BOMAG BC462, BC472 soil compactor pdf service manual

Table of Contents for BOMAG-00892355-SM-EN manual

• BC 462 RB / BC 472 RB
• BC 472 RS / BC 462 EB
  • S/N 101 930 03 ....> / S/N 101 930 00 ....>
  • S/N 101 930 01 ....> / S/N 101 930 02 ....>
• Sanitary landfill compactor
• Fast moving soil compactor
  • 1 General
• 1.1 Introduction
• Safety regulations
  • Important notes
  • General
  • Transport work with cranes and lifting tackle
  • Precautions and codes of conduct for welding work
  • Operation of high-voltage systems
  • Old oils
  • Hydraulics
  • Fuels
  • Hot fuels
  • Synthetic rubber
  • Poisonous substances
  • Engine
  • Air conditioning system
  • Battery
  • Special safety regulations
• General repair instructions
  • General
  • Electrics
  • Battery
  • Generator
  • Starter motor
  • Hydraulic system
  • Air conditioning system
  • Notes on cleanliness for Common Rail engines
  • Fuel hoses
  • Gaskets and mating surfaces
  • Feather keys and keyways
  • Ball and roller bearings
  • Screws and nuts
• Tightening torques
  • 2 Earth compactor - refuse compactor
• Refuse compactor - earth compactor
  • Customized for small landfill sites
  • The perfect combination of application optimized technology
• Technical data
  • Fig. 13
  • Fig. 14
  • Fig. 15
  • Fig. 16
  • Noise value
  • Vibration value
• 4.1 General notes on maintenance
  • Notes on the fuel system
  • Notes on the performance of the engine
  • Notes on the cooling system
  • Notes on the hydraulic system
  • Welding work on the refuse compactor
• 4.2 Fuels and lubricants
  • Engine oil
  • Fuels
  • Coolant
  • Mineral oil based hydraulic oil
  • Bio-degradable hydraulic oil
  • Gear oil
  • Lubrication grease
• 4.3 Table of fuels and lubricants
• 4.4 Running-in instructions
• 4.5 Maintenance table
  • 5 Electrics
• 5.1 Battery service, checking the main battery switch
  • Fig. 18
  • Checking the main battery switch
• 5.2 Starting the engine with jump leads
  • Fig. 20
• 5.3 Main battery switch
  • Fig. 21
• 5.4 Hydraulic oil temperature
  • Temperature sensor, R04
• 5.5 Pressure switch, hydraulic oil filter
  • Differential pressure switches, B21, B22 and B121
• 5.6 Magnetic sensor, hydraulic oil
  • Magnetic sensor, B19
• 5.7 Pressure switch for brake
  • Pressure switch, B05
• 5.8 Fuel gauge
  • Float switch, R03
• Cab electrics
  • Fig. 5
  • Fig. 6
  • Fig. 7
• 5.10 Fuses
  • Fig. 8
  • Fig. 9
  • Fig. 10
  • Fig. 11
• Machine related electrics
  • 6 Engine electrics
• 6.1 EMR3 system components
  • Engine control unit
  • EMR-3 system in connection with injection system and electrics
  • Sensors TCD 2012/2013
  • Sensors TCD 2015
  • Shut down the engine.
• 6.2 Pin assignment of engine control EDC16 / EMR3
• 6.3 Rotary speed sensor for camshaft
  • Speed sensor, B114
• 6.4 Rotary speed sensor for crankshaft
  • Speed sensor, B130
• 6.5 Rail pressure sensor
  • Pressure sensor, B93
  • Disassembling the pressure sensor
  • Installing the rail pressure sensor
• 6.6 Fuel pressure sensor
  • Pressure sensor, B145
• 6.7 Fuel control unit
  • Control unit, Y137
• 6.8 Injector
  • Injectors, Y147, Y148, Y149, Y166, (Y169 and Y170, 6 cylinders engine)
• 6.9 Oil pressure sensor
  • Pressure sensor, B88
• 6.10 Sensor for charge air temperature and charge air pressure
  • Sensor, B133
• 6.11 EMR coolant temperature sensor
  • Temperature sensor, B113
• 6.12 Glow plugs
  • R81 to R86
• 6.13 Sensor, water in fuel
  • Sensor, B124
• 6.14 Fuel pre-heating
  • Fuel pre-heating (option)
• 6.15 Air filter vacuum switch
  • Vacuum switch, B03
• 6.16 Float switch in coolant container
  • Float switch, B55
• 6.17 Coolant temperature gauge
  • Temperature sensor, B152
• 6.18 Charge control light, engine rpm-meter
  • Fig. 1 Generator
  • Charge control light
  • Engine PRM-meter
• 6.19 System faults indicated by flashing code
  • Engine protection function of the electric engine controller EMR3
  • Deleting the fault log
• 6.20 Diagnose with SERDIA
  • SERDIA
• 6.21 Diagnose with CAN-bus
  • Fig. 1
• 6.22 Diagnostics interface
  • Fig. 1 Control unit in electric wiring box
  • Fig. 2 Diagnostics interface in electric wiring box
  • Fig. 3 Diagnostics socket
  • Fig. 4
  • Fig. 5
  • Fig. 6
• Flashing code
• EMR3 List of fault codes
• 6.25 Generator
  • Three-phase generator
  • Charge controller
  • Checking the generator
• 6.26 Electric starter
  • Directly acting electric starter
  • Magnetic switch
  • Trouble shooting "Starter"
  • Testing and measuring the starter
  • Removing and assembling the starter
• 7.1 Diesel engine
  • Fig. 1 Deutz diesel engine TCD 2012 and 2013
• 7.2 Engine description TCD 2013, 4 and 6 cylinder, 2 valves
  • Fig. 1 Deutz diesel engine TCD 2013 L04 2V, right hand side
  • Fig. 2 Deutz diesel engine TCD 2013 L04 V2, left hand side
  • Fig. 3 Deutz diesel engine TCD 2013 L06 2V, right hand side
  • Fig. 4 Deutz diesel engine TCD 2013 L06 2V, left hand side
• 7.3 Lubrication oil circuit TCD 2012 / 2013
  • Fig. 1 Lubrication oil schematic
• 7.4 Coolant circuit TCD 2012 / 2013
  • Fig. 1 Coolant circuit
• 7.5 Fuel system TCD 2012 / 2013
  • Fig. 1 Fuel circuit
  • Fig. 2 Fuel pre-cleaner
  • Fig. 3 TCD 2013 Fuel system
• 7.6 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013
  • Fig. 1 TCD 2012 and 2013
  • Fig. 2 Schematic of the Deutz Common Rail System "DCR"
  • Fig. 3 Fuel Control Unit FCU
  • Fig. 4 High pressure pump
  • Fig. 5 Injector
  • Fig. 6 Excerpt from the wiring diagram
  • Fig. 7 TCD 2013
• 7.7 Exhaust gas recirculation TCD 2012 / 2013
  • Fig. 1 Exhaust/intake valve control TCD 2012 / 2013
• 7.8 Engine problems
• 7.9 Wastegate - charge pressure controller on TCD-engines
  • Fig. 1 Exhaust gas turbocharger with Wastegate
  • Fig. 1 Exhaust gas turbocharger with Wastegate
  • Fig. 2 Exhaust gas turbocharger with Wastegate
• 7.10 Adjust the valve clearance
  • Fig. 3
• 7.11 Checking the engine oil level
  • Fig. 4
  • Fig. 5
• 7.12 Change engine oil and oil filter cartridge
  • Fig. 6
  • Fig. 7
  • Fig. 8
• 7.13 Checking, cleaning the water separator
  • Fig. 9
  • Fig. 10
• 7.14 Replacing the fuel pre-filter cartridge, bleeding the fuel system
  • Change the fuel pre-filter cartridge
  • Bleed the fuel system
• 7.15 Replacing the fuel filter cartridges
  • Fig. 14
  • Fig. 15
• 7.16 Check the coolant level
  • Fig. 16
  • Fig. 17
• 7.17 Changing the coolant
  • Fig. 18
  • Fig. 19
  • Fig. 20
• 7.18 Checking the anti-freeze concentration and the condition of the coolant
  • Fig. 21
• 7.19 Checking the thermostat in disassembled state
  • Fig. 1
  • Fig. 2
  • Fig. 3
• 7.20 Checking ribbed V-belts and compressor V-belts
  • Checking condition and tension of ribbed V-belt.
  • Checking the condition and tension of the compressor V-belt
• 7.21 Replacing ribbed V-belt and idler pulley
  • Fig. 7
• 7.22 Air filter maintenance
  • Fig. 8
  • Fig. 9
  • Fig. 10
  • Fig. 11
  • Fig. 12
  • Fig. 13
  • Fig. 14
  • Replacing the safety element
• 7.23 Special tools, Deutz engine (TCD 2013 2V)
  • 8 Air conditioning system
• 8.1 Physical basics
  • Fig. 1
  • Fig. 2
  • Pressure and boiling point
• 8.2 Refrigerant R134a
  • Environmental aspects
• 8.3 Compressor oil / refrigeration oil
• 8.4 Working principle of the air conditioning system
  • Fig. 1 Principle sketch of an air conditioning system
• 8.5 Monitoring devices
  • Fig. 2 Monitoring chain consisting of:
• 8.6 Description of components
  • Compressor
• 8.7 Measuring the compressor oil level
  • Fig. 1
• 8.8 Checking the magnetic clutch
  • Fig. 1
  • Fig. 2 Measuring the air gap
  • Cross-section of magnetic clutch
• 8.9 Inspection and maintenance work
• 8.10 Service the air conditioning
  • Clean the condenser
  • Checking the refrigerant level
  • Checking the moisture level of the drying agent
  • Checking the condition of the drier/collector unit
• 8.11 Checking ribbed V-belts and compressor V-belts
  • Checking condition and tension of ribbed V-belt.
  • Checking the condition and tension of the compressor V-belt
• 8.12 Replacing ribbed V-belt and idler pulley
  • Fig. 13
• 8.13 Drying and evacuation
• 8.14 Emptying in case of repair
• 8.15 Leak test
  • Fig. 1 Electronic leak tester
  • Fig. 2 Soap bubble test
• 8.16 Filling instructions
  • Fig. 1
  • Filling instructions
• 8.17 Trouble shooting in refrigerant circuit, basic principles
  • Basic principles
  • Overheating
  • Supercooling
• 8.18 Trouble shooting, refrigerant circuit diagram
  • Fig. 1 Refrigerant circuit diagram
• 8.19 Trouble shooting procedure
  • Procedure
• Steam table for R134a
• Module A108
  • 9 Central lubrication system
• 9.1 System layout
  • Fig. 1 Lubrication system RB machine
  • Fig. 2 Lubrication system RS machine
• 9.2 Technical description
  • Fig. 3 Monitoring board
  • Fig. 4 Control board
  • Fig. 5 Push button
  • Fig. 6 Operating states
  • Fig. 7 Control board
• 9.3 Control
  • Control board
• 9.4 Lubrication process
  • Main and sub-distributor
• 9.5 Progressive distributor
  • Components
• 9.6 Lubrication oil pump
  • Components
• 9.7 Checking the central lubrication system, filling up
  • Check
  • Failure of a lubrication point
  • Filling through the grease nipple
  • Filling with the hand pump
• 9.8 Faults and causes
  • Indication of faults
• 9.9 Fault - Cause - Remedy
  • Fig. 38
  • Fig. 39 KIT to check central lubrication systems
• 9.10 Failure of central lubrication system (grease emerges from relief valve)
  • Pressure OK?
  • Grease emerging
• 10.1 Hydraulic circuit
  • Open circuit
• Travel pump A4VG110 DA
  • Variable displacement pumps, A4VG 85 to 110 DA
• Travel pump A4VG110 HT
  • Variable displacement pumps, A4VG 85 to 110 HT
• Steering and working pump
  • Axial piston pumps, A10VO/VSO 18 to 100 DFR1
• Axial piston swash plate principle.
  • Swash plate principle, pump
• 10.6 Troubleshooting axial piston pumps
  • Procedure
• Travel motor
  • Description of function
  • Flushing valve
  • HA2T control
• 10.8 Trouble shooting, variable displacement axial piston motor
  • Procedure
• External gear pumps
  • External gear pumps
• 10.10 Travel circuit
  • Fig. 34 Schematic travel system, hydraulics
  • Travel system
• 10.11 Towing the machine
  • Preparing for towing
  • Releasing the brake
  • After towing
• 10.12 Checking the oil level in the travel gear
  • Fig. 52
• 10.13 Steering and working hydraulics
  • Fig. 1 Page 7 from the hydraulic diagram
  • Steering
• 10.14 Checking the hydraulic oil level
  • Fig. 10
  • Fig. 11
• 10.15 Replace hydraulic oil filter
  • Fig. 12
  • Fig. 13
  • Fig. 14
• 10.16 Change hydraulic oil and breather filter
  • Fig. 15
  • Fig. 16
  • Cleaning the hydraulic oil tank
  • Fill in hydraulic oil.
  • Bleeding the hydraulic system
  • Disassembling the articulated joint
  • Assembling the articulated joint
• 12.1 Replacing the wheel caps
  • Required tools/materials:
• 12.2 Adjust scrapers and edge cutter
  • Scrapers
  • Edge cutter
• 12.3 Checking the cutting plates, replacing the cutting plates if necessary
  • Fig. 19
  • 13.1 Steering and working pump
  • 13.2 Wheel drive
  • 13.3 Travel motor
  • 14.1 Hydraulic diagram 930,108 40
  • 14.2 Wiring diagram 930,107 70
  • 14.3 Wiring diagram 5
  • 14.4 Wiring diagram 95
  • 14.5 Wiring diagram 96
  • 14.6 Wiring diagram 182