16 Engine

008 916 89 BOMAG 593

16.1 Diesel engine

16.1 Diesel engine The engines are characterized by the following posi-
tive features:
Series 4 single drum rollers are powered by 4 or 6 cyl- l compact design
inder Deutz diesel engines type TCD 2013 or a 6-cyl- l
low noise level
inder engine TCD 2012.
l
almost vibration free operation
The engines are water cooled in-line engines with
EMR3 electronics.
l
low fuel consumption
The engines are mainly designed in two-valve tech-
l low exhaust emission EPA/COM IIl
nology with turbo charging and intercooler. They are l
high power density
highly compact and come with a Deutz-Common-Rail l
excellent access to all service locations.
injection system, called DCR in short. l
high reliability
All engines are designed with exhaust gas recircula- l
low running costs,
tion and thus reach emission values complying with l
long lifetime
EPA/ COM/ Tier/ stage lll

Fig. 1 Deutz diesel engine TCD 2012 and 2013

594 BOMAG 008 916 89

Engine description TCD 2012 16.2
16.2 Engine description TCD 2012

Fig. 1 Deutz diesel engine TCD 2012, right hand side 13 Flywheel or (transmission connection SAE)
14 Crankcase ventilation valve
1 Lubrication oil filling neck 15 Transport device
2 Combustion air inlet 16 Charge air line
3 Cover 17 Fuel control unit
4 Fan
5 Generator
6 Fuel lift pump
7 Idler pulley
8 Lubrication oil cooler
9 Fuel filter
10 Replaceable lubrication oil filter
11 Lubrication oil sump
12 Possible installation of hydraulic pump or com-
pressor (optional)

008 916 89 BOMAG 595

16.2 Engine description TCD 2012

Fig. 2 Deutz diesel engine TCD 2012, left hand side

1 Exhaust manifold
2 Exhaust turbo charger
3 Lubrication oil filling neck (optional)
4 Engine mounts
5 Lubrication oil return line from exhaust gas turbo
charger
6 Relay (starter)
7 Ribbed V-belt
8 Coolant inlet
9 Coolant outlet
10 Coolant pump
11 Connection cabin heater ort compensation line

596 BOMAG 008 916 89

Lubrication oil circuit TCD 2012 / 2013 16.3
16.3 Lubrication oil circuit TCD
2012 / 2013

25 26 23 22 18 12
12
123 19 20 21 17 15 11
12

8 7 6
5

24

27 1
1
1 14 13 16 10 9 4 2 3
Fig. 1 Lubrication oil diagram 17 Piston cooling nozzle with pressure maintaining
valve
1 Lubrication oil sump 18 Plunger with rocker arm pulse lubrication
2 Lubrication oil suction pipe 19 Push rod, lubrication oil supply for rocker arm lu-
3 Lubrication oil pump brication
20 Rocker arm
4 Pressure relief valve
21 Return line to lubrication oil sump
5 Lubrication oil cooler
6 Return flow check valve (only on 2012) 22 Lubrication oil flow to exhaust turbo charger
23 Exhaust turbo charger
7 By-pass valve
24 Return line from compressor / hydraulic pump to
8 By-pass valve lubrication oil filter
crankcase
9 Pressure control valve
25 Compressor or hydraulic pump
10 Replaceable lubrication oil filter
26 Lubrication oil line to crankshaft and camshaft,
11 Main lubrication oil lines compressor / hydraulic pump
12 Internally switched exhaust gas recirculation 27 Return flow from exhaust turbo charger
13 Crankshaft bearings
14 Conrod bearings
15 Camshaft bearings
16 Line to spray nozzle

008 916 89 BOMAG 597

16.4 Coolant circuit TCD 2012 / 2013

16.4 Coolant circuit TCD 2012 /

2013

Fig. 1 Fuel diagram

1 Coolant outlet on radiator

2 Thermostat
3 Coolant - supply to water pump
4 Coolant pump
5 Lubrication oil cooler
6 Cylinder cooling
7 Cylinder liner / head cooling
8 Coolant flow to heater
9 Cabin heater (optional)
10 Coolant to thermostat
11 Connection for cabin heater
12 Compensation line
13 Ventilation line to compensation tank
14 Coolant outlet to radiator
15 Compensation tank
16 Compensation line to heat exchanger

598 BOMAG 008 916 89

Fuel system TCD 2012 / 2013 16.5
16.5 Fuel system TCD 2012 / 2013

Fig. 1 Coolant diagram 12 Fuel return flow on cylinder head

13 Fuel return line to fuel tank
1 Fuel tank A= minimum distance 500 mm 14 Fuel lines from fuel control unit to high pressure
2 Fuel pre-filter with pre-pressure pumping possibil- pumps and rail
ity to fill the low pressure section (provided by cus- 15 Fuel lift pump 2013
tomer)
3 Line to fuel lift pump
4 Fuel lift pump
5 Fuel filter
6 Fuel supply line to fuel control unit
7 Rail
8 High pressure pump
9 Fuel supply line to injector
10 Injector
11 FCU (Fuel Control Unit)

008 916 89 BOMAG 599

16.5 Fuel system TCD 2012 / 2013

Fuel pre-filter

Fig. 2 Fuel pre-filter

1 Fuel supply to pump

2 Fuel return flow from FCU (Fuel Control Unit)
3 Manual fuel pump with bayonet lock to lock and
unlock
4 Thermostat valve with shut-down lever
5 Filter cartridge
6 Possibility to connect an electric water level sen-
sor
7 Drain tap
8 Water collecting bowl
9 Fuel inlet from fuel tank
10 Fuel return flow to fuel tank
A Electric water level sensor

600 BOMAG 008 916 89

Fuel system TCD 2012 / 2013 16.5
TCD 2013 Fuel filter system

5
2
2

11 13
4
4

Fig. 3 TCD 2013 Fuel system

1 Fuel pre-filter
2 Hand pump
3 Fuel pressure filter min. 3µm
4 Input fuel control unit
5 Fuel low pressure sensor

008 916 89 BOMAG 601

16.5 Fuel system TCD 2012 / 2013

TCD 2012 Fuel filter system

2
2

2
5
4
1
1 1
4 3 4

Fig. 4 TCD 2012 Fuel system

1 Fuel pre-filter
2 Hand pump
3 Fuel pressure filter min. 3µm
4 Input fuel control unit
5 Fuel low pressure sensor

602 BOMAG 008 916 89

Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 16.6
16.6 Deutz Common Rail (DCR) in- tion solely controlled by mapping is only possible un-
der this condition. Injection timing and injection
jection system for TCD 2012 / quantity are controlled by the engine electronics. The
2013 electric signals control an electrically operated valve
per cylinder, which is integrated in the injection noz-
The diesel engines type TCD 2012 and 2013 are zle. The short distances between valve and injection
equipped with a "Deutz Common Rail" injection sys- nozzle result in short pressure rise times, which has a
tem, DCR in short. positive effect on the combustion process and its con-
The English term "Common Rail" indicates that the trol. Various types of injection van be realized, e.g.
system is based on a common rail. It describes the pre-injection, main injection and post-injection. These
use of a common high pressure fuel line with corre- are freely controllable, in dependence on the control
sponding branches to supply all cylinders with fuel. unit.
The "Common Rail" injection is an injection system for The electric control is accomplished by the electronic
combustion engines, in which a high pressure pump control unit (EDC16) with EMR3, in dependence on
pressurizes the fuel to a high pressure level. The pres- the operating parameters. The system is capable of
surized fuel fills a piping system, which is permanently providing a wide range of limp-home functions, should
under pressure while the engine is running. any of the sensors fail. This ensures a reliable and
safe completion of travel and work.
The general idea is the total isolation of the pressure
generation from the actual injection process. An injec-

Overview of electronic diesel fuel control

Sensors Control unit (EMR3) Actuators

Injector
Rail

Pump

Fig. 1 TCD 2012 and 2013

008 916 89 BOMAG 603

16.6 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013

10
8

7
5

11
9
4 1

12

Fig. 2 Schematic of the Deutz Common Rail System "DCR" Under normal conditions the rail pressure is be-
tween 300 and 1350 bar
1 Fuel filter high pressure The PRV is set to 1600 bar
2 Fuel low pressure sensor (5-7bar) B145
If the PRV is defective or always open, the pres-
3 High pressure pumps
sure in the rail will only build up to max. 700 bar.
4 Fuel lift pump
The rail pressure must be at least 1.5 bar to start
5 Rail (high pressure pipe up to 1600 bar)
the diesel engine
6 PRV (max. rail pressure limitation 1600bar)
7 Rail pressure sensor (B935) The fuel low pressure sensor is located after the
fuel filter and the pressure is normally between 5
8 Injectors (Y148)
and 7 bar.
9 FCU Fuel Control Unit (Y137)
10 Engine control EDC16 - EMR3 The solenoid valve of the Fuel Control Unit (FCU)
is dead, open towards the tank.
11 Fuel filter with water separator
12 Hand pump The voltage applied to the injectors is normally
approx. 40 V.

604 BOMAG 008 916 89

Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 16.6
FCU Fuel Control Unit (Y137)

electric connection

Fig. 3 Fuel Control Unit FCU

Two high pressure pumps

High pressure

Low
pressure

High pressu
pumps

Fig. 4 High pressure pump

008 916 89 BOMAG 605

16.6 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013

Injector ( Y148 )

electric connections

Return flow

Armature group

Nozzle

Supply

Fig. 5 Injector

Wiring diagram page 4

Engine control EDC16 - EMR3

FCUFCU

Fig. 6 Excerpt from the wiring diagram

606 BOMAG 008 916 89

Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 16.6
TCD 2013

5
7 6

2
4

1 3

Fig. 7 TCD 2013

1 Fuel pre-filter
2 Hand pump
3 Fuel filter
4 FCU Fuel Control Unit (Y137)
5 Rail
6 Fuel low pressure sensor (B145)
7 Connecting plug EMR3

008 916 89 BOMAG 607

16.6 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013

TCD 2012

2 5
6
7
4
2
4
5 1
6

Fig. 8 Diesel engine TCD 2012

1 Rail pressure sensor (B93)

2 Rail pressure PRV
3 Fuel filter
4 FCU Fuel Control Unit (Y137)
5 Rail
6 Fuel low pressure sensor (B145)
7 Connecting plug EMR3

608 BOMAG 008 916 89

Exhaust gas recirculation TCD 2012 / 2013 16.7
16.7 Exhaust gas recirculation TCD
2012 / 2013
In order to be able to meet the exhaust gas stand-
ards EC and stage/Tier3, all engines are designed
with exhaust gas recirculation.

On 4-cylinder engines TCD 2012/2013 the exhaust

gas recirculation has been realized internally
through the intake valves, on 6-cylinders through
the exhaust valves. For this purpose the camshaft
has been manufactured with an additional cam for
short-term opening of the intake valve or exhaust
valve respectively.

Fig. 1 Exhaust/intake valve control TCD 2012 / 2013

008 916 89 BOMAG 609

16.8 Wastegate - charge pressure controller on TCD-engines

16.8 Wastegate - charge pressure tion with the exhaust gas bypass valve. Depending on
this bypass valve hot exhaust gases flow past the ex-
controller on TCD-engines haust gas turbine into the exhaust without the availa-
ble energy being utilized
The Wastegate is a exhaust gas bypass valve and
is located on or in the exhaust turbocharger The bypass valve is normally closed
The Wastegate (exhaust gas bypass valve) is used
to control the charge pressure
The charge pressure control takes place by means of
a charge pressure triggered pressure valve in connec-

Control line

Pressure contro

Bypass valve
closed

Fig. 1 Exhaust gas turbocharger with Wastegate

Wastegate active, charge pressure control, i.e. by-

pass valve open

Bypass valve
open

Fig. 1 Exhaust gas turbocharger with Wastegate

610 BOMAG 008 916 89

Wastegate - charge pressure controller on TCD-engines 16.8
Wastegate on TCD 2013

Fig. 2 Exhaust gas turbocharger with Wastegate

008 916 89 BOMAG 611

16.9 Engine problems

16.9 Engine problems

Fault Possible cause Remedy

Engine does not Temperature below starting limit Check

start or starts Oil level too low Fill up lubrication oil
poorly
Lubrication oil level too high Check the lubrication oil level, drain off
Lubrication oil cooler defective if necessary
Check

Exhaust gas counter pressure too high Check

V-belt/ribbed V-belt (fuel pump in belt drive) check, whether torn or loose

Engine oil with wrong SAE viscosity class Change the lubrication oil

Fuel quality not as specified in the operating Change the fuel

instructions

Air in the fuel system Bleed the fuel system

Battery defective or not charged Check the battery

Cable to starter loose or oxidized Check cable connection

Starter defective or pinion does not engage Check starter

Engine does not Engine electronics prevent starting Check fault by fault code, repair as nec-
start and diag- essary
nostic lamp
flashing

Engine starts, V-belt/ribbed V-belt (fuel pump in belt drive) check, whether torn or loose
but runs irregu-
larly or misfires Incorrect valve clearance Adjust

Injector defective Replace

Injection valve defective Check / replace the injection valve

Glow plug defective Replace

Air in the fuel system Bleed the fuel system

Fuel pre-cleaner soiled Clean/replace

Fuel quality not as specified in the operating Change the fuel

instructions

Injection line leaking Check the injection line

Speed changes Engine electronics detected a system fault Check fault by fault code, repair as nec-
are possible and and activates a substitute speed essary
diagnostic lamp
lights

612 BOMAG 008 916 89

Engine problems 16.9
Fault Possible cause Remedy

Engine over- Bleeding line clogged Clean ventilation line

heating, temper-
ature warning Injector defective Replace
system re- Coolant heat exchanger soiled Clean
sponds
Coolant pump defective (V-belt torn or check, whether torn or loose
loose)

Lack of coolant Fill up

Charge air pipe leaking Check the charge air pipe

V-belt/ribbed V-belt (fuel pump in belt drive) check, whether torn or loose

Lubrication oil filter soiled Replace

Lubrication oil level too low Fill up lubrication oil

Lubrication oil level too high Check the lubrication oil level, drain off
if necessary

Air filter clogged / exhaust turbocharger de- Check/replace

fective

Fan defective / V-belt torn or loose Check fan / V-belt, replace if necessary

Short circuit of heat in cooling system Check the cooling system

Resistance in cooling system too high / flow Check the cooling system
quantity too low

Engine has to Lubrication oil level too low Fill up lubrication oil
low or no oil
pressure Engine oil with wrong SAE viscosity class Change the lubrication oil

Insufficient en- Engine oil level too high Drain the engine oil down to the top dip-
gine power stick mark

Fuel quality not as specified in the operating Change the fuel

instructions

Air filter clogged / exhaust turbocharger de- Check/replace

fective

Charge air pipe leaking Check the charge air pipe

Intercooler soiled Clean

Injection line leaking Check the injection line

Injector defective Replace

Injection valve defective Check the injection valve

Insufficient en- Engine electronics reduces the power Check fault by fault code, repair as nec-
gine power and essary
diagnostic lamp
lights

Engine does not Injection line leaking Check the injection line
work with all cyl-
inders Injection valve defective Check / replace the injection valve

008 916 89 BOMAG 613

16.9 Engine problems

Fault Possible cause Remedy

Engine has ex- Lubrication oil level too high Check the lubrication oil level, drain off
cessive oil con- if necessary
sumption

Blue engine ex- Lubrication oil level too high Check the lubrication oil level, drain off
haust smoke if necessary

White engine Temperature below starting limit Check

exhaust smoke
Fuel quality not as specified in the operating Change the fuel
instructions

Injection valve defective Check/replace

Black engine ex- Air filter clogged / exhaust turbocharger de- Check/replace
haust smoke fective

Charge air pipe leaking Check charge air line

Injection valve defective Check / replace the injection valve

Injector defective Replace

614 BOMAG 008 916 89

Check the engine oil level 16.10
16.10Check the engine oil level 16.11Change engine oil and oil filter
cartridge
Danger
!

Danger of injury! Danger

!

Support the engine hood for all maintenance and Danger of scalding!
repair work.
Danger of scalding by hot oil when unscrewing
the filter cartridge.
i Note
The machine must be parked horizontally with the en- Caution
!
gine shut down.
Drain the oil only when the engine is warm.
For quality and quantity of oil refer to the "table of
fuels and lubricants".

Environment
Catch running out oil and dispose of environmen-
tally together with the oil filter cartridge.

Fig. 3
l
Pull the dipstick (Fig. 3) out, wipe it off with a lint-
free, clean cloth and reinsert it until it bottoms.
l
Pull the dipstick back out again.
l
If the oil level is below the "MAX" mark fill in oil.
l
If the oil level is above the “Max” mark determine the
cause and drain the oil off. Fig. 4
l
Unscrew the drain plug (Fig. 4) and catch running
!Caution out oil.
Before longer work periods you should always top l Turn the drain plug tightly back in.
the oil up to the "MAX"-mark.

For quality and quantity of oil refer to the table of

fuels and lubricants.

Fig. 5
l
Thoroughly clean the outside of the filter cartridge
(Fig. 5).
l Unscrew the filter cartridge using an appropriate fil-
ter wrench.

008 916 89 BOMAG 615

16.12 Change the fuel pre-filter cartridge

l
Clean the sealing face on the filter carrier from any 16.12Change the fuel pre-filter car-
dirt.
tridge
l
Slightly oil the rubber seal on the new filter car-
tridge.
Danger
!

Fire hazard!
When working on the fuel system do not use open
fire, do not smoke and do not spill any fuel.
Catch running out fuel, do not let it seep into the
ground.
Do not inhale any fuel fumes.

Fig. 6
l
Turn the new filter cartridge (Fig. 6) on by hand, until
the seal contacts.
l
Tighten the filter element for another half turn.

Fig. 8
l
Slacken the bleeding screw (Fig. 8) on the fuel pre-
filter for 2 to 3 turns.

Fig. 7
l
Fill in new engine oil (Fig. 7).
l
Tighten the oil filler cap properly.
l
After a short test run check the oil level on the dip-
stick . The oil level should reach the MAX-mark, top
up oil if necessary.
Fig. 9
l
Check filter cartridge and drain plug for leaks.
l
Pull the cable off the water separator and unscrew
the fuel filter cartridge (Fig. 9) using an appropriate
filter wrench.
l
Clean the sealing face on the filter carrier from any
dirt.

616 BOMAG 008 916 89

Change the fuel pre-filter cartridge 16.12
Environment
Catch running out fuel and dispose of environ-
mentally.

Fig. 10
l Unscrew the water separator from the filter car-
tridge (Fig. 10).

Fig. 12
l With the bleeding pump loosened operate the hand
pump manually, until fuel flows out of the slackened
bleeding screw (Fig. 12) without air bubbles.
l Then tighten the bleeding screw while pumping.

Fig. 11
l
Apply a thin coat of oil to the rubber seal of the water
separator 1 (Fig. 11).
l Screw the water separator on by hand (2), until the
seal contacts.
l Tighten the water separator for another half turn (3).
l
Fill the filter cartridge with clean diesel fuel (4).
l
Apply some oil to the rubber seal of the filter ele-
ment (5) and screw it on by hand, until the seal con-
tacts.
l
Tighten the filter element for another half turn (6).
l
Plug the water sensor cable back on.
l
Check the filter cartridge for leaks after a short test
run.

i Note
Air in the fuel system causes irregular running of the
engine, a drop in engine power, stalls the engine and
makes starting impossible.
Therefore bleed the fuel system after changing the
fuel pre-filter.

008 916 89 BOMAG 617

16.13 Replace the fuel filter cartridge

16.13Replace the fuel filter car-

tridge

Danger
!

Fire hazard! Health hazard!

When working on the fuel system do not use open
fire, do not smoke and do not spill any fuel.
Do not inhale any fuel fumes.

Caution
!

Ensure strict cleanliness! Thoroughly clean the Fig. 14

area around the fuel filters. l Slightly oil the rubber seal (Fig. 14) on the new filter
The filter cartridge must never be filled before- cartridge.
hand. l
Turn the new filter cartridge on by hand, until the
After work on the fuel system bleed the system, seal contacts.
perform a test run and check for leaks. l
Tighten the filter element for another half turn.
Additional bleeding of the fuel system by a 5 l
Check the filter cartridge for leaks after a short test
minute test run in idle speed or low load is manda-
run.
tory.

Environment
Catch running out fuel and dispose of environ-
mentally.

Fig. 13
l
Loosen and unscrew the fuel filter cartridge (Fig.
13) using an appropriate filter wrench.
l
Clean the sealing face on the filter carrier from any
dirt.

618 BOMAG 008 916 89

Check, clean the water separator 16.14
16.14Check, clean the water sepa- 16.15Check the coolant level
rator
Danger
!

Danger
! Danger of scalding!
Danger of injury! Fill up coolant only when the engine is cold.
Support the engine hood for all maintenance and
repair work. !Caution
If, during the daily inspection the coolant level is
i Note found to have dropped, check all lines, hoses and
The service intervals for the water separator depend engine for leaks.
on the water content in the fuel and can therefore not Do not use radiator sealant to seal leaks.
be determined precisely. After taking the engine into
For quality and quantity of coolant refer to the "ta-
operation you should therefore check the water sepa-
ble of fuels and lubricants".
rator every day for signs of water.
If a to high quantity is drained off, the filter must be re-
filled with fuel. See chapter "maintenance as re-
quired", bleeding the fuel system.

Environment
Catch running out fuel and dispose of environ-
mentally.

Fig. 16
l
Check the coolant level (Fig. 16).
l
To top up unscrew the filler cap and fill in coolant up
to the MAX-mark.

Fig. 15
l Slacken the drain plug (Fig. 15) for a few turns and
catch running out fuel / water.
l Tighten the drain plug again and check for leaks, if
necessary replace the seal ring.

008 916 89 BOMAG 619

16.16 Change the coolant

16.16Change the coolant

Danger
!

Danger of scalding!
Change the coolant only when the engine is cold.

Environment
Catch running out coolant and dispose of environ-
mentally.

Fig. 19
l Unscrew the cap and fill in coolant up to the MAX-
mark (Fig. 19).

For quality of coolant refer to the chapter 5.2, fuels

and lubricants.
l
Start the diesel engine and run it warm to operating
temperature.
l
Let the engine cool down and check the coolant lev-
el again, top up if necessary.

Fig. 17
l Set the cock valve for the cabin heater (Fig. 17) to
position "warm".

Fig. 18
l
Unscrew the plug (Fig. 18), let the coolant run out
and catch it .
l
Screw the plug back in once all coolant has run out.

620 BOMAG 008 916 89

Checking the thermostat in disassembled state 16.17
16.17Checking the thermostat in The temperature increase should not exceed 1°C/
min, as otherwise the start of opening will be delayed
disassembled state accordingly.
The thermostat serves the optimal temperature con-
trol of the coolant, in order to promote efficient com-
bustion and to bring the engine quickly to operating
temperature after starting. At temperatures below ap-
prox. 83°C the thermostat is closed. Once the coolant
temperature has reached about 83°C, the thermostat
will start to open, at about 95° C it is fully open. In this
condition the full coolant flow is guided through the ra-
diator.

Fig. 3
l
Measure and write down the measurement "b" on
the thermostat . (Fig. 3).
l
Calculate the stroke.

Stroke = b - a

i Note
Fig. 1 The stroke at the given temperature (T2) should be
min. 8 mm.
l Measure and write down the measurement "a" on
the thermostat (Fig. 1).

i Note
"a" = beginning of stroke at approx. 83 ± 2°C (T1)
"b" = end of stroke at approx. 95 °C (T2)

Fig. 2
l Warm up the thermostat in a water bath (Fig. 2).

i Note
In order to determine the exact start of opening the
temperature should be measured as close to the ther-
mostat as possible, but without touching it.
The water must thereby be stirred continuously, to en-
sure even temperature distribution.

008 916 89 BOMAG 621

16.18 Service the combustion air filter

16.18Service the combustion air fil- Removing the main filter element
ter

Caution
!

Perform cleaning, maintenance and repair work

only with the engine shut down. Do not start the
engine after removing the filter element.

Fig. 6
l
Loosen both locking hooks (Fig. 6) on the housing
cover and take the cover off.

Fig. 4
Maintenance of the dry air filter is due when control
light 1 (Fig. 4) in the fault monitoring board lights per-
manently when the engine is running, but at the latest
after 2 years.

i Note
Once the air filter service indicator lights up, work may
be continued until the end of the day.
Fig. 7
l
Pull out the main filter element (Fig. 7) with light
turning movements.

Cleaning the main filter element

!Caution
If necessary, the main filter element may be
cleaned up to five times. It must be renewed at the
latest after a maximum utilization period of two
years.
The number of cleaning intervals of the main filter
Fig. 5 element can be marked on the safety element with
a ball pen or a felt pen.
l
Open the engine hood (Fig. 5) completely and se-
cure it. Cleaning does not make sense if the main filter el-
ement is covered with a sooty deposit. Use a new
filter cartridge.
Incorrectly handled inserts may be ineffective be-
cause of damage (e.g. cracks) and cause damage
to the engine.
Replace the safety cartridge if the main filter ele-
ment is defective!

622 BOMAG 008 916 89

Service the combustion air filter 16.18
Additional cleaning intervals between two filter Cleaning the dust bowl
services signalized by the fault monitoring board
are not necessary.

Fig. 10
l
Pull the internal part (Fig. 10) out and remove the
Fig. 8
dust from the cover.
l
Blow the filter cartridge out from inside to outside l Reinsert the inner part.
with dry compressed air (max. 5 bar) (Fig. 8), until
all dust has been removed.
!Caution
When assembling the inner part make sure that
the notch in the cover engages in the opening of
the inner part.

Installing the main filter element

l Slide the main filter element carefully into the hous-
ing.
When closing the housing cover the main filter ele-
ment is automatically forced in the correct position.

Changing the safety filter element

Fig. 9
l Examine the filter cartridge with a torch for cracks ! Caution
and holes in the paper bellows (Fig. 9). The safety filter element must not be cleaned and
should not be used again after it has been re-
Caution
!
moved.
Do not continue to run the machine with a dam- Break the seal only to replace the safety filter ele-
aged main filter element. If in doubt use a new ment.
main filter element. The safety filter element must be replaced:
If the main filter element is defective.
after five service intervals of the filter cartridge,
at the latest after 2 years,
if the warning light comes on again after servicing
the main filter cartridge.
l
Remove the housing cover and pull the main filter
element off.

008 916 89 BOMAG 623

16.19 Check the dust separator

16.19Check the dust separator

Fig. 11
l Pull the safety element (Fig. 11) out by slight turning
movements. Fig. 12
l
Push in a new safety filter element. l
Unscrew wing nut 1 (Fig. 12) and remove cover (3).
l
Reassemble main filter element and cover. l
Clean housing (2).
l
Reassemble the dust separator.
Caution
!

Make sure that the cover locks engage correctly.

624 BOMAG 008 916 89

Cleaning the oil bath air filter 16.20
16.20Cleaning the oil bath air filter * 16.21Adjust the valve clearance

!Caution
We recommend to have this work carried out by
trained personnel or our after sales service.
Before checking the valve clearance let the engine
cool down for at least 30 minutes. The engine oil
temperature must be less than 80 °C.
l
Remove the valve covers.
l Turn the crankshaft with the cranking device until
the valves are overlapping.

i Note
Fig. 13
Firing sequence 1-5-3-6-2-4
l
Loosen the quick locks (Fig. 13), take the filter bowl
Overlapping of valves: Exhaust valve not yet closed,
off and empty it.
intake valve starts to open.
l Clean the filter mesh by repetitive dipping into die-
sel fuel.
Valves Cylinder
l Clean the filter bowl with diesel fuel and fill in engine overlapping 1 5 3 6 2 4
oil up to the level mark.
adjustment 6 2 4 1 5 3
l reinstall the filter bowl.

Fig. 14
l Loosen the counter nut (1) (Fig. 14).
l
Attach the rotation angle disc (3) and the spanner
socket (4) to the valve clearance adjustment screw
(2).
l
Fix the magnet (5) of the rotation angle disc.
l
Turn the rotation angle disc clockwise against the
stop (rocker arm no clearance) and set the scale to
zero.
l
Turn the rotation angle disc counterclockwise, until
the specified angle is reached.
* Option

008 916 89 BOMAG 625

16.22 Checking / replacing the ribbed V-belt

Intake valve = 75° +10° 16.22Checking / replacing the

Exhaust valve = 120° +10° ribbed V-belt
l Hold the rotation angle disc tight, so that it does not
turn, and tighten counter nut (1) .
Danger
!
Tightening torque: 20 Nm
Danger of injury!
l
Repeat this adjustment procedure an all other cylin-
Work on the V-belt must only be performed with
ders, after cranking the crankshaft accordingly.
the engine shut down.
l
Assemble the cylinder head cover with a new gas-
ket. Checking the wear limit of the ribbed V-
Tightening torque: 13 Nm belt
l
After a short test run check the engine for leaks.

Fig. 15
l
Check the distance between the tongue of the
moveable tensioner arm and the fixed tensioner
housing (Fig. 15).
l
If measurement "a" is smaller than 3 mm, replace
the ribbed V-belt.

Changing the ribbed V-belt

Fig. 16
l
Unscrew the fastening screws (Fig. 16) and slide
the fan forward.

626 BOMAG 008 916 89

Check the engine mounts 16.23
16.23Check the engine mounts

Fig. 17
l
Press idling pulley 1 (Fig. 17) in direction of arrow
using a socket wrench (3), until the locking pin (4) Fig. 18
engages in the assembly bore. l
Tighten fastenings of intake and exhaust manifolds
The ribbed V-belt (2) is thus relieved from tension. (Fig. 18) on the cylinder heads.
l Remove the ribbed V-belt first from the smallest roll- l
Check sockets and clamps between air filter, ex-
er or from the idling pulley. haust turbocharger and charge air line as well as
l Check the condition of the idling pulley, replace if the lubrication air line for tight fit and leaks.
necessary. l
Retighten the fastening screws for oil sump and en-
l
Install the new ribbed V-belt. gine mounts.
l
Counter the idling pulley with the socket wrench and
remove the locking pin.
l Relieve the idling pulley and tension the ribbed V-
belt.

008 916 89 BOMAG 627

16.24 Replacing the crank case pressure ventilation valve

16.24Replacing the crank case 16.25Engine conservation

pressure ventilation valve If the engine is to be shut down for a longer period of
time (e.g. over winter), please consult the service de-
partment of the engine manufacturer for further de-
tails.

Fig. 19
l
Replace the crank case ventilation valve (Fig. 18).

628 BOMAG 008 916 89