 72. 8.2.2 Checking the intake area of the combustion air Safety notes CAUTION Danger of burns. There is a danger of burns when working on a hot engine. ▪ Let the engine cool. ▪ Wear safety gloves. NOTICE i In case of heavy contamination, shorten the maintenance inter- vals accordingly (see the chapter 8.2.1 Maintenance plan, page 52). Maintenance 4H50TIC 54 Operator's Manual HATZ

1 Intake opening for combustion air 2 Dust discharge valve Procedure Step Activity 1 Check the intake opening (1) for coarse contamination such as leaves, heavy dust deposits, etc., and clean if necessary. 2 Check that the dust discharge valve (2) is clear. Remove dust seals by pressing them together. 8.2.3 Checking the radiator fins for dirt accumulation Safety notes CAUTION Danger of burns. There is a danger of burns when working on a hot engine. ▪ Let the engine cool. ▪ Wear safety gloves. 4H50TIC Maintenance HATZ Operator's Manual 55

When working with compressed air, foreign bodies may fly into your eyes. ▪ Wear safety goggles. ▪ Never direct the compressed air jet toward people or toward yourself. CAUTION Danger of engine damage from overheating. The engine temperature display (option) lights up as soon as the engine becomes impermissibly hot. ▪ Switch off the engine immediately and eliminate the cause. NOTICE i In case of heavy contamination, shorten the maintenance inter- vals accordingly (see the chapter 8.2.1 Maintenance plan, page 52). Overview 1 Radiator fins Maintenance 4H50TIC 56 Operator's Manual HATZ

leaves, heavy dust deposits, etc., and clean if necessary (see the chapter 8.2.6 Cleaning the radiator fins, page 64). 8.2.4 Checking the cooling system Safety notes CAUTION Danger of scalding and risk of environmental damage due to hot coolant. ▪ Excessive coolant is blown off from the sealing cap on the expansion tank. After topping up the cooling system never move parts of your body or face close to the sealing cap. ▪ Never top up coolant above the MAX - mark on the expan- sion tank. ▪ Never stop escaping coolant with your bare hands. CAUTION Danger of burns. There is a danger of burns when working on a hot engine. ▪ Let the engine cool before maintenance. CAUTION Danger of burns. There is a danger of burns when working on a hot cooling sys- tem. The cooling system is pressurized. ▪ Let the engine cool. ▪ Wear safety gloves. 4H50TIC Maintenance HATZ Operator's Manual 57

▪ Operating the engine with a coolant level below the MIN. mark can lead to engine damage. ▪ When checking the coolant level, the engine must be hori- zontal and be switched off. Overview MAX MIN MAX MIN 1 2 4 3 1 Expansion tank for coolant 2 Sealing cap 3 MAX - Maximum coolant level 4 MIN - Minimum coolant level Procedure for checking the coolant level Step Activity 1 The coolant must be between the MIN and MAX marks on a switched-off and cooled-down engine. For a warm engine, the level can also be slightly above the MAX mark. Procedure for topping up coolant Step Activity 1 Open the sealing cap (2). 2 Top up prepared coolant to the MAX mark on the expansion tank. Preparation of the coolant, see the chapter 4.4 Coolant, page 23. 3 Tighten the sealing cap (2) by hand all the way. Maintenance 4H50TIC 58 Operator's Manual HATZ

Coolants losses are mostly caused by leaks in the cooling system. On a non-leaking cooling system, losses only occur when the coolant boils and this then causes coolant to be pressed out of the cooling system at the sealing cap on the expansion tank. The cause of this can be contamination in the area of the radiator fins (see the chapter 8.2.3 Checking the radiator fins for dirt accumulation, page 55). Overview 1 Hose clip Procedure Step Activity 1 Check the cooling system for leaks and rectify the cause imme- diately - in case of doubt consult HATZ Service for advice. 2 When hose connections are loose, retighten the hose clips (1). 8.2.5 Changing the engine oil and oil filter Safety notes CAUTION Danger of burns. When working on the engine there is a danger of burns from hot oil. ▪ Wear personal protective equipment (gloves). 4H50TIC Maintenance HATZ Operator's Manual 59

Used oil is water-polluting. ▪ Do no allow it to enter the ground water, water bodies, or sewage system. ▪ Collect the used oil and dispose of it according to local envi- ronmental regulations. CAUTION Danger of later engine damage. ▪ Operating the engine with an oil level below the min. mark or above the max. mark can lead to engine damage. ▪ When checking the oil level, the engine must be horizontal and have been switched off for a few minutes. NOTICE i ▪ The engine must be level. ▪ The engine must be switched off. ▪ Only drain engine oil while it is warm. Overview of draining engine oil 1 Oil drain screw (side) 2 Oil drain screw (front) 3 Gasket Maintenance 4H50TIC 60 Operator's Manual HATZ

drain screw (1) or (2). Unscrew the oil drain screw and drain the used oil entirely. 2 Screw in the cleaned oil drain screw with the new gasket (3) and tighten. Overview of changing the oil filter (horizontal installation) 1 Oil filter 2 Sealing surface 3 Gasket Procedure Step Activity 1 Loosen the oil filter (1) with a strap wrench or similar and un- screw it. 2 Dispose of the old filter in accordance with local environmental regulations. 3 Thoroughly clean the sealing surface (2). 4 Lightly oil the sealing lip (3) of the new oil filter. 5 Screw in the oil filter and tighten it by hand. 4H50TIC Maintenance HATZ Operator's Manual 61

1 Oil filter 2 Collar on the oil filter 3 Shaped element 4 Sealing surface 5 Gasket 6 Guard ring Procedure Step Activity 1 Loosen the oil filter (1) with a strap wrench or similar and un- screw it until the collar (2) of the oil filter is at the same level as the shaped element (3). In this position, a valve releases the oil return into the crankcase which allows the oil filter to empty. 2 Fully unscrew the oil filter after a waiting period of approx. 30 seconds. Maintenance 4H50TIC 62 Operator's Manual HATZ

regulations. 4 Thoroughly clean the shaped element (3) and sealing surface (4). 5 Lightly oil the sealing lip (5) of the new oil filter. 6 Screw in the oil filter and tighten it by hand. 7 Make sure that the guard ring (6) seats fully on the shaped ele- ment (3). The guard ring prevents dirt from accumulating be- tween the oil filter and shaped element. Overview of filling the engine oil 1 Dipstick 2 Oil filler plug, top 3 Oil refilling container 4 Oil filler plug, bottom 4H50TIC Maintenance HATZ Operator's Manual 63

2 Depending on accessibility, unscrew oil filler plug (2) or (4). 3 Fill engine oil. For the specification, viscosity and filling quantity, see the chapter 4.3 Engine oil, page 22. 4 Reinsert the dipstick. 5 Pull out the dipstick and check the oil level. 6 If required, top up engine oil to the max. mark. 7 Reinsert the dipstick. 8 Screw in the oil filler plug. Concluding inspection work Step Activity 1 Check the oil level after a short test run and correct if necessary. 2 Check the oil filter for tightness and retighten by hand if neces- sary. 8.2.6 Cleaning the radiator fins Safety notes DANGER Danger of explosion from flammable cleaning agents. Cleaning with benzene is an explosion hazard. It is highly flam- mable, can become electrostatically charged and can generate an explosive gas-air mixture. ▪ Use halogen-free, cold cleaners with a high flashpoint for cleaning. Maintenance 4H50TIC 64 Operator's Manual HATZ

Cleaning materials soaked with cold cleaner may produce heat together with atmospheric oxygen and combust spontaneously. ▪ Collect cleaning materials soaked with cold cleaner only in fire-proof, tightly sealed containers. ▪ Do not dispose of cold cleaner residues and used cleaning materials with domestic waste, rather only in accordance with manufacturer instructions. ▪ Comply with the instructions for preventing fire on the safety data sheet for the cold cleaner. CAUTION Danger of burns. There is a danger of burns when working on a hot engine. ▪ Let the engine cool. ▪ Wear safety gloves. CAUTION Danger of injury. When working with compressed air, foreign bodies may fly into your eyes. ▪ Wear safety goggles. ▪ Never direct the compressed air jet toward people or toward yourself. CAUTION Danger of damage to the machine from incorrect engine cleaning. ▪ Let the engine fully cool down before cleaning. ▪ Do not spray components of the electrical equipment with a water jet or high pressure jet during cleaning. ▪ Do not use gasoline or acid-based cleaning agents. 4H50TIC Maintenance HATZ Operator's Manual 65

▪ Never spray the radiator fins with a high pressure jet. ▪ Never clean the radiator fins with a tool such as a spatula or screwdriver. A reduction in radiator performance through bent radiator fins or radiator leaks may be the result. NOTICE i In case of heavy contamination, shorten the maintenance inter- vals accordingly (see the chapter 8.2.1 Maintenance plan, page 52). Overview 1 2 3 1 Radiator fins 2 Direction of flow of the cooling air with suction fan 3 Direction of flow of the cooling air with forced-draught fan Procedure Step Activity Cleaning in case of dry dirt contamination 1 Clean the radiator fins either with compressed air or flush with a water jet - depending on the amount of accumulated dirt. Work first against the direction of flow of the cooling air and then in the direction of flow. Cleaning of wet or oily dirt contamination Maintenance 4H50TIC 66 Operator's Manual HATZ

the manufacturer's instructions and then clean off with a water jet. Work first against the direction of flow of the cooling air and then in the direction of flow. 2 Identify the cause of the oiling and seal the leak. 8.2.7 Tensioning the poly v belt Safety note CAUTION Danger of burns. There is a danger of burns when working on a hot engine. ▪ Let the engine cool before maintenance. NOTICE i ▪ Regularly check poly v belts for wear. Replace the poly v belt immediately when the ribbed profile (inside of the belt) is worn or broken off. ▪ The cause of running noises for the poly v belt is mostly that the pretension on the belt is too low. ▪ A too low belt pretension causes early wear of the poly v belt. Regularly check the belt tension, in case of doubt re- tension the poly v belt. ▪ The vibration frequency is decisive for adjustment of the belt tension. The torque values are only a guide value. Pretension force (belt) Torque (belt tensioner) Frequency (frequency me- ter) New belt 480 N (+ 50 N) 80 Nm (+ 10 Nm) 210 Hz (+ 10 Hz) Belt after serv- ice 250 N (+ 30 N) 70 Nm (+ 10 Nm) 150 Hz (+ 10 Hz) Minimum ten- sion 170 N 125 Hz 4H50TIC Maintenance HATZ Operator's Manual 67

2 Bracket 3 Belt tensioner 4 Hex nut 5 Clamping claw 6 Torque wrench with dial gage display 7 Measurement point for frequency measurement Procedure Step Activity 1 Check the poly v belt for wear. Do not retension a worn poly v belt, but immediately replace it. Maintenance 4H50TIC 68 Operator's Manual HATZ

3 Position the belt tensioner (3) with the guiding groove on the bracket (2). 4 Feed in the hexagon nut (4) of the mounting bolt into the clamp- ing claw (5). Move the belt tensioner for this. 5 Adjusting the belt tension with a torque wrench: Place the torque wrench (with dial gage) on the belt tensioner, lay the counter support on the alternator housing. 6 Tighten the torque wrench (6) until the required torque is reached. 7 Hold the torque wrench and tighten the alternator mounting bolt at this position. 8 Checking the belt tension with a frequency meter: Vibrate the end of the belt between the alternator and fan by lightly hitting it with the hand. 9 Measure the frequency with a commercially available optical or acoustic frequency meter by following the meter manufacturer's instructions. 10 If necessary, retension the belt by using a belt tensioner as de- scribed above. 8.2.8 Replacing the poly v belts Safety note CAUTION Danger of burns. There is a danger of burns when working on a hot engine. ▪ Let the engine cool before maintenance. NOTICE i ▪ The poly v belt must be replaced after 3000 operating hours at the latest. If wear is detected, the poly v belt must be im- mediately replaced. 4H50TIC Maintenance HATZ Operator's Manual 69

2 Fixing screw, protective guard (top and bottom) 3 Protective guard (left half) 4 Alternator mounting bolt 5 Poly v belt 6 Fan blade Procedure Step Activity 1 Disassemble the left half of the protective guard (3) by unscrew- ing the screws (1) and (2) (at the top and bottom). 2 Loosen the alternator mounting bolt (4) one or two revolutions. 3 Manually press the alternator towards the water pump, slide the loose poly v belt from the belt wheels. 4 Carefully lift the poly v belt over a fan blade. Turn the fan further in the counterclockwise direction and lift the belt over the re- maining fan blades until it is completely free. 5 Feed a new poly v belt over the fan blade in the same way from the radiator side. 6 Lay the poly v belt over the belt wheels and tension (see 8.2.7 Tensioning the poly v belt, page 68). 7 Reassemble the protective guard. Maintenance 4H50TIC 70 Operator's Manual HATZ

Safety note CAUTION Danger of burns. There is a danger of burns when working on a hot engine. ▪ Let the engine cool before maintenance. Overview 4 1 Mounting bolts (captive) 2 Breather cap 3 Oil separator cartridge 4 Vent hose Procedure Step Activity 1 Release the four mounting bolts (1) on the breather cap (2). 2 Carefully lift the breather cap. If necessary, release the vent hose (4). 3 Remove the used oil separator cartridge dispose of it according to local environmental regulations. 4 Wipe out the breather housing with a clean cleaning cloth. Make sure that dirt is not brought into the breather housing. 5 Insert a new oil separator cartridge. 6 Put on the breather cap and tighten the four mounting bolts (max. 4 Nm). If necessary, reattach the vent hose. 4H50TIC Maintenance HATZ Operator's Manual 71

Safety note NOTICE i ▪ Only retighten loose screw connections. Screw connections can be secured with thread locking ad- hesive or tightened to a defined torque. Retightening tight screw connections can cause damage. ▪ The adjustment screws on the injection system are secured with locking varnish and are not permitted to be tightened or adjusted. ▪ Do not retighten the screws for attaching the cylinder head. Overview 1 2 3 1 Engine base mounting bolts 2 Vibration damper mounting bolt 3 Chassis frame mounting bolts Procedure Step Activity 1 Check the mounting bolts of the engine mountings (4x) and tighten if needed. 2 Check the condition of all remaining screw connections and ensure that they are tight (for exceptions, see note). 3 Tighten any lose screw connections. Maintenance 4H50TIC 72 Operator's Manual HATZ

Safety note CAUTION Danger of environmental damage from spilled fuel. When water is drained from the water separator, a small amount of fuel is drained as well. ▪ Catch the emerging water-fuel mixture and dispose of it in an environmentally compatible manner. The fuel prefilter has a water separator. An electronic water level sensor sig- nals when the maximum permissible water level is reached in the water sep- arator. A corresponding fault message is displayed on the instrument box or CAN display. Overview 1 2 3 4 5 1 Bleed screw 2 Drain plug 3 Water level sensor connector 4 Drain socket for extension hose 5 Hose clip (for a fuel tank positioned low) Procedure Step Activity 1 Place a suitable container under the drain socket (4) of the drain plug (2). NOTE: In inaccessible locations, an extension hose can be con- nected to the drain socket on the drain plug. 4H50TIC Maintenance HATZ Operator's Manual 73

3 If not enough liquid escapes, undo additional bleed screw (1). NOTE: If the fuel tank lies lower than the fuel prefilter, the fuel feed line must be clamped off with a hose clip (5). Otherwise fuel runs back into the fuel tank after the drain plug has been unscrewed. 4 As soon as fuel escapes, close the drain plug (2) and bleed screw (1). NOTE: First water escapes then fuel. This can be seen by a clear separator. 5 If necessary, release the fuel feed line, dispose of the water-fuel mixture in an environmentally compatible manner. 8.2.12 Changing the fuel prefilter Safety notes DANGER Fire hazard from fuel Leaked or spilled fuel can ignite on hot engine parts and cause serious burn injuries. ▪ Do not spill fuel. ▪ No open flames when working on the fuel system. ▪ Do not smoke. CAUTION Danger of burns. There is a danger of burns when working on a hot engine. ▪ Let the engine cool. ▪ Wear safety gloves. Maintenance 4H50TIC 74 Operator's Manual HATZ

Repeated contact with diesel fuel can cause chapped and cracked skin. ▪ Wear safety gloves. CAUTION Danger of environmental damage from spilled fuel. When the filter is removed, a small amount of fuel is drained as well. ▪ Collect emerging fuel and dispose of it in an environmentally compatible manner. CAUTION Dirt particles can damage the injection system. ▪ Maintain clean conditions to ensure that dirt does not enter the fuel line. ▪ Only install fuel filters dry and do not prefill in order to avoid contamination. Overview 1 4 2 3 1 Hose clip (fuel feed line) 2 Fuel prefilter 3 Drain plug with integrated water level sensor 4H50TIC Maintenance HATZ Operator's Manual 75

Procedure Step Activity 1 Block the fuel feed line (1) between the fuel tank and fuel prefil- ter. 2 Place a suitable container under the filter to collect emerging fuel. 3 Disconnect the water level sensor cable (4) from the drain plug (3). 4 Release the drain screw (3) and drain the fuel. 5 Unscrew the fuel prefilter, fully unscrew the drain plug with inte- grated water level sensor. 6 Dispose of the used fuel prefilter according to local environmen- tal regulations. 7 Clean the drain plug with integrated water level sensor and light- ly oil the sealing surfaces. Screw in the drain plug into the new fuel prefilter. 8 Lightly oil the gasket of the new fuel prefilter, fit the filter and tighten it by hand. 9 Release the fuel feed line and connect the cable of the water level sensor. 10 Start the engine and perform a test run. NOTE: When starting the engine, adhere to the procedure under "7.4 Starting the engine for the first time/after a filter change, page 42". 11 After the test run, check the fuel prefilter and drain plug for leaks. Maintenance 4H50TIC 76 Operator's Manual HATZ

Safety notes DANGER Fire hazard from fuel Leaked or spilled fuel can ignite on hot engine parts and cause serious burn injuries. ▪ Do not spill fuel. ▪ No open flames when working on the fuel system. ▪ Do not smoke. WARNING Danger of injury from fuel escaping under pressure. Large quantities of fuel under high pressure may escape when changing the fuel fine filter. ▪ Never open the bleed screw on the fuel fine filter. ▪ Wear safety goggles. CAUTION Danger of burns. There is a danger of burns when working on a hot engine. ▪ Let the engine cool. ▪ Wear safety gloves. 4H50TIC Maintenance HATZ Operator's Manual 77

Repeated contact with diesel fuel can cause chapped and cracked skin. ▪ Wear safety gloves. CAUTION Danger of environmental damage from spilled fuel. When the filter is removed, a small amount of fuel is drained as well. ▪ Collect emerging fuel and dispose of it in an environmentally compatible manner. CAUTION Dirt particles can damage the injection system. ▪ Maintain clean conditions to ensure that dirt does not enter the fuel line. ▪ Only install fuel filters dry and do not prefill in order to avoid contamination. Overview 1 2 3 4 5 Maintenance 4H50TIC 78 Operator's Manual HATZ

2 Fuel feed line 3 Fuel fine filter 4 Hose clip 5 Strap wrench Procedure Step Activity 1 Block the fuel feed line (2) using the hose clip (4). 2 Place a suitable container under the filter to collect emerging fuel. 3 Unscrew the fuel fine filter (3) and according to local environ- mental regulations. 4 Lightly oil the gasket of the new fuel fine filter, fit the filter and tighten it by hand. 5 Release the fuel feed line. 6 Start the engine and perform a test run. NOTE: When starting the engine, adhere to the procedure under "7.4 Starting the engine for the first time/after a filter change, page 42". 7 After the test run, check the fuel fine filter for leaks. 4H50TIC Maintenance HATZ Operator's Manual 79

Safety notes CAUTION Danger of injury. When working with compressed air, foreign bodies may fly into your eyes. ▪ Wear safety goggles. ▪ Never direct the compressed air jet toward people or toward yourself. NOTICE i ▪ Change the filter elements when there is oily or damp dirt contamination, cleaning is not possible. ▪ Even minor damage in the areas of the sealing surface, filter paper, or filter cartridge makes reuse impossible. ▪ The filter cartridge may not be washed out or beaten out. ▪ The filter cartridge may be blown out only in exceptional cases. The pressure must not exceed 5 bar. Overview 1 5 6 2 3 4 2 Maintenance 4H50TIC 80 Operator's Manual HATZ

2 Retaining clips 3 Air filter cover 4 Dust discharge valve 5 Secondary filter 6 Primary filter 7 Air gun with extension tube (tip bent) 8 Lamp 9 Sealing surfaces Replacing the primary/secondary filters Step Activity 1 Open the retaining clips (2) and remove the air filter cover (3). 2 Pull out the primary filter (6) and either replace (recommended) or clean (see below). Replace or clean the primary filter according to the service inter- val indicator. The primary filter must be replaced every two years at the latest however, cleaning is no longer possible after this time. 3 Remove dirt adhering to the inside of the air filter housing (1), air filter cover (3), and dust discharge valve (4). 4 Pull out and check the secondary filter (5), replace if required. The secondary filter can not be cleaned. The secondary filter must be replaced after every fifth replacement of the primary fil- ter, though no later than every two years. 5 Carefully insert new filter elements. 4H50TIC Maintenance HATZ Operator's Manual 81

taining clips making sure that the dust discharge valve points vertically downwards. Cleaning the primary filter Step Activity 1 Blow out the primary filter (6) with dry compressed air from the inside to the outside until dust no longer emerges. Use an air gun with an extension tube (7) with the end bent by approx. 90°. The end of the extension tube must not touch the filter paper. 2 Check the sealing surfaces (9) of the filter cartridge for damage. 3 Check the filter cartridge for tears or other damage in the filter paper by holding it against the light at a slant or shining light from a lamp (8) through it. In case of doubt, always replace the primary filter. NOTE: The primary filter may only be cleaned once, then it must be replaced. 8.2.15 Changing coolant Safety notes CAUTION Danger of scalding and risk of environmental damage due to hot coolant. ▪ Excessive coolant is blown off from the sealing cap on the expansion tank. After topping up the cooling system never move parts of your body or face close to the sealing cap. ▪ Never top up coolant above the MAX - mark on the expan- sion tank. ▪ Never stop escaping coolant with your bare hands. CAUTION Danger of burns. There is a danger of burns when working on a hot cooling sys- tem. The cooling system is pressurized. ▪ Let the engine cool. ▪ Wear safety gloves. Maintenance 4H50TIC 82 Operator's Manual HATZ

Coolant is water-polluting. ▪ Do no allow it to enter the ground water, water bodies, or sewage system. ▪ Collect coolant and dispose of it in an environmentally com- patible manner. Overview MAX MIN MAX MIN 1 2 4 3 7 8 9 6 5 4H50TIC Maintenance HATZ Operator's Manual 83

2 Sealing cap 3 MAX - Maximum coolant level 4 MIN - Minimum coolant level 5 Drain plug on the radiator 6 Gasket 7 Oil cooler 8 Hose clamp 9 Bottom coolant hose 10 Connector on the oil cooler Procedure Step Activity 1 Position a suitable container to collect the used coolant (approx. 12.5 liters for the Hatz standard radiator or 13.2 liters for the HATZ OpenPowerUnit radiator). 2 Open the sealing cap (2) of the expansion tank (1). 3 Unscrew the drain plug (5) and drain the coolant into the con- tainer. 4 Screw in the drain plug (5) with a new gasket (6) and tighten. 5 Place the collecting contain under the oil cooler (7). 6 Release the hose clamp (8) on the bottom coolant hose (9) and pull off the hose. 7 Drain coolant out of the oil cooler (10) and then reconnect the bottom coolant hose. Maintenance 4H50TIC 84 Operator's Manual HATZ

system, page 35). 4H50TIC Maintenance HATZ Operator's Manual 85

If the cases listed below have been worked through but the fault continues to persist, please contact your nearest Hatz service station. Type of fault Possible causes Remedy Chapter The engine does not start or does not start immedi- ately, but it can be turned with the starter. No fuel at the high pressure pump. Refuel. 7.7 Refuel- ing, page 49 Systematically check the entire fuel supply. If this does not yield results: ▪Open the shutoff valve. ▪Check the feed line to the en- gine. ▪Check the fuel prefilter. ▪Check the fuel fine filter. ▪Check the func- tion of the feed pump. 8.2.12 Changing the fuel pre- filter, page 74 8.2.13 Changing the fuel fine filter, page 77 Insufficient compression. Contact Hatz serv- ice. Cylinder and/or pis- ton ring wear. Contact Hatz serv- ice. Injector not fully functional. Contact Hatz serv- ice. Hydraulic load too high (especially for multiple hydraulic pumps). Reduce the hy- draulic load – if possible. For low tempera- tures (engine does not start) Pre-glow system defective. Contact Hatz serv- ice. Faults 4H50TIC 86 Operator's Manual HATZ

Possible causes Remedy Chapter Fuel gelled due to insufficient cold re- sistance. Check whether the fuel that emerges from the fuel feed line directly in front of the high pres- sure pump is clear and not cloudy. If the fuel has gelled, either warm the en- gine or drain the entire fuel supply system. Fill with a temperature-resist- ance fuel mixture. 4.5 Fuel, page 26 8.2.12 Changing the fuel pre- filter, page 74 8.2.13 Changing the fuel fine filter, page 77 Oil is too viscous causing a too low starter speed. Change the engine oil and add oil of the right viscosity class. 8.2.5 Changing the engine oil and oil fil- ter, page 59 4.3 Engine oil, page 22 Insufficiently charg- ed battery. Check the battery and contact the service center if necessary. 3.2.4 Elec- trical equip- ment, page 18 Machine is not un- coupled. If possible, sepa- rate the engine from the machine by uncoupling it. 4H50TIC Faults HATZ Operator's Manual 87

Possible causes Remedy Chapter The starter does not switch on and the engine does not turn. Irregularities in the electrical equip- ment: ▪Battery and/or other cable con- nections are in- correctly con- nected. ▪Cable connec- tions are loose and/or oxidized. ▪Ground connec- tion between the chassis and en- gine is corroded. ▪Battery is faulty and/or not load- ed. ▪Faulty starter. ▪Faulty relay, monitoring ele- ments, etc. Check the electri- cal equipment and their components. Contact Hatz serv- ice. 3.2.4 Elec- trical equip- ment, page 18 The engine starts, but does not con- tinue running after the starter is switched off. Machine is not un- coupled. If possible, sepa- rate the engine from the machine by uncoupling it. Fuel prefilter is clogged. Change the fuel prefilter. 8.2.12 Changing the fuel pre- filter, page 74 Fuel fine filter is clogged. Change the fuel fine filter. 8.2.13 Changing the fuel fine filter, page 77 Fuel supply is inter- rupted. Systematically check the entire fuel supply. Faults 4H50TIC 88 Operator's Manual HATZ

Possible causes Remedy Chapter Stop signal from monitoring ele- ments that are as- sociated with the automatic switch- off (optional): ▪No oil pressure. ▪Dirty air filter unit. ▪Fuel pressure too low. ▪Coolant level too low. ▪Excess coolant temperature. ▪Excess charge air temperature. ▪Faulty three phase alternator. ▪Check the oil lev- el. ▪Check the de- gree of dirt con- tamination of the air filter, and clean or renew it if necessary. ▪Check the fuel flow, if necessary change the fuel prefilter and fine filter. ▪Top up coolant. ▪Check radiator fins and clean if needed. ▪Contact Hatz service. 7.6 Check- ing the oil level and adding oil if necessary, page 47 8.2.14 Serv- icing the air filter (option- al), page 80 8.2.12 Changing the fuel pre- filter, page 74 8.2.13 Changing the fuel fine filter, page 77 8.2.4 Checking the cooling system, page 57 8.2.6 Clean- ing the radi- ator fins, page 64 Engine switches off spontaneously dur- ing operation. The tank ran out of fuel during opera- tion Fill with fuel. 7.7 Refuel- ing, page 49 Fuel prefilter or fine filter is clogged Change the fuel fil- ter. 8.2.12 Changing the fuel pre- filter, page 74 8.2.13 Changing the fuel fine filter, page 77 4H50TIC Faults HATZ Operator's Manual 89

Possible causes Remedy Chapter Poly v belt torn. Renew the poly v belt. 8.2.8 Re- placing the poly v belts, page 69 Mechanical faults. Contact Hatz serv- ice. Engine switches off by the automatic electrical switch-off. Stop signal of mon- itoring elements for: ▪Oil pressure too low. ▪Dirty air filter unit. ▪Fuel pressure too low. ▪Coolant level too low. ▪Excess coolant temperature. ▪Excess charge air temperature. ▪Faulty three phase alternator. ▪Check the oil lev- el. ▪Check the de- gree of dirt con- tamination of the air filter, and clean or renew it if necessary. ▪Check the fuel flow, if necessary change the fuel prefilter and fine filter. ▪Top up coolant. ▪Check radiator fins and clean if needed. ▪Contact Hatz service. 7.6 Check- ing the oil level and adding oil if necessary, page 47 8.2.14 Serv- icing the air filter (option- al), page 80 8.2.12 Changing the fuel pre- filter, page 74 8.2.13 Changing the fuel fine filter, page 77 8.2.4 Checking the cooling system, page 57 8.2.6 Clean- ing the radi- ator fins, page 64 Faults 4H50TIC 90 Operator's Manual HATZ

Possible causes Remedy Chapter Irregularities in the electrical equip- ment, such as: ▪Loose contacts on cable connec- tions. ▪Faulty three phase alternator. ▪Faulty relay. Check the electri- cal equipment and its components, contact Hatz serv- ice if necessary. 3.2.4 Elec- trical equip- ment, page 18 The engine loses power and speed. Engine runs due to an error in the emergency pro- gram. Switch off the en- gine, wait for a min. of 2 minutes, then restart the engine. (This deletes minor errors). 7.5 Switch- ing off the engine, page 45 7.3 Starting the engine, page 39 The fuel supply is impaired ▪The tank ran out of fuel during op- eration. ▪Fuel prefilter or fine filter is clog- ged. ▪Inadequate tank venting. ▪Line connections are not leak tight. Add fuel. Change the filter. Ensure that the tank is sufficiently vented. Check the line screw connections for leak tightness. 7.7 Refuel- ing, page 49 8.2.12 Changing the fuel pre- filter, page 74 8.2.13 Changing the fuel fine filter, page 77 The engine loses power and speed, and black smoke emerges from the exhaust. Dirty air filter unit. Check the degree of dirt contamina- tion of the air filter, and clean or renew it if necessary. 8.2.14 Serv- icing the air filter (option- al), page 80 Turbocharger faulty or leaking hoses. Check hoses or contact Hatz serv- ice. Injector not fully functional. Contact Hatz serv- ice. 4H50TIC Faults HATZ Operator's Manual 91

Possible causes Remedy Chapter Engine becomes very hot. Indicator light for excess coolant temperature lights up. Too much engine oil in the engine. Drain the engine oil to the max mark on the dipstick. 7.6 Check- ing the oil level and adding oil if necessary, page 47 Inadequate cool- ing: ▪Contamination in the entire area of the cooling air guides. ▪Radiator fins dirty, or radiator blocked. ▪Thermostat or water pump faul- ty. ▪Clean the cooling air area. ▪Clean the radia- tor fins, ensure air flow through radiator is not hindered. ▪Contact Hatz service. 8.2.6 Clean- ing the radi- ator fins, page 64 8.2.4 Checking the cooling system, page 57 Combined indicator on instrument box flashes. Various errors in different assem- blies. Use the flash code table to identify and rectify errors. Flash code table Flash signal Short – Long Possible causes Remedy Chapter 1 – 1 Area affected: Monitoring of indi- cating and control elements ▪Indicator(s) or cabling faulty. ▪Insufficient con- trol unit power supply. ▪Other errors not specified in more detail. ▪Check the func- tion and cabling of the indicators. ▪Check the power supply of the control unit. 1 – 2 Area affected: Speed sensor sys- tem ▪Crankshaft or camshaft sensor cabling faulty. ▪Check the ca- bling. Faults 4H50TIC 92 Operator's Manual HATZ

Possible causes Remedy Chapter 1 – 3 Area affected: Air supply ▪Air filter is dirty. ▪Charge air after charge air cooler too high. ▪Charge air sen- sor/intake low pressure sensor cabling faulty. ▪Service the air fil- ter ▪Clean the radia- tor fins. ▪Check the ca- bling. 8.2.14 Serv- icing the air filter (option- al), page 80 8.2.6 Clean- ing the radi- ator fins, page 64 1 – 4 Area affected: Exhaust gas recir- culation ▪EGR sensor ca- bling faulty. ▪EGR radiator/ valve clogged by deposits. ▪Check the ca- bling. ▪Clean the EGR radiator/valve. 2 – 1 Area affected: Fuel low pressure system ▪Water in fuel. ▪Fuel pressure too low. ▪Fuel temperature too high. ▪Fuel pump or sensor cabling faulty. ▪Drain water from the fuel prefilter. ▪Check the fuel tank level, refuel if required. ▪Replace both fuel filters. ▪Ensure the fuel is sufficiently cooled. ▪Check the ca- bling. 8.2.11 Draining the water sepa- rator, page 73 7.7 Refuel- ing, page 49 8.2.12 Changing the fuel pre- filter, page 74 8.2.13 Changing the fuel fine filter, page 77 2 - 2 Area affected: Fuel high pressure system ▪Sensor system (injectors, rail pressure sensor, pressure control valve, high pres- sure pump) ca- bling faulty. ▪Check the ca- bling. 4H50TIC Faults HATZ Operator's Manual 93

Possible causes Remedy Chapter 2 – 3 Area affected: Engine oil tempera- ture/engine oil pressure ▪Engine oil pres- sure too high/too low. ▪Engine oil tem- perature too high. ▪Sensor cabling faulty. ▪Check the oil lev- el, top up engine oil if required. ▪Use engine oil with a suitable viscosity. ▪Check the water hoses for the oil cooler (hose kinked). ▪Clean the oil cooler if required. ▪Check the ca- bling. 7.6 Check- ing the oil level and adding oil if necessary, page 47 4.3 Engine oil, page 22 3 – 1 Area affected: Liquid cooling ▪Coolant level too low. ▪Coolant tempera- ture too high. ▪Coolant tempera- ture sensor ca- bling faulty. ▪Temperature sensor faulty. ▪Top up coolant. ▪Clean the radia- tor fins. ▪Check the ca- bling. ▪Replace the tem- perature sensor. 8.2.4 Checking the cooling system, page 57 8.2.6 Clean- ing the radi- ator fins, page 64 3 – 2 Area affected: Pre-glow system ▪Glow plugs ca- bling faulty. ▪One or multiple glow plugs faulty. ▪Glow control unit (GCU) faulty. ▪Check the ca- bling. ▪Check the func- tion of the glow plugs. Faults 4H50TIC 94 Operator's Manual HATZ

10.1 Storing the machine NOTICE Comply with the safety chapter! Follow the basic safety instructions in the chapter 3 Sicherheit, page 7. In addition, follow all safety instructions in the manufacturer doc- umentation (see the list of documentation in the Appendix). Storing the machine for a lengthy period Take the following measures if you intend to take the machine out of service for a lengthy period: Step Activity 1 Drain the fuel tank until it is nearly empty and fill with RME-free fuel. Run the engine for a few minutes so that only RME-free fuel is still in the fuel system. 2 After the machine has cooled down, cover it to protect it against dust and store it in a dry and clean place. The machine can normally be stored for up to 1 year. The protection lasts up to approx. 6 months at very high humidity and with sea air. If the storage time is longer, please contact the nearest Hatz service. 10.2 Disposing of the machine Disposal information Dispose of the machine (including machine parts, engine oil, coolant, and fuel) according to the local disposal regulations and the environmental laws in the country of use. Because of the danger of possible environmental damage, only permit an approved specialist company to dispose of the machine. 4H50TIC Storage and disposal HATZ Operator's Manual 95

that it is disposed of safely and properly, especially parts and substances that can be dangerous to the environment. These al- so include fuel, coolant, lubricants, plastics, and batteries (if present). ▪ Do not dispose of the battery with the household trash. ▪ Dispose of the battery at a collection point for possible recy- cling. Storage and disposal 4H50TIC 96 Operator's Manual HATZ