Fayat BOMAG BC 462 RB User manual

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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