BW216 219DH 4 Service Training

Service Training

Single Drum Rollers

BW 216 DH / PDH - 4

08/2005

Part-No. 008 097 20

BW 219 DH / PDH - 4

BW 226 DH / PDH - 4

Service Training

Table of contents

Technical data and adjustment values B 1

Maintenance C 1

Maintenance chart and table of fuels and lubricants C2

DEUTZ diesel engine 2012C with EMR D 1

Service side D 2

Starter side D 3

Lubrication oil circuit D 4

Coolant circuit D 5

Fuel system D 6

EMR D10

Trouble shooting D22

Diagnostics SERDIA D24

Checking and adjusting the valve clearance D26

Assembly of plug-type injection pump D28

Engine components D44

Travel system E 1

Travel pump E 3

Control E 7

Charge pressure relief valve E 8

High pressure relief valve E 9

Pressure override valve E11

Axle drive motor E14

Drum drive motor E17

Test and adjustment points, travel system E19

Service Training

BW 216 / 219 / 226 DH / PDH -4

Vibration F 1

Vibration pump F 3

High pressure relief valves F 6

Control F 7

Vibration motor F 8

Drum F11

Test and adjustment points, vibration system F13

Trouble shooting vibration F15

Steering G 1

Charge pump G 2

Steering pump G 3

Steering valve G 5

Articulated joint G 7

Measuring and adjustment points G 9

Trouble shooting steering G10

Electrics H 1

Wiring diagram

Service Training

Foreword and new features

Reliable construction equipment is of greatest advantage for all parties involved:

• for the customer/user it is a basis for an exact calculation of utilization periods and the completion of projects as scheduled.

• in the rental business it means that the equipment can be reliably used and planned without having to stock a large number of stand-by machines.

• for the manufacturer it means that customers are satisfied, provides him with a good image and gives him a feeling of confidence.

It is BOMAG’s philosophy to design and produce the machines with highest possible reliability. This aspect of simple and easy maintenance was one of the key issues when developing and designing the machine:

• the location of components in the machine eases maintenance work,

• the high quality standard of BOMAG is the basis for the considerable extension of the service and maintenance intervals.

• the After Sales Service of BOMAG, including excellent operating and maintenance instruction manuals, high quality training courses and on-site machine demonstrations helps the customer to maintain their machines in good condition over a long period of time.

Permanent training of BOMAG’s own service personnel as well as the service personnel of BOMAG Profit Centres and dealers is therefore a general prerequisite for BOMAG’s excellent world-wide service. This program of permanent training is only possible with appropriate and up-to-date training material for trainers as well as persons attending the training courses.

This training manual has not only been written as a support for the professional work of the trainer, but also for the trainees attending these training courses.

The different levels of product training demand, that the training performed by BOMAG, its Profit Centres or its dealers reflects the high quality of the training conducted at the Training Centre at BOMAG in Boppard. For this reason we invested a lot of time in the preparation of these materials .

The structure of this training manual enables us to change or up-date individual chapters in case of alterations to the machine.

Service Training

BW 216 / 219 / 226 DH / PDH -4 A 2

-Documentation

This Service Training is valid for the following BOMAG single drum rollers of series 4:

BW 216 DH / PDH -4

BW 219 DH / PDH-4

BW 226 DH / PDH-4

with Deutz diesel engine BF6M 2012C EMR

For the BOMAG machines described in this training manual the following documentation is additionally available:

1. Operating and maintenance instructions

2. Spare parts catalogue

3. Wiring diagram *

4. Hydraulic diagram *

5. Repair instructions

6. Service Information

* The document versions valid at the date of printing are part of this training manual.

Attention!

The currently valid part numbers for the documents can be taken from the Doclist or the Customer Service page in the BOMAG (BOMAG Secured Area) in accordance with the serial number of the machine.

Service Training

General

The new BOMAG single drum rollers of series 4 are mainly further developments of their predecessors of series 3.

These machines have been successfully and reliably used for years on construction sites all over the world, especially in earth construction and on sanitary landfill sites.

High compaction power and excellent traction are characteristics, which are of utmost importance for this type of machine.

All components installed in these machines are manufactured in series production and are subjected to stringent quality tests. This guarantees a high level of reliability and safety.

As with many other BOMAG products, and here especially with the large single drum rollers of the new generation, we have decided to use the same successful drive concept with diesel engine (water cooled) and hydrostatic drives also for these machines. The hydrostatic drives transfer the output power of the engine directly to drum, drive wheels and steering.

The drive wheels are driven by fast rotating hydraulic motors and axle, whereas the drum is driven by slow running radial piston motors.

On construction machines the work place of the operator is of utmost importance. Under such working conditions the health and safety of the operator must be the greatest concern.

The cabin is very spacious and clearly arranged. The driver’s seat is very comfortable and can be individually adjusted for every operator, even for his weight.

All control elements and gauges are within the reach and in the sight of the operator.

A monitoring display with light emitting diodes and clear pictograms informs the operator about any operating faults. The operator is therefore always informed about the present condition of the machine. The generously glazed cabin with windscreen wiper and washer systems for front and rear windscreens, as well as a heated rear windscreen, offers clear vision to all sides.

Service Training

BW 216 / 219 / 226 DH / PDH -4 A 4

-Important characteristics of the new generation of single drum rollers are • strong ROPS/FOPS according to SAE-standard

• wear free service brake by closed hydrostatic travel circuits

• disc brakes in axle and drum drive motor serve as parking and emergency brakes • high stability due to low centre of gravity and the use of an articulated joint

• operating safety due to the use of monitoring boards for all important system data • automatic engine shut down after 15 seconds, if the engine temperature is too high • automatic engine shut down after 10 seconds, if the coolant level is too low

and the engine oil pressure is too low.

The single drum rollers of series 4 are well designed down to the smallest detail, so that they can meet the toughest demands on large scale construction sites all over the world.

Service Training

New features

The multi-function travel lever and the display

Back

Front

up

Service Training

BW 216 / 219 226 DH / PDH 4 A

Service Training

Vibr. Taste Vibr. button

Links Left

Ab Down

INFO Teste 1 INFO button 1

INFO Taste 2 INFO button 2

Translation:

Fahrhebel Travel lever

Datensammler Data collector

Luftfilter Air filter

Blink. L Indic. l

Blink. R Indic. r

Licht an Lights on

D+ Signal D+ signal

Hyd. Ölfilt. Hyd. oil filter

Hyd. Temp. Hyd. temp.

Klimaanl. Aircon

Ampere Ampere

Wasserab. Water separ.

Kühl. Füll. Coolant level

Fahrhebel Travel lever

Stufenschalter Speed range switch

Sitzkontaktschalter Seat contact switch

Drucksensor Pressure sensor

Verstellung Control

Sensor Sensor

Vorderrahmen Front frame

Hinterrahmen Rear frame

Verstellung Control

Fahrmotor vorne Front travel motor

Neigungssensor Inclination sensor

Sensor Sensor

Verstellung Control

Fahrmotor hinten Rear vtravel motor

Service Training

BW 216 / 219 / 226 DH / PDH 4 A

Service Training

Service Training

BW 216 / 219 / 226 DH / PDH -4 B 1

-Technical data and adjustment values

The following pages contain technical data valid at the date of printing (see front page of this manual). Attention!

The currently valid technical data and adjustment values can be taken from the BOMAG Intranet or Extranet (BOMAG Secured Area) in accordance with the serial number of the machine.

BOMAG Central Service - Technical data and adjustment values

Product type:

BW 216 DH Serie 4

Type No.: 582 60

Serial numbers from: 101 582 60 1001

Engine:

Type: BF6M2012C

Combustion principle: 4-stroke-Diesel

Cooling: Water

Number of cylinders: 6 Power acc. to ISO 9249: 147 kW Power data at nominal speed of: 2300 1/min Low idle speed: 850+/-150 1/min High idle speed: 2475+/-125 1/min Spec. fuel consumption: 222 g/kWh Valve clearance, inlet: 0,3 mm Valve clearance, outlet: 0,5 mm Opening pressure, injection valves: 250 bar

Starter voltage: 12 V

Starter power: 3,1 kW

Travel pump:

Type: 90R 075 (EP)

System: Axial piston-swash plate

Max. displacement: _{75 cm}3_/U

Max. flow ratio: 75ccm x n l/min High pressure limitation: 400 bar

Charge pressure, high idle: 25+/-1 bar

Reduction gear, drum:

Type: CR 51

Transmission ratio: 73,5

Travel motor, rear:

Type: 51D110 (EP)

System: Axial piston-bent axle

Max. displacement (stage 1): _{110 cm}3_/U

Min. displacement (stage 2): _{55,3 cm}3_/U

Perm. leak oil quantity: 2 + 10 l/min Rinsing oil quantity: 10 l/min Rinsing oil pressure limitation: 16 bar

Drum drive:

Type: 51C 110 (EP)

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BOMAG Central Service

110 cm3_/U

Displacement stage 2: _{31,4 cm}3_/U

Perm. leak oil quantity: 2 + 10 l/min Rinsing oil quantity: 10 l/min Rinsing oil pressure limitation: 16 bar

Vibration pump:

Type: 90R 075 (EP)

System: Axial piston-swash plate

Max. displacement: _{75 cm}3_/U

Starting pressure: 365+/-65 bar Operating pressure, soil dependent: ca.100 bar

Vibration motor:

Type: A2FM 56 HDD

System: Axial piston-bent axle

Displacement: 56 cm3_/U

Frequency: 31 / 36 Hz

Amplitude: 2,0/0,9 mm

Rinsing oil quantity: 6 l/min Rinsing oil pressure limitation: 13 bar

Steering and charge pump:

Type: HY/ZFS11/16

System: Gear pump

Displacement: _{16 cm}3_/U

Max. steering pressure: 175+26 bar

Rear axle:

Filling capacities:

Engine coolant: 16 l (50% Water, 50% Anti-freeze agent on Ethane-diol-basis)

Engine oil: 12,5 l (SAE 15W-40, API CG-4 (for details see maintenance manual))

Hydraulic oil: 60 l (HVLP 46 VI 150)

Vibration bearing housing: 2x 0,8 l (SAE 15W-40, API SJ/CF) Rear axle: 11 l (SAE 90 EP, API GL 5) Rear axle wheel hubs: 2 l (SAE 90 EP, API GL 5) Rear axle, transmission: 1,9 l (SAE 90 EP, API GL 5) Reduction gear, drum: 3,2 l (SAE 90 EP, API GL 5) AC refrigerant: 1400 g (R 134a)

Compressor oil (filling the system): 100 ml (PAG Öl)

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05.08.2005

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BOMAG Central Service - Technical data and adjustment values

Product type:

BW 219 DH Serie 4

Type No.: 582 70

Serial numbers from: 101 582 70 1001

Engine:

Type: BF6M2012C

Combustion principle: 4-stroke-Diesel

Cooling: Water

Number of cylinders: 6 Power acc. to ISO 9249: 147 kW Power data at nominal speed of: 2300 1/min Low idle speed: 850+/-150 1/min High idle speed: 2475+/-125 1/min Spec. fuel consumption: 222 g/kWh Valve clearance, inlet: 0,3 mm Valve clearance, outlet: 0,5 mm Opening pressure, injection valves: 250 bar

Starter voltage: 12 V

Starter power: 3,1 kW

Travel pump:

Type: 90R 100 EP

System: Axial piston-swash plate

Max. displacement: _{100 cm}3_/U

Max. flow ratio: 100ccm x n l/min High pressure limitation: 435 +/-15 bar Charge pressure, high idle: 26+/-1 bar

Reduction gear, drum:

Type: CR 51

Transmission ratio: 73,5

Travel motor, rear:

Type: 51D110 (EP)

System: Axial piston-bent axle

Max. displacement (stage 1): _{110 cm}3_/U

Min. displacement (stage 2): _{55,3 cm}3_/U

Perm. leak oil quantity: 2 + 10 l/min Rinsing oil quantity: 10 l/min Rinsing oil pressure limitation: 16 bar

Drum drive:

Type: 51C 110 (EP)

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BOMAG Central Service

110 cm3_/U

Displacement stage 2: _{31,4 cm}3_/U

Perm. leak oil quantity: 2 + 10 l/min Rinsing oil quantity: 10 l/min Rinsing oil pressure limitation: 16 bar

Vibration pump:

Type: 90R 075 (EP)

System: Axial piston-swash plate

Max. displacement: _{75 cm}3_/U

Starting pressure: 365+/-65 bar Operating pressure, soil dependent: ca.100 bar

Vibration motor:

Type: A2FM 63 HDD

System: Axial piston-bent axle

Displacement: 63 cm3_/U

Frequency: 26 / 31 Hz

Amplitude: 2,0/0,9 mm

Rinsing oil quantity: 6 l/min Rinsing oil pressure limitation: 13 bar

Steering and charge pump:

Type: HY/ZFS11/16

System: Gear pump

Displacement: _{16 cm}3_/U

Max. steering pressure: 175+26 bar

Rear axle:

Filling capacities:

Engine coolant: 16 l (50% Water, 50% Anti-freeze agent on Ethane-diol-basis)

Engine oil: 12,5 l (SAE 15W-40, API CG-4 (for details see maintenance manual))

Hydraulic oil: 60 l (HVLP 46 VI 150)

Vibration bearing housing: 2x 0,8 l (SAE 15W-40, API SJ/CF) Rear axle: 11 l (SAE 90 EP, API GL 5) Rear axle wheel hubs: 2 l (SAE 90 EP, API GL 5) Rear axle, transmission: 1,9 l (SAE 90 EP, API GL 5) Reduction gear, drum: 3,2 l (SAE 90 EP, API GL 5) AC refrigerant: 1400 g (R 134a)

Compressor oil (filling the system): 100 ml (PAG Öl)

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BOMAG Central Service - Technical data and adjustment values

Product type:

BW 226 DH Serie 4

Type No.: 582 80

Serial numbers from: 101 582 80 1001

Engine:

Type: BF6M2012C

Combustion principle: 4-stroke-Diesel

Cooling: Water

Number of cylinders: 6 Power acc. to ISO 9249: 147 kW Power data at nominal speed of: 2300 1/min Low idle speed: 850+/-150 1/min High idle speed: 2475+/-125 1/min Spec. fuel consumption: 222 g/kWh Valve clearance, inlet: 0,3 mm Valve clearance, outlet: 0,5 mm Opening pressure, injection valves: 250 bar

Starter voltage: 12 V

Starter power: 3,1 kW

Travel pump:

Type: 90R 100 EP

System: Axial piston-swash plate

Max. displacement: _{100 cm}3_/U

Max. flow ratio: 100ccm x n l/min High pressure limitation: 435 +/-15 bar Charge pressure, high idle: 26+/-1 bar

Reduction gear, drum:

Type: 715 C 3B

Transmission ratio: 129,2

Travel motor, rear:

Type: 51D110 (EP)

System: Axial piston-bent axle

Max. displacement (stage 1): _{110 cm}3_/U

Min. displacement (stage 2): _{55,3 cm}3_/U

Perm. leak oil quantity: 2 + 10 l/min Rinsing oil quantity: 10 l/min Rinsing oil pressure limitation: 16 bar

Drum drive:

Type: 51C 110 (EP)

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BOMAG Central Service

110 cm3_/U

Displacement stage 2: _{31,4 cm}3_/U

Perm. leak oil quantity: 2 + 10 l/min Rinsing oil quantity: 10 l/min Rinsing oil pressure limitation: 16 bar

Vibration pump:

Type: 90R 075 (EP)

System: Axial piston-swash plate

Max. displacement: _{75 cm}3_/U

Starting pressure: 365+/-65 bar Operating pressure, soil dependent: ca.100 bar

Vibration motor:

Type: A2FM 80 HDD

System: Axial piston-bent axle

Displacement: 80 cm3_/U

Frequency: 26 / 26 Hz

Amplitude: 2,1/1,1 mm

Rinsing oil quantity: 6 l/min Rinsing oil pressure limitation: 13 bar

Steering and charge pump:

Type: HY/ZFS11/16

System: Gear pump

Displacement: _{16 cm}3_/U

Max. steering pressure: 175+26 bar

Steering valve:

Type: OSPC 500 ON

System: Rotary valve

Rear axle:

Filling capacities:

Engine coolant: 16 l (50% Water, 50% Anti-freeze agent on Ethane-diol-basis)

Engine oil: 12,5 l (SAE 15W-40, API CG-4 (for details see maintenance manual))

Hydraulic oil: 60 l (HVLP 46 VI 150)

Vibration bearing housing: 2x 0,8 l (SAE 15W-40, API SJ/CF) Rear axle: 11 l (SAE 90 EP, API GL 5) Rear axle wheel hubs: 2 l (SAE 90 EP, API GL 5) Rear axle, transmission: 1,9 l (SAE 90 EP, API GL 5)

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Service Training

Maintenance

Single drum rollers are heavy-duty construction machines for extremely difficult tasks in earth

construction. To be able to meet these demands the machines must always be ready to be loaded up to their limits. Furthermore, all safety installations, protections and guards must always be in place and fully functional.

Thorough maintenance of the machine is therefore mandatory. This not only guarantees a remarkably higher functional safety, but also prolongs the lifetime of the machine and of important components. The time required for thorough maintenance is only minor when being compared with the malfunctions and faults that may occur if these instructions are not observed.

The maintenance intervals are given in operating hours. It is quite obvious that with each maintenance interval all the work for shorter preceding intervals must also be performed. During the 2000 hours interval you must also perform the work described for the service intervals after 50, 250 and 500 hours. During maintenance work you must only use the fuels and lubricants mentioned in the table of fuels and lubricants (oils, fuels, grease etc.).

The designation specified under No: in the first column of the maintenance chart refers to the corresponding number of the service work to be performed, as specified in the operating and maintenance instructions. This also helps to find detailed information on the individual maintenance tasks.

Maintenance

BOMAG

82 BW 216 DH-4

5.3

Table of fuels and

lubri-cants

Assembly Fuel or lubricant Quantity approx.

Summer Winter Attention

Observe the level marks

Engine Engine oil ACEA: E3-96/E5-02 or approx. 12,5 litres without

oil filter API: CG-4/CH-4 SAE 10W/40 (-20 °C to +40 °C) SAE 15W/40 (-15 °C to +40 °C) Fuel

Diesel Winter diesel fuel approx. 300 litres

Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity approx. 60 litres

46 mm2/s at 40 °C

Vibration bearings Engine oil SAE 15W/40 approx. 2x0.8 litres

Drive axle Gear oil SAE 90, API GL5 approx. 11 litres

Wheel hubs Gear oil SAE 90, API GL5 approx. 2.9 per side

Axle reduction gear Gear oil SAE 90, API GL5 approx. 1,9 litres

Drum drive gear Gear oil SAE 90, API GL5 approx. 2,8 litres

Air conditioning system Refrigerant R134A 1400 g

Engine cooling system Cooling system protection agent approx. 16 litres

Tires Water approx. 195 litres

Calcium chloride (CaCl2) or magnesium chloride

(MgCl2)

Maintenance

5.4

Running-in instructions

The following maintenance work must be per-formed when running in new machines or overhauled engines:

! Caution

Up to approx. 250 operating hours check the engine oil level twice every day.

Depending on the load the engine is subjected to, the oil consumption will drop to the normal level after approx. 100 to 250 operating hours. After a running-in time of 30 minutes

l Retighten the V-belt

After 250 operating hours

l Retighten bolted connections on intake and exhaust tubes, oil sump and engine mounts.

l Retighten the bolted connections on the ma-chine.

l Retighten all wheel fastening screws with the specified tightening torque.

l 1. Oil change vibration bearings

l Oil change in drive axle

l Oil change in wheel hubs

l Oil change, axle reduction gear

l 1. Oil change, drum drive reduction gear

After 500 operating hours

l 2. Oil change vibration bearings

Maintenance

BOMAG

84 BW 216 DH-4

5.5

Maintenance chart

No. Maintenance work Remark

R u nn in g-in in s truc ti on s af te r 2 50 o p e ra ti n g h o u rs e v e ry 1 0 o p e ra ti ng ho ur s , da il y e very 250 o p erati n g h o u rs e very 500 o p erati n g h o u rs e very 1000 o p erati n g h o u rs e very 2000 o p erati n g h o u rs e very 3000 o p erati n g h o u rs as re q u ir e d

5.6 _{Check the engine oil level Dipstick mark X}

5.7 _{Check the water separator X}

5.8 _{Check the fuel level X}

5.9 _{Check the hydraulic oil level Inspection glass X}

5.10 Check the coolant level Inspection glass X

5.11 Check the dust separator X

5.12 Check the tire pressure X

5.13 Clean the cooling fins on engine and hydraulic oil cooler

X

5.14 Check the oil level in the drive axle X

5.15 Check the oil level in the wheel hubs X

5.16 Check the oil level in the axle reduc-tion gear

X 5.17 Check the oil level in the drum

reduc-tion gear

X 5.18 Check the oil level in the vibration

bearings

X 5.19 Change engine oil and oil filter

car-tridge*

min. 1x per year X

5.20 Change the fuel filter cartridge X

5.21 Drain the sludge from the fuel tank X

5.22 Service the battery Pole grease X

Maintenance

5.24 Check, replace the refrigerant com-pressor V-belt

X

5.25 Service the air conditioning X

5.26 Check, adjust the valve clearance Intake = 0,3 mm Exhaust = 0,5 mm

X

5.27 Check, replace the ribbed V-belt X

5.28 Check the engine mounts X X

5.29 Oil change in drive axle min. 1x per year X X

5.30 Oil change in wheel hubs min. 1x per year X X

5.31 Oil change, axle reduction gear min. 1x per year X X

5.32 Oil change in drum drive reduction gear**

min. 1x per year X X

5.33 Oil change vibration bearings** _{see foot note, min. 1}

x per year

X X

5.34 Retighten the fastening of the axle on the frame

X

5.35 Tighten the wheel nuts X X

5.36 Check the ROPS X

5.37 Clean the oil bath air filter min. 1x per year X

5.38 Change hydraulic oil and breather fil-ter***

at least every 2 years

X 5.39 Change the hydraulic oil filter**** _{at least every 2}

years

X

5.40 Change the coolant at least every 2

years

X

5.41 Check the injection valves X

No. Maintenance work Remark

R u nn in g-in in s tru c ti o n s after 250 o p erati n g h o u rs ever y 1 0 o p e ra ti n g h o u rs, d a il y ever y 2 50 o p er ati n g h o u rs ever y 5 00 o p er ati n g h o u rs ever y 1 000 o p e rati n g h o u rs ever y 2 000 o p e rati n g h o u rs ever y 3 000 o p e rati n g h o u rs as req u ired

Maintenance

BOMAG

86 BW 216 DH-4

5.42 Service the combustion air filter min. 1x per year, safety cartridge at least every 2 years

X

5.43 Adjusting the scrapers X

5.44 Adjust the parking brake X

5.45 Change the tires X

5.46 Change the fresh air filter in the cabin X

5.47 Tightening torques X

5.48 Engine conservation X

* Oil change intervals depend on quality of oil and fuel (sulphur content)

** Oil change intervals after 50 h, after 500 h, after 1000 h, and then every 1000 h. *** Also in case of repair in the hydraulic system.

**** Also in case of repair in the hydraulic system.

No. Maintenance work Remark

R u nn in g-in in s tru c ti o n s after 250 o p erati n g h o u rs ever y 1 0 o p e ra ti n g h o u rs, d a il y ever y 2 50 o p er ati n g h o u rs ever y 5 00 o p er ati n g h o u rs ever y 1 000 o p e rati n g h o u rs ever y 2 000 o p e rati n g h o u rs ever y 3 000 o p e rati n g h o u rs as req u ired

Maintenance

5.3

Table of fuels and

lubri-cants

Assembly Fuel or lubricant Quantity approx.

Summer Winter Attention

Observe the level marks

Engine Engine oil ACEA: E3-96/E5-02 or approx. 12,5 litres without

oil filter API: CG-4/CH-4 SAE 10W/40 (-20 °C to +40 °C) SAE 15W/40 (-15 °C to +40 °C) Fuel

Diesel Winter diesel fuel approx. 150 litres

Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity approx. 60 litres

46 mm2/s at 40 °C

Vibration bearings Engine oil SAE 15W/40 approx. 2 x 1,8 litres

Drive axle Gear oil SAE 90, API GL5 approx. 12,5 litres

Wheel hubs Gear oil SAE 90, API GL5 approx3.5 l per side

Axle reduction gear Gear oil SAE 90, API GL5 approx. 1,9 litres

Drum drive gear Gear oil SAE 90, API GL5 approx. 7,5 litres

Air conditioning system Refrigerant R134A

Engine cooling system Cooling system protection agent approx. 16 litres

Tires Water approx. 390 litres

Calcium chloride (CaCl2) or magnesium chloride

(MgCl2)

Maintenance

BOMAG 63

BW 226 DH-4/PDH-4

5.4

Running-in instructions

The following maintenance work must be per-formed when running in new machines or overhauled engines:

! Caution

Up to approx. 250 operating hours check the engine oil level twice every day.

Depending on the load the engine is subjected to, the oil consumption will drop to the normal level after approx. 100 to 250 operating hours. After a running-in time of 30 minutes

l Retighten the V-belt

After 50 operating hours

l Retighten bolted connections on intake and exhaust tubes, oil sump and engine mounts.

l Retighten the bolted connections on the ma-chine.

l Retighten all wheel fastening screws with the specified tightening torque.

l Oil change vibration bearings

l Oil change in drive axle

l Oil change in wheel hubs

l Oil change, axle reduction gear

l Oil change, drum drive reduction gear

After 500 operating hours

Maintenance

5.5

Maintenance chart

No. Maintenance work Remark

R u nn in g-in in s truc ti on s a ft e r 5 0 o pe ra ti ng h o u rs e v e ry 1 0 o p e ra ti ng ho ur s , da il y e very 250 o p erati n g h o u rs e very 500 o p erati n g h o u rs e very 1000 o p erati n g h o u rs e very 2000 o p erati n g h o u rs e very 3000 o p erati n g h o u rs as re q u ir e d

5.6 _{Check the engine oil level Dipstick mark X}

5.7 _{Check the water separator X}

5.8 _{Check the fuel level X}

5.9 _{Check the hydraulic oil level Inspection glass X}

5.10 Check the coolant level Inspection glass X

5.11 Check the dust separator X

5.12 Check the tire pressure X

5.13 Clean the cooling fins on engine and hydraulic oil cooler

X

5.14 Check the oil level in the drive axle X

5.15 Check the oil level in the wheel hubs X

5.16 Check the oil level in the axle reduc-tion gear

X 5.17 Check the oil level in the drum

reduc-tion gear

X 5.18 Check the oil level in the vibration

bearings

X 5.19 Change engine oil and oil filter

car-tridge*

min. 1x per year X

5.20 Change the fuel filter cartridge X

5.21 Drain the sludge from the fuel tank X

5.22 Service the battery Pole grease X

Maintenance

BOMAG 65

BW 226 DH-4/PDH-4

5.24 Check, replace the refrigerant com-pressor V-belt

X

5.25 Service the air conditioning X

5.26 Check, adjust the valve clearance Intake = 0,3 mm Exhaust = 0,5 mm

X

5.27 Check, replace the ribbed V-belt X

5.28 Check the engine mounts X X

5.29 Oil change in drive axle min. 1x per year X X

5.30 Oil change in wheel hubs min. 1x per year X X

5.31 Oil change, axle reduction gear min. 1x per year X X

5.32 Oil change in drum drive reduction gear

min. 1x per year X X

5.33 Oil change vibration bearings** _{see foot note, min. 1}

x per year

X X

5.34 Retighten the fastening of the axle on the frame

X

5.35 Tighten the wheel nuts X X

5.36 Check the ROPS X

5.37 Clean the oil bath air filter min. 1x per year X

5.38 Change hydraulic oil and breather fil-ter***

at least every 2 years

X 5.39 Change the hydraulic oil filter**** _{at least every 2}

years

X

5.40 Change the coolant at least every 2

years

X

5.41 Check the injection valves X

No. Maintenance work Remark

R u nn in g-in in s tru c ti o n s a ft e r 5 0 o p e ra ti ng ho ur s ever y 1 0 o p e ra ti n g h o u rs, d a il y ever y 2 50 o p er ati n g h o u rs ever y 5 00 o p er ati n g h o u rs ever y 1 000 o p e rati n g h o u rs ever y 2 000 o p e rati n g h o u rs ever y 3 000 o p e rati n g h o u rs as req u ired

Maintenance

5.42 Service the combustion air filter min. 1x per year, safety cartridge at least every 2 years

X

5.43 Adjust the scrapers X

5.44 Adjust the parking brake X

5.45 Change the tires X

5.46 Change the fresh air filter in the cabin X

5.47 Tightening torques X

5.48 Engine conservation X

* Oil change intervals depend on quality of oil and fuel (sulphur content)

** Oil change intervals after 50 h, after 500 h, after 1000 h, and then every 1000 h. *** Also in case of repair in the hydraulic system.

**** Also in case of repair in the hydraulic system.

No. Maintenance work Remark

R u nn in g-in in s tru c ti o n s a ft e r 5 0 o p e ra ti ng ho ur s ever y 1 0 o p e ra ti n g h o u rs, d a il y ever y 2 50 o p er ati n g h o u rs ever y 5 00 o p er ati n g h o u rs ever y 1 000 o p e rati n g h o u rs ever y 2 000 o p e rati n g h o u rs ever y 3 000 o p e rati n g h o u rs as req u ired

Service Training

BW 216 / 219 / 226 DH / PDH -4 D 1

-Deutz diesel engine

The single drum rollers of product range BW 216 / 219 / 226 DH/PDH-4 are powered by a Deutz diesel engine of series BF6M 2012 COM2 with electronic engine management (EMR). The engine cooling system uses an external radiator. The cooling fan is mounted to the engine fan block and is directly driven by the engine.

These engines are characterized by the following positive features: • short and compact design,

• low noise level,

• almost vibration-free running, • low fuel consumption,

• low exhaust emissions (EPA II), • high power reserves and

• good access to all service points.

Crankcase and cylinders of this engine are made of alloyed cast iron. This provides strength and ensures high wear resistance.

The forged steel conrods are fitted with compensation weights near the conrod bearing seats. These weights compensate manufacturing tolerances with respect to weight and centre of gravity.

The pistons are made of an aluminium alloy. The combustion chamber recess is slightly offset from the middle at its side walls are inclined for 10° towards the inside. All pistons are fitted with three piston rings and a cast iron ring carrier for the first ring. The pistons are lubricated by an oil mist.

The forged crankshaft is equipped with integrated counterweights.

The block-type cylinder head is made of cast steel. Each cylinder is fitted with one intake and one exhaust valve. The valve guides are shrunk into the cylinder head. The valve seat rings are made of high-grade steel and are also shrink fitted.

Service Training

Service side

Fig. 1: Service side BFM 2012

1 Oil filler neck 8 Fuel pump

2 Valve, boost fuel supply 9 Engine mounting

3 Engine solenoid 10 Fuel filter

4 Oil pressure switch 11 Lubrication oil filter

5 Cooling air blower 12 Oil sump

6 Coolant pump 13 Dipstick

7 V-belt pulley 14 Steering/charge pump

1 2 3 ₄ 5 6 7 8 9 10 11 12 13 14

Service Training

BW 216 / 219 / 226 DH / PDH -4 D 3

-Starter side

Fig. 2: Starter side

1 Flywheel

2 Ground cable

3 Starter

4 Turbo charger

5 Generator

6 Coolant temperature switch

1 2 3 4 5 6

Service Training

Lubrication oil circuit

Fig. 3: Lubrication oil circuit

1 Oil sump 12 Piston cooling nozzle

2 Return flow turbo charger to crankcase 13 Camshaft bearing

3 Turbo charger 14 Main oil channel

4 Oil line to turbo charger 15 Lubrication oil cooler

5 Line to mass balance wheel (2 x) 16 Lubrication oil pump

6 Oil pressure sensor 17 Pressure relief valve

7 Valve with pulse lubrication 18 Leak oil return line

8 Push rod, oil supply to rocker arms 19 Lubrication oil filter

9 Line to spray nozzles 20 Suction line

10 Rocker arm 21 Crankshaft bearing

11 Return flow to oil sump 22 Conrod bearing

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Service Training

BW 216 / 219 / 226 DH / PDH -4 D 5

-Lubrication oil circuit

Fig. 4: Lubrication oil circuit

1 Cooler

2 To cooler

3 From cooler

4 Coolant pump

5 Lubrication oil cooler

6 Cylinder cooling

7 Cylinder head cooling

8 Ventilation connection between cylinder head and heat exchanger

1 2 3 4 5 6 7 8

Service Training

FuelFuel system

7

6

4

Fuel tank

1b

1c

1d

1a

Service Training

BW 216 / 219 / 226 DH / PDH -4 D 7

-Legend Fig. 6:

1a Fuel lift pump

1b Fuel pre-filter

1c Water separator

1d) Water proportion sensor

2 Feed to fuel lift pump

3 Fuel lift pump

4 Connecting line lift pump – main filter (fuel pre-pressure up to 10 bar)

5 Main fuel filter (pressure resistant)

6 Connecting line main filter – supply for injection pump

7 Single injection pump

8 High pressure line

9 Injection nozzle

10 Leakage line

11 Pressure retaining valve - 5 bar

Service Training

Fuel pre-filter with water separator

Fig. 6: Fuel pre-filter with water separator

1) Lift pump

2) Vent valve

3 Filter element

4) Water and dirt collecting bowl

5 Drain valve

6 Electric connection for water level sensor

The fuel pre-filter / water separator consists mainly of:

• the dirt / water sediment bowl with water level warning sensor • and the filter element

3 5 4 1 2 6

Service Training

BW 216 / 219 / 226 DH / PDH -4 D 9

-Function:

The fuel lift pump draws the fuel through both filters.

The water resistant filter element retains remaining smaller dirt and water particles.

Once the water level reaches the height of the warning connections, the warning light in the dashboard lights up.

Draining off water or fuel :

If the filter element is clogged before a service is due (indicated by e.g. a power drop), the filter may be regenerated as follows to keep up operation of the engine:

• Open the bleeding screw (this applies atmospheric pressure to the filter element and releases bigger dirt particles from the bottom side of the filter, which will then sink down.

• Open the drain valve and let approx. 0.5 l of fuel run out. The fuel above the filter element presses through the filter element and cleans the underside of the filter element from dirt.

• Close the drain valve.

Draining off larger dirt particles or sludge:

• Unscrew the water separator housing

Bleed the system by operating the fuel lift pump and then tighten the bleeding screw.

Main fuel filter

Attention!

The main fuel filter is subjected to approx. 10 bar fuel pre-pressure from the fuel lift pump. This pressure is considerably higher than on other engines. For this reason only original filter elements must be used. Filter elements of similar design or with adequate dimensions are not necessarily pressure resistant!

A filter element of insufficient pressure resistance will be damaged by the high pressure and will disintegrate. This causes severe damage to the injection system!

Service Training

Electronic engine control EMR II

The Deutz engines in single drum rollers DH-4 are equipped with an electronic engine speed control (Deutz EMR II).

The most important benefits of this system are:

• shorter response times compared with mechanically controlled engines, i.e. the response times are significantly better. This improvement is achieved without increasing the acceleration fumes or the fuel consumption.

• electronic idle speed control enabling a higher starting torque

• no mechanical throttle control (light moving, maintenance free, less susceptible for faults) • in comparison to the first version of the Deutz-EMR the essential advantage is

that an EMR-fault is directly displayed in form of a fault code.

The EMR-injection system is based on the approved Deutz-injection system of series 2012 with individual injection pumps for each cylinder. However, the fuel quantity per stroke is not regulated mechanically via a throttle cable, but is controlled by the EMR II-system by means of an electromagnetic actuator acting on the governor rod.

The essential components of the EMR II-system for engine speed control are: • EMR II control unit [A48] at the left under the operator's stand.

• The control unit processes the input signals from:

• displacement measuring system in the EMR actuator [Y 137] (current position of the injection pump control rod)

• the coolant temperature sensor [B 113] on the cylinder head • the rotary speed sensor [B 114] on the camshaft

• the engine oil pressure sensor [B 88] on the oil filter housing

• the charge air pressure and charge air temperature sensor [B 115] connected to the intake manifold • The cold start device (heating flange) is additionally triggered by the EMR II in dependence on the

Service Training

BW 216 / 219 / 226 DH / PDH -4 D 11

-These input signals are processed, sent as output signals to the EMR actuator Y 137 and there they are converted to the required fuel quantity per stroke.

In ECO-mode the travel lever determines the engine speed setpoint. The control unit compares this nominal value with the actual speed value detected by the engine speed sensor. If the nominal value corresponds with the actual value, the signal to the EMR actuator will remain unchanged.

However, if the nominal speed deviates from the actual speed (e.g. when changing the travel lever position or under higher load), the control unit uses the current turbo charger pressure and the coolant temperature to determine the necessary change in fuel quantity to achieve the nominal speed value. The control unit then sends a signal to the EMR actuator to change the control rod position and thereby the engine speed.

This automatic speed adaptation only takes place in ECO-mode (in the first DH-4 machines this was called "AUTO")

Service Training

Individual EMR II components

Control unit EMR II

The EMR control unit is located above the central electrics under the operator's stand in the access area. This is the computer unit of the EMR and it processes the input signals from the sensors to output signals for the EMR actuator (governor rod).

Pos. Designation Pos. in wiring

diagram

Deutz designation

Measuring values

1 Control unit EMR II A 48 EMR II

2 Plug, engine side X 31

3 Plug, vehicle side X 30

3

2

1

Service Training

BW 216 / 219 / 226 DH / PDH -4 D 13

-Connection overview EMR sensors/actuators on engine

C ont ro l uni t EM R II P lu g on v e hic le [X 3 0 ] P lug, e ngine s ide [X 3 1 ] 14 17 18 9 13 22 20 21 11 2 1 5 7 15 19 16 8 12 21 25 23 10 3 4 6

Pi

n as

signme

n

t

X 31

EMR ce

nt

ra

l pl

u

g

engine

[

X

57

]

P

in a

ssi

gnment

compl

ies

wit

h X

31

E

M

R

engine wiring h

a

rnes

s

Connec

ting ca

ble

E

ngine w

iring ha

rnes

s

Control unit E

M

R I

I

Service Training

Plug assignment X 31 (engine plug on EMR control unit)

Pos. Deutz designation Description

1 Spare Spare

2 not used

3 Output: Digital 4 Switching output heating flange (ground!)

4 empty

5 Input temp. (option) Charge air temperature

6 empty

7 empty

8 GND Reference potential for signal pin 9 coolant temperature sensor B 113

9 Input: Analogue 7 Analogue input coolant temperature sensor B 113

10 GND Reference potential Pin 11 crankshaft speed sensor B 130

11 Input: Speed 2 Digital input rotary speed sensor crankshaft B 130

12 GND Reference potential Pin 13 camshaft speed sensor B 114

13 Input: Speed 1 Digital input rotary speed sensor camshaft B 114

14 STG - PWM-output, signal for EMR-actuator coil Y 137

15 STG + PWM-output, signal for EMR-actuator coil Y 137

16 Screen not used

17 RF - common connection for reference and measuring coil EMR-actuator Y 137 18 RF REF analogue input, measuring signal of

reference coil of EMR-actuator Y 137 19 RF MESS analogue input, measuring signal of

measuring coil of EMR-actuator Y 137 20 GND Reference potential for signal on pin 21, oil

pressure sensor B 88

21 Input: Analogue 4 Analogue input, sensor signal oil pressure sensor B 88

22 +5V REF + 5 V reference voltage for signal on Pin 21, oil pressure sensor S 88

23 GND Reference potential for signal on pin 24, boost pressure sensor B 115

24 Input: Analogue 2 Analogue input, sensor signal boost pressure B 115

25 + 5V LDA + 5 V reference voltage for signal on pin 24 (max. 15mA), boost pressure sensor B 115

Service Training

BW 216 / 219 / 226 DH / PDH -4 D 15

-Plug assignment X 30 (vehicle plug on EMR control unit)

Pos. Designation Description

1 U Batt - Vehicle ground through X1:182 2 3 4 5 Output: Digital/ PWM 1 empty 6 Spare Spare 7 NC empty 8 NC empty 9 NC empty

10 L-line to diagnostics plug EMR, X32:L 11 K-line to diagnostics plug EMR, X32:K 12 CAN high X1:180,

CAN2-13 CAN low X1:181, CAN2+

14 U Batt + Power supply, vehicle voltage (ignition on) from relay K11, X1:179

15 16 Output: Digital/ PWM/Frequency empty 17 Ground empty 18 Input: digital/PWM 1 empty 19 Input: digital / analogue empty 20 Input: digital / analogue empty 21 Input: digital/PWM 2 empty 22 23 24 25

Service Training

EMR actuator Y 137

The EMR actuator is directly connected with the governor rod of the injection pump and moves this rod by being excited by the signal currents from the EMR control unit. At the same time the actual position of the actuator is fed back to the EMR control unit. This component is generally a proportional magnet with integrated path measuring system.

In case of a fault in the path measuring system the engine is shut down and a fault code displayed.

EMR-actuator

Pos. Designation Pos. in wiring

diagram

Deutz designation

Measuring values

Pin 1 Signal input actuator coil STG

-Pin 2 Signal input actuator coil STG +

Pin 3 common connection for measuring and reference coil

RF -Pin 4 Measuring signals measuring coil RF MESS Pin 5 Measuring signals reference coil RF REF Pin 6 not used

Pin 7 not used

8

EMR-plug

X 57

9

EMR-actuator

Y 137

-Pin assignment of EMR-actuator looking towards actuator (plug pins mirror inverted)

Pin assignment EMR-actua view on actuator

(plug pins mirror inverted)

8

Service Training

BW 216 / 219 / 226 DH / PDH -4 D 17

-Temperature sensor B 113

The EMR coolant temperature sensor is mounted to the flywheel end of the engine. The EMR sensor is the bottom sensor.

The coolant temperature influences the calculated injection quantity of the EMR.

The EMR sensor value is not only used for the EMR itself, but also for the high coolant temperature control light in the display and for the heating flange control.

In case of a too high temperature the EMR shuts down the engine and a fault code is displayed. In case of a sensor failure the display shows a fault code.

Pos. Designation Pos. in wiring

diagram

Deutz designation

Measuring values 1 EMR temperature sensor for

coolant

B 113 Switching point

110°C

1

Service Training

Speed sensors: Camshaft B114 and crankshaft B 130

The sensors for camshaft and crankshaft speeds are installed in the side of the engine block. These sensors deliver the actual engine speed value for the EMR control unit.

If the engine speed is too high (pushing operation) the governor rod is returned to zero position, until the speed has dropped to the permissible range.

In case of a sensor failure the engine is shut down and the fault code appears in the display.

With a missing rotary speed signal from standstill the engine will not start, however, no fault message will be displayed, because the EMR assumes that the engine is at standstill and does therefore not release any fuel.

The EMR speed sensor has a fixed stop and does not need to be adjusted after installation.

Pos. Designation Pos. in wiring

diagram

Deutz designation

Measuring values 1 EMR speed sensor camshaft SAE

housing

B 114 2 EMR speed sensor crankshaft SAE B 130

1

2

1

Service Training

BW 216 / 219 / 226 DH / PDH -4 D 19

-Engine oil pressure sensor B88

The engine oil pressure sensor is mounted on the engine oil filter housing. The oil pressure is permanently monitored by the EMR.

With a too low engine oil pressure the display shows a fault code.

• In case of a too low pressure the EMR shuts down the engine and a fault code is displayed. • In case of a sensor cable defect or a broken sensor cable the engine keeps on running and the

display shows a fault code. .

Fig. 7Oil pressure sensor

Pos. Designation Pos. in wiring

diagram

Deutz designation

Measuring values 1 EMR oil pressure sensor B 88

Pin 1 (AGND) Pin 2 (Signal) Pin 3 (+ 5 V from EMR)

Ventilation

Ventilation

1

Service Training

Charge air pressure and temperature sensor B 115

The Deutz engine BF4M 2012C (EMR) is fitted with a combination sensor for charge air pressure and charge air temperature. This sensor measures the pressure and temperature in the intake manifold. The sensor itself is located on the intake manifold. Charge air pressure and charge air temperature inform the EMR about the actual load state of the engine.

Pos. Designation Pos. in wiring

diagram

Deutz designation

Measuring values 1 EMR charge air pressure and

temperature sensor

B 115

1

1

Service Training

BW 216 / 219 / 226 DH / PDH -4 D 21

-Heating flange R 19

Instead of glow plugs this engine is fitted with a heating flange before the intake air manifold, which heats up the passing air with resistance heated wires when the engine is cold. This system is electrically supplied via high current relay K14, located to the left next to the engine. This high current relay is triggered by the EMR-control unit (ground triggering) in dependence on the coolant temperature.

Pos. Designation Pos. in wiring

diagram Deutz designation Measuring values 1 Heating flange R 19

2 High current relay K14

1

2

1

2

1

2

Service Training

Trouble shooting

The display shows the fault codes

For a detailed description of how to read out fault codes and the display

please refer to the page on "Electrics" (Service Training Electrics)

Service Training WZ-4 DH Version and higher

Version/Status: V2.07 / 24.06.05 Page 6 of 67

Author: Seis / TE

Dateiname: p:\schulung\wz-4\elektrik\esx\englisch\schulung elektrik wz4 v2_07_gb.doc

2 Selected Fault Reactions of the ESX Control

Symbol in fault message display Warning Code output without buzzer Warning Code output with buzzer Engine stop Code output with buzzer Engine oil pressure

(from EMR)

5100

5112

5101

5112

after 10s

5100

5116

5101

5116

after 15s

5024

after 5s

5025

after 10s

Engine air filter

5026

after 5s

5027

after 2min.

Various error causes and reaction times.

See error codes

Hydraulic oil filter

₅₅₀₂

after 5s

5503

after 2min.

Water separator in fuel filter

5028

after 5s

5029

after 2min.

Ant-theft warning display (Option)

Seat contact (Option)

Air conditioning fault (Option)

1)

After reaching the warning limit! 3) Shut-down currently deactivated via parameter Reaktion

Service Training

Possible diagnostics with SERDIA

with fault code 5140: a fault diagnose is only possible via SERDIA

SERDIA is a software program from Deutz which can be used in connection with a laptop computer to perform more detailed fault analyses, especially reading out of the error log.

This displays information on

• Fault location (e.g. ’sensor’, ’coolant temperature sensor’)

• Nature of fault (e.g. ’fallen short of bottom limit value’, ’sporadic fault’)

• Environmental data / operating data (speed and operating hours at the time of the last fault occurrence)

• Number of fault locations • Frequency of fault

• Fault status (active – fault present / passive- fault no longer present) Fault messages for non-present / rectified faults can be deleted with SERDIA.

Further display possibilities:

• Function test: With the engine shut down the control outputs and the travel of the governor rod can be activated.

• Assignment of inputs/outputs Display of the current input/output assignment of the EMR-control • Representation of measuring values: There are a lot of measuring values available which can be

used if no EMR II fault is present (starting performance, engine sawing, lack of power). •

Service Training

BW 216 / 219 / 226 DH / PDH -4 D 25

-Connection of SERDIA (in electric installation box)

For this purpose the PC or Laptop is connected to the diagnostic interface with a special interface cable. The EMR diagnostics plug is located in the electric installation box of the machine.

Replacement of system components

• Replacement of the EMR II-control unit:

Each control unit is clearly designated to the engine, in accordance with the respective application. In case of a replacement the control unit therefore needs to be completed with the engine specific data set. When ordering a new control unit you must not only specify the part-number, but also the engine serial number (see sticker on EMR-control unit).

Note: The Deutz part-number specified on the EMR-control unit is the part number without software specific for the engine. The correct part number can be found in the spare parts catalogue.

• Replacement of the EMR actuator (Y137)

On engines of types 1013 and 2012 the actuators can be replaced without any additional programming of the control unit.

• Replacement of other EMR-components

All other EMR-components (sensors etc.) must not be repaired, but should only be replaced if they are faulty. Programming of the control unit is not required

Service Training

Checking and adjusting the valve clearance

Excessive or insufficient valve clearance can cause failure of the engine as a result of mechanical and thermal overloads. The valve clearance must therefore be checked and, if necessary, adjusted at the intervals specified in the operating and maintenance instructions.

Note: The valve clearance must be checked and adjusted when the engine is cold.

Intake valve: = 0.3 mm

Exhaust valve= 0.5 mm

• Turn the crankshaft until both valves on cylinder 1 are overlapping (the exhaust valve is not yet closed, the intake valve starts to open).

Fig. 9: Crankshaft position 1

• Check and adjust the valve clearance by following the black marking in the adjustment schematics. For control purposes mark the respective rocker arm with chalk.

Fig. 10: Crankshaft position 2 Flywheel side

1

2

3

4

1

2

3

4

Service Training

plug-in injection pump

Deutz diesel engines of product range 2012 are equipped with plug-in injection pumps of series PF 33 from Bosch.

The concept of the plug-in fuel injection pumps enables the realization of high injection pressures in connection with extremely short injection lines, which contributes to a high hydraulic stiffness of the injection system. This in turn provides the prerequisite for low exhaust emission values (soot) in combination with a low fuel consumption.

Plug-in fuel injection pumps have the following plunger dimensions:

• Stroke 12 mm

• Diameter 9 mm

Cavitation in the injection lines and injection overrun, which is normally associated with high pressures, is prevented by a return flow nozzle arranged after the pressure valve

The constant volume relief is 50 mm³.

Assembling the plug-type injection pumps

The adjustment of the injection pump timing (FB) affects: • the fuel consumption,

• the power

• the exhaust emission of the engine.

On engines of series 2012 the start of delivery is adjusted without tolerance. The start of delivery is entered in degree of crank angle measured from the top dead centre of the piston and depends on application, power and speed setting of the engine.

The plug-in injection pump is in position of start of delivery when the plunger just closes the fuel supply bore in the plunger sleeve.

Service Training

BW 216 / 219 / 226 DH / PDH -4 D 29

-On engines with inline injection pumps the engine drive is turned to start of delivery position and closing of the fuel supply bore is determined by means of a high pressure pump. Occurring tolerances are compensated in the coupling of the injection pump drive, whereby the injection pump camshaft is turned to start of delivery position against the fixed engine drive.

The injection pump cams on engines of series 2012 are arranged on the camshaft of the engine. For this reason the conventional adjustment method for the start of delivery cannot be used.

The start of delivery of the injection pump must be adjusted using the new method.

For this the conventional adjustment method is subdivided into length measurements of individual engine parts and calculations.

The permissible manufacturing tolerances for the components • cylinder crankcase,

• camshaft, • plunger

• plug-in injection pump

are measured and eliminated by the adjustment of the start of delivery.

However, in cases of interest for BOMAG engineers the engine will not be overhauled completely, but individual injection pumps will be replaced.

Crankcase, camshaft and plunger remain unchanged.

This results in a certain installation measurement for the engine drive, which is stamped on the engine type plate.

In column „EP“ it is stamped as „CODE“ for each cylinder.

Note:

If an injection pump and/or nozzle is replaced, the respective high pressure line between pump and nozzle must also be replaced..

1. Remove crankcase ventilation and cylinder head cover.

Service Training

Fig. 11:

2. EMR engines are not fitted with a lift

solenoid !

Fig. 12:

3. Insert the pressing device, WILBÄR No. 100 830 carefully into the groove in the governor rod and tighten.

Fig. 13:

4. Turn the knurled fastening screw to press the governor rod to stop position.

Note: