Hatz Diesel 4H50TIC Скачать руководство пользователя

Страница: 57 / 129

3 - 4H50 / 07.2015

Special tool

651 692 00

M 01 Connector housing

Place connector hous-

ing on cylinder b

loc

and tighten slightly b

hand with the three

scre

Scre

w special tool

onto cylinder b

loc

(

)

Scre

w special tool onto

connector housing

(

);

this aligns the flange

surf

ace

Tighten only the three

scre

with

10-12

Loosen scre

order to a

void distor

tion,

tighten all 19 combi

scre

ws (

Tighten special tool

with scre

again

(camshaft / cr

ankshaft

is b

loc

ed).

19x combi scre

ISO

10644 (ISO

4017

+ 10673 N)

M 8x25 - 8.8 - A3B

Содержание 4H50TIC

Страница 1: ...Workshop Manual 4H50 TIC 439 002 00 07 2015e Printed in Germany...

Страница 2: ......

Страница 3: ...etails Lubricating oil circuit Cooling circuit Sealants and adhesives Special tools and workshop equipment 2 Additional equipment Z 01 Main fuel filter Z 02 Suction hose Z 03 Oxidation catalytic conve...

Страница 4: ...7 Rocker arm M 08 Cylinder head cover Z 05 Glow plugs M 07 Thermostat temp sensor M 28 Exhaust manifold M 28 Turbocharger M 30 Lifting device M 37 Exhaust gas return M 14 Injection system M 31 Crankca...

Страница 5: ...t is a prerequisite that normal hand tools are at hand With respect to maintenance work tools troubleshooting etc we refer to the operator s manual Only use genuine Hatz original spare parts for repai...

Страница 6: ...1 3 4H50 07 2015...

Страница 7: ...1 3 4H50 07 2015 1 General...

Страница 8: ...Oil filter 8 Fine fuel filter 9 Side oil drain screw 10 Starter low installation position 11 Electric fuel pump 12 Fuel pre filter 13 Drain screw on the fuel pre filter 14 Engine type plate 15 Dipsti...

Страница 9: ...n 2 Oil filler screw top 3 Exhaust gas turbocharger 4 Oxidation catalytic converter 5 Exhaust gas discharge 6 Starter high installation position 7 Oil drain screw front 8 Poly v belt 9 Radiator option...

Страница 10: ...x 1 of fuel consumption with respect to full load Engine oil pressure 2 5 bar to 4 5 bar Coolant quantity with HATZ standard radiator and expansion tank Approx ltr 12 5 Direction of rotation when look...

Страница 11: ...CI engines Use in Constant Speed Applications only EU Type e197 68PA 2011 88 0699 01 IIIB 120R 001022 00 24R 033147 www hatz diesel com E1 187_44_C_3B The engine type plate is affixed to the crankcas...

Страница 12: ...1 Oil intake pipe 2 Oil pressure relief valve 3 Oil pump 4 Oil cooler 5 Oil filter 6 Check valve 7 Camshaft 8 Oil pressure sensor 9 Roller tappet with HVA element 10 Push rod 11 Rocker arm bearing blo...

Страница 13: ...pump intake Coolant pump Water pump pressure side EGR manifold Bypass Radiator Coolant expansion tank EGR main radiator Oil radiator EGR pre radiator Cabin heating Crank case input manifold Cylinder...

Страница 14: ...ing circuit diagram 4H50 within the engine Return coolant radiator Return expansion tank Water pump intake Bypass thermostat Water pump Water pump pressure side Crank case Input manifold Crank case ou...

Страница 15: ...circuit Cooling circuit diagram 4H50 radiator and cabin heating Intake from crank case output manifold Air vent radiator Return pipe cabin heating Supply from radiator to water pump intake Input radia...

Страница 16: ...ake EGR manifold crankcase manifold EGR Valve EGR manifold EGR pre cooler Return from EGR to coolant manifold EGR main cooler Coolant manifold Intake from EGR manifold to oil radiator Return from oil...

Страница 17: ...ives Application of sealant and adhesive material 502 230 01 Loctite Activator 500 ml 700 189 18 Loctite 243 50 ml 502 234 00 Loctite 648 10 ml 502 825 01 Silicon 30 ml 700 218 15 Silicon 300 ml 502 8...

Страница 18: ...474 00 700 113 94 702 534 99 702 534 97 702 534 98 Piston ring collet chuck 70 100mm Multi tooth wrench socket M8 Strap wrench Piston ring expander Socket wrench for cyl K E14 1 2 Socket wrench SW 27...

Страница 19: ...1 3 4H50 07 2015 1 2 3 4 5 6 7 8 9 10 11 12 13...

Страница 20: ...ssembly engine Designation 1 2 3 4 5 653 480 00 653 466 00 653 464 00 653 517 00 702 517 89 Counterholder for flywheel Assembly pin for roller tappet Magnet holder for roller tappet guide Turning devi...

Страница 21: ...1 3 4H50 07 2015 1 2 3 4 5...

Страница 22: ...50 07 2015 Special tools and workshop equipment Component servicing Designation 1 2 3 629 223 01 634 142 00 634 143 00 Valve lifting tool Honing tools 50 175 Replacement stones for honing tools Ident...

Страница 23: ...1 3 4H50 07 2015 1 2 3...

Страница 24: ...197 00 Part cannot be ordered individually please order group Part cannot be ordered individually please order group Engine mountings F2F Guard tube Adapter for guard device Base frame large Machine...

Страница 25: ...1 3 4H50 07 2015 1 2 3 1 2 4 5 6 7 10 8 9 8 9...

Страница 26: ...624 851 01 624 861 01 653 290 00 635 303 90 631 147 90 630 705 00 630 706 00 634 287 00 634 286 00 Temperature measurement device Sensor extension cable Assembly table Adapter flange 6 8 hole Driven f...

Страница 27: ...1 3 4H50 07 2015 C 1 2 3 4 6 7 8 9 5...

Страница 28: ...0 702 503 97 Revolution counter for fuel pressure pipe Part cannot be ordered individually please order group Charging cable with 12V pole clamps Part cannot be ordered individually please order group...

Страница 29: ...1 3 4H50 07 2015 7 4 2 3 5 6 11 12 10 9 8 1 2 7 13 13...

Страница 30: ...nostic equipment Designation 1 2 3 4 5 653 772 00 702 536 30 Part cannot be ordered individually please order group Part cannot be ordered individually please order group Diagnostic tool Bosch VCI BG...

Страница 31: ...1 3 4H50 07 2015 1 2 3 4 1 3 VCI 5...

Страница 32: ...1 3 4H50 07 2015 Special tools and workshop equipment Cooling system Designation 1 2 702 530 56 702 530 57 Radiator vacuum filling device Tank for filling device Ident no No...

Страница 33: ...1 3 4H50 07 2015 1 2...

Страница 34: ...1 3 4H50 07 2015 Special tools and workshop equipment Electrical equipment Designation 1 2 700 318 32 700 348 26 Crimping pliers Garant F28 95 Mounting pliers Deutsch HDT 48 00 Ident no No...

Страница 35: ...1 3 4H50 07 2015 1 2...

Страница 36: ......

Страница 37: ...2 3 4H50 07 2015 2 Additional equipment...

Страница 38: ...2 x cylinder screw M 10x30 46 Nm KRST main fi lter 2 x sealing ring A 16x22 Ring nipple KRST line Hollow screw 10 3 55 5 Nm Absolute cleanliness Protective caps may only be removed from the parts dir...

Страница 39: ...2 3 4H50 07 2015 Hexagon nut M 6 2 x cylinder screw M 6x12 9 5 Nm Bracket Cylinder screw M 6x16 9 5 Nm Pressure sensor Sleeve Adapter fittings Z 02 Suction hose...

Страница 40: ...ping flange and support 2 x washer 10 5 2 x cylinder screw M 10x30 Secure with Loctite 243 46 Nm Gasket 2 x spacers 2 x washer 10 5 2 x cylinder screw M 10x60 46 Nm Fastening 2 x washer A 8 4 2 x hexa...

Страница 41: ...belt 480 50 N Pretensioning after service 250 30 N Minimum pretensioning force 170 N Cylinder screw M 10x130 46 Nm Hexagon nut M 8 Washer B 8 4 Flange sleeve Cylinder screw M 8x35 23Nm Alternator 14V...

Страница 42: ...2 3 4H50 07 2015 Z 05 Starter Starter bracket cover 2 x washer 10 4 2 x cylinder screw M 10x35 46 Nm Starter 12V 2 2 kW 2 x washer 10 4 2 x cylinder screw M 10x45 46 Nm...

Страница 43: ...M 10x55 46 Nm 2 x cylinder screw M 10x35 in the crankcase 46 Nm 4 x cylinder screw M 10x40 in connection housing 46 Nm 3 x engine base Cover plate with oil filler and engine base O ring 7x2 FPM Apply...

Страница 44: ...2 3 4H50 07 2015 Threaded pin M 8x10 Oil cooler_KTR Double nipple Secure with Loctite 648 40 Nm Throw away filter 10 Nm Z 07 Oil cooler...

Страница 45: ...Shaped hose piece fastened with 2 x hose clamp DIN 3017 A 12 22x9 3 Nm 1 x hose clamp DIN 3017 A 16 27x12 5 Nm 1 x hose clamp DIN 3017 A 20 32x13 5 Nm Pipe clamp RSGU 1 25 15 Washer 6 4 Hexagon bolt...

Страница 46: ...2 3 4H50 07 2015 Exhaust fan 3 x spring washer A 6 3 x cylinder screw M 6x35 9 5 Nm Spacer for fan Z 30 Fan...

Страница 47: ...3 3 4H50 07 2015 3 Basic engine equipment...

Страница 48: ...3 3 4H50 07 2015 M 01 Cylinder crankcase Dipstick complete Oil pressure sensor DS M1 TF 37 5 Nm Check valve Heed installation posi tion...

Страница 49: ...spring Sealing ring A 24x29 Screw plug M 24x1 5 100 10 Nm Secure tube connectors with Loctite 648 and press into cylinder block up to the stop Secure check valve Provent with Loctite 243 12 5 2 5 Nm S...

Страница 50: ...3 3 4H50 07 2015 Oil spray nozzle Valve screw N8 27 2 Nm Piston cooling complete M 01 Cylinder crankcase...

Страница 51: ...in bearing halves into cylinder block main bearing bracket and moisten with engine oil Heed the correct posi tion of the oil holes and the position groove Insert thrust washer with grease Oil pockets...

Страница 52: ...gh correct mounting of the main bearing bracket with thrust washers Before tightening the screws on the main bearing bracket put the crankshaft and the main bearing bracket in the specified direction...

Страница 53: ...3 3 4H50 07 2015 3 1 5 7 9 4 2 6 8 10 M 02 Crankshaft Tighten main bearing bracket in the specified sequence Tightening torque 1st level 10 Nm 2nd level 45 Nm 3rd level 90 Nm...

Страница 54: ...ar ing points with engine oil and insert camshaft into cylinder block M 04 Camshaft Cylinder pin 8 x 50 Threaded pin M10 x 10 Mount with Loctite 243 Tighten threaded pin up to stop max 5 Nm then loose...

Страница 55: ...3 4H50 07 2015 M 02 Crankshaft gear wheel Place crankshaft gear wheel on crankshaft heeding the correct positioning of the mark ings Press spring pin into crankshaft gear wheel to specified dimension...

Страница 56: ...3 3 4H50 07 2015 Apply sealing agent Loctite 5910 according to the black curve M 01 Connector housing WDRI 55x70x8 Oil slightly and press in until flush with flange surface...

Страница 57: ...al tool onto cylinder block 2 23 Nm Screw special tool onto connector housing 3 23 Nm this aligns the flange surface Tighten only the three screws 1 with 10 12 Nm Loosen screws 3 in order to avoid dis...

Страница 58: ...amaged by the sprocket Keep soiling to a mini mum Front side is magnetic Avoid contact with iron particles M 17 Flywheel Speed sensor DG6 S for flywheel Cylinder screw M 6x20 8 8 9 5 Nm Sprocket Mount...

Страница 59: ...5x10 8 8 5 5 Nm Bulkhead Rotor set M 10 Oil pump Rope seal Grease slightly for mounting 2x spring pin 8x8 Cover for oil pump WDRI 40x62x7 Grease slightly for mounting and press in flush with housing 8...

Страница 60: ...4H50 07 2015 Special tool 651 692 00 Remove after tighten ing the pulley Z 30 Pulley Pulley crankshaft 103 PK6 Bevel to the crankshaft Tension washer 16 Cylinder screw M 16x1 5x40 LH Left thread 200...

Страница 61: ...0 heed notch for oil spray nozzle Tighten conrod screws 20 Nm 65 M 05 Piston and conrod Connect piston to con rod position grooves of the conrod bearing and notch for the oil spray nozzle on the pisto...

Страница 62: ...3 3 4H50 07 2015 Intake manifold complete 2 x cylinder screw M 8x16 8 8 Glued in with Loctite 243 23 Nm M 10 Intake manifold Apply surface sealant Loctite 5910 here...

Страница 63: ...ning Cu sealing ring Magnet screw plug AM 22x1 5 50 Nm M 01 Oil sump Apply surface sealant Loctite 5910 here ac cording to the red area 2nd screw connection long hole serves the alignment Combi screw...

Страница 64: ...3 3 4H50 07 2015 2 x spring pin 8x8 first mount in crank shaft Cylinder screw M 6x20 9 5 Nm Phase encoder for NW 11x cylinder screw M 6x20 9 5 Nm M 36 Water pump...

Страница 65: ...Insert guide pins with special tool 653 464 00 into crankcase Ensure with a slight turning of the roller tap pet that the guide pin is in the groove of the roller tappet Threaded pin M 10x10 Mount wit...

Страница 66: ...lve cone MK6 Plate spring Valve spring inlet outlet Valve spring outlet Valve shaft seal Plate for valve spring Valve disk inlet Valve disk outlet Insert and remove valves with special tool 629 223 01...

Страница 67: ...74 00 and select cylinder head seal according to table M 07 Cylinder head Choosing the right cylinder head seal engine H50 Gap 0 6 0 7 projecting measurement Gap SM mm projecting measurement of the pi...

Страница 68: ...ombi screw M 12x130 Tightening process 1 10 1st stage 20 2 Nm 2ndstage 75 5 3rdstage 75 5 greased with TA White Cylinder screw M 6x80 Tightening process 11 14 9 5 Nm 1 5 7 3 9 2 4 8 6 10 12 11 13 14 M...

Страница 69: ...cker arm bearing block with axle Rocker arm outlet com plete Locking ring A 18x1 M 07 Rocker arm Rocker arm inlet com plete Locking ring A 18x1 as needed Adjusting ring 15x21x0 2 Adjusting ring 15x21x...

Страница 70: ...the lock nut and turn adjusting screw in until the calotte of the ad justing screw lies against the spherical head of the push rod From this position turn the adjusting screw 1 1 4 turns in and secure...

Страница 71: ...3 3 4H50 07 2015 Hexagon bolt M 6x20 F A3B 9 5 Nm Cylinder head cover Paper seal for the cylinder head cover M 08 Cylinder head cover Screw plug for oil filler with RK ring 26x35x3 tighten hand tight...

Страница 72: ...3 3 4H50 07 2015 Hexagon nut M 4 max 2 5 Nm Washer 4 3 Pencil glow plug GLP 2 11V apply high temperature paste 10 15 Nm Z 05 Glow plugs...

Страница 73: ...5 Housing thermostat Washer 6 4 Hexagon bolt M 6x25 M 07 Thermostat temp sensor Temperature sensor TS cooling water max 25 Nm O ring 58x2 Only fasten with silicone grease OPTISIL FM High temperature s...

Страница 74: ...3 3 4H50 07 2015 Gasket installation position the raised side of the bead must point towards the exhaust manifold Hexagon nut VM 8 25 2 Nm Sealing ring Screw plug G 1 4 30 Nm M 28 Exhaust manifold...

Страница 75: ...45 Nm M 28 Turbocharger Hollow screw 6 S 10 Nm 2 x sealing ring A 10x13 5 2 x sealing ring A 12x15 5 Hollow screw M 12x1 5 26 Nm Pressure oil line Turbocharger Gasket for the turbo charger position f...

Страница 76: ...3 3 4H50 07 2015 Lifting eye 2 x cylinder screw M 8x20 23 Nm M 30 Lifting device...

Страница 77: ...nd the housing with bracket must first be pre mounted with out tightening and then tightened in the speci fied sequence Washer 10 5 2 x hexagon bolt M 10x70 A3C 2 x cylinder screw M 8x25 A3C 23 Nm Con...

Страница 78: ...3 4H50 07 2015 2 x gasket AGR cooler Heed installation posi tion marking 4 x cylinder screw M 8x25 A3C Bracket 4 x cylinder screw M 8x20 A3C 2 x hexagon nut VM 8 Housing Gasket M 37 Exhaust gas retur...

Страница 79: ...gas return Tightening sequence Position 1 2 x hexagon nut VM 8 23 Nm Position 2 2 x cylinder screw M 8x25 23 Nm Position 3 2 x cylinder screw M 8x25 23 Nm Position 4 2 x hexagon bolt M 10x70 46 Nm Pos...

Страница 80: ...015 4 x cylinder screw M 5x12 5 5 Nm Bar AGR valve 2 x hexagon bolt M 6x16 9 5 Nm O ring 8x2 Shaped hose piece 16x4 5 2 x hose clamp 12x22x9 Shaped hose piece 22x4 5 2 x hose clamp 20x32x13 M 37 Exhau...

Страница 81: ...7 2015 Hose clamp with wave spring Shaped hose piece 45 x 5 Hose clamp with wave spring Cylinder screw M 5x16 5 5 Nm Washer 5 3 Pressure temp sensor DS S3 TF for charge air Sensor holder M 37 Exhaust...

Страница 82: ...fastened properly before start up If necessary injector specific data such as the IMA code must be transferred to the control unit These serve the correct activation of the injectors and thus the inte...

Страница 83: ...ounting aids The mounting of the return line on the engine is done by hand Mounting Plug return plug on injector return connection until contact of the contact surface is on the injector picture 1 The...

Страница 84: ...he position CP4 marking visible through inspection hole in the connection housing The marking on the high pressure pump is now in the position shown This is the basic position for the mounting of the...

Страница 85: ...3 3 4H50 07 2015 Fuel line mount on the return connection before installation of the high pressure pump High pressure pump CP4 3 x hexagon bolt with flange M 8x30 23 Nm M 14 Injection system...

Страница 86: ...Fuel line Washer 8 1x20x3 Hexagon nut M 8 Lug Fuel pressure tube 10 Nm 60 rail side 15 Nm 60 pump side 2 x cylinder screw M 8x20 23 Nm High pressure rail 2 x hexagon bolt with flange M 8x30 23 Nm M 14...

Страница 87: ...4H50 07 2015 Fuel pressure tube Cylinder 3 4 10 Nm 60 Fuel pressure tube Cylinder 1 2 10 Nm 60 Fuel return line CR injector Hexagon nut M 8 23 Nm Bushing for injector Clamping claw M 14 Injection sys...

Страница 88: ...2015 Provent 100 with exchangeable oil sepa rator Shaped hose piece 2 x hexagon bolt with flange M 8x30 23 Nm 2 x wire hose clamp ID 23x1 Shaped hose piece 2 x wire hose clamp ID 18x1 M 31 Crankcase...

Страница 89: ...4 3 4H50 05 2016 4 Tables...

Страница 90: ...4 3 4H50 05 2016...

Страница 91: ...tightening torque 8 8 5 8 10 9 12 9 Thread Screw quality M 4 M 5 M 6 M 8 M10 M12 M14 M16 M18 M20 M22 1 7 3 4 6 0 14 29 50 80 120 170 240 320 2 8 5 5 9 5 23 46 80 130 190 270 380 510 3 9 7 8 13 33 65...

Страница 92: ...4 3 4H50 05 2016 Screw tightening torque...

Страница 93: ...4 3 4H50 05 2016 Screw tightening torque...

Страница 94: ...r Indicator light for alternator control Indicator light for oil pressure Indicator light for engine temperature Indicator light for air filter maintenance switch Indicator light for belt break Indica...

Страница 95: ...for speed adjustment Temperature switch for engine temperature Oil pressure switch Pressure switch for air filter Fan monitoring switch Temperature switch for pre glowing Remote start switch Remote s...

Страница 96: ...eed fine adjustment 12 Oil pressure sensor 13 Reserved for special application 14 Speed adjustment magnet excitation circuit 15 Reserved for special application 16 Lift magnet for decompression 17 Mai...

Страница 97: ...CRankshaft Speed Sensor ATS B8 Ansaugluft Temperatur Sensor Air Temperature Sensor WFS B9 Wasser im Kraftstoff Sensor Water in Fuel Sensor CLS S7 K hlmittel Niveau Sensor Coolant Level Sensor AFDPS B1...

Страница 98: ...t c h F T L S W 2 F u e l t a n k l e v e l s e n s o r 2 E N G N E n g i n e s p e e d o u t p u t C O N V C l u t c h s w i t c h K 6 8 R H 2 2 S w i t c h e d b a t t e r y U B 2 H i g h s i d e d...

Страница 99: ...n s o r W F S W a t e r i n f u e l l e v e l s e n s o r E G R P S E G R P 3 d i f f e r e n t i a l p r e s s u r e s e n s o r S T R T L P S P R L Y 1 S t a r t r e l a y e l e c t r i c f u e l p...

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Страница 110: ...Pin No Pin assignment Pin 1 Supply B cc 2 Supply B dd 3 CAN high aa 4 CAN low bb 5 shield 6 not assigned sensor output signal motor connector Customer control unit Connection CAN speed adjustment cust...

Страница 111: ...rotary knob Pin No Pin assignment Farbe Pin Signal 1 1 Voltage supply 5 V Rot A 2 Ground Blau C 4 Signal 0 5 V 4 5 V Braun B Signal 2 6 Voltage supply 5 V Orange D 5 Ground Schwarz F 3 Signal 0 25 V 2...

Страница 112: ...4 3 4H50 05 2016...

Страница 113: ...4 3 4H50 05 2016...

Страница 114: ...4 3 4H50 05 2016 Cable routing DPF...

Страница 115: ...4 3 4H50 05 2016 Cable routing...

Страница 116: ...4 3 4H50 05 2016 Cable routing...

Страница 117: ...4 3 4H50 05 2016 Cable routing...

Страница 118: ...4 3 4H50 05 2016 Cable routing...

Страница 119: ...4 3 4H50 05 2016 Cable routing...

Страница 120: ...4 3 4H50 05 2016 Cable routing...

Страница 121: ...4 3 4H50 05 2016 Cable routing...

Страница 122: ...4 3 4H50 05 2016 Cable routing...

Страница 123: ...4 3 4H50 05 2016 Cable routing...

Страница 124: ...4 3 4H50 05 2016 Cable routing...

Страница 125: ...4 3 4H50 05 2016 Cable routing...

Страница 126: ...4 3 4H50 05 2016 Cable routing...

Страница 127: ...ror Water in fuel pressure too low fuel temperature too cabling pump or sensor faulty Remedies Drain water at fuel pre check tank contents or replace clogged fuel ensure cooling of the check cabling 2...

Страница 128: ...4 3 4H50 05 2016 Charge current curve 12 V Charge current A Engine speed rpm Ambient temperature 25 C Ambient temperature 80 C...

Страница 129: ...4 3 4H50 05 2016 Charge current curve 24 V Charge current A Engine speed rpm Ambient temperature 25 C Ambient temperature 80 C...

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