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Fayat Group BOMAG BC 972 RB-2 User manual

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Service - Manual
Catalogue number.
008 917 09 04/2012
BC 972 RB-2 / BC 1172 RS-2
S/N 101 570 84 ... > S/N 101 570 85 ... >
S/N 101 570 86 ... > S/N 101 570 87 ... >
Sanitary landfill compactor
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Table of Contents
BOMAG 3008 917 09
General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 14
1.4 Tightening torques 26
BOMAG Refuse Compactor 31
2.1 BOMAG Refuse Compactor 32
Technical data 39
3.1 Technical data 40
Maintenance 47
4.1 General notes on maintenance 48
4.2 Fuels and lubricants 49
4.3 Table of fuels and lubricants 52
4.4 Running-in instructions 53
4.5 Maintenance table 54
E-Plan wiring diagrams 57
5.1 Understanding wiring diagrams 58
5.2 Circuit symbols in the circuit diagram 68
5.3 Identification of switch blocks in the wiring diagram 71
5.4 Designation of components in the wiring diagram 72
5.5 Terminal designations in wiring diagram 73
Electrics 75
6.1 Battery ground and analog ground 76
6.2 Current and voltage 76
6.3 Pulse Width Modulation (PWM) 79
6.4 Resistance 81
6.5 Series / parallel connection 83
6.6 Ohm's law 85
6.7 Electrical energy 85
6.8 Formula diagram 86
6.9 Metrology 87
6.10 Diodes, relays, fuses 91
6.11 Telemecanique switch 94
6.12 Plug connectors 96
6.13 Magnetic coil plug 96
6.14 Deutsch plug, series DT and DTM 98
6.15 Plugs and terminals in spring clamping technology 103
6.16 Inductive proximity switches 107
6.17 Batteries 108
6.18 Battery service, checking the main battery switch 111
6.19 Starting the engine with jump leads 113
6.20 Main battery switch 113
6.21 Main fuse 114
6.22 Hydraulic oil temperature 114
6.23 Pressure switch, hydraulic oil filter 116
6.24 Magnetic sensor, hydraulic oil 119
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Table of Contents
BOMAG4008 917 09
6.25 Pressure switch for brake 120
6.26 Level sensor in diesel tank (R03) 121
6.27 Blower monitoring module A53 122
6.28 Electric installation box 123
6.29 Fuses 123
6.30 Fuse, cabin 124
6.31 Cab electrics 125
6.32 Machine related electrics 129
6.33 Electronic control units 135
6.34 Checking the voltage supply for the control unit 137
6.35 Diagnostics concept 145
Electronic control 149
7.1 ESX control 151
Engine electrics 239
8.1 Engine control unit 240
8.2 Pin assignment 242
8.3 System faults indicated by flashing code 248
8.4 Flashing code 250
8.5 Diagnose with SERDIA 252
8.6 Diagnose with CAN-bus 255
8.7 Diagnostics interface 256
8.8 EMR3 List of fault codes 258
8.9 Sensors 329
8.10 Oil pressure sensor 331
8.11 Fuel temperature sensor 335
8.12 Charge air temperature - charge air pressure sensor 336
8.13 EMR coolant temperature sensor 338
8.14 Rotary speed sensor for crankshaft 342
8.15 Rotary speed sensor for camshaft 343
8.16 Preheating system 344
8.17 Checking the preheating system. Maintenance in case of frost. 347
8.18 Sensor, water in fuel 348
8.19 Air filter vacuum switch 349
8.20 Coolant temperature sensor 350
8.21 Float switch, coolant tank 351
8.22 Charge control light, engine RPM-meter 352
8.23 Generator 353
8.24 Replacing the voltage regulator 362
8.25 Electric starter 364
Engine 371
9.1 Diesel engine 372
9.2 Engine description TCD 2015 V 8 cylinder 373
9.3 Lubrication oil circuit TCD 2015 375
9.4 Coolant circuit TCD 2015 376
9.5 Fuel circuit TCD 2015 377
9.6 Injection system (MVS) TCD 2015 380
9.7 Exhaust gas recirculation TCD 2015 383
9.8 Wastegate - charge pressure controller on TCD-engines 384
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Table of Contents
BOMAG 5008 917 09
9.9 Checking, adjusting the valve clearance 385
9.10 Checking the engine oil level 387
9.11 Changing engine oil and oil filter 388
9.12 Replace the fuel filter 389
9.13 Check, clean the water separator 391
9.14 Checking condition of radiator, intercooler and hydraulic oil cooler, clean,
cleaning the engine 392
9.15 Checking the coolant level 393
9.16 Changing the coolant 394
9.17 Check the anti-freeze concentration and the condition of the coolant 395
9.18 Checking the thermostat in disassembled state 396
9.19 Servicing the fan V-belt 397
9.20 Servicing the generator V-belt 399
9.21 Check the engine mounts 400
9.22 Check fastening of engine / turbocharger / combustion air hoses 401
9.23 Intercooler, draining off oil/condensation water 401
9.24 Checking the crankcase pressure 402
9.25 General trouble shooting chart TCD 2015 403
9.26 Special tools, Deutz engine (TCD 2015) 405
Automatic belt tensioner 425
10.1 Removing the belt tensioner (Deutz 2015 V6 & V8) 426
10.2 Preassembly of a belt tensioner for diesel engines 2015 V6 and V8 428
10.3 Installing the belt tensioner (Deutz 2015 V6 & V8) 437
Hydraulics 439
11.1 Hydraulic circuit 440
11.2 Travel pump A4VG110 DA 442
11.3 Travel pump A4VG110 HT 449
11.4 Steering and working pump, HA10VO 100 & HA 10 VO 100 454
11.5 Axial piston swash plate principle. 458
11.6 Troubleshooting axial piston pumps 460
11.7 Travel motor, A6VM 215EP 463
11.8 Trouble shooting, variable displacement axial piston motor 466
11.9 External gear pumps 468
11.10 Travel system 470
11.11 Towing the machine 479
11.12 Cooling 481
11.13 Steering and working hydraulics 484
11.14 Measuring and adjustment points on control valve block 488
11.15 Control valve block for steering and dozer blade 493
11.16 Replacing control block components 507
11.17 Check the hydraulic oil level 508
11.18 Replace hydraulic oil filter 509
11.19 Changing hydraulic oil and breather filter 510
11.20 Checking the oil level in the transfer box 512
11.21 Change oil and filter in the transfer box 512
Automatic air conditioning 515
12.1 Overview 516
12.2 Physical basics 517
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Table of Contents
BOMAG6008 917 09
12.3 Refrigerant R134a 520
12.4 Compressor oil / refrigeration oil 521
12.5 Working principle of the air conditioning system 522
12.6 Monitoring devices 522
12.7 Description of components 524
12.8 Climatronic control 533
12.9 Measuring the compressor oil level 538
12.10 Checking the magnetic clutch 538
12.11 Inspection and maintenance work 539
12.12 Servicing the air conditioning 540
12.13 Servicing the air conditioning compressor V-belt 542
12.14 Drying and evacuation 543
12.15 Emptying in case of repair 544
12.16 Leak test 544
12.17 Filling instructions 545
12.18 Trouble shooting in refrigerant circuit, basic principles 548
12.19 Trouble shooting, refrigerant circuit diagram 552
12.20 Trouble shooting procedure 553
12.21 Steam table for R134a 563
Central lubrication system 569
13.1 System layout 571
13.2 Technical description 572
13.3 Control 574
13.4 Lubrication process 578
13.5 Progressive distributor 578
13.6 Lubrication oil pump 581
13.7 Check the central lubrication system, top up 583
13.8 Faults and causes 584
13.9 Fault - Cause - Remedy 586
13.10 Failure of central lubrication system (grease emerges from relief valve) 588
Oscillating articulated joint 591
14.1 Articulated joint, repair overview 592
14.2 Disassembling and assembling the top bolt 594
14.3 Removing and installing the steering cylinders 600
Compactor wheels and dozer blade 607
15.1 Welding on new wheel caps 608
15.2 Adjust scrapers and edge cutter 610
15.3 Checking the condition of cutters, replacing the cutters if necessary 611
Suppliers documentation 613
16.1 Steering/working pump 615
16.2 Wheel drive 641
Circuit diagrams 715
17.1 Hydraulic diagram 717
17.2 Hydraulic diagram 571 908 16 721
17.3 Wiring diagram 79 725
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BOMAG 7008 917 09
1 General
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1.1 Introduction
BOMAG8008 917 09
1.1 Introduction
This manual addresses the professionally qualified
personnel or the after sales service of BOMAG, and
should be of help and assistance in correct and effi-
cient repair and maintenance work.
This manual describes the disassembly, dismantling,
assembly, installation and repair of components and
assemblies. The repair of components and assem-
blies is only described as this makes sense under due
consideration of working means and spare parts sup-
ply.
Documentation
For the BOMAG machines described in this manual
the following documentation is additionally available:
1 Operating and maintenance instructions
2 Spare parts catalogue
3 Wiring diagram*
4 Hydraulic diagram*
5 Service Information
Use only genuine BOMAG spare parts.
Spare parts needed for repairs can be taken from the
spare parts catalogue for the machine.
This manual is not subject of an updating service; for
this reason we would like to draw your attention to our
additional "Technical Service Bulletins".
In case of a new release all necessary changes will be
included.
In the course of technical development we reserve the
right for technical modifications without prior notifica-
tion.
Information and illustrations in this manual must not
be reproduced and distributed, nor must they be used
for the purpose of competition. All rights according to
the copyright law remain expressly reserved.
!Danger
These safety regulations must be read and ap-
plied by every person involved in the repair /main-
tenance of this machine. The applicable accident
prevention instructions and the safety regulations
in the operating and maintenance instructions
must be additionally observed.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG
* The applicable documents valid at the date of print-
ing are part of this manual.
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Safety regulations
BOMAG 9008 917 09
1.2
1.2 Safety regulations
Important notes
These safety regulations must be read and ap-
plied by every person involved in the repair /main-
tenance of this machine. The applicable accident
prevention instructions and the safety regulations
in the operating and maintenance instructions
must be additionally observed.
Repair work shall only performed by appropriately
trained personnel or by the after sales service of
BOMAG.
Workshop equipment and facilities as well as the
use and waste disposal of fuels and lubricants,
cleaning agents and solvent as well as gases and
chemicals are subject to legal regulations, which
are intended to provide a minimum on safety. It is
obviously your own responsibility to know and
adhere to these regulations.
This manual contains headers like "Note", "Attention",
"Danger" and "Environment", which must be strictly
complied with in order to inform about and avoid dan-
gers to persons, property and the environment.
i
Note
Paragraphs marked like this contain technical infor-
mation for the optimaleconomical use of the machine.
!
Caution
Paragraphs marked like this highlight possible
dangers for machines or parts of the machine.
!Danger
Paragraphs marked like this highlight possible
dangers for persons.
Environment
Paragraphs marked like this point out practices
for safe and environmental disposal of fuels and
lubricants as well as replacement parts.
Observe the regulations for the protection of the
environment.
General
lFor repair and maintenance work move the ma-
chine on a firm base and shut it down.
lAlways secure the machine against unintended roll-
ing.
lSecure the engine reliably against unintentional
starting.
lMark a defective machine and a machine under re-
pair by attaching a clearly visible warning label to
the dashboard.
lBlock the articulated joint with the articulation lock.
lUse protective clothes like hard hat, safety boots
and gloves.
lKeep unauthorized persons away from the machine
during repair work.
lTools, lifting gear, lifting tackle, supports and other
auxiliary equipment must be fully functional and in
safe condition.
lUse only safe and approved lifting gear of sufficient
load bearing capacity to remove and install parts or
components from and to the machine.
lDo not use easily inflammable or harmful substanc-
es, such as gasoline or paint thinners for cleaning.
lDo not smoke or use open fire and avoid sparks
when cleaning or repairing a tank.
lWhen performing welding work strictly comply with
the respective welding instructions.
Transport work with cranes and lifting
tackle
i
Note
Cranes must only be operated by instructed persons
who had been trained in handling cranes.
lFollow the operating instructions of the manufactur-
er when working with cranes.
lFollow the operating instructions of the operator
when working with cranes.
lAlways comply with the applicable accident preven-
tion instructions when working with cranes and lift-
ing tackle.
Precautions and codes of conduct for
welding work
Welding work must only be carried out by properly
trained personnel.
!Danger
Electric shock!
Sparks, fire hazard, burning of skin!
Infrared or ultraviolet radiation (arc), flashing of
eyes!
Health hazard caused by welding work on highly
alloyed work pieces, metal coatings, paint coat-
ings, plastic coatings, oil containing dirt deposits,
grease or solvent residues, etc.!
lCheck welding equipment and cables for damage
before use (also the validity of inspection stickers).
lEnsure good conductivity between ground cable
and workpiece, avoid joints and bearings.
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1.2 Safety regulations
BOMAG10 008 917 09
lStart the extraction fan before starting work and
guide with the progressing work as required.
lAlways isolate the burner when laying it down (re-
move possible electrode residues).
lProtect cables from being damaged, use cables
with insulated couplings.
lEnsure sufficient fire protection, keep a fire extin-
guisher at hand.
lWelding work in areas where there is a risk of fire or
explosion, must only be carried out with welding
permission.
lRemove any combustible materials from the weld-
ing area or cover such items appropriately.
lName a fire watch during and after welding work.
lPlace welding rod holders and inert gas welding
guns only on properly insulated bases.
lPlace the inert gas bottles in a safe place and se-
cure them against falling over.
lUse a protective screen or hand shield with welding
filter, wear welding gloves and clothes.
lSwitch the welding unit off before connecting weld-
ing cables.
lCheck electrode holders and electric cables at reg-
ular intervals.
Behaviour in case of faults
lIn case of faults on the welding unit switch of the
welding unit immediately and have it repaired by ex-
pert personnel.
lIn case of failure of the extraction system switch the
system off and have it repaired by expert personnel.
Maintenance; waste disposal
lReplace damaged insulating jaws and welding rod
holders immediately.
lReplace the welding wire reels only in de-energized
state.
What to do in case of accidents; First Aid
lKeep calm.
lCall first air helpers.
lReport the accident.
lIn case of an electric accident: Interrupt the power
supply and remove the injured person from the
electric circuit. If breathing and heart have stopped
apply reactivation measures and call for an emer-
gency doctor.
Operation of high-voltage systems
i
Note
The rules and statutory regulations valid in the corre-
sponding do apply in addition to the notes given here.
!
Caution
The high-voltage system must only be operated
and serviced by qualified and authorized person-
nel.
Before starting operation the operator must check
the proper condition of the system.
!Danger
Possibility of injury or even death caused by elec-
tric shock:
lif persons come into contact with live parts,
lin case of faulty insulation of live parts,
linadequate, unsuitable insulation,
lif melted parts flake off in case of short circuits.
Old oils
Prolonged and repetitive contact with mineral oils will
remove the natural greases from the skin and causes
dryness, irritation and dermatitis. Moreover, used en-
gine oils contain potentially hazardous contaminants,
which could cause skin cancer. Appropriate skin pro-
tection agents and washing facilities must therefore
be provided.
lWear protective clothes and safety gloves, if possi-
ble.
lIf there is a risk of eye contact you should protect
your eyes appropriately, e.g. chemistry goggles or
full face visor; a facility suitable for rinsing the eyes
should also be available.
lAvoid longer and repetitive contacts with oils. In
case of open incisionsand injuries seek medical ad-
vice immediately.
lApply protective cream before starting work, so that
oil can be easier removed from the skin.
lWash affected skin areas with water and soap (skin
cleansers and nail brushes will help). Lanolin con-
taining agents will replace natural skin oils that were
lost.
lDo not use gasoline, kerosene, diesel, thinner or
solvents to wash the skin.
lDo not put oil soaked cloths into your pockets.
lAvoid clothes getting soiled by oil.
lOveralls must be washed at regular intervals. Dis-
pose of non-washable clothes environmentally.
lIf possible degrease components before handling.
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