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  9. Fayat BOMAG BC 462 RB User manual

Fayat BOMAG BC 462 RB User manual

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Service - Manual
Catalogue number.
008 917 13 02/2012
BC 462 RB / BC 472 RB
BC 472 RS / BC 462 EB
S/N 101 930 03 ....> S/N 101 930 07 ....> / S/N 101 930 00 ....> S/N 101 930 04 ....>
S/N 101 930 01 ....> S/N 101 930 05 ....> / S/N 101 930 02 ....> S/N 101 930 06 ....>
Sanitary landfill compactor
Fast moving soil compactor
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Table of Contents
BOMAG 3008 917 13
General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 14
1.4 Tightening torques 28
Earth compactor - refuse compactor 33
2.1 Refuse compactor - earth compactor 34
Technical data 39
3.1 Technical data 40
Maintenance 49
4.1 General notes on maintenance 50
4.2 Fuels and lubricants 51
4.3 Table of fuels and lubricants 54
4.4 Running-in instructions 55
4.5 Maintenance table 56
E-Plan wiring diagrams 59
5.1 Understanding wiring diagrams 60
5.2 Circuit symbols in the circuit diagram 69
5.3 Identification of switch blocks in the wiring diagram 72
Electrics 73
6.1 Designation of components in the wiring diagram 74
6.2 Terminal designations in wiring diagram 75
6.3 Battery ground and analog ground 77
6.4 Current and voltage 77
6.5 Resistance 79
6.6 Series / parallel connection 81
6.7 Ohm's law 83
6.8 Electrical energy 84
6.9 Formula diagram 85
6.10 Metrology 86
6.11 Diodes, relays, fuses 90
6.12 Telemecanique switch 93
6.13 Plug connectors 95
6.14 Magnetic coil plug 95
6.15 Deutsch plug, series DT and DTM 97
6.16 Plugs and terminals in spring clamping technology 102
6.17 Inductive proximity switches 106
6.18 Batteries 107
6.19 Battery service, checking the main battery switch 110
6.20 Starting the engine with jump leads 111
6.21 Main battery switch 112
6.22 Main fuse 112
6.23 Hydraulic oil temperature 113
6.24 Pressure switch, hydraulic oil filter 114
6.25 Magnetic sensor, hydraulic oil 115
6.26 Pressure switch for brake 115
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Table of Contents
BOMAG4008 917 13
6.27 Fuel gauge 116
6.28 Cab electrics 117
6.29 Fuse, cabin 120
6.30 Fuses 120
6.31 Machine related electrics 122
Engine electrics 127
7.1 EMR3 system components 128
7.2 Pin assignment of engine control EDC16 / EMR3 133
7.3 Rotary speed sensor for camshaft 138
7.4 Rotary speed sensor for crankshaft 139
7.5 Rail pressure sensor 142
7.6 Fuel pressure sensor 143
7.7 Fuel control unit 145
7.8 Injector 146
7.9 Oil pressure sensor 147
7.10 Sensor for charge air temperature and charge air pressure 149
7.11 EMR coolant temperature sensor 151
7.12 Glow plugs 152
7.13 Sensor, water in fuel 153
7.14 Fuel pre-heating 154
7.15 Air filter vacuum switch 155
7.16 Float switch in coolant container 155
7.17 Coolant temperature gauge 156
7.18 Charge control light, engine rpm-meter 157
7.19 System faults indicated by flashing code 158
7.20 Diagnose with SERDIA 160
7.21 Diagnose with CAN-bus 163
7.22 Diagnostics interface 164
7.23 Flashing code 166
7.24 EMR3 List of fault codes 168
7.25 Generator 239
7.26 Electric starter 249
Engine 255
8.1 Diesel engine 256
8.2 Engine description TCD 2013, 4 and 6 cylinder, 2 valves 257
8.3 Lubrication oil circuit TCD 2012 / 2013 261
8.4 Coolant circuit TCD 2012 / 2013 263
8.5 Fuel system TCD 2012 / 2013 264
8.6 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 267
8.7 Exhaust gas recirculation TCD 2012 / 2013 273
8.8 Engine problems 274
8.9 Wastegate - charge pressure controller on TCD-engines 277
8.10 Adjust the valve clearance 279
8.11 Checking the engine oil level 280
8.12 Change engine oil and oil filter cartridge 280
8.13 Checking, cleaning the water separator 281
8.14 Replacing the fuel pre-filter cartridge, bleeding the fuel system 282
8.15 Replacing the fuel filter cartridges 284
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Table of Contents
BOMAG 5008 917 13
8.16 Check the coolant level 285
8.17 Changing the coolant 285
8.18 Checking the anti-freeze concentration 287
8.19 Checking the thermostat in disassembled state 287
8.20 Checking ribbed V-belts and compressor V-belts 288
8.21 Replacing ribbed V-belt and idler pulley 289
8.22 Combustion air filter service 290
8.23 Replacing the crank case ventilation valve 292
8.24 Checking the fastening of engine / turbocharger / combustion air hoses 293
8.25 Checking the engine mounts 293
8.26 Special tools, Deutz engine (TCD 2013 2V) 294
Air conditioning system 313
9.1 Physical basics 314
9.2 Refrigerant R134a 317
9.3 Compressor oil / refrigeration oil 318
9.4 Working principle of the air conditioning system 319
9.5 Monitoring devices 319
9.6 Description of components 320
9.7 Measuring the compressor oil level 326
9.8 Checking the magnetic clutch 326
9.9 Inspection and maintenance work 327
9.10 Service the air conditioning 328
9.11 Checking ribbed V-belts and compressor V-belts 330
9.12 Replacing ribbed V-belt and idler pulley 331
9.13 Drying and evacuation 331
9.14 Emptying in case of repair 332
9.15 Leak test 332
9.16 Filling instructions 333
9.17 Trouble shooting in refrigerant circuit, basic principles 336
9.18 Trouble shooting, refrigerant circuit diagram 340
9.19 Trouble shooting procedure 341
9.20 Steam table for R134a 351
9.21 Module A108 356
Central lubrication system 357
10.1 System layout 358
10.2 Technical description 359
10.3 Control 361
10.4 Lubrication process 365
10.5 Progressive distributor 365
10.6 Lubrication oil pump 368
10.7 Checking the central lubrication system, filling up 370
10.8 Faults and causes 371
10.9 Fault - Cause - Remedy 373
10.10 Failure of central lubrication system (grease emerges from relief valve) 375
Hydraulics 377
11.1 Hydraulic circuit 378
11.2 Travel pump A4VG110 DA 380
11.3 Travel pump A4VG110 HT 386
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Table of Contents
BOMAG6008 917 13
11.4 Axial piston swash plate principle. 391
11.5 Troubleshooting axial piston pumps 393
11.6 Travel circuit 396
11.7 Trouble shooting, variable displacement axial piston motor 409
11.8 Steering and working hydraulics 411
11.9 Check the hydraulic oil level 424
11.10 Change the hydraulic oil fine filter 424
11.11 Changing hydraulic oil and breather filter 426
Oscillating articulated joint 429
12.1 Repair overview 430
12.2 Repairing the articulated joint 433
Compactor wheels and dozer blade 441
13.1 Replacing the wheel caps 442
13.2 Adjust scrapers and edge cutter 443
13.3 Checking the cutting plates, replacing the cutting plates if necessary 444
Suppliers documentation 445
14.1 Steering and working pump 447
14.2 Wheel drive 477
14.3 Travel motor 531
Circuit diagrams 585
15.1 Hydraulic diagram 930,108 40 589
15.2 Wiring diagram 930,107 70 603
15.3 Wiring diagram 5 639
15.4 Wiring diagram 75 681
15.5 Wiring diagram 95 727
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BOMAG 7008 917 13
1 General
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1.1 Introduction
BOMAG8008 917 13
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 13
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 13
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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