E. Deutz BF 4 M 2012 C Introduction [PDF]

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BOMAG FAYAT GROUP



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TRAINING



Deutz Engine Type BF 4 M 2012



by winni 14.03.2011



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These are the characteristics of the 2012 engines. Modern liquid-cooled 4-and 6 cylinder in-line engines,



Compact design and high power-to-volume-ratio, Turbocharging and turbocharging with charge air cooling, Low noise level, Almost vibration free operation, Low fuel consumption, Low exhaust emissions, (EPA ll) Excellent access to all service locations,



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Engine description



Type of cooling:



Liquid cooling, thermostatically at engine outlet. charge-air cooled engines with air-to-air charge air cooler.



Crankcase:



High grey cast iron crankcase, for monoblock construction.



Crankcase breather:



Closed-circuit crankcase breather.



Cylinder head:



Grey cast block-type cylinder head.



Valve arrangement/



Two valves per cylinder, actuated from gear driven camshaft via tappets.



timing:



push rods and rocker arms.



Piston:



Three-ring aluminium piston.



Piston cooling:



Oil cooled with spray nozzles.



Connecting rod:



Forged steel rod.



Crankshaft:



Forged steel shaft with integral counterweights.



Camshaft:



Steel shaft.



Lubrication system:



Forced-feed circulation lubrication with gear pump.



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Engine description



(continued from previous page)



Lube oil cooler:



Oil cooler integrated in coolant circuit.



Oil and fuel filter:



Paper-type microfilter as replaceable cartridge.



Injection pump/ governor:



Single injection pumps integrated in crankcase. mechanical centrifugal governor.



Fuel lift pump:



Mechanical gear pump integrated in v-belt drive.



Injection nozzle:



Six-hole nozzle, without leakoil.



Alternator:



Three-phase alternator 12V or 24 V.



Starter motor:



12 V or 24 V.



BOMAG FAYAT GROUP



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TRAINING Engine modell designation



B



Exhaust gas turbocharger



F



Automotive and industrial engine for mobile use



4



four (4) Cylinder Diesel engine (four stroke)



M



Liquid cooled engine (water)



20



Engine series (model) (serial index)



12



Piston stroke in cm (approx.)



C



Charge air cooler



(High-speed 4-stroke engine)



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Rotation of engine



Left side of engine Looking onto the flywheel Direction of rotation Looking onto the flywheel rotating to the left: counter-clockwise



1



EX



IN



2



EX



IN



3



EX



IN



4



EX IN



Right side of engine Looking onto the flywheel Cylinder arrangement



1



The cylinders are counted consecutively, starting from flywheel 1.



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Location of engine plate



Crankcase Right side of engine Looking onto the flywheel



Engine plate: The type, engine number and performance data are stamped on the engine plate. The engine type and number must be stated when purchasing spare parts.



BOMAG FAYAT GROUP



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TRAINING Location of engine plate



*



*



Location of engine plate



Engine serial number



The engine plate is fixed to the cylinder head cover and / or on to crankcase.



The engine serial number is stamped onto the crankcase (arrow) Right side of engine Looking onto the flywheel



BOMAG FAYAT GROUP



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TRAINING View from right side of engine (excample) 1 Oil filler neck 2 Lubrication oil cooler 3 Engine solenoid valve 4 Oil pressure switch (B06) 5 Radiator fan 6 Fuel pump 7 V-belt pulley 8 Main fuel filter 9 Lubrication oil filter 10 Oil sump 11 Oil dipstick 12 Compressor (only BW24/27RH) 13 Plug-in injection pumps 14 Generator 15 Heating flange (R19, option) 16 Hydraulic pump 17 Tension roller with torsion spring 18 Crankcase ventilation valve



BOMAG FAYAT GROUP



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TRAINING View from left side of engine (excample)



1 Exhaust manifold 2 Exhaust turbocharger 3 Oil filling (optional) 4 Engine mounts 5 Oil return line from turbocharger 6 Relay (starter) 7 Ribbed V-belt 8 Coolant inlet 9 Coolant outlet 10 Coolant pump 11 Connection of compensation line



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Fuel supply



1 Water separator sensor connection



2 Flow to fuel lift pump 3 Fuel lift pump 4 Connection line between fuel lift pump and main filter (fuel pre-pressure up to 10 bar) 5 Main fuel filter (pressure proof) 6 Connecting line between main filter and flow to injection pumps 7 Single-cylinder injection pump 8 High pressure line 9 Injection nozzle 10 Leak oil line 11 Pressure retaining valve 5 bar 12 Return flow to tank 13 Fuel tank 14 Manual fuel pump



15 Fuel pre-filter 16 Water separator 17 Fuel pre-heating connection (option) 18 Fuel pre-heating (R29) 200 Watt (option) 19 Water separator sensor (B124)



BOMAG FAYAT GROUP



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TRAINING Main fuel filter



Main fuel filter, (pressure resistant 10 bar) Use original fuel filter only. P/N 057 128 17



The main fuel filter must be pressure resistant. (min. 10 bar) If the main fuel filter is not pressure resistant, the fuel filter will be destroyed inside by pressure. The cpl. fuel system will be contaminated, injection pumps and injection nozzles will be destroyed.



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DEUTZ (fuel lift pump)



S



1 P



2



Fuel feed pump The fuel feed pump is designed as rotary pump which is driven via V-belt. The pump is provided with a two-way valve (No. 1: Pop = 6 + – 0,5 bar, No. 2: Pop = 0,5 bar). The overpressure relief valve (1) is designed as plunger valve and opens at 6+ – 0,5 bar.



This valve simultaneously limits the system pressure to 10+ – 0,5 bar. The bypass valve (2) is a ball valve. When the fuel lines have run empty, the fuel system can be primed with a hand pump. This prevents an excessive engine starting procedure (starter protection). Note: Do not reduce the line cross section and connection to fuel feed pump, as this may result in engine power loss.



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Check valve



(return flow line to tank)



Observe the direction of flow



Note: From August 2006 the check valve 1 is used by Bomag in series machines.



Caution: This valve must strictly be installed into the fuel return line by our customers.



BOMAG FAYAT GROUP



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TRAINING Lubrication oil circuit 1 Oil sump



17 Pressure relief valve



2 Return flow from turbocharger to crankcase



18 Leak oil return line 19 Oil filter



3 Turbocharger 20 Suction line 4 Oil line to turbocharger 21 Crankshaft bearings 5 Line to mass balancing gear (2 x) 6 Oil pressure sensor 7 Valve with pulse lubrication 8 Push rod, oil supply to rocker arms 9 Line to spray nozzles 10 Rocker arm 11 Return flow to oil sump 12 Nozzle for piston cooling 13 Camshaft bearing 14 Main oil channel 15 Lubrication oil cooler 16 Oil pump



22 Conrod bearings



BOMAG FAYAT GROUP



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TRAINING Lubrication oil circuit (Lubrication oil filter)



Use original oil filter only.



P/N 057 106 40



BOMAG FAYAT GROUP



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TRAINING BOMAG Engine Oil SAE 10W – 40



Ultra-high-performance, fuel-efficient engine oil – Specially developed for maximum utilization of extended oil change intervalls. Application: BOMAG Engine Oil has a higher performance capacity than the usual high-performance engine oils. Regardless of service life, even older diesel engines can be changed to BOMAG Oil without flushing. BOMAG Engine Oil offers reliable protection against deposits, sludge and adhesion. This capacity enables longest oil change intervalls.



Advantages: reduced fuel consumption due to low-friction characteristics high wear protection even under continuous stress at full engine load fastest possible oil circulation after start, thus reducing cold start and warm up wear reduction of exhaust gas particles protection against corrosion even when using diesel fuels with high sulphur content optimal compatibility with sealing materials environmentally friendly due to longest oil change intervalls and low evaporation losses



BOMAG Engine Oil approvals ACEA E7/E5/E4 API CI-4 20Ltr. BOMAG Part No. 009 920 06



BOMAG FAYAT GROUP



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TRAINING Coolant circuit



1 Radiator 2 To radiator 3 From radiator 4 Coolant pump 5 Lubrication oil cooler 6 Cylinder cooling 7 Cylinder head cooling



8 Ventilation connection from cylinder head to heat exchanger 9 Fan



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Engine coolant In liquid-cooled engines, the coolant must be conditioned and monitored, otherwise the engine could be damaged by: corrosion cavitation freezing boiling Never operate the engine without coolant, even for a short time! To ensure proper corrosion protection you must use the cooling system protection agent all year around, Whereby the following concentration must not be fallen short of or exceeded. Cooling system protection agent



Fresh water



Cold protection down to



min. 35%



65%



–22° C



40%



60%



–28° C



max. 45%



55%



–35° C



BOMAG Coolant Additive approvals ASTM D 3306



20Ltr. BOMAG Part No. 009 940 08



Caution A proportion of more than 45% of cooling system protection agent causes a drop in cooling power. The use of corrosion protection oils as cooling system protection is not permitted.



Changing the coolant at least every 2 years



BOMAG FAYAT GROUP



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TRAINING Position of thermostat



Note: Observe mounting position of thermostat. Arrow (bleeder notch) pointing up.



BOMAG FAYAT GROUP



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TRAINING Check thermostat in removed condition



1. Measure dimension “a“ on the thermostat. Note: “a“ = stroke beginning at approx. 83 +/- 2°C (T1) “b“ = stroke ending at approx. 95 °C (T2)



2.Heat up thermostat in the water bath. For a determination of the exact opening point, the temperature reading should take place as closely as possible to the thermostat, however, without contacting the latter. The water must be continuously stirred to arrive at a uniform distribution of temperature. The rate of rise of temperature should not exceed 1° C / min. at a maximum otherwise opening will be delayed correspondingly.



3. Measure dimension “b“ on the thermostat. Stroke lenght at indicated temperature (T2) 8 mm minimum.



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Location of engine control components 3



2



1 1 Boost fuel solenoid 12 Volt, approx. 3,5 Amp. (Y01) 2 Coolant temperature switch Contact switches at approx. 110° C to engine ground



7



5



4 6



3 Temperature sensor for heating flange 4 Engine governor 5 Engine stop lever 6 Engine speed adjusting lever 7 LDA Control line



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(LDA)



Manifold – pressure compensator



LDA control line, (0,8 – 1 bar, measured at full load)



Charge air pipe



Governor



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(LDA)



Manifold – pressure compensator



LDA – Function To avoid in the case of supercharged engines a smoke puff upon a sudden load change from low partial load to full load, the governor is additionally provided with a manifold-pressure compensator. It only releases the fuel volume corresponding to the available combustion air.



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Location of oil pressure switch



Y13



1 Oil pressure switch (B06) Below 0,8 bar the contact switches to engine ground, closed without pressure.



2



2 Engine oil cooler



1 In case of too low engine oil pressure if engine is running, the electric power supply to the solenoid (Y13) will be time delayed (10 sec.) interrupt and the Diesel engine shut down.



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Engine shut-down solenoid (Y13) and injection pumps



Y13



1 Engine solenoid Y13 (engine shut down) 12 Volt, approx. 4 Amp.



2



Injection pumps



BOMAG FAYAT GROUP



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TRAINING Heating flange



Heating flange The heating power is approx. 2000 Watt



The heating flange is a component with an electrically operated heating wire and high density used to heat up the intake air in case of very low ambient temperatures.



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Three-phase generator (G02)



B+



Batterie Plus



14,4 Volt, 90 Amp.



D+



Dynamo Plus



14,4 Volt, maximum load 0,2 Amp.



W



Rotational speed speed



pulsing D.C. voltage to determine the engine speed



BOMAG FAYAT GROUP



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Methods of valve clearance setting:



with a feeler gauge and rotary angle disc



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Schematic for valve clearance adjustment 4 – Cylinder, Firing order: 1 – 3 – 4 – 2 Direction of rotation Looking onto the flywheel rotating to the left: counter-clockwise



1



2



3



4 Valve clearance can be adjusted



on the engine in cold or warm EX



IN



EX



IN



EX



IN



EX IN



condition allowing the engine to cool down for 0,5 h. at a minimum. 80° C



^



Oil temperature



Crankshaft position 1 Turn engine until valves of cylinder No. 1 overlap. The black marked valves can be checked and adjusted. (Note: Valve overlap means: Exhaust valve about to close, inlet valve about to open)



Not ready for adjustment



Valve clearance:



Inlet valve 0,3 mm / 0,012 inch



Ready for adjustment



Exhaust valve 0,5 mm / 0,02 inch



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Schematic for valve clearance adjustment 4 – Cylinder, Firing order: 1 – 3 – 4 – 2 Direction of rotation Looking onto the flywheel rotating to the left: counter-clockwise



1



2



3



4 Valve clearance can be adjusted



on the engine in cold or warm EX



IN



EX



IN



EX



IN



EX IN



condition allowing the engine to cool down for 0,5 h. at a minimum. 80° C



^



Oil temperature



Crankshaft position 2 Turn engine further by one complete revolution until valves of cylinder No. 4 overlap. (360°) The black marked valves can be checked and adjusted. (Note: Valve overlap means: Exhaust valve about to close, inlet valve about to open)



Not ready for adjustment



Valve clearance:



Inlet valve 0,3 mm / 0,012 inch



Ready for adjustment



Exhaust valve 0,5 mm / 0,02 inch



BOMAG FAYAT GROUP



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TRAINING Valve clearance setting, Valve train with pressure disc



Methods of setting the valve clearance, The setting method for the valve clearance used until now, with a feeler gauge, is no longer possible for all engine types. In engines which are equipped with a pressure disc in the spring plate of the valve, the setting of the valve clearance can only be carried out with a rotary angle disc. However, the universal method with the rotary angle disc may also used on engines which until now were set with the feeler gauge.



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Valve clearance setting, Valve train with pressure disc



Pressure disc 1 Setting screw 2 Locking nut Spring cup



3 Rocker arm pin 4 Pressure disc 5 Valve stem X Valve clearance



BOMAG FAYAT GROUP



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Valve clearance setting method with rotary angle disc, Valve train with pressure disc Attention! Note design of the adjusting screw (with slot, wrench size or hexagon socket).



Loosen lock nut (1). Screw in the setting screw (2) to the stop.



Set the rotation angle disc on the setting screw with a screwdriver insert for slotted screws. Fix magnet of rotation angle disc on cylinder head.



Note: The rocker arm must touch the thrust washer of the spring cap (arrow)



Set the rotation angle disc in the direction of the arrow to zero. Be careful to turn the setting screw correctly.



BOMAG FAYAT GROUP



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Valve clearance setting method with rotary angle disc, Valve train with pressure disc



Take the setting values from Table 1. Excample: BFM 2012 Outlet valve: Setting angle 120° Turn the setting screw back by 120° in direction of the arrow.



Hold the setting screw to prevent it turning and tighten the lock nut (1) with the open wrench. Remove rotation angle disc. Set all other valves according to the valve setting schematic Table 1.



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(Table T1) Valve clearance Setting angle (degree)



Series



Inlet valve



B/FL 513/C



46+ 10



BF6M 1013 GenSet 200 kVA



90



BFM 1015



Outlet valve 70+10



Setting values and tools Tightening torque (Nm)



Lock nut



Tools part number



Deutz



BOMAG



20



(8190) 05725072 (8191) 05725074



150



20



(8190) 05725072 (8191) 05725074



90+10



108+10



20



(8190) 05725072 (8191) 05725074



BFM 2012



75



120



20



(8190) 05725072 (8191) 05725074



BFM 2013



(160)(1)



(195)(1)



20



(100 340)



TCD 2012 2V



75



120



20



(8190) 05725072 (8191) 05725074 (8194) 05725075



TCD 2012 2V with exhaust gas return



75



120



20



(8190) 05725072 (8191) 05725074 (8194) 05725075 (8199) 05725077



20



(100 340)



TCD 2012 4V



(160)(1)



(195) (1)



TCD 2013 2V



90



150



20



(8190) 05725072 (8191) 05725074 (8194) 05725075



TCD 2013 2V with exhaust gas return



90



150



20



(8190) 05725072 (8191) 05725074 (8194) 05725075 (8199) 05725077



TCD 2013 4V



75



105



20



(8190) 05725072 (8193) 05725059



TCD 2015



90+10



108+10



20



(8190) 05725072 (8191) 05725074



(1) = only corresponding to the markings (IN / EX) on the valve clearance setting tool 100 340 Deutz service info 23.04.2009



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Special tools for valve clearance setting, Tools part number Deutz / BOMAG



(8196) 057 250 71



(8199) 057 250 77



(8190) 057 250 72



5mm (8191) 057 250 74



(8193) 057 250 59



4mm (8194) 057 250 75



100 340



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Engine and setting data, Motortyp



Dimension



Valve clearance setting



TD 2012 L04 2Vm TCD 2012 L04 2Vm TCD 2012 L04 2V TCD 2012 L06 2V



Working princple



Four-stroke diesel engine



Charging



Turbocharger



Turbocharger with charge air cooling



Type of cooling



water-cooled



Cylinder arrangement



in series



No. of cylinders



4



Bore / stroke



(mm)



Total displacement



(cm3)



Combustion prcess



6



101 / 126 4038



6067



Direct injection



Injection system



Mechanical injection system



Deutz Common Rail (DCR)



Exhaust gas recirculation



internal



Valves per cylinder



2



Valve clearance: Inlet / outlet



(mm)



Setting with rotary angle disc



(°)



Firing order of the engine



1-3-4-2



Direction of rotation looking onto flywheel Engine power rating according to ISO 3046



75° +10° / 120° +10° left



(kW)



see engine rating plate



Speed (nominalrevolution)



(min-1)



see engine rating plate



Injection timing



(°BTDC)



see engine rating plate



Coolant volume ( only engine content without cooler /



1-5-3-6-2-4



≈ (I)



5,6



7,3



Coolant volume DEUTZ PowerPack cooler



≈ (I)



18,5



22,7



Permissible continuous coolant temperature



(°C)



Temperature difference between coolant inlet/-



(°C)



4–8



Start of thermostat opening



(°C)



86



Thermostat fully open



(°C)



102



hoses and pipes) max. 110



outlet



General technical data DEUTZ TR 25.01.2010



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Deutz BF 4/6 M 2012



Injection pump replacement, Adjustment of the injection pump timing, Determination of the compensation shim thickness, Note: If an injection pump and / or nozzle is replaced, the respective high pressure line between pump and nozzle must also be replaced.



BOMAG FAYAT GROUP



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TRAINING



Special tools for injection pump replacement. The following tools can be ordered from BOMAG or Wilbär (Deutz) under the stated part number. (Deutz) / BOMAG



Press-on device for control rod



Clay-grip wrench across flats 17 for injection lines



Deutz P/N (100 830) Bomag P/N 079 947 20



Deutz P/N (8018) Bomag P/N 079 947 54



Serrated wrench for turning injection pump



Engine turning gear



Deutz P/N (8117) Bomag P/N 079 947 57



Deutz P/N (100 320) Bomag P/N 057 250 80



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Injection pump replacement, Determining the start of injection and compensation shim thickness,



The adjustment of the injection pump



The permissible manufacturing



timing (FB) affects:



tolerances for the components:



the fuel consumption



cylinder crankcase



the power



camshaft



the exhaust emission



plunger



of the engine.



plug-in injection pump



The plug-in injection pump is in position of



are measured and eliminated by the



start of delivery when the plunger just



adjustment of the start of delivery.



closes the fuel supply.



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Injection pump replacement, Determining the start of injection and compensation shim thickness,



Remove crankcase ventilation and cylinder head cover.



Remove the engine solenoid



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Injection pump replacement, Determining the start of injection and compensation shim thickness,



Insert the pressing device carefully into the groove in the governor rod and tighten.



Pressing device, Deutz PN 100 830



Turn the knurled fastening screw to press the



governor rod to stop position. Note: Tighten the knurled fastening screw by hand.



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Injection pump replacement, Determining the start of injection and compensation shim thickness, TDC – top dead center (ignition)



Set the cylinder of the injection pump to be disassembled to top dead centre (TDC) for ignition (valves overlapping). Then turn the crankshaft for approx. 120° against the sense of rotation.



Note: View on flywheel



Remove injection line and injection pump.



BOMAG FAYAT GROUP



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TRAINING Injection pump replacement,



Determining the start of injection and compensation shim thickness,



Carefully remove the compensation shim with a rod-type magneto..



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FAYAT GROUP



Injection pump replacement, Determining the start of injection and compensation shim thickness, Note Sequence of reading “EP“ code: Line 1 = cylinder 1, line 2 = cylinder 2, etc.



Example: The injection pump for cylinder 3 is to be replaced on an engine BF4M 2012. Procedure: Read the EP-code for cylinder 3 in the column “EP“ on the type plate, e.g. 295 Take the corrected injection pump installation measurement (EK) matching the EP-code from the table 1.



(e.g. EP-code 295 – EK (mm) = 120,875)



BOMAG FAYAT GROUP



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TRAINING Engine type plate,



Engine type plate BF 4 M 2012



EP-code



Engine type plate BF 6 M 2012 C



EP-code



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FAYAT GROUP



Injection pump replacement, Determining the start of injection and compensation shim thickness,



EK (mm) = corrected injection pump measurement, determined by EP-code on type plate and from table 1



120,875



Table 1



295



BOMAG FAYAT GROUP



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TRAINING Injection pump replacement,



Determining the start of injection and compensation shim thickness, Basic measurement of injection pump “LO“



Basic measurement of injection pump (LO) = 117,5 mm.



Lo “A“



Measurement “A“ in 1/100 mm has been A/100 written on the pump with an electric marker. A/100



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Injection pump replacement, Determining the start of injection and compensation shim thickness, Coefficient of the injection pump (A) During the manufacture of the plug-in fuel injection pump the high pressure method is used to determine the wear in the fuel supply bore. In this position – injection pump plunger in start of fuel delivery position – the distance between pump contact face and plunger foot contact face is measured.



Note Measurement “A“ determines by how many 1/100 of mm the distance between cylinder crankcase contact sureface and plunger foot is longer than the basic measurement LO.



Measurement “A“ in 1/100 mm has been written on the pump with an electric marker.



42



Read the coefficent for the injection pump lenght (A) on the new injection pump, e.g. 42.



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Injection pump replacement, Determining the start of injection and compensation shim thickness, Injection pump installation dimension



LO plus A



Example Basic measurement of injection pump (LO) = 117,5 mm + A/100 = Injection pump installation dimension



0,42 mm 117,92 mm



Lo 42



A/100



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Injection pump replacement, Determining the start of injection and compensation shim thickness, Determine the theoretical thickness of shim (TS). TS = Theoretical thickness of shim EK = Injection pump installation measurement from table 1 LO + A/100 = Injection pump installation dimension SS = Compensation shim thickness (select from table 2)



Example



EK = LO + A/100 TS =



120,875 mm – 117,92 mm 2,955 mm



Select compensation shim thickness (SS) from table 2)



BOMAG FAYAT GROUP



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TRAINING Injection pump replacement,



Determining the start of injection and compensation shim thickness, Select compensation shim thickness (SS) from table 2



2,95 - 3,049



Table 2



3,0



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Installation of injection pump



1 2 2 Loop rings



3 2 3 2



1 Injection pump 2 Loop ring 3 Spacer ring



Note: Always replace all loop rings and spacer rings.



BOMAG FAYAT GROUP



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TRAINING Installation of injection pump



Lay the newly determined shim on roller plunger.



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FAYAT GROUP



Installation of injection pump Caution: the roller plunger for the corresponding injection pump must be positioned on the base circle of camshaft.



Turn the injection pump control lever approx. to middle position.



Slightly oil the receiving bore in the crankcase and the o-rings on the injection pump. Carefully insert the injection pump control lever (1) into the governor rod.



BOMAG FAYAT GROUP



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TRAINING Installation of injection pump



Attach the flange



Slightly oil the screws and tighten with a torque of 5 Nm.



Caution The chamfer must face towards the injection pump body.



BOMAG FAYAT GROUP



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TRAINING Installation of injection pump



Loosen the screws again for 60°.



Carefully turn the injection pump with an serrated wrench anti-clockwise against the noticeable end stop. Serrated wrench for turning injection pump Deutz P/N 8117 Bomag P/N 079 947 57



BOMAG FAYAT GROUP



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TRAINING Installation of injection pump



Turn the screws in again for 60°, then tighten in steps to a torque of 7 Nm, 10 Nm, und 30 Nm.



Turn the knurled fastening screw back.



Note



Caution



Always start with the outer screw furthest away



Check whether the governor rod is light moving



from the flywheel.



between stop and start position.



Remove the pressing device.



Operate the shut-down lever to do so.



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Installation of engine shut-down solenoid.



Assemble a new O-ring.



Use the shut-down lever to push the governor rod to stop position and hold t.



Note Cover the O-ring slightly with oil.



Install the engine shut-down solenoid. Thighten the screws with 21 Nm. Plug the cable plug onto the shut-down magneto.



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Installation of injection line



Caution Take care that the sealing cones match exactly when assembling the injection line. Subsequent bending is not permitted. The injection line must never be used twice. Install the new injection line with the sealing rubber. Pre-tension the injection line cap nuts on injection pump and injection valve with a torque of approx. 5 Nm. Thighten the cap nut with 25 +/– 3,5 Nm.



Install the gasket for the cylinder head cover.



BOMAG FAYAT GROUP



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TRAINING Installation of cylinder head cover



Assemble cylinder head cover and holding plate. Tighten the screws with 11 Nm. Note Ensure the sealing rubber is fitted correctly. If necessary assemble the pressure control valve with a new seal. Tighten the screws with 8,5 Nm.



BOMAG FAYAT GROUP



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TRAINING



Changing the injection pump, Injection pump adjustment without known EP – Code Engine Type BF4M 2012 – BF6M 2012 TD / TCD 2012 L04 2V – TD / TCD 2013 L04 2V



BOMAG FAYAT GROUP



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TRAINING



Remove the injection pump and the shim,



BOMAG FAYAT GROUP



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Write down the cylinder number and tolerance measure of the pump.



BOMAG FAYAT GROUP



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TRAINING “Ss“



Shim



“Ss“ Note: The same shim must be used for the same cylinder.



Measure the shim thickness “Ss“



BOMAG FAYAT GROUP



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TRAINING



30 New injection pump



Write down the tolerance measure of the new injection pump.



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BOMAG



TRAINING



FAYAT GROUP



Note: If the tolerance measure on the new injection



If tolerance measure on the new injection



pump is smaller than on the old one



pump is larger than on the old one



the shim “Ss“ should be thicker.



the shim “Ss“ should be thiner.



30



Old injection pump



new injection pump



50



Old injection pump



new injection pump



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BOMAG



TRAINING



FAYAT GROUP



Determine the new shim thickness “Ss“ (mm) Excample Old injection pump tolerance measure



0,42 mm



New injection pump tolerance measure



– 0,30 mm + ∆ 0,12 mm



“Ss“ old (mm)



+/- ∆ Mass A (mm) = “Ts“ new (mm)



“Ss“ old 2 mm



+



∆ 0,12 mm



= “Ts“ 2,12 mm



( choose the shim thickness “Ss“ from the table next page )



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BOMAG



TRAINING



FAYAT GROUP



Theoretical shim thickness “Ts“ ( mm )



Shim thickness “Ss“ ( mm )



Theoretical shim thickness “Ts“ ( mm )



Shim thickness “Ss“ ( mm )



0,95 – 1,049



1,0



2,35 – 2,449



2,4



1,05 – 1,149



1,1



2,45 – 2,549



2,5



1,15 – 1,249



1,2



2,55 – 2,649



2,6



1,25 – 1,349



1,3



2,65 – 2,749



2,7



1,35 – 1,449



1,4



2,75 – 2,849



2,8



1,45 – 1,549



1,5



2,85 – 2,949



2,9



1,55 – 1,649



1,6



2,95 – 3,049



3,0



1,65 – 1,749



1,7



3,05 – 3,149



3,1



1,75 – 1,849



1,8



3,15 – 3,249



3,2



1,85 – 1,949



1,9



3,25 – 3,349



3,3



1,95 – 2,049



2,0



3,35 – 3,449



3,4



2,05 – 2,149



2,1



3,45 – 3,549



3,5



2,15 – 2,249



2,2



3,55 – 3,649



3,6



2,25 – 2,349



2,3



3,65 – 3,749



3,7



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BOMAG



TRAINING



FAYAT GROUP



Determine the new shim thickness “Ss“ (mm) Excample Old injection pump tolerance measure



0,42 mm



New injection pump tolerance measure



– 0,50 mm – ∆ 0,08 mm



“Ss“ old (mm)



+/- ∆ Mass A (mm) = “Ts“ new (mm)



“Ss“ old 2 mm



–



∆ 0,08 mm



= “Ts“ 1,92 mm



( choose the shim thickness “Ss“ from the table next page )



72 of 88



BOMAG



TRAINING



FAYAT GROUP



Theoretical shim thickness “Ts“ ( mm )



Shim thickness “Ss“ ( mm )



Theoretical shim thickness “Ts“ ( mm )



Shim thickness “Ss“ ( mm )



0,95 – 1,049



1,0



2,35 – 2,449



2,4



1,05 – 1,149



1,1



2,45 – 2,549



2,5



1,15 – 1,249



1,2



2,55 – 2,649



2,6



1,25 – 1,349



1,3



2,65 – 2,749



2,7



1,35 – 1,449



1,4



2,75 – 2,849



2,8



1,45 – 1,549



1,5



2,85 – 2,949



2,9



1,55 – 1,649



1,6



2,95 – 3,049



3,0



1,65 – 1,749



1,7



3,05 – 3,149



3,1



1,75 – 1,849



1,8



3,15 – 3,249



3,2



1,85 – 1,949



1,9



3,25 – 3,349



3,3



1,95 – 2,049



2,0



3,35 – 3,449



3,4



2,05 – 2,149



2,1



3,45 – 3,549



3,5



2,15 – 2,249



2,2



3,55 – 3,649



3,6



2,25 – 2,349



2,3



3,65 – 3,749



3,7



BOMAG FAYAT GROUP



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TRAINING



Fault and remedies



First examine, then screw!!!



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BOMAG



TRAINING



FAYAT GROUP



Fault and remedies,



(Fault table 1 of 2)



Faults



Measures



Engine does not start or is difficult to start (Starting speed ist not achieved on starting)



Check



Engine starts, but runs irregularly or fails Engine becomes excessively hot, Temperature warning system responds Engine output is deficient Engine does not run on all cylinders Engine oil pressure is non-existant or excessively low



P



Adjust



E



Replace



W



Clean



R



Top up



A



Reduce



S



Engine oil consumption excessive



Engine smokes – blue Engine smokes – white Engine smokes – black Cause Not declutched (where possible)



Section Engine operation



P



Below starting limit temperature



P



Engine shut-off lever still in stop position (shut-off magnet defective)



P



Oil level too low



A



Oil level too high



S



Excessive inclination of engine



P/E



Adjust throttle to half actuation travel Air cleaner clogged / turbocharger defective



P/E Combustion air



Air cleaner service switch / indicator defective



P



CPD* defective (connection line leaks)



P/W



Charge air line leaking Coolant pump defective



P/W



P/R Cooling system



Intercooler soiled



P/R P/R



Coolant heat exchanger soiled



P/R



Cooling fan defective, torn or loose V-belt



P/W



(fuel pump in belt drive) Cooling air temperature rise / heating short circuits Battery defective or discharged



* CPD = Charge pressure-dependent full-load stop



P Elektrics



P



75 of 88



BOMAG



TRAINING



FAYAT GROUP



Fault and remedies,



(Fault table 2 of 2)



Faults



Measures



Engine does not start or is difficult to start (Starting speed is not achieved on starting)



Check



P



Adjust



E



Replace



W



Engine starts, but runs irregularly or fails Engine becomes excessively hot, Temperature warning system responds Engine output is deficient



Engine does not run on all cxlinders Engine oil pressure is non-existant or excessively



Clean



R



Top up



A



Reduce



S



Engine oil consumption excessive Engine smokes – blue Engine smokes – white Engine smokes – black Cause



Section



Cable connections, starter, electrical circuit loose or oxidised



Elektrics



P



Engine



E



Starter defective or pinion does not engage Incorrect valve clearance



P



Injection line leaks



P



Ventilation line blocked (coolant heat exchanger)



P/R



Sheathed glow plugs defective



P



Injection valve defective



P/W



Air in the fuel system



P/W



Fuel filter / fuel pre-cleaner soiled



P/R/W



Oil filter defective Incorrect engine lube oil SAE class or quality



W Operating media



W



Fuel quality not as per operation manual



P/W



Coolant deficiency



P/A



76 of 88



BOMAG



TRAINING



FAYAT GROUP



Fault and remedies,



(fuel pressure relief valve 5.0 bar, leak oil)



Fuel pressure relief valve identification



1



Pressure relief valve 5.0 bar: groove turned in at the hexagon head



1 fuel pressure relief valve 5.0 bar (if pressure retaining valve is leaky, engine does not start or badly)



BOMAG FAYAT GROUP



77 of 88



TRAINING Fault and remedies



Engine becomes excessively hot, temperature warning system activates



The thermostat housing rusted strongly and has deposits. The cooling water circuit is disabled and the cooling water temperature rises. The engine was operated without cooling system protective agent concentration.



BOMAG FAYAT GROUP



78 of 88



TRAINING Fault and remedies



Engine becomes excessively hot, temperature warning system activates



(Fan bracket) The screwing in connection piece to the compensation tank is in cross-section due to rust and deposits greatly reduced. The cooling water circuit is disabled and the cooling water temperature rises. The engine was operated without cooling system protective agent concentration.



BOMAG FAYAT GROUP



79 of 88



TRAINING Fault and remedies Engine oil is in the cooling water,



The engine oil cooler is damaged by cavitation. This allowed the engine oil get into the coolant. The engine was operated without or with insufficient cooling system protective agent concentration.



BOMAG FAYAT GROUP



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TRAINING



BOMAG Coolants and Lubricants. Developed for optimisation of performance and liftime.



81 of 88



BOMAG



TRAINING



FAYAT GROUP



BOMAG Coolants and Lubricants. Developed for optimisation of performance and liftime.



Developed to protect your machine. BOMAG Coolants and Lubricants are developed according to strict quality standards and particularly designed for your BOMAG machine. BOMAG Genuine Engine Oils, Hydraulic Oils, Gear Oils and Coolant Additives are exactly adjusted to the respective component of the machine.



They help prevent unnecessary wear and thus avoid costly damage and down-time of your BOMAG machine. BOMAG Coolants and Lubricants stand out through their high grade and constant quality and increase performance extended lifetime reduce fuel and oil consumption



BOMAG FAYAT GROUP



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TRAINING BOMAG Engine Oil SAE 10W – 40



Ultra-high-performance, fuel-efficient engine oil – Specially developed for maximum utilization of extended oil change intervalls. Application: BOMAG Engine Oil has a higher performance capacity than the usual high-performance engine oils. Regardless of service life, even older diesel engines can be changed to BOMAG Oil without flushing. BOMAG Engine Oil offers reliable protection against deposits, sludge and adhesion. This capacity enables longest oil change intervalls.



Advantages: reduced fuel consumption due to low-friction characteristics high wear protection even under continuous stress at full engine load fastest possible oil circulation after start, thus reducing cold start and warm up wear reduction of exhaust gas particles protection against corrosion even when using diesel fuels with high sulphur content optimal compatibility with sealing materials environmentally friendly due to longest oil change intervalls and low evaporation losses



BOMAG Engine Oil approvals ACEA E7/E5/E4 API CI-4 20Ltr. BOMAG Part No. 009 920 06



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BOMAG



TRAINING



FAYAT GROUP



BOMAG Gear Oil 80W - 140 Super-high-performance Gear Oil for extended machine lifetime. Application: BOMAG Gear Oil is particularly developed for use highly stressed gears, planetary drive axles and pump transfer gears. It is also suitable for synchromesh and non-synchromesh gearboxes, power distributors and auxiliary gearboxes for which an oil in accordance to API GL-4/GL-5 is mandatory. In order to exploit the full product properties, a complete gear oil replacement is recommended when changing to BOMAG Gear Oil.



Advantages: exceptionally shear stable and thus within fresh oil viscosity in accordance



to SAE class 80W – 140 even after very long application periods high additive reserves extend oil change intervals according to manufacturer specification stable lubrication film even under highest stress guarantees outstanding wear protection at best possible gearbox efficiency extraordinary protection against corrosion avoid oil thickening and deposits good elastomer compatibility avoids leakages



BOMAG Gear Oil approvalls



safe disposal of BOMAG Gear Oil 80W – 140 as waste oil



API GL-4/GL-5 20Ltr. BOMAG Part No. 009 925 07



BOMAG FAYAT GROUP



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TRAINING BOMAG Exciter Oil SAE 75W – 90



Fully-synthetic, high-performance oil for noticeable extended operating times of exciter systems.



Application: BOMAG Exciter Oil SAE 75W – 90 is especially developed for use in highly stressed exciter units. It can also be applied as an all-purpose, energy-saving, low-friction exciter oil for certain axles with brakes or limited slip differentials.



Advantages: particularly developed, synthetic oil with noticeable extended operating times of exciter systems and thus reduction of costs when compared to common engine oils maximal utilization of il change intervals, even under extreme strain extended oil change intervals for certain applications (see BOMAG maintenance manuals and operating instructions)



BOMAG Exciter Oil approvals Exceeds



API GL-4/5 20Ltr. BOMAG Part No. 009 925 05



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BOMAG



TRAINING



FAYAT GROUP



BOMAG Hydraulic Oil with high viscosity index – for best shear stability. Application: BOMAG Hydraulic Oil is a HVI multi-grad hydraulic oil with extraordinary high-pressure and high temperature resistance. For hydraulic applications involving low starting temperatures or strongly erratic temperatures, oils offering a high viscosity index are recommended and employed. BOMAG Hydraulic Oil reduce the energy input when starting the equipment and thus also the wear and cavitation risk on the pump. At the same time, the viscosity remains stable under higher higher temperatures and ensres sufficientlubrication even under high pressures. This results in improved wear protection and thus increases efficiency and lifetime of hydraulic components.



Advantages: outstanding shear stability very good viscosity-temperature-characteristcs high viscosity index excellent low temperature characteristics low foaming tendency remarkable air release properties high durability and good corrosion protection



BOMAG Hydraulic Oil



substantial wear protection



wide temperature range



approvals HVLP 46 20Ltr. BOMAG Part No. 009 930 09



BOMAG FAYAT GROUP



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TRAINING BOMAG Coolant Additive



Reliable protection against damage due to cavitation, frost, corrosion and overheating. Application: BOMAG Coolant Additive is a coolant antifreeze concentrate based on monoethylene glycol and is free from nitrites, amines and phosphates. Due to the configuration of ist active agents, it is classified as a hybrid antifreeze. BOMAG Coolant Additive offers relable protection against cavitation, frost, corrosion and overheating. Ist highly effective formula protects the metals used in the cooling system from corrosion and deposits and also preserves all common salings, plastics and hose lines.



Advantages: distinguished for aluminium engines, cylinder heads and radiators safe protection against deposits, cavitation and corrossion



BOMAG Coolant Additive approvals ASTM D 3306



BOMAG Coolant Additive is a concentrate and can be individually diluted according to requirements 20Ltr. BOMAG Part No. 009 940 08



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BOMAG



TRAINING



FAYAT GROUP



BOMAG Coolants and Lubricants Overview of applications



20Ltr. Pallet =30 x 20Ltr. 205Ltr.



BOMAG Engine Oil Part No. 00992006 Part No. 00992006C30 Part No. 00992004



Diesel engines Gasoline engines* Vibration – Excitersystems Tamper exciter units BW24/25/27RH gearboxes Engine cooling systems Hydraulic systems Planetary driving axles Planetary gearboxes



Pump transfer gears * ( Petrol) Gasoline engines in BOMAG machines



BOMAG Exciter Oil Part No. 00992505 Part No. 00992505C30



BOMAG Coolant Additive Part No. 00994008 Part No. 00994008C30



BOMAG Hydraulic Oil Part No. 00993009 Part No. 00993009C30



BOMAG Gear Oil Part No. 00992507 Part No. 00992507C30



BOMAG FAYAT GROUP



Thank you very much for your attention.



by winni 14.03.2011



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