Bomag BC 462 RB

Service - Manual
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
Catalogue number.
008 917 13 02/2012
Find manuals at https://best-manuals.com
Table of Contents
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
008 917 13 BOMAG 3

Table of Contents
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
4 BOMAG 008 917 13

Table of Contents
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
008 917 13 BOMAG 5

Table of Contents
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
6 BOMAG 008 917 13

1 General
008 917 13 BOMAG 7

1.1 Introduction
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.
8 BOMAG 008 917 13

Safety regulations 1.2
Important notes Block the articulated joint with the articulation lock.
1.2 Safety regulations
l
l Use protective clothes like hard hat, safety boots

These safety regulations must be read and ap-
and gloves.
plied by every person involved in the repair /main-
tenance of this machine. The applicable accident l Keep unauthorized persons away from the machine
prevention instructions and the safety regulations during repair work.
in the operating and maintenance instructions l Tools, lifting gear, lifting tackle, supports and other
must be additionally observed.
auxiliary equipment must be fully functional and in
Repair work shall only performed by appropriately safe condition.
trained personnel or by the after sales service of l Use only safe and approved lifting gear of sufficient
BOMAG. load bearing capacity to remove and install parts or
components from and to the machine.
Workshop equipment and facilities as well as the
use and waste disposal of fuels and lubricants, l Do not use easily inflammable or harmful substanc-
cleaning agents and solvent as well as gases and es, such as gasoline or paint thinners for cleaning.
chemicals are subject to legal regulations, which l Do not smoke or use open fire and avoid sparks
are intended to provide a minimum on safety. It is when cleaning or repairing a tank.
obviously your own responsibility to know and
adhere to these regulations.
l When performing welding work strictly comply with
the respective welding instructions.
This manual contains headers like "Note", "Attention",
"Danger" and "Environment", which must be strictly
complied with in order to inform about and avoid dan- Transport work with cranes and lifting
gers to persons, property and the environment. tackle
i Note i Note
Paragraphs marked like this contain technical infor- Cranes must only be operated by instructed persons
mation for the optimal economical use of the machine. who had been trained in handling cranes.
l Follow the operating instructions of the manufactur-
Caution
! er when working with cranes.
Paragraphs marked like this highlight possible l Follow the operating instructions of the operator
dangers for machines or parts of the machine. when working with cranes.
l Always comply with the applicable accident preven-
Danger
!
tion instructions when working with cranes and lift-
ing tackle.
Paragraphs marked like this highlight possible
dangers for persons.
Precautions and codes of conduct for
welding work
Environment
Welding work must only be carried out by properly
Paragraphs marked like this point out practices
trained personnel.
for safe and environmental disposal of fuels and
lubricants as well as replacement parts.
Danger
!
Observe the regulations for the protection of the
environment. Electric shock!
Sparks, fire hazard, burning of skin!
General Infrared or ultraviolet radiation (arc), flashing of
l For repair and maintenance work move the ma- eyes!
chine on a firm base and shut it down. Health hazard caused by welding work on highly
l Always secure the machine against unintended roll- alloyed work pieces, metal coatings, paint coat-
ing. ings, plastic coatings, oil containing dirt deposits,
grease or solvent residues, etc.!
l Secure the engine reliably against unintentional
starting.
l Check welding equipment and cables for damage
before use (also the validity of inspection stickers).
l Mark a defective machine and a machine under re-
pair by attaching a clearly visible warning label to
l Ensure good conductivity between ground cable
the dashboard. and workpiece, avoid joints and bearings.
008 917 13 BOMAG 9

l Start the extraction fan before starting work and Operation of high-voltage systems
guide with the progressing work as required.
l Always isolate the burner when laying it down (re- i Note
move possible electrode residues).
The rules and statutory regulations valid in the corre-
l Protect cables from being damaged, use cables sponding do apply in addition to the notes given here.
with insulated couplings.
l Ensure sufficient fire protection, keep a fire extin- !Caution
guisher at hand. The high-voltage system must only be operated
l Welding work in areas where there is a risk of fire or and serviced by qualified and authorized person-
explosion, must only be carried out with welding nel.
permission.
Before starting operation the operator must check
l Remove any combustible materials from the weld- the proper condition of the system.
ing area or cover such items appropriately.
l Name a fire watch during and after welding work. !Danger
l Place welding rod holders and inert gas welding Possibility of injury or even death caused by elec-
guns only on properly insulated bases. tric shock:
l Place the inert gas bottles in a safe place and se- l if persons come into contact with live parts,
cure them against falling over. l in case of faulty insulation of live parts,
l
Use a protective screen or hand shield with welding l
inadequate, unsuitable insulation,
filter, wear welding gloves and clothes. l
if melted parts flake off in case of short circuits.
l
Switch the welding unit off before connecting weld-
ing cables. Old oils
l
Check electrode holders and electric cables at reg- Prolonged and repetitive contact with mineral oils will
ular intervals. remove the natural greases from the skin and causes
Behaviour in case of faults dryness, irritation and dermatitis. Moreover, used en-
gine oils contain potentially hazardous contaminants,
l
In case of faults on the welding unit switch of the which could cause skin cancer. Appropriate skin pro-
welding unit immediately and have it repaired by ex- tection agents and washing facilities must therefore
pert personnel. be provided.
l
In case of failure of the extraction system switch the l
Wear protective clothes and safety gloves, if possi-
system off and have it repaired by expert personnel. ble.
Maintenance; waste disposal l
If there is a risk of eye contact you should protect
your eyes appropriately, e.g. chemistry goggles or
l Replace damaged insulating jaws and welding rod
full face visor; a facility suitable for rinsing the eyes
holders immediately.
should also be available.
l Replace the welding wire reels only in de-energized l Avoid longer and repetitive contacts with oils. In
state.
case of open incisions and injuries seek medical ad-
What to do in case of accidents; First Aid vice immediately.
l Keep calm. l Apply protective cream before starting work, so that
oil can be easier removed from the skin.
l Call first air helpers.
l Wash affected skin areas with water and soap (skin
l Report the accident.
cleansers and nail brushes will help). Lanolin con-
l In case of an electric accident: Interrupt the power taining agents will replace natural skin oils that were
supply and remove the injured person from the lost.
electric circuit. If breathing and heart have stopped l Do not use gasoline, kerosene, diesel, thinner or
apply reactivation measures and call for an emer-
solvents to wash the skin.
gency doctor.
l Do not put oil soaked cloths into your pockets.
l Avoid clothes getting soiled by oil.
l
Overalls must be washed at regular intervals. Dis-
pose of non-washable clothes environmentally.
l
If possible degrease components before handling.
10 BOMAG 008 917 13

Environment l Fire extinguishers charged with FOAM, CO2 GAS
It is strictly prohibited to drain off oil into the soil, or POWDER must be available wherever fuel is
the sewer system or into natural waters. Old oil stored, filled in, drained off, or where work on fuel
must be disposed of according to applicable envi- systems is performed.
ronmental regulations. If in doubt you should con- l The vehicle battery must always be disconnected,
sult your local authorities. BEFORE work in the fuel system is started. Do not
disconnect the battery while working on the fuel
Hydraulics system. Sparks could cause explosion of the fuel
fumes.
l Always relieve the pressure in the hydraulic system
before disconnecting any lines. Hydraulic oil escap-
l Wherever fuel is stored, filled, drained off or where
ing under pressure can penetrate the skin and work on fuel systems is carried out, all potential ig-
cause severe injury. nition sources must be extinguished or removed.
Search lights must be fire proof and well protected
l Always make sure that all screw fittings have been against possible contact with running out fuel.
tightened properly and that hoses and pipes are in
mint condition before pressurizing the system
again.
Hot fuels
Please apply the following measures before draining
l Hydraulic oil leaking out of a small opening can
of fuel to prepare for repair work:
hardly be noticed, therefore please use a piece of
cardboard or wood when checking for leaks. When l Allow the fuel to cool down, to prevent any contact
injured by hydraulic oil escaping under pressure with a hot fluid.
consult a physician immediately, as otherwise this l
Vent the system, by removing the filler cap in a well
may cause severe infections. ventilated area. Screw the filler cap back on, until
l Do not step in front of or behind the drums, wheels the tank is finally emptied.
or crawler tracks when performing adjustment work
in the hydraulic system while the engine is running. Synthetic rubber
Block drums, wheels or crawler tracks with wedges.
Many O-rings, hoses, etc. are made of synthetic ma-
Reattach all guards and safety installations after terial, a so-called fluorocarbon elastomer. Under nor-
all work has been completed. mal operating conditions this material is safe and does
not impose any danger to health.
Environment However, if this material becomes damaged by fire or
extreme heat, it may decompose and form highly
It is strictly prohibited to drain off oil into the soil,
caustic hydrofluoric acid, which can cause severe
the sewer system or into natural waters. Oil oil
burns in contact with skin.
must be disposed of according to applicable envi-
ronmental regulations. If in doubt you should con- l
If the material is in such a state it must only be
sult your local authorities. touched with special protective gloves. The protec-
tive gloves must be disposed of according to appli-
Fuels cable environmental regulations immediately after
use.
l
If the material has contacted the skin despite these
!Danger
measures, take off the soiled clothes and seek
Repair work shall only performed by appropriately medical advice immediately. In the meantime cool
trained personnel or by the after sales service of and wash the affected area of skin over a sufficient
BOMAG. time with cold water or lime water.
Follow the valid accident prevention instructions when
handling fuels. Poisonous substances
The following notes refer to general safety precau- Some of the fluids and substances used are toxic and
tions for danger free handling of fuel. must under no circumstances be consumed.
Fuel vapours not only are easily inflammable, but also Skin contact, especially with open wounds, must be
highly explosive inside closed rooms and toxic; dilu- avoided.
tion with air creates an easily inflammable mixture. These fluids and substances are, amongst others,
The vapours are heavier than air and therefore sink anti-freeze agents, hydraulic oils, fuels, washing addi-
down to the ground. Inside a workshop they may eas- tives, refrigerants, lubricants and various bonding
ily become distributed by draft. Even the smallest por- agents.
tion of spilled fuel is therefore potentially dangerous.
008 917 13 BOMAG 11

Engine air conditioning system. The development of heat

may cause the refrigerant to develop toxic and high-
ly corrosive breakdown products.
Danger
!
l Pungent smell! The toxic substances, which are re-
Do not work on the fuel system while the engine is
sponsible for the pungent smell, must not be in-
running. (Danger to life!)
haled, since this may cause damage to the
Once the engine has stopped wait approx. 5 min- respiratory system, the lung and other organs. Ex-
utes for the system to depressurize. The systems tract toxic breakdown products with a suitable ex-
are under high pressure. (Danger to life!) traction system (workshop extraction system).
Keep out of the danger zone during the initial test l When blowing out components with compressed air
rung. Danger caused by high pressure in case of and when flushing with nitrogen the gas mixture es-
leaks. (Danger to life!) caping from the components must be extracted via
When performing work on the fuel system make suitable extraction facilities (workshop extraction
sure that the engine cannot be started uninten- systems).
tionally during repair work. (Danger to life!) Handling pressure vessels
l Maintenance and cleaning work on the engine must l Since the fluid container is pressurized, the manu-
only be performed with the engine stopped and facture and testing of these pressure vessels is gov-
cooled down. Make sure that the electric system is erned by the pressure vessel directive. The
switched off and sufficiently secured against being pressure vessels must be repetitively tested by an
switched on again (e.g. pull off ignition key, attach a expert as specified in TRB 532 Inspection by Ex-
warning label). perts, Repetitive Tests. In this case periodically re-
l Observe the accident prevention regulations for curring inspections consist of external
electric systems (e.g. -VDE-0100/-0101/-0104/- examinations, normally on containers in operation.
0105 Electric precautions against dangerous con- In combination with the inspection, the refrigerant
tact voltages). collector must be visually examined two times per
year. Special attention must thereby be paid to
l Cover all electric components properly before wet
signs of corrosion and mechanical damage. If the
cleaning.
container is in no good condition, it should be re-
placed for safety reasons, in order to protect the op-
Air conditioning system erator or third parties against the dangers when
handling or operating pressure vessels.
!Caution l
Secure pressure vessels against tipping over or roll-
Work on air conditioning systems must only be ing away.
carried out by persons who can provide sufficient l
Do not throw pressure vessels! Pressure vessels
evidence of their ability (proof of professionalism) may thereby be deformed to such an extent, that
and only with the appropriate technical equip- they will crack. The sudden evaporation and escape
ment. of refrigerant releases excessive forces. This ap-
l
Always wear goggles and protective clothing when plies also when snapping off valves on bottles. Bot-
performing maintenance and repair work on air con- tles must therefore only be transported with the
ditioning systems. Refrigerant withdraws heat from safety caps properly installed.
the environment when evaporating, which can l Refrigerant bottles must never be placed near heat-
cause injury by freezing when in contact with skin ing radiators. Higher temperatures will cause higher
(boiling point of R134a -26,5 °C at normal pres- pressures, whereby the permissible pressure of the
sure). vessel may be exceeded.
l
Perform maintenance and repair work on air condi- l Do not heat up refrigerant bottles with an open
tioning systems only in well ventilated rooms! Es- flame. Excessive temperatures can damage the
caping refrigerant vapours will mix with the ambient material and cause the decomposition of refriger-
air and displace the oxygen required for breathing ant.
(danger of suffocating).
l Do not overfill refrigerant bottles, since any temper-
l Smoking is prohibited when performing mainte- ature increase will cause enormous pressures.
nance and repair work on air conditioning systems!
Toxic breakdown products may be generated if re-
frigerant comes into contact with heat. Environment
It is strictly prohibited to release refrigerant into
l Refrigerant should always be extracted and re-
the atmosphere during operation, maintenance
moved by flushing with nitrogen before starting
welding or soldering work near components of the
12 BOMAG 008 917 13

and repair work and when taking air conditioning l Dispose of used filters in accordance with applica-
systems into or out of service. ble environmental regulations.
l When performing repair and maintenance work col-
Battery lect oils and fuels in suitable containers and dispose
l Always wear goggles and protective clothing to of in compliance with applicable environmental reg-
service or clean batteries! Battery acid can cause ulations.
severe injury by cauterization when coming in con- l Do not heat up oils higher than 160 °C because they
tact with skin. may ignite.
l Work only well ventilated rooms (formation of oxy- l Wipe off spilled or overflown oil using suitable
hydrogen gas). cleaning means and dispose of in accordance with
l Do not lean over the battery while it is under load, applicable environmental regulations.
being charged or tested (danger of explosion). l Dispose of old batteries according to applicable en-
l Keep ignition sources away from the battery. Burn- vironmental regulations.
ing cigarettes, flames or sparks can cause explo-
sion of the battery
l There is a danger of scalding when draining off en-
gine or hydraulic oil at operating temperature! Allow
l Use battery chargers etc. only in strict compliance
engine and hydraulic system to cool down to a suf-
with the operating instructions.
ficient level.
l After an accident with acid flush the skin with a suf- l Do not exceed the max. permissible tire pressure.
ficient amount of water and seek medical advice.
l Do not allow children access to batteries.
l
When mixing battery fluid always pour acid into wa-
ter, never vice-versa.
Special safety regulations

l
Use only genuine BOMAG spare parts for repair
and maintenance work. Genuine spare parts and
original accessories were specially developed, test-
ed and approved for the machine.
l
The installation and use of non-genuine spare parts
or non-genuine accessories may therefore have an
adverse effect on the specific characteristics of the
machine and thereby impair the active and/or pas-
sive driving safety. The manufacturer explicitly ex-
cludes any liability for damage caused by the use of
non-original parts or accessories.
l Unauthorized changes to the machine are prohibit-
ed for safety reasons.
l Do not perform any cleaning work while the engine
is running.
l If tests on the articulated joint need to be performed
with the engine running, do not stand in the articu-
lation area of the machine (danger of crushing!).
l If tests must be performed with the engine running
do not touch rotating parts of the engine (danger of
injury!).
l Always ensure an adequate supply of fresh air
when starting in closed rooms. Exhaust gases are
highly dangerous!
l Refuel only with the engine shut down. Ensure strict
cleanliness and do not spill any fuel.
l Always ensure an adequate supply of fresh air
when refuelling in closed rooms.
008 917 13 BOMAG 13

1.3 General repair instructions
General Electrics
l Before removing or disassembling parts, assem- General

blies, components or hoses mark these parts for
easier assembly. Due to the fast technical development electric and
electronic vehicle systems become more intelligent
l Before assembling and installing parts, assemblies and more comprehensive day by day, and can hardly
or components oil or grease all movable parts or be dispensed with in hydraulic and mechanical vehicle
surfaces as required and in compliance with the systems.
compatibility of materials.
Diagnostics according to plan
Well structured trouble shooting procedures can save
time and money.
Random tests have revealed that purely electronic
components or control units only very rarely are the
actual cause of failures:
l In approx. 10 % of the examined cases the prob-
lems were caused by control units.
l In approx. 15 % sensors and actuators were the
cause of the problems.
By far the highest proportion of all faults could be
traced back to wiring and connections (plugs, etc.).
General:
l
Before changing any expensive components, such
as control units, you should run a systematic trouble
shooting session to eliminate any other possible
fault sources. Knowledge in basic electrics is re-
quired for this purpose. If a fault was diagnosed
without having pulled the plug of the control unit or
inspected the wiring, this should be done before
changing any parts.
l
Check for good cable and ground contacts, there-
fore keep all mechanical transition points between
electric conductors (terminals, plugs) free of oxide
and dirt, as far as this is possible.
l Always use the machine related wiring diagram for
testing. If one or more faults were detected, these
should be corrected immediately.
l Do not disconnect or connect battery or generator
while the engine is running.
l Do not operate the main battery switch under load.
l Do not use jump leads after the battery has been re-
moved.
l Sensors and electric actuators on control units must
never be connected individually or between exter-
nal power sources for the purpose of testing, but
only in connection with the control unit in question.
l It is not permitted to pull plugs off while the voltage
supply is switched on (terminal 15 "ON")! Switch the
voltage supply "OFF" first and pull out the plug.
l Even with an existing polarity reversal protection in-
correct polarity must be strictly avoided. Incorrect
polarity can cause damage to control units!
14 BOMAG 008 917 13

General repair instructions 1.3
l Plug-in connectors on control units are only dust Battery
and water tight if the mating connector is plugged
on! Control units must be protected against spray Rules for the handling of batteries
water, until the mating connector is finally plugged When removing a battery always disconnect the mi-
on! nus pole before the plus pole. When installing the bat-
l Unauthorized opening of control electronics (Micro- tery connect the minus pole after the plus pole to avoid
controller MC), modifications or repairs in the wiring short circuits.
can cause severe malfunctions. Fasten the terminal clamps with a little force as possi-
l Do not use any radio equipment or mobile phones ble.
in the vehicle cab without a proper aerial or in the vi- Always keep battery poles and terminal clams clean to
cinity of the control electronics! avoid high transition resistances when starting and
the related development of heat.
Electrics and welding
Make sure the battery is properly fastened in the vehi-
cle.
!Caution
Before starting welding work you should discon-
nect the negative battery pole or interrupt the
electric circuit with the main battery switch, dis-
connect the generator and pull the plugs off all
control units in order to protect the electrical sys-
tem of the machine.
l Disconnect the minus pole of the battery or interrupt
the electric circuit with the main battery switch.
l Isolate the generator and all control units from the
electric circuit.
l Always fasten the earth clamp of the welding unit in
the immediate vicinity of the welding location.
l When choosing the location for the earth clamp
make sure that the welding current will not pass
through joints or bearings.
008 917 13 BOMAG 15

Generator Starter motor

Before removing the generator you must disconnect So-called jump starting (using an additional external
the ground cable from the minus pole of the battery battery) without the battery connected is dangerous.
while the ignition is switched off. Do not disconnect When disconnecting the cables from the poles high in-
the generator while the engine is running, because ductivities (arcs, voltage peaks) may occur and de-
this may cause extremely high voltage peaks in the stroy the electrical installation.
vehicle wiring system ("Load Dump"), which could For purposes like e.g. purging the fuel systems, start-
possibly damage control units, radios or other elec- ers may be operated for maximum 1 minute without
tronic equipment. interruption. Then you should wait for at least 30 min-
When disassembling the battery cable, the B+-nut un- utes (cooling down) until trying again. During the 1
derneath on the generator side may also be loosened. minute starting period this process should not be inter-
This nut must in this case be retightened. rupted.
When connecting e.g. the battery cable to the terminal Starter motors must not be cleaned with high pressure
of the generator you must make sure that the polarity steam cleaning equipment.
is correct (generator B+ to the + pole of the battery). The contacts on starter terminals 30, 45, 50 must be
Mixing up the polarities by mistake causes short cir- protected against unintended shorting (jump protec-
cuit and damage to the rectifier elements - the gener- tion).
ator will be out of function.
When replacing the starter the ring gear on the engine
The generator can only be operated with the battery flywheel must be checked for damage and its number
connected. Under special conditions emergency op- of teeth - if necessary replace the ring gear.
eration without battery is permitted, the lifetime of the
generator is in such cases especially limited. Always disconnect the battery before starting assem-
bly work in the starter area of the engine or on the
Plus and minus cables must be disconnected during starter itself.
rapid charging of the battery or electric welding on the
vehicle.
When cleaning the generator with a steam or water jet
make sure not to direct the steam or water jet directly
on or into the generator openings or ball bearings. Af-
ter cleaning the generator should be operated for
about 1 - 2 minutes to remove any deposits of water
from the generator.
16 BOMAG 008 917 13

Hydraulic system l Perform measurements at operating temperature of
the hydraulic oil (approx. 40 ¯C).
!Caution
l After changing a component perform a high and
charge pressure test, if necessary check the speed
Repair work on hydraulic elements shall only per-
of the exciter shaft.
formed by appropriately trained personnel or by
the after sales service of BOMAG. l The operating pressure of the exciter shaft to a
great extent depends on the base under the vibrat-
Please note ing drum. On hard ground place the drums on a suit-
able base and check the drum pressure. Do not
i Note activate the vibration on a hard, concreted base,
danger of bearing damage.
Cleanliness is of utmost importance. Dirt and other
contaminations must strictly be kept out of the system. l After the completion of all tests perform a test run
and then check all connections and fittings for leaks
l Connections and screw fittings, filler neck covers
with the engine still stopped and the hydraulic sys-
and their immediate surrounding areas must be
tem depressurized.
cleaned before removal.
l Before loosening hoses, pipe lines etc. relieve all Before commissioning
pressure from the system. l Fill the housings of hydraulic pumps and motors
l During repair work keep all openings closed with with hydraulic oil. Use only hydraulic oils according
clean plastic plugs and caps. to the specification in the maintenance instructions.
l Never run pumps, motors and engines without oil or
l
After changing a component flush the hydraulic sys-
hydraulic oil. tem as described in the flushing instructions.
l When cleaning hydraulic components take care not Taking into operation
to damage any fine machine surfaces. l
Bleed the hydraulic circuits.
l Chemical and rubber soluble cleansing agents may l
Start up the hydraulic system without load.
only be used to clean metal parts. Do not let such
substances come in contact with rubber parts.
l
Check the hydraulic oil level in the tank, if neces-
sary top up with hydraulic oil as specified in the op-
l Rinse of cleaned parts thoroughly, dry them with erating and maintenance instructions or drain oil off
compressed air and apply anti-corrosion oil immedi- into a suitable container.
ately. Do not install parts that show traces of corro-
sion. After taking into operation
l Avoid the formation of rust on fine machined caused l
Check fittings and flanges for leaks.
by hand sweat. l
After each repair check all adjustment data, system
l
Use new O-rings or seal rings for reassembly. pressures, rotational speeds and nominal values in
l Use only hydraulic oil as sliding agent when reas- the hydraulic system, adjust if necessary.
sembling. Do not use any grease! l Do not adjust pressure relief valves and control
l
Use only the specified pressure gauges. Risk of valves to values above their specified values.
damaging the pressure gauges under too high pres-
sure.
l
Check the hydraulic oil level before and after the
work.
l
Fill in only clean oil as specified in the maintenance
instructions.
l
Check the hydraulic system for leaks, if necessary
find and rectify the cause.
l
Before taking new hydraulic components into oper-
ation fill these with hydraulic oil as specified in the
operating and maintenance instructions.
l After changing a hydraulic component thoroughly
flush, refill and bleed the complete hydraulic sys-
tem.
008 917 13 BOMAG 17

Air conditioning system l Damaged or leaking parts of the air conditioning

must not be repaired by welding or soldering, but
Chemicals/ozone layer regulation must generally be replaced.
The chemicals/ozone layer regulation, which became l Do not fill up refrigerant, but extract existing refrig-
effective on 01.12.2006, supplements the still directly erant and refill the system.
applicable regulation (EG) no. 2037/2000 from
29.06.2000 concerning substances, which cause de-
l Different types of refrigerant must not be mixed.
composition of the ozone layer and at the same time Only the refrigerant specified for the corresponding
replaces the previously valid German CFC-halon air conditioning system must be used.
0prohibition from 06.05.1991. l Refrigerant circuits with refrigerant type R134a
Work on air conditioning systems must only be carried must only be operated with the compressor oil / re-
out by persons who: frigeration oil approved for the compressor.
l have proven to have sufficient expert knowledge, l Used compressor oil/refrigeration oil must be dis-
l have the necessary equipment to undertake such posed of in strict compliance with applicable envi-
tasks, ronmental regulations.
l are reliable and l Due to its chemical properties compressor oil / re-
frigeration oil must never be disposed of together
l are not any directives regarding their activities when
with engine or transmission oil.
carrying out inspection and maintenance work acc.
to § 4 section 2 of the chemical/ozone layer regula- l Compressor oil / refrigeration oil is highly hydro-
tion. scopic. Oil cans must strictly be kept closed until
The inspection and maintenance tasks, including leak use. Oil rests should not be used, if the can had
tests and possible repair activities, must be recorded been opened over a longer period of time.
in the operating instructions together with information l
All O-rings/seal rings as well as pipe/ hose fittings
about the refrigerant quantities used and regained, must be oiled with compressor/refrigeration oil bfore
whereby the operator is obliged to keep these records assembly.
over a period of at least five years. l
When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil/refrigeration oil
i Note lost by exchanging the components, must be re-
Cleanliness is of utmost importance. Dirt and other placed with fresh oil.
contaminations must strictly be kept out of the system. l
A too high compressor oil / refrigeration oil level ad-
l Tools used on refrigeration circuits must be of ex- versely affects the cooling performance and a too
cellent condition, thus to avoid the damage of any low oil level has a negative effect on the lifetime of
connections. the compressor.
l During repairs on refrigerant lines and components,
l
Use new O-rings or seal rings for reassembly.
these must be kept closed, as far as this is possible, l Always used 2 spanners to work on pipes/hoses to
to prevent the system from being contaminated by avoid damages .
air, moisture and dirt. The operational safety of the l Tighten screw fittings with the specified torque.
system can only be assured as long as all compo-
nents in the refrigerant circuit are kept internally l Check all pipes/hoses, screw fittings or components
clean and dry. for damage, replace if necessary.
l Connections, screw fittings and their immediate sur- l Do not leave the refrigerant circuit unnecessarily
rounding areas must be cleaned before removal. open to the atmosphere.
l Before loosening hoses, pipe lines etc. relieve all l In case of a repair on the refrigeration system you
pressure from the system. should first evacuate the air conditioning system for
at least 45 minutes to remove any moisture from the
l During repair work keep all openings closed with
system, before you start to refill. Moisture bonded in
clean plastic plugs and caps.
the compressor oil / refrigeration oil (PAG oil) can
l All parts to be reused should be cleaned with a only be removed from the system by changing the
gasoline free solvent and blow-dried with clean oil.
compressed air or dried with a lint-free cloth. l Compressor valves must only be opened after the
l
Before opening all components should have system has been properly sealed.
warmed up to ambient temperature, to avoid that l The use of leak detection spray is not permitted. If
damp air is drawn into the component by the differ-
such substances are used the WARRANTY will be-
ence in temperatures.
come null and void.
18 BOMAG 008 917 13

l If the air conditioning system had been opened for Notes on cleanliness for Common Rail
repair work, a new drier should be installed in the re- engines
frigerant circuit.
Special requirements with respect to cleanliness in
l After completion of repair work screw locking caps the fuel system do apply for commissioning, mainte-
(with seals) on all valve connections service con- nance and repair work, particularly for TEIRIII engines
nections. with the DEUTZ Common Rail System. Contamina-
l Before start up of the air conditioning system after a tion like dirt, welding residues or similar can lead to the
new filling: - Turn the compressor approx. 10 revo- failure of individual components and adversely affect
lutions by hand using the clutch or V-belt pulley of engine operation.
the magnetic clutch. - Start the engine with the com-
pressor/control valve switched off. - Once the idle
speed of the engine has stabilized switch on the
compressor and run it for at least 10 minutes at idle
speed and maximum cooling power.
l Never run the compressor with an insufficient
amount of refrigerant.
Fig. 1
l
Spare parts should be left in their original packaging
as long as possible and should only be unpacked
just before use.
l
When parts are unpacked any connections must be
closed with suitable plugs or caps, in order to pre-
vent (Fig. 1) contamination of hose connections. If
e.g. fuel hoses are connected to one side, while the
second side cannot yet be connected, there is a
danger of dirt entering into the system. The free
connection must in this case also be appropriately
closed.
Notes and measures to be applied before starting

work in the fuel system
l The fuel system must be closed. Visual examination
for leaks / damage in the fuel system.
l Before starting work in the fuel system clean the
complete engine and the engine compartment with
the system still closed.
l
The engine should be dry before work is started in
the fuel system.
008 917 13 BOMAG 19

l Blow drying with compressed air is only permitted l Do not use any previously used cleaning or testing
while the fuel system is still closed. fluids for cleaning.
l When using steam cleaning equipment cover con- l Compressed air should never be used for cleaning
trol unit, cable plugs, all other electrical connections when the fuel system is open.
and the generator beforehand and do not expose l Work on disassembled components must only be
these items to the direct steam jet.
carried out at a specially furnished work place.
l Electrical plug connections must be plugged in dur- l When disassembling or assembling components
ing jet cleaning.
you should not use any materials from which parti-
l Remove loose parts (e.g. paint scales that may cles or fibres could flake off (cardboard, wood, tow-
have come off during assembly work) with an indus- els).
trial vacuum cleaner or any means of extraction. l Dismantled parts must only be wiped off with clean,
l Vacuum cleaning equipment must generally be lint-free cloths if required. No dirt particles must be
used for cleaning when the fuel system is open. wiped into the components.
l Perform work on the fuel system only in a clean en- l Close openings on components and engine imme-
vironment (no dust, no grinding or welding work). diately with suitable plugs/caps.
Avoid draughts (dust). The workshop floor must be l Plugs/caps must only be removed just before the in-
cleaned at regular intervals. No brake or power test
stallation.
stand should be present or operated in the same
room. l Keep plugs/caps in their original packaging, where
they are protected against dust and dirt, dispose of
l
Air movements, which could swirl up dust, such as after one time use.
brake repairs or starting of engines, must be strictly
avoided. l
Take new parts out of their original packaging just
before installation.
l
For work, such as disassembly and assembly of de-
fective hydraulic components in the Common Rail l
Disassembled components must be stored in new,
System, it is strongly recommended to set up a sep- sealable bags or – if available – in the packaging
arate workshop area, i.e. an area which is spatially material of the new components.
separated from all other areas (general vehicle re- l
Always use the original packaging material of the
pairs, brake repairs). new part to return the disassembled old component.
l
No general machine tools should be operated in this
Notes and measures concerning the workshop
room.
area
l
Periodic cleaning of this workshop area is obligato- l
For work, such as disassembly and assembly of de-
ry, draughts, ventilation system and heating blow-
fective hydraulic components in the Common Rail
ers must be minimized.
System, it is strongly recommended to set up a sep-
l Engine compartment area where dirt particles could arate workshop area, i.e. an area which is spatially
come loose, should be covered with new, clean foil. separated from all other areas (general vehicle re-
l Working means and tools must be cleaned before pairs, brake repairs).
being used for work. Use only tools without dam- l The workshop floor must be sealed or tiled.
aged chromium coating, or tools without chromium l No welding equipment, grinding machines, general
coating.
machine tools, brake or power test benches must
Notes and measures to be applied during work in be operated in this room.
the fuel system l Periodic cleaning of this workshop area is obligato-
l Wear clean working clothes. ry, draughts, ventilation system and heating blow-
ers must be minimized.
l Use only lint-free cleaning cloths for work in the fuel
system. Notes and measures for work place and tools in
l Remove loose parts (e.g. paint scales that may the workshop
have come off during assembly work) with an indus- l A special work place must be set up for work on dis-
trial vacuum cleaner or any means of extraction. assembled components.
Vacuum cleaning equipment must generally be l Clean disassembly and assembly tools at regular
used for cleaning when the fuel system is open.
intervals and keep these in a closed tool cabinet.
l Working means and tools must be cleaned before
being used for work. Use only tools without dam-
aged chromium coating, or tools without chromium
coating.
20 BOMAG 008 917 13

l Remove loose parts (e.g. paint scales that may Fuel hoses
have come off during assembly work) with an indus-
trial vacuum cleaner or any means of extraction.
l Working means and tools must be cleaned before
being used for work. Use only tools without dam-
aged chromium coating, or tools without chromium
coating.
Fig. 2
! Caution
All fuel hoses have two layers of material, a rein-
forced rubber coating outside and an internal Vi-
ton hose. If a fuel hose has come loose one must
make absolutely sure that the internal Viton layer
has not been separated from the reinforced outer
layer. In case of a separation the hose needs to be
replaced.
008 917 13 BOMAG 21

Gaskets and mating surfaces able, you should use a plastic tube or adhesive tape
to prevent the sealing lip from being damaged.
Leaking sealing faces can mostly be traced back to in-
correct assembly of seals and gaskets. l Lubricate the outer rim (arrow 3 (Fig. 3)) of the seal
and press it flat on the housing seat.
l Before assembling a new seal or gasket make sure
that the sealing surface is free of pitting, flutes, cor-
rosion or other damage.
l Inappropriately stored or handled seals (e.g. hang-
ing from hooks or nails) must under no circumstanc-
es be used.
l Assemble seals and gaskets only with sealing com-
pound, grease or oil, if this is specifically specified
in the repair instructions.
l If necessary remove any old sealing compound be-
fore assembling. For this purpose do not use any
tools that could damage the sealing surfaces.
l Sealing compound must be applied thin and evenly
on the corresponding surfaces; take care that the
compound does not enter into oil galleries or blind Fig. 4
threaded bores.
l
Press or knock the seal into the housing, until it is
l
Examine the contact faces for scratches and burrs, flush with the housing surface.
remove these with a fine file or an oilstone; take
care that no grinding dust and dirt enters into
tapped bores or enclosed components. i Note
If possible, use a "bell" (1 (Fig. 4)), to make sure that
l
Blow out lines, ducts and gaps with compressed air,
the seal will not skew. In some cases it may be ad-
replace any O-rings and seals that have been dis-
visable to assemble the seal into the housing first, be-
lodged by the compressed air.
fore sliding it over the shaft. Under no circumstances
Assembly of radial seals should the full weight of the shaft rest on the seal.
If you have no proper service tools at hand, use a suit-
able drift punch with a diameter which is about 0,4 mm
smaller than the outer diameter of the seal. Use VERY
LIGHT blows with the hammer if no press is available.
Fig. 3
l Lubricate the sealing lips (2) (Fig. 3) with clean
grease; in case of double seals fill the space be-
tween the sealing lips with a generous amount of
grease.
l Slide the seal over the shaft, with the lip facing to-
wards the fluid to be sealed.
i Note
If possible, use an assembly sleeve (1 (Fig. 3)), to
protect the lip from being damaged by sharp edg-
es, threads or splines. If no assembly sleeve is avail-
22 BOMAG 008 917 13

Feather keys and keyways Ball and roller bearings
Caution
! !Caution
Feather keys may only be reused if they are free of Ball and roller bearings may only be reused if they
damage. are free of damage and do not show any signs of
wear.
Fig. 5
l Clean and thoroughly examine the feather key.
l Deburr and thoroughly clean the edges of the key-
way with a fine file before reassembling.
Fig. 6
l
If a ball or roller bearing of a bearing pair shows de-
fects, both ball or roller bearings need to be re-
placed.
l Remove any lubricant residues from the ball or roll-
er bearing to be examined by washing it with gaso-
line or any other appropriate degreasing agent.
Ensure strict cleanliness.
l Check balls or rollers, running surfaces, outer faces
of outer races and inner faces of inner races for vis-
ible damage. Replace the ball or roller bearing if
necessary.
l Check the ball or roller bearing for clearance and re-
sistance between the inner and outer races, replace
if necessary.
l Lubricate the ball or roller bearing with the recom-
mended type of grease before assembly or reas-
sembly.
l
On greased bearings (e.g. wheel bearings) fill the
space between ball or roller bearing and outer seal
with the recommended type of grease before as-
sembling the seal.
008 917 13 BOMAG 23

l Check shaft and bearing housing for discolouration Screws and nuts
or other signs of movement between ball or roller
bearing and seats. Tightening torque
l Make sure that shaft and housing are free of burrs
before assembling the ball or roller bearing. !Caution
l Always mark the individual parts of separable ball or Tighten nuts or screws with the tightening tor-
roller bearings (e.g. taper roller bearings) to enable ques specified in the following tables of tighten-
correct reassembling. Never assemble the rollers to ing torques. Tightening torques deviating from
an outer race that has already been used, replace the ones in the table are specially mentioned in
the complete ball or roller bearing instead. the repair instructions.
Damaged screws must under no circumstances
be used any longer. Recutting threads with thread
cutters or taps adversely affects the strength and
leak tightness of the screw joint. Damaged or cor-
roded thread pitches can cause incorrect torque
value readings.
Self-locking nuts must generally be replaced after
disassembly.
The use of screws with too high strength can
cause damage!
l Nut of a higher strength can generally be used in-
Fig. 7
stead of nuts of a lower strength classification.
l When checking or retightening screw joints to the
!Caution
specified tightening torque you should first relieve
When assembling the ball or roller bearing to the by a quarter turn and then tighten to the correct
shaft load must only be applied to the inner race 1 torque.
(Fig. 7).
l Before tightening you should lightly oil the thread, in
When fitting the bearing into the housing load order to ensure low friction movement. The same
must only be applied to the outer race (2). applies for self-locking nuts.
l Make sure that no oil or grease will enter into blind
tapped bores. The hydraulic power generated when
turning in the screw could cause breakage of the ef-
fected part.
24 BOMAG 008 917 13

Strength classes, metric screws Strength classes of metric nuts
The strength classes (from 3.6 to 12.9) are specified Nuts are differentiated by three load groups. Each
for all strength classes from a nominal diameter of load group has a special designation system for the
5mm. The corresponding identification can be found strength class assigned, so that the load group can be
where allowed for by the shape of the screw. clearly identified.
Nuts for screw joints with full load capability (4, 5,

6, 8, 10, 12)
Fig. 9 Identification of nuts

In a connection with a screw, these nuts 1 (Fig. 9)
must be able to bear the full pre-load at the yield point.
Nut height above 0.8 d (d = nominal dimension).
Strength class of Strength class of associated

nut screw
4 3.6, 4.6, 4.8
5 3.6, 4.6, 4.8
5.6, 5.8
Fig. 8 Identification of screws 6 6.8
8 8.8
Example: A screw is identified with 12.9.
9 9.8
The first number corresponds with 1/100 of the nomi- 10 10.8
nal tensile strength (minimum tensile strength) in N/ 12 12.8
mm2.
Nuts for screw joints with limited load factor (04,
l
The nominal tensile strength is 12 X 100 N/mm2 = 05)
1200 N/mm2.
The preceding "0" indicates that, due to their low
The second number specifies 10-times the ration be- height, nuts 2 (Fig. 9) in this group are only able to
tween lower yield point and nominal tensile strength withstand the force of a screw to a limited extent.
(yield point ratio). Nut height below 0,8 d (d = nominal dimension).
Nuts for screw joints without specified load factor

i Note
(11H, 14H, 17H, 22H)
When exceeding the lower yield point, the material will
return to its original shape when being relieved (plas- This standard contains strength classes (hardness
tic deformation). classes) for nuts 3 (Fig. 9), for which no load values
can be specified, e.g. because of their shape and di-
When exceeding the upper yield point the material will mensions, but which can only be classified by their
not restore its original shape after being relieved. hardness.
l The lower tensile strength is 9/10 X 1200 N/mm2 = Nut height below 0,5 d (d = nominal dimension).
1080 N/mm2.
i Note
However, these values are by no means identical with
the tightening torques, which are to be set on a torque
wrench. The corresponding calculation requires a
higher effort and, in the end, depends on the materials
to be bolted together.
008 917 13 BOMAG 25

Identification in clock system Identification of UNF-threads
Fig. 10 Identification of nuts in clock system

For small nuts (Fig. 10) the clock system can be used
for identification.
l The 12 o'clock position is identified by a dot or the
manufacturer's symbol.
l
The strength class is identified by a dash (b).
Fig. 11
Screws
The screw head is marked with a stamped in, round
cavity 3 (Fig. 11).
Nuts
An uninterrupted series of stamped in circles parallel
to the axis of the nut on a hexagon area (2).
Studs and brake rods

At the outmost end a short end of the component is re-
duced to its core diameter (1).
26 BOMAG 008 917 13

Cotter pins
Fig. 12
In places where cotter pins are used, these must be
reassembled. Cotter pins must generally be renewed
after disassembly.
Cotter pins must be assembled as shown in the illus-
tration, unless specified differently.
008 917 13 BOMAG 27

1.4 Tightening torques
The values specified in the table apply for screws:

l black oiled
l with surface protection A4C
l with surface protection DACROMET
i Note
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques for screws with metric unified thread*
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M4 3 5 5
M5 6 9 10
M6 10 15 18
M8 25 35 45
M10 50 75 83
M12 88 123 147
M14 137 196 235
M16 211 300 358
M18 290 412 490
M20 412 578 696
M22 560 785 942
M24 711 1000 1200
M27 1050 1480 1774
M30 1420 2010 2400
* Coefficient of friction μ tot. = 0,14
Tightening torques for screws with metric unified fine thread*
Screw dimension
8.8 10.9 12.9
M8 x 1 26 37 48
M10 x 1.25 52 76 88
M12 x 1,25 98 137 126
M12 x 1.5 93 127 152
M14 x 1.5 152 216 255
M16 x 1.5 225 318 383
M18 x 1.5 324 466 554
M20 x 1.5 461 628 775
M22 x 1.5 618 863 1058
M24 x 2 780 1098 1294
M27 x2 1147 1578 1920
M30 x 2 1568 2254 2695
28 BOMAG 008 917 13

Tightening torques 1.4
Tightening torques for screws treated with anti-seizure paste OKS 240* (copper paste)
Screw dimension
8.8 10.9 12.9
M16 169 240 287
M16 x 1.5 180 255 307
M18 232 330 392
M18 x 1.5 260 373 444
M20 330 463 557
M20 x 1.5 369 502 620
M22 448 628 754
M22 x 1.5 495 691 847
M24 569 800 960
M24 x 2 624 879 1036
M27 840 1184 1520
M27 X 2 918 1263 1536
M30 1136 1608 1920
M30 x 2 1255 1804 2156
3/4“ - 10 UNC 276 388 464
3/4“ - 16 UNC 308 432 520
* Anti-seizure paste (copper paste) is used for the assembly of screw connections, which are exposed to high temperatures and corrosive
effects. Prevents seizure and corrosion.
Tightening torques for wheel nuts (fine thread) * **
Thread diameter
10.9
M12x1.5 100
M14x1.5 150
M18x1.5 300 - 350
M20x1.5 400 - 500
M22x1.5 500 - 600
** These values result in a 90% utilization of the yield point
008 917 13 BOMAG 29

The values specified in the table apply for screws:

l black oiled
l with surface protection A4C
l with surface protection DACROMET
i Note
The difference between Withworth and UNF/UNC threads is the fact that UNF and UNC threads have 60° flanks,
as the metric ISO-thread, whereas Withworth has a flank of only 55°.
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques for screws with UNC thread, * UNC Unified Coarse Thread Series, American Unified
Coarse Thread
Screw dimension
8.8 10.9 12.9
1/4“ - 20 11 15 19
5/16“ - 18 23 32 39
3/8“ - 16 39 55 66
7/16“ - 14 62 87 105
1/2“ - 13 96 135 160
9/16“ - 12 140 200 235
5/8“ - 11 195 275 330
3/4“ - 10 345 485 580
7/8“ - 9 560 770 940
1“ - 8 850 1200 1450
1 1/8“ - 7 1200 1700 2000
1 1/4“ - 7 1700 2400 2900
1 3/8“ - 6 2200 3100 3700
1 1/2“ - 6 3000 4200 5100
Tightening torques for screws with UNF thread, * UNF Unified National Fine Thread Series, American
Unified Fine Thread
Screw dimension
8.8 10.9 12.9
1/4“ - 28 13 18 22
5/16“ - 24 25 35 42
3/8“ - 24 45 63 76
7/16“ - 20 70 100 120
1/2“ - 20 110 155 185
9/16“ - 18 155 220 260
5/8“ - 18 220 310 370
3/4“ - 16 385 540 650
7/8“ -14 620 870 1050
30 BOMAG 008 917 13

Tightening torques 1.4
Tightening torques for screws with UNF thread, * UNF Unified National Fine Thread Series, American
Unified Fine Thread
Screw dimension
8.8 10.9 12.9
1“ - 12 930 1300 1600
1 1/8“ - 12 1350 1900 2300
1 1/4“ - 12 1900 2700 3200
1 3/8“ - 12 2600 3700 4400
1 1/2“ - 12 3300 4600 5600
008 917 13 BOMAG 31

32 BOMAG 008 917 13

2 Earth compactor - refuse compactor
008 917 13 BOMAG 33

2.1 Refuse compactor - earth compactor
21 to 25 t
Customized for small landfill sites

All over the world BOMAG refuse compactors of the medium and high weight range as well as the fast running
BOMAG earth compactors convince with efficiency abd reliability on large landfill sites and in earth construction.
The consequent technical implementation of decades of application related experience pays off for the user in
form of effectiveness and efficiency.
The technology that ensures effectiveness and reliability on very large sanitary landfill and construction sites is
also of great use on smaller landfill sites and medium size constructions. This is why BOMAG has designed a
new, lighter family of machines, which provide a maximum of the technical benefits of the large BOMAG com-
pactors, also for smaller scale applications.
Four machines – common benefits.No matter whether you choose the fast running earth compactor or one of
the three refuse compactor versions, each of these machines incorporates decades of experience of BOMAG
and is perfectly adapted to your needs and manufactured to the highest quality standard. And only BOMAG will
offer you this combination of technical advantages:
l No entry of refuse into frame or engine compartment due to the fully closed belly pan.
l Optimal compaction effect and traction due to constant ground contact of the compactor wheels and tension
free frame due to the robust oscillating articulated joint designed for highest loads in landfill operation.
l Various designs of compactor wheels for perfect adaptation to your application.
l Highest compaction due to the special BOMAG wheel concept with teeth and compacting elements.
34 BOMAG 008 917 13

Refuse compactor - earth compactor 2.1
BC 462 RB – Refuse compactor with dozer blade (21 t). BC 472 RB – Refuse compactor with dozer blade (24 t).
BC 472 RS – Refuse compactor with bucket (25 t). BC 462 EB – Fast running earth compactor (21 t).
008 917 13 BOMAG 35

Oscillating articulated joint:

+/- 40° steering angle
Fully closed frame +/- 15° Oscillation of frame
Highly effective wheel and scraper system. Special wheel concept for optimal compaction
The perfect combination of application optimized technology

l
Highest possible compaction of soil and refuse as well as traction for all wheel versions, because the wheels
are kept clean by the adjustable scraper system.
l Modern, powerful turbo diesel engine with 195 kW.
l Low wear travel system with hydraulic overload protection and 4 hydrostatic wheel motors: no powershift
transmission, no axles, no drive shafts.
l Trouble free operation and long maintenance intervals due to highly effective fine filtration in the hydraulic sys-
tem.
l Modern, powerful turbo diesel engine with 195 kW.
l Comfortable driver's work place with vibration insulated cabin and joystick control for steering and dozer blade
or bucket.
l Excellent access to the daily maintenance points due to the wide opening engine hood.
l Easy transportation between points of use: The fast running earth compactor and some of the refuse compac-
tors are only 3 m in width - and can therefore be simply transported without special permission.
36 BOMAG 008 917 13

Refuse compactor - earth compactor 2.1
Refuse compactor wheel with teeth - Refuse compactor wheel with teeth and segments.
basic version for low refuse quantities. for highest compaction.
No coiling up of wires by the wheels due to

Earth compactor with tamper feet and segments wire deflector on the refuse compactor
Easy transportation due to the narrow profile
008 917 13 BOMAG 37

Refuse compactor bucket version with full truck loading height
38 BOMAG 008 917 13

3 Technical data
008 917 13 BOMAG 39

3.1 Technical data
3.1 Technical data
Fig. 13
Dimensions in mm A B B2 B3 D H H4 K L
BC 462 RB 3500 2998 2660 2885 1660 3390 1990 600 8290
BC 472 RB 3500 3600 2660 3335 1660 3390 1990 600 8290
* BC 462 RB BC 472 RB
Weights
Operating weight (CECE) kg 21300 24000
Front axle load (CECE) kg 10600 12000
Rear axle load (CECE) kg 10700 12000
Max. operating weight kg 22500 26000
Dimensions
Rear overhang mm 1460 1460
Travel characteristics
Travel speed range I (forward, reverse) km/h 0 – 4.5 0 – 4.5
Travel speed in speed range II (forward, reverse) km/h 0 – 12 0 – 12
Gradability (soil dependent) % 100 100
Max. pushing force kN 230 259
Drive
Engine manufacturer Deutz Deutz
Type TCD 2013 L06 2V TCD 2013 L06 2V
Cooling Water Water
Number of cylinders 6 6
Rated power ISO 9249 kW 190 190
Rated power acc. to SAE J 1349 hp 261 261
Rated speed rpm 2300 2300
Drive system hydrostatic hydrostatic
Operating voltage V 12 12
Compactor wheels
Width (front/rear) mm 900/900 1125/900
Diameter, outer (front/rear) mm 1660/1660 1660/1660
Number of teeth (front/rear) 40/40 50/40
Compaction width per wheel side mm 1013 1238
40 BOMAG 008 917 13

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Service - Manual

Sanitary landfill compactor

008 917 13 BOMAG 3

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6.27 Fuel gauge 116

4 BOMAG 008 917 13

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8.16 Check the coolant level 285

008 917 13 BOMAG 5

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11.4 Axial piston swash plate principle. 391

6 BOMAG 008 917 13

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008 917 13 BOMAG 7

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This manual addresses the professionally qualified

Use only genuine BOMAG spare parts.

These safety regulations must be read and ap-

8 BOMAG 008 917 13

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l Use protective clothes like hard hat, safety boots

008 917 13 BOMAG 9

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10 BOMAG 008 917 13

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008 917 13 BOMAG 11

Engine air conditioning system. The development of heat

12 BOMAG 008 917 13

Special safety regulations

008 917 13 BOMAG 13

l Before removing or disassembling parts, assem- General

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008 917 13 BOMAG 15

Generator Starter motor

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008 917 13 BOMAG 17

Air conditioning system l Damaged or leaking parts of the air conditioning

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Notes and measures to be applied before starting

008 917 13 BOMAG 19

20 BOMAG 008 917 13

008 917 13 BOMAG 21

22 BOMAG 008 917 13

008 917 13 BOMAG 23

24 BOMAG 008 917 13

Nuts for screw joints with full load capability (4, 5,

Fig. 9 Identification of nuts

Strength class of Strength class of associated

Nuts for screw joints without specified load factor

008 917 13 BOMAG 25

Identification in clock system Identification of UNF-threads

Fig. 10 Identification of nuts in clock system

Studs and brake rods

26 BOMAG 008 917 13

008 917 13 BOMAG 27

The values specified in the table apply for screws:

Tightening torques for screws with metric unified thread*

Tightening torques for screws with metric unified fine thread*

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