Operating instructions

Maintenance instructions
Original operating instructions

BC 672 RB-2
BC 772 RB-2 / BC 772 RS-2
S/N 101 570 59 1036> S/N 101 570 44 .... S/N 101 570 49 ....
S/N 101 570 58 1130> S/N 101 570 43 .... S/N 101 570 48 .... / S/N 101 570 57 1029> S/N 101 570 51 ....

Sanitary landfill compactor

Catalogue No.
008 061 41 11/2010
Foreword

These BOMAG machines are products from provided container. These operating and mainte-
F oreword

the wide product range of BOMAG machines nance instructions are part of the machine.
for earth and asphalt construction, refuse You should only operate the machine after you
compaction and stabilizing/recycling. have been instructed and in compliance with these
BOMAG’s vast experience in connection with instructions.
state-of-the-art production and testing meth- Strictly observe the safety regulations.
ods, such as lifetime tests of all important Please observe also the guidelines of the Civil En-
components and highest quality demands gineering Liability Association ”Safety Rules for
guarantee maximum reliability of your ma- the Operation of Road Rollers and Soil Compac-
chine. tors” and all relevant accident prevention regula-
tions.
This manual comprises:
l Safety regulations For your own personal safety you should only
use original spare parts from BOMAG.
l Operating instructions
In the course of technical development we re-
l Maintenance instructions
serve the right for technical modifications
l Trouble shooting without prior notification.

Using these instructions will These operating and maintenance instructions are
also available in other languages.
l help you to become familiar with the machine.
Furthermore, the spare parts catalogue is availa-
l avoid malfunctions caused by unprofessional ble from your BOMAG dealer against the serial
operation. number of your machine.

Compliance with the maintenance instructions will Your BOMAG dealer will also supply you with in-
formation about the correct use of our machines
l enhance the reliability of the machine on con- on landfill sites.
struction sites,
The above notes do not constitute an extension of
l prolong the lifetime of the machine, the warranty and liability conditions specified in the
l reduce repair costs and downtimes. general terms of business of BOMAG.
We wish you successful work with your BOMAG
BOMAG will not assume liability for the function of machine.
the machine
BOMAG GmbH
l if it is handled in a way not complying with the
Printed in Germany
usual modes of use,
Copyright by BOMAG
l if it is used for purposes other than those men-
tioned in these instructions.

No warranty claims can be lodged in case of dam-

age resulting from
l operating errors,
l insufficient maintenance and
l wrong fuels and lubricants.

Please note!
This manual was written for operators and mainte-
nance personnel on landfill sites.
Always keep this manual close at hand, e.g. in the
tool compartment of the machine or in a specially

BC 672/772 RB-2, BC 772 RS-2 BOMAG 3

Foreword

Please fill in
............................
Machine type (Fig. 1)
............................
Serial-number (Fig. 1 and 2)
............................
Motor type (Fig. 3)
............................
Motor number (Fig. 3)

i Note Fig. 1
Supplement the above data together with the com-
missioning protocol.
During commissioning our organisation will in-
struct you in the operation and maintenance of the
machine.
Please observe strictly the safety regulations and
all notes on risks and dangers!

Fig. 2

Fig. 3

4 BOMAG BC 672/772 RB-2, BC 772 RS-2

Table of Contents

Technical Data 9
Safety regulations 15
Indicators and Controls 23
3.1 General notes 26
3.2 Description of indicators and control elements 26
Operation 41
4.1 General 42
4.2 Tests before taking into operation 42
4.3 Starting the engine 43
4.4 Starting the engine with jump leads 46
4.5 Resetting the trip mileage to zero 47
4.6 Driving the machine 47
4.7 Driving the machine with rotary speed pre-selection/deceleration pedal 50
4.8 Switching off the rotary speed pre-selection/deceleration pedal 53
4.9 What to do in events of emergency 54
4.10 Operating the dozer blade 55
4.11 Operating the bucket (RS) 56
4.12 Operating the service brake 58
4.13 Operating the parking brake 59
4.14 Starting and adjusting the air conditioning 60
4.15 Air conditioning, switching Reheat – operation on/off 64
4.16 Air conditioning, changing between circulation air/fresh air operation 65
4.17 Air conditioning, heating operation 66
4.18 Shutting down the engine 67
4.19 Parking on a slope 69
4.20 Towing the machine 70
4.21 Transport of the machine 72
Maintenance 75
5.1 General notes on maintenance 76
5.2 Fuels and lubricants 77
5.3 Table of fuels and lubricants 81
5.4 Running-in instructions 82
5.5 Maintenance table 83
5.6 Checking the engine oil level 87
5.7 Checking the fuel level 87
5.8 Check the hydraulic oil level 89
5.9 Check the coolant level 89
5.10 Checking the oil level in the transfer box 90
5.11 Visual inspection of the machine for damage and leaks 91
5.12 Lubricating the joints and bearings on the bucket (RS) 91
5.13 Changing engine oil and oil filter 93

BC 672/772 RB-2, BC 772 RS-2 BOMAG 5

Table of Contents

5.14 Checking, cleaning the water separator 94

5.15 Servicing the generator V-belt 95
5.16 Servicing the air conditioning compressor V-belt 97
5.17 Servicing the fan V-belt 98
5.18 Battery service, checking the main battery switch 100
5.19 Check the engine mounts 102
5.20 Servicing the air conditioning 102
5.21 Checking condition of radiator, intercooler and hydraulic oil cooler, clean, cle-
aning the engine 105
5.22 Check the fastening of the scrapers 107
5.23 Checking the oil level in the travel gear 108
5.24 Checking, filling the central lubrication system 109
5.25 Replacing the fresh air and circulation air filters 111
5.26 Check, adjust the valve clearance 113
5.27 Replacing the fuel filter cartridges 114
5.28 Replacing the fuel pre-filter cartridge, bleeding the fuel system 115
5.29 Checking the anti-freeze concentration and the condition of the coolant 117
5.30 Intercooler, draining off oil/condensation water 118
5.31 Checking the fastening of engine / turbo charger / combustion air hoses 118
5.32 Checking the crankcase pressure 119
5.33 Oil change in travel gear 120
5.34 Changing the fuel filter for the cabin heater (diesel) 122
5.35 Checking, cleaning the oil bath air filter for the cabin heater 122
5.36 Change the hydraulic oil fine filter 123
5.37 Changing hydraulic oil and breather filter 125
5.38 Change the coolant 127
5.39 Oil and filter change in transfer box 128
5.40 Checking the condition of the articulated joint 130
5.41 Changing the injection valve 131
5.42 Replacing the crankcase ventilation valve 133
5.43 Changing the coolant pump 133
5.44 Changing the pressure retaining valve on te injection pump 134
5.45 Replacing the glow plugs 134
5.46 Cleaning, changing the dry air filter cartridge 135
5.47 Clean the condenser 137
5.48 Adjust scrapers and edge cutter 139
5.49 Replacing the wheel caps 140
5.50 Checking the cutting plates, replacing the cutting plates if necessary 141
5.51 Fill the provision tank for the windscreen washer system 142
5.52 Drain off dirty fluids from front and rear frame 142
5.53 Retightening bolted connections 143
5.54 Conservation 144
Trouble shooting 147

6 BOMAG BC 672/772 RB-2, BC 772 RS-2

Table of Contents

6.1 General notes on trouble shooting 148

6.2 Engine problems 149
6.3 General notes on diagnostic push button and control light 153

BC 672/772 RB-2, BC 772 RS-2 BOMAG 7

Table of Contents

8 BOMAG BC 672/772 RB-2, BC 772 RS-2

1 Technical Data

BC 672/772 RB-2, BC 772 RS-2 BOMAG 9

Technical Data

Fig. 4

Dimensions in A B B2 B3 D H H2 H4 K L
mm
BC 672 RB-2 3500 3800 3550 3775 1660 4120 3820 1950 600 8120
BC 772 RB-2 3500 3800 3550 3775 1660 4120 3820 1950 600 8120

*
BC 672 RB-2 BC 772 RB-2
Weights
Operating weight (CECE) kg 32100 36500
Front axle load (CECE) kg 15300 17400
Rear axle load (CECE) kg 16800 19100
Max. operating weight kg 32700 37100

Travel characteristics
Travel speed range I (forward/reverse) km/h 0 – 4.5 0 – 4.5
Travel speed range II (forward/reverse) km/h 0 – 12 0 – 12
Max. gradability (depending on soil) % 100 100
Max. pushing force kN 346 394

Engine
Engine manufacturer Deutz Deutz
Type TCD 2015 V06 TCD 2015 V06
Cooling Water Water
Number of cylinders 6 6
Rated power ISO 9249 kW 330 330
Rated power acc. to SAE J 1349 hp 442 442
Rated speed rpm 2100 2100
Electrical equipment V 24 24
Drive system hydrostatic hydrostatic

Compactor wheels

10 BOMAG BC 672/772 RB-2, BC 772 RS-2

Technical Data

* BC 672 RB-2 BC 772 RB-2

Width, front mm 1350 1350
Width, rear mm 1125 1125
Outer diameter front mm 1660 1660
Outer diameter rear mm 1660 1660
Number of teeth, front 60 60
Number of teeth, rear 50 50
Compaction width per wheel side mm 1350 1350

Brake
Service brake hydrostatic hydrostatic
Parking brake mechanical mechanical

Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation hydraulic hydraulic
Steering/oscillation angle ±° 40/15 40/15
Inner track radius mm 3090 3090

Dozer blade
Height adjustment above ground level mm 1200 1200
Height adjustment below ground level mm 120 120

Filling capacities
Fuel (diesel) l approx. 500 approx. 500
Engine oil l approx. 36 approx. 36
Coolant l approx. 50 approx. 50
Hydraulic oil l approx. 350 approx. 350
* Subject to technical alterations.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 11

Technical Data

Fig. 5

Dimensions in A B B2 B3 D H H2 H4 K L
mm
BC 772 RS-2 3875 3800 3550 3775 1660 4120 3820 1800 600 9275

* BC 772 RS-2
Weights
Operating weight (CECE) kg 37300
Front axle load (CECE) kg 20800
Rear axle load (CECE) kg 16500
Max. operating weight kg 37900

Travel characteristics
Travel speed range I (forward/reverse) km/h 0 – 4.5
Travel speed range II (forward/reverse) km/h 0 – 12
Max. gradability (depending on soil) % 75
Max. pushing force kN 403

Drive
Engine manufacturer Deutz
Type TCD 2015 V06
Cooling Water
Number of cylinders 6
Rated power ISO 9249 kW 330
Rated power acc. to SAE J 1349 hp 442
Rated speed rpm 2100
Electrical equipment V 24
Drive system hydrostatic

12 BOMAG BC 672/772 RB-2, BC 772 RS-2

Technical Data

* BC 772 RS-2
Compactor wheels
Width, front mm 1350
Width, rear mm 1125
Outer diameter front mm 1660
Outer diameter rear mm 1660
Number of teeth, front 60
Number of teeth, rear 50
Compaction width per wheel side mm 1350

Brake
Service brake hydrostatic
Parking brake mechanical

Steering
Type of steering Oscill.-articul.
Steering operation hydraulic
Steering/oscillation angle ±° 30/15
Inner track radius mm 3750

Dozer blade
Height adjustment above ground level mm 5350
Height adjustment below ground level mm 50

Filling capacities
Fuel (diesel) l approx. 750
Engine oil l approx. 36
Hydraulic oil l approx. 350
Coolant l approx. 50
* Subject to technical alterations.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 13

Technical Data

The following noise and vibration data acc. to

- EC Machine Regulation edition 2006/42/EC

- the noise regulation 2000/14/EG, noise protection guideline 2003/10/EC

- Vibration Protection Regulation 2002/44/EC

were determined during conditions typical for this type of equipment and by application of harmo-
nized standards.

During operation these values may vary because of the existing operating conditions.

Noise value
Sound pressure level on the place of the operator:
BC 672 RB-2: LpA = 73 dB(A), determined acc. to ISO 11204 and EN 500
BC 772 RB-2: LpA = 73 dB(A), determined acc. to ISO 11204 and EN 500
BC 772 RS-2: LpA = 73 dB(A), determined acc. to ISO 11204 and EN 500

Guaranteed sound power level:

BC 672 RB-2: LWA = 110 dB(A), determined acc. to ISO 3744 and EN 500
BC 772 RB-2: LWA = 110 dB(A), determined acc. to ISO 3744 and EN 500
BC 772 RS-2: LWA = 110 dB(A), determined acc. to ISO 3744 and EN 500

Vibration value
Vibration of the entire body (driver’s seat)
The weighted effective acceleration value determined according to ISO 7096 is ≤ 0.5 m/s2.

Hand-arm vibration values

The weighted effective acceleration value determined according to ISO 5349 is ≤ 2.5 m/s2.

14 BOMAG BC 672/772 RB-2, BC 772 RS-2

2 Safety regulations

BC 672/772 RB-2, BC 772 RS-2 BOMAG 15

Safety regulations

General l Driving on ground with insufficient load bear-

ing capacity (soft spots, edges, embank-
This BOMAG machine has been built in com- ments),
pliance with the latest technical standard and
l Driving on subbases or under conditions,
complies with the applicable regulations and
which could be destroyed by the wheels,
technical rules. However, dangers for persons
and property may arise from this machine, if: l Fire fighting operations,
l Lifting gear operation; mounting of lifting gear
l it is used for purposes other than the ones it is
to dozer blade/bucket
intended for,
Transporting persons, except the machine driver,
l it is operated by untrained personnel,
is prohibited.
l it is changed or converted in an unprofessional Starting and operation of the machine in explosive
way, environments and in underground mining is pro-
l the safety instructions are not observed. hibited.

Each person involved in the operation, mainte-

nance and repair of the machine must there-
Remaining dangers, remaining risks
fore read and comply with these safety Despite careful work and compliance with stand-
regulations. If necessary, this must be con- ards and regulations it cannot be ruled out that fur-
firmed by obtaining the signature of the cus- ther dangers may arise when working with and
tomer. handling the machine.
Furthermore, the following obviously also applies: Both the machine as well as all other system com-
ponents comply with the currently valid safety reg-
l applicable accident prevention instructions,
ulations. Nevertheless, remaining risks cannot be
l generally accepted safety and road traffic reg- ruled out completely, even when using the ma-
ulations, chine for the purpose it is intended for and follow-
l country specific safety regulations. It is the ing all information given in the operating
duty of the operator to be acquainted with instructions.
these instructions and to apply these accord- A remaining risk can also not be excluded beyond
ingly. This applies also for local regulations the actual danger zone of the machine. Persons
concerning different types of handling work. remaining in this area must pay particular attention
Should the recommendations in these instruc- to the machine, so that they can react immediately
tions be different from the regulations valid in in case of a possible malfunction, an incident or
your country, you must comply with the safety failure etc.
regulations valid in your country. All persons remaining ion the area of the machine
must be informed about the dangers that arise
Intended use from the operation of the machine.
This machine must only be used for:
l Compaction and distribution of refuse on the
Regular safety inspections
landfill site. Have the machine inspected by an expert (proper-
ly trained person) once every year.
Unintended use
Dangers may arise from the machine when it is
Who is allowed to work with the ma-
used for purposes other than the one it is intended chine?
for. The machine must only be operated by trained
Any danger caused by intended use is the sole re- and authorized persons which are at least 18
sponsibility of the customer or driver/operator, the years of age. The responsibilities for the operation
manufacturer cannot be made liable. of the machine must be clearly specified and com-
plied with.
Examples for unintended use are:

16 BOMAG BC 672/772 RB-2, BC 772 RS-2

Safety regulations

Persons who are under the influence of alcohol, Environment

medication or drugs must not operate, service or
repair the machine. Sections marked like this highlight activities
for the safe and environmental disposal of fu-
Maintenance and repair tasks require specific els and lubricants as well as replaced parts.
knowledge and must therefore only be carried out
by trained and qualified personnel. Observe all environment protection regula-
tions.
Conversions and alterations to the ma-
chine Loading the machine The ramp inclina-
tion must be lower than the gradability
Unauthorized conversions to the machine are pro-
hibited for safety reasons.
of the machine.
Original parts and accessories have been special- Secure the machine against falling or slipping off.
ly designed for this machine. We wish to make ex- On the transport vehicle secure the machine
pressly clear that we have not tested or authorized against rolling off, slipping about or turning over.
any original parts or special equipment not sup- Persons are highly endangered when
plied by us. The installation and/or use of such
products can impair the active and/or passive driv- l they step or stand under loads being lifted
ing safety. The manufacturer expressly excludes l they remain in the danger zone of the machine
any liability for damage resulting from the use of during an ongoing demonstration or during
non-original parts or accessories. loading.

Damage, deficiencies, misuse of safety Towing the machine

installations Use a towing vehicle with appropriate tractive
Machines which are not safe to operate or in traffic power to tow the machine.
must be immediately taken out of service and shall Max. towing speed 1 km/h, max. towing distance
not be used, until these deficiencies have been 500 m.
properly rectified.
Before releasing the multi-disc brake secure the
Safety installations and switches must neither be machine against unintended rolling.
removed nor must they be made ineffective.
Checking the Roll Over Protective
Safety notes in the operating and main- Structure (ROPS)
tenance instructions:
i Note
! Danger
On machines with cab the ROPS is an integral part
Sections marked like this point out possible of the cab.
dangers for persons.
The frame of the machine must not be warped,
bent or cracked in the area of the ROPS fastening.
! Caution
The ROPS must not show any rust, damage, hair-
Sections marked like this point out possible line cracks or open fractures.
dangers for the machine or for parts of the ma-
chine. The actual weight of the machine must not exceed
the testing weight of the ROPS.
The ROPS must not rattle about when driving.
i Note
This indicates that it is not properly fastened. All
Sections marked like this provide technical infor- bolted connections must comply with the specifi-
mation concerning the optimal economical use of cations and should be absolutely tight (observe
the machine. the tightening torques). Screw and nuts must not
be damaged, bent or deformed.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 17

Safety regulations

With the cab assembled check also the state of the Do not climb onto or off the machine while the ma-
cabin mounts (rubber elements and screws). chine is driving.
No accessories may be welded or bolted on and Change the travel direction only at standstill.
no additional holes must be drilled without the con- Do not use the machine to transport persons.
sent of the manufacturer, since this will impair the
strength of the unit. Do not use the dozer blade/bucket to transport
persons - danger to life!
The ROPS must therefore also not be straight-
ened or repaired if it is damaged. In case of unusual noises and development of
smoke perform trouble shooting and have the fault
A defect ROPS must generally be replaced with an corrected.
original spare part in close coordination with the
manufacturer. Always keep a sufficient distance to edges and
embankments and do not use working methods
that could impair the stability of the machine.
Driving the machine
Match the speed to the working conditions.
Persons in the danger area Always give way to loaded transport vehicles.
Before taking up work, also after breaks, you Switch the lights on if the visibility is poor.
should always convince yourself that the danger
zone is free of persons or obstructions, especially Driving on inclinations and slopes
when driving in reverse. Do not drive on gradients exceeding the maximum
Give warning signals, if necessary. Stop work im- gradability of the machine.
mediately if persons remain in the danger zone, On slopes drive extremely careful and always di-
despite the warning. rectly up or down the slope. Change to a lower
Do not step or stand in the articulation area of the gear before starting to drive.
machine when the engine is running. Danger of Wet and loose soils considerably reduce the
squashing! ground adhesion of the machine on inclinations
Driving and slopes. Higher risk of accident!

In events of emergency and in case of danger ac-

tuate the emergency stop switch immediately. Do Parking the machine
not use the emergency stop switch as service Park the machine on horizontal, level, firm ground.
brake. Before leaving the machine:
Restart the machine only after the danger that l lower the dozer blade to the ground.
caused the actuation of the emergency stop switch
has been eliminated. l return the control lever to neutral position
If the machine has contacted high-voltage power l shut the engine down, pull the ignition key off
lines: l lock the cabin
l do not leave the operator’s stand Do not jump off the machine, but use hand grips
l warn others from coming close to or touching and access steps.
the machine Mark machines, which could be in the way, with a
l if possible drive the machine out of the danger clearly visible sign.
zone Pull off the main battery switch.
l have the power switched off
Operate the machine only from the operator’s Refuelling
stand. Do not inhale any fuel fumes.
Keep the cabin doors closed. Refuel only with the engine stopped and the auxil-
Do not adjust the driver’s seat while driving. iary heater switched off.
Always use access steps.

18 BOMAG BC 672/772 RB-2, BC 772 RS-2

Safety regulations

Do not refuel in closed rooms. Relieve hydraulic pressures before working on hy-
No open fire, do not smoke. draulic lines. Hydraulic oil escaping under pres-
sure can penetrate the skin and cause severe
Watch the complete refuelling process. injury. When being injured by hydraulic oil seek
Do not spill any fuel. Catch running out fuel, do not medical advice immediately, as otherwise this may
let it seep into the ground. cause severe infections.
Wipe off spilled fuel. Keep dirt and water away Do not step in front of or behind the wheels when
from the fuel. performing adjustment work in the hydraulic sys-
A leaking fuel tank can cause an explosion. En- tem.
sure tight fit of the fuel tank cover, if necessary re- Do not change the setting of pressure relief valves.
place immediately. Drain the hydraulic oil at operating temperature –
Fire protection measures danger of scalding!

Familiarise yourself with the location and the oper- Catch running out hydraulic oil and dispose of en-
ation of fire fighting equipment. Observe all fire re- vironmentally.
porting and fire fighting possibilities. Always catch and dispose of hydraulic oils sepa-
rately.
Maintenance work Do not start the engine after draining the hydraulic
Maintenance work must only be performed by oil.
qualified and authorized persons. Once all work is completed (with the system still
Comply with the maintenance work described in depressurized!) check all connections and fittings
the operating and maintenance instructions, in- for leaks.
cluding the information concerning the replace- Changing hydraulic hoses
ment of parts.
Hydraulic hoses must not be mixed up by mistake.
For overhead maintenance and assembly work
use the access steps and working platforms pro- Hydraulic hoses must be visually inspected at reg-
vided or other secure means. Do not use machine ular intervals.
parts as access steps. Hydraulic hoses must be immediately replaced if:
When performing maintenance work on machines l the outer layer is damaged down to the inlay
used in contaminated environments, all applicable (e.g. chafing, cuts, cracks),
national or local safety regulations must be ap-
l embrittlement of the outer layer (formation of
plied.
cracks in the hose material)
Keep unauthorized persons away from the ma-
l the hose shows deformations in pressurized
chine.
and depressurized condition, which do not
Do not perform maintenance work while the ma- comply with the original shape of the hydraulic
chine is driving or the engine is running. hose,
Park the machine on level, firm ground. l the hose shows deformations in bends, e.g.
Lower the dozer blade/bucket to the ground. squeezing, buckling, layer separation, forma-
Pull the key out of the ignition switch. tion of blisters,

pull the key off the main battery switch. l parts of the hose are leaking,
Secure the articulated joint with the articulation l hoses are not correctly installed,
lock. l the hydraulic hose has separated from the fit-
ting,
Work on hydraulic lines
In order to depressurize the hydraulic system low- l the fitting shows corrosion that impairs both
er the dozer blade/bucket to the ground and shut function and strength,
the engine down.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 19

Safety regulations

l fittings are damaged or deformed, whereby Do not let acid come in contact with hands or
the function and strength of the hose - hose clothes! When injured by acid flush off with clear
connection is impaired, water and seek medical advice.
l expiration of storage time and utilization peri- Metal objects (e.g. tools, rings, watch straps) must
od. not come in contact with the battery poles – dan-
ger of short circuit and burning!
hoses are mixed up by mistake.
When recharging non-serviceable batteries re-
Only genuine BOMAG replacement hydraulic hos-
move all plugs, to avoid the accumulation of explo-
es ensure that the correct hose type (pressure
sive gases.
range) is used at the right location.
Observe the applicable instructions when starting
Working on the engine with an auxiliary battery.
Do not work on the fuel system while the engine is Dispose of old batteries according to regulations.
running – danger to life due to high pressures!
Switch off the charging current before removing
l Wait approx. 5 minutes after the engine has the charging clamps.
stopped.
Ensure sufficient ventilation, especially if the bat-
l Keep out of the danger zone during the initial tery is to be charged in a closed room.
test rung.
Working on the fuel system
l In case of leaks return to the workshop imme-
Do not inhale any fuel fumes.
diately.
Avoid open fire, do not smoke, do not spill any fuel.
l Make sure that the engine cannot be started
unintentionally during service and repair work. Catch running out fuel, do not let it seep into the
ground and dispose off environmentally.
Drain the engine oil at operating temperature –
danger of scalding! Working on the air conditioning
Wipe off spilled oil, catch running out oil and dis- Faults on the air conditioning should only be rem-
pose of environmentally. edied by professional personnel.
Store used filters and other oil contaminated ma- According to the regulation for pressure reservoirs
terials in a separate, specially marked container all pressure reservoirs must be repeatedly inspect-
and dispose of environmentally. ed by a specialist.
Do not leave any tools or other objects, that could In connection with this inspection the drier/collec-
cause damage, in the engine compartment. tor unit must be visually examined twice every
year. During these inspections special attention
Working on the cooling system
must be paid to corrosion and mechanical dam-
Check and change coolant only when the engine age.
is cold.
Do not perform welding work in the vicinity of the
Catch coolant and dispose of environmentally. air conditioning - danger of explosion.
Working on electric parts of the machine Do not clean the condenser in the air conditioning
system with a hot water jet - danger of explosion.
Before starting to work on electric parts of the ma-
chine disconnect the battery and cover it with insu- Do not release refrigerant into the atmosphere, but
lating material. dispose of environmentally.
Do not use fuses with higher ampere ratings and Working on the dozer blade/bucket
do not repair fuses with a piece of wire. Fire haz-
Lower the dozer blade to the ground and shut the
ard!
engine down.
Working on the battery
Cleaning work
When working on the battery do not smoke, do not
Do not perform cleaning work while the motor is
use open fire!
running.

20 BOMAG BC 672/772 RB-2, BC 772 RS-2

Safety regulations

Do not use gasoline or other easily inflammable

substances for cleaning.
When using a steam cleaner for cleaning do not
subject electrical parts and insulation material to
the direct jet or cover these items beforehand.
Do not guide the cleaning jet into the exhaust.

After maintenance work

After all maintenance work is completed reinstall
all guards and safety installations.

Repair
Mark a defective machine by attaching a warning
tag to the steering wheel.
Repair work must only be performed by qualified
and authorized persons. Use our repair instruc-
tions for this work.
Exhaust gases are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
in closed rooms!
Do not work on the fuel system while the engine is
running - danger to life!
The system is under high pressure! Keep away
from leakages in the high pressure system, be-
cause fuel squirting out may cause severe injury.
After shutting down the engine wait for another
minute, until the pressure has dropped to a per-
missible level. In case of leakages you should con-
tact the Service Department of the engine
manufacturer and refrain from starting the engine.
When performing electric welding work on the
refuse compactor, the plug connectors must be
pulled off the control units as a measure to protect
the electronics in engine control unit and ESX.

Test
The safety of compaction equipment must be
checked by a specialist as required in dependence
on the application and the operating conditions,
however at least once every year.

Information and safety stickers/decals

on the machine
Keep stickers/decals complete (see spare parts
catalogue) and fully legible and observe their
meaning.
Replace damaged or illegible stickers/decals im-
mediately.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 21

Safety regulations

Fig. 6

Stickers and decals

1 Information sticker "Always wear seat belt". 8 Information sticker "Battery disconnecting
2 Warning sign "Danger of scalding when open- switch"
ing the radiator cap" 9 Warning sign "Danger of cutting and getting
3 Warning decal caught by radiator fan"
4 Maintenance sticker "Clean radiator". 10 Warning sign "Danger of being pulled in" Shut-
ting down the engine
5 Information sticker "Guaranteed sound capac-
ity level" 11 Information sticker "Lashing points"
6 Information sticker "Hydraulic oil" 12 Warning sticker "Danger of crushing"
7 Information sticker "Hydraulic oil temperature". 13 Information sticker "Diesel"

22 BOMAG BC 672/772 RB-2, BC 772 RS-2

3 Indicators and Controls

BC 672/772 RB-2, BC 772 RS-2 BOMAG 23

Indicators and Controls

Fig. 7

24 BOMAG BC 672/772 RB-2, BC 772 RS-2

Indicators and Controls

1 Instrument cluster, left 14 Push button for central lubrication system

2 Instrument cluster, right 15 Control unit for air conditioning*
3 Ignition switch 16 Rotary switch for cabin fan
4 Air distribution nozzles 17 Potentiometer for throttle control*
5 Lever for dozer blade control 18 Rotary switch to activate rotary speed pre-se-
6 Warning light and diagnostic push button for lection/deceleration pedal with indicator light*
engine control 19 Emergency stop push button
7 Warning light water in fuel filter 20 Travel pedal for throttle control
8 Utility socket 24V 21 Deceleration pedal with emergency braking
9 Rotary switch for travel ranges kick-down*
10 Travel lever 22 Steering lever
11 Rotary switch for parking brake 23 Push button for warning horn
12 Rotary switch for seat cushion heating
13 Cigarette lighter * Optional equipment

BC 672/772 RB-2, BC 772 RS-2 BOMAG 25

Indicators and Controls

3.1 General notes 3.2 Description of indicators

and control elements
Please read this section thoroughly before operat-
ing this machine if you are not yet conversant with
the indicators and control elements. All functions
are described in detail hereunder.
Paragraph 4 Operation contains only concise de-
scriptions of the individual operating steps.

Fig. 8
No. 1 = Instrument cluster, left

i Note
With the ignition switch in position "I" all gauges
and instruments are switched on for a moment.
a yellow = Pre-heating control light
Lights when temperatures are low
(pre-heating for starting)
b yellow = Cabin filter warning light
Lights when the cabin filter is soiled
or the cabin fan is defective.
Clean the cabin filter, if necessary
use a new one. Check the cabin fan,
repair if necessary.
c red = Warning light, engine oil pressure
Flashes if engine oil pressure is too
low, the warning buzzer sounds, the
engine will possibly be shut down by
the engine control.
Check engine oil level, repair the en-
gine if necessary.
d red = Coolant level warning light
Flashes when the coolant level is too
low, the warning buzzer sounds, the
engine is shut down after 10 sec-

26 BOMAG BC 672/772 RB-2, BC 772 RS-2

Indicators and Controls

onds.
Check coolant level. Check cooling
system for leaks, repair if necessary.
e yellow = Charge control light
Lights if the battery is not being
charged.
Check V-belt, if necessary repair the
generator.
f red = Warning light, overheating of engine
Flashes if engine is overheating, the
warning buzzer sounds, the engine
will possibly be shut down by the en-
gine control.
Run the engine with idle speed or
shut it down if necessary, clean en-
gine oil cooler and radiator, if neces-
sary repair the engine.
g yellow = Air filter warning light
Lights when the combustion air filter
is contaminated.
Clean or replace, as necessary.
h red = Fault warning light
Light in case of faults in the electronic
control.
i = not triggered
j = Fuel level gauge
k = RPM-meter
l = Operating hour meter
Counts the operating hours while the
engine is running (the "hourglass"
symbol flashes).
All maintenance work must be per-
formed according to the indicated op-
erating hours.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 27

Indicators and Controls

p yellow = Differential pressure switch 1 on hy-

draulic oil filter.
Replace the front hydraulic oil filter,
check the hydraulic system if it
comes on too early.
q red = Hydraulic oil temperature warning
light
Lights if the hydraulic oil temperature
is too high, the warning buzzer
sounds, the engine is shut down after
2 minutes.
Clean the hydraulic oil cooler if nec-
essary.
r red = Hydraulic oil level warning light
Flashes when the hydraulic oil level
is too low, the warning buzzer
sounds, the engine is shut down after
20 seconds.
Check the hydraulic oil level, check
Fig. 9 the hydraulic system for leaks, repair
if necessary.
No. 2 = Instrument cluster, right
s green = Control light speed range II
Lights when the rotary travel speed
i Note range switch is in position "Right".
With the ignition switch in position "I" all gauges
t green = Control light speed range I
and instruments are switched on for a moment.
Lights when the rotary travel speed
m yellow = Control light for central lubrication range switch is in position "Left".
system u yellow = Parking brake warning light
Flashes with 1 second on, 1 second Lights when the parking brake is ap-
off in case of a fault in the lubricant plied
pump.
Flashes with 0.5 seconds on, 0.5 v green = Control light for neutral position of
seconds off when the grease contain- travel lever
er is empty. Lights when the travel lever is in neu-
Flashes with 0,5 second on, 1 sec- tral position Goes out when the travel
ond off in case of a malfunction. lever is actuated.
Permanent light for about 45 seconds w yellow = Contamination sensor warning light
during the lubrication process Lights when the contamination sen-
n red = Warning light for hydraulic oil return sor is soiled, the warning buzzer
flow filter sounds
Lights, if the hydraulic oil return flow x = Voltmeter
filter is blocked y = Coolant temperature gauge
Change the hydraulic oil return flow
filter. z = Hydraulic oil temperature gauge

o yellow = Differential pressure switch 2 on hy-

draulic oil filter.
Replace the rear hydraulic oil filter,
check the hydraulic system if it
comes on too early.

28 BOMAG BC 672/772 RB-2, BC 772 RS-2

Indicators and Controls

Fig. 10 Fig. 11
No. 3 = Ignition switch No. 4 = Air distribution nozzles
Position "0" = Ignition off, key can be pulled Adjusting the di-
out rection = turn the outside of the nozzle
Position "I" = Ignition on, all control and Regulating the air
warning lights in the instru- quantity = open or close by swivelling the
ment clusters light up for 3 flap
seconds (test function).
Fault warning light, parking
brake warning light, charge
control light and travel lever
neutral position control light
stay on.

i Note
The ignition switch is designed with a re-start lock.
For a new starting attempt the ignition key must
first be turned back to position "0".
Position "II" = Turn further against spring
pressure, the engine starts,
turn the ignition key back to Fig. 12
position "I" once the engine No. 5 = Lever for dozer blade control
has started. Charge control
Position "0" (neu-
light and fault warning light go
tral position) = no actuation, lever returns au-
out. The parking brake warn-
tomatically to "0"-position.
ing light goes out when the
parking brake is released. Position "I" = Dozer blade down
Position "I" and
push button "a" = Dozer blade in floating position
! Caution
(e.g. to level the surface while
Run the engine warm for a short while before driving backwards)
starting work. Do not rev up a cold engine to
high idle speed/full load speed. Position "II" = Dozer blade up, float position
off
Do not shut down the engine all of a sudden
from full load speed, but let it idle for about 2
minutes.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 29

Indicators and Controls

i Note
The diesel engine with EMR (Electronic Engine
Control) has some protective functions for the en-
gine.
Depending on the severity of the detected fault the
engine may continue operation with limitations
(limp home), whereby the warning light will perma-
nently be on.
With flashing warning light the engine is shut
down. If the fault indicators for engine oil pressure,
engine temperature or coolant level, light up as
well, eliminate the fault.
Fig. 13
When the fault is eliminated the control light will go
Lever for bucket control (RS) out.
Middle position = No actuation, lever returns au- The diagnostic button provides the possibility to
tomatically to middle position read out existing faults in form of flashing codes.
Position front = Bucket down With the ignition switch in position "I" the control
light lights for about 2 seconds (function check)
Position rear = Bucket up
permanent light = A fault message is present, the
Position left = Tipping bucket to fill
engine can be started and the
Position right = Tipping bucket to empty vehicle is still operable with
Press button limitations. Inform the service
(a). = Bucket in floating position (e.g. department.
to level the surface while driv- the control light
ing backwards) flashes after 2
Press button (a) seconds = Severe fault, the engine can-
again = Bucket float position deactivat- not be started, inform the serv-
ed ice department.
goes out after 2
seconds = The engine function is free of
faults.
does not light = Start the engine, press the di-
agnostic push button for 3 sec-
onds. Control light flashes 2x.
EMR-control ok.

!Caution
In case of a fault make a note of the fault code
and inform the BOMAG customer service or
the customer service of the engine manufac-
turer.
Fig. 14
See chapter "Trouble shooting".
No. 6 = Warning light and diagnostic push
button for engine control

30 BOMAG BC 672/772 RB-2, BC 772 RS-2

Indicators and Controls

Fig. 15 Fig. 17
No. 7 = Warning light water in fuel filter No. 9 = Rotary switch for travel ranges
lights = Lights when the water content Position "left" = Speed range I, slow working
in the fuel pre-cleaner reaches speed range
the sensor contacts. The control light for travel
stage I in the right instrument
cluster lights.
Environment
Position "right" = Speed range II, transport
Drain off the water and other impurities and
speed
dispose of environmentally.
The control light for travel
goes out = if fuel is clean. stage II in the right instrument
cluster lights up.

Fig. 16
No. 8 = Socket 24V Fig. 18

Permanent current, loadable up to max. 10 A. No. 10 = Travel lever

Position "0" = Zero position (to start the en-
gine)
The control light for travel lever
in the right instrument cluster
lights.
Position "front" = Forward travel
The control light for travel lever
in the right instrument cluster
goes out.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 31

Indicators and Controls

Position "rear" = Reverse travel

The control light for travel lever
in the right instrument cluster
goes out.

! Danger
Danger of accident!
Before starting to reverse make sure that the
drive range behind the machine is absolutely
safe.

i Note
Fig. 20
In travel lever position "0" (neutral position) the
No. 12 = Rotary switch for seat heating
machine is automatically braked.
Position"left" = seat heating off.
Position"right" = seat heating on.

Fig. 19
No. 11 = Rotary switch for parking brake
Fig. 21
Position "left" = Parking brake released
The parking brake warning No. 13 = Cigarette lighter
light in the right instrument
cluster goes out.
Position "right" = Parking brake operated
The parking brake warning
light in the right instrument
cluster lights up after 4 sec-
onds.

Fig. 22
No. 14 = Push button for central lubrication
system

32 BOMAG BC 672/772 RB-2, BC 772 RS-2

Indicators and Controls

press for 2 sec- k = 12 digit LED bar display for evapora-

onds = The central lubrication system tor fan speed (in 10%-steps)
triggers an additional lubrica- l = Push button to raise the nominal val-
tion cycle. ue, may also be used to increase the
press for 1 sec- fan speed manually.
ond = An existing fault is reset. The m = Push button to activate and deacti-
flashing of the central lubrica- vate the control unit.
tion control light in the right in-
strument cluster changes to
permanent light.

Fig. 24
No. 16 = Rotary switch for cabin fan
Fig. 23 The cabin fan is forced to run with the ignition
No. 15 = Control unit for air conditioning * switch in position "I" and when the engine is run-
ning. It permanently supplies fresh air to the cabin
a = Push button to activate and deacti- and thereby creates a slight overpressure in the
vate operation of air conditioning. cab.
b = Push button to raise the nominal val- Position "1", "2"
ue, may also be used to increase the and "3" = Fan stages of different
fan speed manually. strengths
c = LED with symbol for operation of air
conditioning activated.
i Note
d = LED with symbol for air circulation In case of a cabin fan fault or a soiled cabin filter
activated. the cabin filter warning light in the left instrument
e = LED with symbol for fan speed man- cluster lights up.
ually adjusted.
Clean the cabin filter or use a new one, repair or
f = 4-digit LED display for room temper- replace a defective cabin fan.
ature, nominal value (in °F
or °C), as well as fault indication for
temperature sensors.
g = Button to start REHEAT-operation.
h = Button to activate the heating.
i = Button to switch over circulation air/
fresh air operation.
j = Push button for manual adjustment of
the evaporator fan speed.

* Optional equipment

BC 672/772 RB-2, BC 772 RS-2 BOMAG 33

Indicators and Controls

on. The indicator light in the ro-

tary switch lights up.

Fig. 25
No. 17 = Potentiometer for throttle control*
Regulates the engine speed between 1600...2100 Fig. 27
min-1 when the travel speed pre-selection/deceler-
No. 19 = Emergency stop push button
ation pedal* is switched on.
Turn anti-clock-
wise = to reduce the engine speed. ! Danger
Turn clockwise = to increase the engine speed. Danger of accident!
Use only in events of emergency during oper-
ation.
Do not use as parking brake.
Restart the machine only after the danger that
caused the actuation of the emergency stop
switch has been eliminated.
The machine is braked immediately, the engine
is shut down.
actuate = press the button completely
down, it automatically locks in
fully pressed position.
switch off/un-
Fig. 26
lock = Turn button clockwise. Re-
start the engine.
No. 18 = Rotary switch to activate rotary speed
pre-selection/deceleration pedal with
indicator light*
The rotary switch has the function to switch the ro-
tary speed pre-selection and the deceleration ped-
al* on and off.
Position "left" = Rotary speed pre-selection/
deceleration pedal switched
off. The indicator light in the ro-
tary switch does not light. Posi-
tion to start the engine
Position "right" = Rotary speed pre-selection/
deceleration pedal switched
* Optional equipment

34 BOMAG BC 672/772 RB-2, BC 772 RS-2

Indicators and Controls

Fig. 28 Fig. 30
No. 20 = Travel pedal for throttle control No. 22 = Steering lever
Position "0" = Engine running at idle speed Steering lever to
Position "I" = higher idle speed/full load the left = steering movement to the left
Steering lever to
the right = steering movement to the right
i Note
The engine speed is displayed by the engine rpm-
meter in the left instrument cluster

Fig. 31
No. 23 = Push button for warning horn
Fig. 29
No. 21 = Deceleration pedal* with emergency
braking kick-down
Normal brake = Do not push down the deceler-
ation pedal all the way to kick-
down and hold it in this posi-
tion.
Emergency
brake = Push the deceleration pedal all
the way down to kick-down po-
sition.

Fig. 32

* Optional equipment
No. 24 = Tachograph**

BC 672/772 RB-2, BC 772 RS-2 BOMAG 35

Indicators and Controls

automatic recording of speed on the diagram disc

Fig. 33
No. 25 = Subsidiary display Tachograph*
a = Display field for total mileage
(Total) or trip mileage (Trip).
b = Push button: press short to
toggle between total mileage
and trip mileage or vice versa.
Press for about 2,5 seconds to
set the trip mileage to 0.

Fig. 35
i Note
When switching the ignition on only the total mile- Fuses
age (Total) will be displayed.
Terminal
Total mileage and trip mileage remain saved.
X1:20 (15A) = (F50) Climatronic**
X1:21 (30A) = (F89) Cigarette lighter
X1:22 = (F94) Spare, safety ventilation
system
X1:23 (30A) = (F13) Ignition switch
X1:24 (25A) = (F93) EDC 7 Control, potential
30
X1:25 (30A) = (F05) Socket
X1:26 (10A) = (F84) Processor control
X1:27 (30A) = (F67) Power control
X1:28 = (F123) Spare, safety ventila-
tion system
Fig. 34
X1:29 (15A) = (F24) Instruments
No. 26 = Electric installation box
X1:30 (10A) = (F16) Central lubrication sys-
The installation box is installed in the console be- tem
hind the driver’s seat.
X1:31 (15A) = (F29) Driver’s seat

** Optional equipment
* Optional equipment ** Optional equipment

36 BOMAG BC 672/772 RB-2, BC 772 RS-2

Indicators and Controls

X1:32 (10A) = (F122) EDC 7 Control, poten- switch off = turn lamp glass anti-clockwise
tial 15
X1:33 (20A) = (F31) Cyclone separator i Note
X1:34 (15A) = (F23) Warning horns Additionally switch on the toggle switch in the cab-
X1:35 (10A) = (F25) Driving and braking in dashboard
X1:36 (10A) = (F33) Climatronic (option)
X1:37 = Spare

Fig. 38
No. 28 = Air circulation nozzle for cabin heater
*

Fig. 36
Adjusting the di-
Main fuses for battery rection = turn the outside of the nozzle
(1) 250A = (F00) main fuse for battery Regulating the air
quantity = adjust, open or close by swiv-
(2) 80A = (F48) Main fuse for pre-heating sys- elling the flap
tem

!Caution
i Note
This air circulation nozzle must always be
The batteries with the main fuses are located in-
completely open when running the cabin heat-
side the battery compartment under the cover in
er. Otherwise malfunction of the cabin heater.
front of the driver's door.

Fig. 39
Fig. 37
No. 29 = Timer for cabin heating
No. 27 = Cabin light
a = Memory display
switch on = turn lamp glass clockwise
* Optional equipment

BC 672/772 RB-2, BC 772 RS-2 BOMAG 37

Indicators and Controls

b = Weekday or preselected day (8) 15A = (F66) 2 working head lights left, right
c = Symbol for radio remote control Fuse box F2 (bottom)
d = Current time or preselected time (1) 10A = Spare
e = Temperature display (2) 10A = (F125) Reversing camera*
f = Operating display (3) 10A = (F98) Mirror heater
g = Temperature preselection – control (4) 10A = (F41) Flashing beacon
range 10°C ...30°C
(5) 10A = (F42) Cabin lights
h = Push button extend time
(6) 5A = (F90) Timer for cabin heater
i = Push button shorten time
(7) 25A = (F40) cabin heater*
j = Push button to switch heater on/off
(8) 10A = (F49) Transformer for radio
k = Push button select, activate, deacti-
vate memory
l = Push button to set time and weekday

Fig. 41
No. 31 = Dashboard, cabin
Fig. 40 a = Toggle switch for front windscreen
wipers
No. 30 = Fuse boxes, cabin
b = Toggle switch for front washer

! Danger c = Toggle switch/push button for rear

windscreen wiper/washer
Fire hazard!
d = Toggle switch for interior lights
Do not use fuses with higher ampere ratings
and do not bridge fuses. e = Toggle switch for front working head
lights
Fuse box F1 (top) f = Toggle switch for working head
(1) 10A = (F27) Windscreen wiper, washer, lights, sides
front g = Toggle switch for working head
(2) 10A = (F28) Windscreen wiper, washer, lights, rear
rear h = Toggle switch for rear view mirror
(3) 10A = Spare heatings
(4) 20A = (F85) 4 working headlights, front i = Toggle switch for flashing beacon
(5) 15A = (F86) 2 working headlights, rear j = Toggle switch for engine compart-
(6) 10A = (F02) Fresh air fan ment light

(7) 15A = (F99)2 headlight, engine compart-

ment light
* Optional equipment

38 BOMAG BC 672/772 RB-2, BC 772 RS-2

Indicators and Controls

compartment as well as pro-

tection against unauthorized
use.

! Caution
Pull out the main battery switch at the earliest
40 seconds after switching off the ignition, ex-
cept in cases of emergency.
With engine-independent air heating systems*
allow the heating to run for another 2 minutes.

Fig. 42
No. 32 = Comfort seat
a = Lever, seat inclination
b = Lever, seat enlargement
c = Rotary button, arm rest adjustment
d = Rotary button, backrest curvature
(Drehknopf, Lehnenwölbung (sup-
port for intervertebral disc)
e = Lever, backrest inclination
f = Lever, length adjustment
Fig. 44
g = Foldable lever, horizontal suspension
h = Lever, adjustment of vertical suspen- Reversing camera **
sion, seat height with the monitor connected it enables the driver to
i = Snap-in lever to turn the seat check the working range behind the machine with-
out direct vision.
j = Lever to displace the arm rest
Angle of vision = 110° horizontal, 75° vertical

Fig. 43

Main battery switch

Position "I" = Normal position, operation
Position "II" = Separates batteries from the
on-board electrics in case of * Optional equipment
cable fire and fire in the engine ** Optional equipment

BC 672/772 RB-2, BC 772 RS-2 BOMAG 39

Indicators and Controls

for the distances in the travel range behind the ma-

chine.
The following text explains how to rub marks for
distances,

Fig. 45

Monitor for reversing camera*

With the reversing camera connected the driver is
able to check the working area behind the ma-
chine without having a direct view. Fig. 47
a = Selector switch for permanent or au- A = tail edge and maximum width
tomatic operation
B = distance point approx. 1 m
b = Adjusting the contrast (1.1 yard)
c = Adjusting the brightness C = distance point approx. 3m
d = Switching the brightness for day or (3.3 yards)
night operation D = distance point approx. 5m
(5.5 yards)
Distance mark on monitor

Fig. 46
Rubbing on distance marks A (Fig. 46) onto the
screen of tghe monitor enables a rough estimation
of the travel range behind the machine.

i Note
Distance marks should always be rubbed on by
the operator himself, so that he will have a feeling

* Optional equipment

40 BOMAG BC 672/772 RB-2, BC 772 RS-2

4 Operation

BC 672/772 RB-2, BC 772 RS-2 BOMAG 41

Operation

4.1 General 4.2 Tests before taking into op-

eration
If you are not yet acquainted with the controls
and indicating elements on this machine you Before the everyday use or before a longer work-
should thoroughly read chapter 3 “Indicators ing period the following tests and inspections must
and control elements” before starting work. be performed.
All indicators and control elements are de-
scribed in detail in this chapter. ! Danger
Danger of accident!
Please observe strictly the safety regulations
in chapter 2 of this instruction manual!
l Park the machine on ground as level as possi-
ble.

Check:
l fuel tank and fuel lines for leaks
l screw joints for tight fit
l function of steering
l function of brakes
l function of emergency stop
l hydraulic oil tank and lines for leaks
l Presence of the appropriate operating and
maintenance instructions
l proper maintenance of the machine
l service doors closed and locked
l Scrapers for compactor wheels
l Edge cutter for compactor wheels
l Check inner sides of compactor wheels, re-
move wires, cables, ropes, etc.

! Caution
Remove refuse residues, cables, ropes, wires
etc. to prevent premature wear of the wheel
shell edge.

i Note
For a description of the following tasks refer to the
chapter "maintenance every 10 operating hours".
l Engine oil level, top up if necessary
l Fuel level, top up if necessary.
l Hydraulic oil level, top up if necessary.
l Coolant level, top up if necessary

42 BOMAG BC 672/772 RB-2, BC 772 RS-2

Operation

l Transfer case oil level, change if necessary

4.3 Starting the engine
l Check machine for damage and leak tightness
l Lubricate joints and bearings on the bucket
(RS). ! Caution
In this chapter it is assumed that the operator
is fully acquainted with the functions of the
control elements on the machine.

Fig. 48

l Turn the main battery switch (Fig. 48) to posi-

tion "I".

Fig. 49

l Fasten your seat belt (Fig. 49).

BC 672/772 RB-2, BC 772 RS-2 BOMAG 43

Operation

Fig. 50 Fig. 53

l Check, whether the emergency stop switch l Turn the rotary switch for activation of speed
(Fig. 50) is unlocked. pre-selection/deceleration pedal* (Fig. 53) to
position "Left".

i Note
Do not press the drive pedal before and during
starting.

Fig. 51

l Shift the dozer blade control lever (A) or

bukket control lever (B) (Fig. 51) to position
”0”.

Fig. 54

l Turn the ignition key (Fig. 54) to position "I".

Fig. 52

l Shift the travel lever (Fig. 52) to position "0".

* Optional equipment

44 BOMAG BC 672/772 RB-2, BC 772 RS-2

Operation

i Note
The ignition switch is designed with a re-start lock.
For a new starting attempt the ignition key must
first be turned back to position "0".

Fig. 55
All control and warning lights in the instrument
clusters (Fig. 55) are switched on for a moment.
Charge control light (e), fault warning light (h),
parking brake warning light (u) and travel lever
neutral position control light (v) stay on. Fig. 57

Under cold ambient temperatures the preheating l Turn the ignition key (Fig. 57) to position "II",
control lamp (a) will also light up. the starter will crank the engine.
l As soon as the engine ignites return the igni-
i Note tion key to position "I".
Do not start before the preheating control lamp (a) The fault warning light and the charge control light
has gone out. go out.

! Caution
Run the engine warm for a short while before
starting work. Do not rev up a cold engine to
high idle speed/full load speed.

Fig. 56
The engine control warning light (EMR) (Fig. 56)
lights for approx. 2 seconds (test function).

! Caution
Run the starting process for maximum 20 sec-
onds without interruption and pause for a
minute between starting attempts.
If the engine has not started after two attempts
perform trouble shooting.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 45

Operation

l After starting disconnect the negative poles

4.4 Starting the engine with (ground cable) first and the positive poles af-
jump leads ter.
l Switch off the consumer.

! Caution !Caution
When using external starting aid two external Run the engine warm for a short while before
batteries are required, one for each on-board starting work. Do not rev up a cold engine to
battery. high idle speed/full load speed.
l Open the maintenance door to the battery
compartment.

Fig. 58

!Caution
A wrong connection will cause severe damage
in the electric system.
l When starting with external batteries connect
the positive poles (Fig. 58) first and the nega-
tive poles (ground cable) after.
l Start as described under "Starting the engine".

i Note
The ignition switch is designed with a re-start lock.
For a new starting attempt the ignition key must
first be turned back to position "0".

!Caution
If no powerful consumer is switched on volt-
age peaks may occur when separating the con-
necting cables between the batteries, which
could damage electrical components.
l Once the engine is running switch on a power-
ful consumer (working light, etc.).

46 BOMAG BC 672/772 RB-2, BC 772 RS-2

Operation

4.5 Resetting the trip mileage to 4.6 Driving the machine

zero*
! Danger
Danger of accident!
i Note
After starting the engine the total mileage (Total) is Wet and loose soils considerably reduce the
displayed. ground adhesion of the machine on inclina-
tions and slopes.
Soil conditions and weather influences impair
the gradability of the machine.
Before starting to drive make sure that the
drive range is absolutely safe.
Always keep the cabin doors closed while driv-
ing.

Fig. 59

l Press push button b (Fig. 59) briefly.

l The display field (a) shows the trip mileage
(trip).

Fig. 61

l Pre-select the desired speed range (Fig. 61).

Fig. 60

l Press push button b (Fig. 60) for approx. 2.5

seconds.
l The trip mileage value (trip) in the display field
has been reset to zero.
Fig. 62
The control lights for travel stage I (t) or travel
stage II (s) (Fig. 62) in the right instrument cluster
light up.
* Optional equipment

BC 672/772 RB-2, BC 772 RS-2 BOMAG 47

Operation

Fig. 63 Fig. 65

l Pull the dozer blade control lever (A) (Fig. 63) The travel lever neutral position control light (v)
or the bucket control lever * (B) back and raise (Fig. 65) in the right instrument cluster goes out.
the dozer blade/bucket.

Fig. 66
Fig. 64 l Turn the rotary switch for parking brake (Fig.
l Shift the travel lever (Fig. 64) to the desired 66) to position "left".
travel direction.
Position "I" = Forward travel
Position "II" = Reverse travel
When reversing the backup alarm sounds.

Fig. 67
The parking brake warning light (u) (Fig. 67) in the
right instrument cluster goes out.

* Optional equipment

48 BOMAG BC 672/772 RB-2, BC 772 RS-2

Operation

Fig. 68 Fig. 70

l Actuate the throttle pedal (Fig. 68). l Steer the machine with the steering lever (Fig.
70) to the desired direction.

i Note
When reversing the backup alarm sounds.
When releasing the travel pedal the machine is au-
tomatically braked.

Fig. 69

l Read the engine speed on the RPM-meter (k)

(Fig. 69) in the left instrument cluster.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 49

Operation

4.7 Driving the machine with ro-

tary speed pre-selection/de-
celeration pedal*

Danger
!

Danger of accident!
Wet and loose soils considerably reduce the
ground adhesion of the machine on inclina-
tions and slopes.
Soil conditions and weather influences impair Fig. 72
the gradability of the machine. Push the deceleration pedal (Fig. 72) all the way
Before starting to drive make sure that the down to kick-down position and hold it.
drive range is absolutely safe.
Always keep the cabin doors closed while driv-
ing.

Fig. 73

l Turn the rotary switch for activation of speed

pre-selection/deceleration pedal (Fig. 73)
Fig. 71 clockwise to position "Right".
l Shift the travel lever (Fig. 71) to position "0".
i Note
The light in the rotary switch lights up.

* Optional equipment

50 BOMAG BC 672/772 RB-2, BC 772 RS-2

Operation

Fig. 74 Fig. 76
l Release the deceleration pedal (Fig. 74) from l Release the deceleration pedal (Fig. 76).
kick-down position, but hold it actuated.

i Note
The machine starts off and the engine revs up to
the pre-selected speed.

Fig. 75

l Shift the travel lever (Fig. 75) to the desired

travel direction.
Position "I" = Forward travel Fig. 77
Position "II" = Reverse travel l Turn the potentiometer for engine speed con-
When reversing the backup alarm sounds. trol (Fig. 77) clockwise to increase the engine
speed and anti-clockwise to reduce the engine
speed.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 51

Operation

Fig. 78 Fig. 80

l Read the engine speed on the RPM-meter (k) l Steer the machine with the steering lever (Fig.
(Fig. 78) in the left instrument cluster. 80) to the desired direction.

Change in travel direction

Fig. 79

l Actuate the throttle pedal (Fig. 79).

Fig. 81

l Do not push down the deceleration pedal (Fig.

i Note
81) all the way to kick-down and hold it in this
When reversing the backup alarm sounds. position.
With the drive pedal you may reach a higher travel
speed, but you cannot reduce the travel speed i Note
lower than the pre-adjusted speed. The machine decelerates slowly until it comes to a
halt.
l Select the new travel direction and release the
deceleration pedal. The machine travels to the
new direction with the pre-selected speed.

52 BOMAG BC 672/772 RB-2, BC 772 RS-2

Operation

Emergency brake function

4.8 Switching off the rotary
speed pre-selection/decel-
eration pedal*

Fig. 82

l Push the deceleration pedal (Fig. 82) once all

the way down to kick-down position.

i Note Fig. 83
The machine decelerates excessively. l Do not push down the deceleration pedal (Fig.
83) all the way to kick-down and hold it in this
When holding the deceleration pedal approx. 4
position.
seconds in kick-down position, the parking brake
warning light in the instrument cluster will addition-
ally light up. i Note
l To continue driving you must first return the The machine decelerates slowly until it comes to a
travel lever to neutral position. Then select the halt.
new travel direction.

Fig. 84

l Shift the travel lever (Fig. 84) to position "0"

and release the deceleration pedal.

Danger
!

Danger of accident!

* Optional equipment

BC 672/772 RB-2, BC 772 RS-2 BOMAG 53

Operation

If the travel lever is now unintentionally moved

to any travel direction the machine will imme- 4.9 What to do in events of
diately start to drive. emergency
Always switch off the rotary speed pre-selec-
tion/deceleration pedal before leaving the driv-
er’s seat. Actuating the emergency stop switch

Danger
!

Danger of accident!
In events of emergency and in case of danger
actuate the emergency stop switch immediate-
ly.
Start travel operation of the machine only after
the danger that caused the actuation of the
emergency stop switch has been eliminated.

!Caution
Do not use as service brake. The deceleration
Fig. 85
is extremely high. In case of frequent use the
l Set the throttle control potentiometer (Fig. 85) wear on the multi-discs brakes will be very
to the left to minimum engine speed. high.

Fig. 86
Fig. 87
l Turn the rotary switch for activation of rotary l Press the button of the emergency stop switch
speed pre-selection/deceleration pedal (Fig. (Fig. 87) completely down, it automatically
86) anti-clockwise to position "0". locks in fully pressed position.

i Note
i Note
Normal driving of the machine is possible again. Shuts the engine down and closes the brake.
l Turn the button clockwise to unlock the emer-
gency stop switch.
l Start the engine again, see chapter "Starting
the engine".

54 BOMAG BC 672/772 RB-2, BC 772 RS-2

Operation

Emergency exit
4.10 Operating the dozer blade
! Danger
Danger of injury by glass splinters! ! Danger
Turn your face away when smashing the win- Life hazard!
dow.
Do not use the dozer blade to transport per-
sons.
Moving other vehicles with the dozer blade is
prohibited!
Attaching hoisting gear to the dozer blade is
prohibited!
Always lower the dozer blade to the ground be-
fore shutting down the engine.

Fig. 88

i Note
If a machine has turned over and the cabin door is
jammed, all cabin windows can be used as escape
doors.
l Take the emergency hammer (Fig. 88) out of
its holder and smash the cabin window need- Fig. 89
ed to escape.
l Pull the lever for dozer blade control (Fig. 89)
back to position "II" and raise the dozer blade.

Fig. 90

l Push the lever for dozer blade control (Fig. 90)

forward to position "I" and lower the dozer
blade.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 55

Operation

4.11 Operating the bucket (RS)

! Danger
Life hazard!
Do not use the bucket to transport persons.
Moving other vehicles with the bucket is pro-
hibited!
Attaching hoisting gear to the bucket is pro-
hibited!
Always lower the bucket to the ground before
Fig. 91
shutting down the engine.
l To switch on floating position operate push
button "a" (Fig. 91) and shift the dozer blade
control lever forward to position "I".

Fig. 93

l Pull the bucket control lever (Fig. 93) back and

Fig. 92 raise the bucket.
l Shift the lever (Fig. 92) to position "II" to switch
off floating position.

Fig. 94

l Shift the bucket control lever (Fig. 94) forward

and lower the bucket to the ground.

56 BOMAG BC 672/772 RB-2, BC 772 RS-2

Operation

Fig. 95 Fig. 97

l Press push button a (Fig. 95) in the lever. The l Shift the bucket control lever (Fig. 97) to the
bucket changes to float position. left to fill the bucket. The bucket tips back.
l Press the push button again to disable the
float position. i Note
When releasing the bucket control lever, it will au-
tomatically return to middle position.

Fig. 96

l Shift the bucket control lever (Fig. 96) to the

right to empty the bucket. The bucket tips for-
ward.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 57

Operation

4.12 Operating the service brake

Fig. 100
The travel lever neutral position control light (v)
(Fig. 100) in the right instrument cluster lights up.
Fig. 98

l Relieve the drive pedal (Fig. 98).

Fig. 99

l Shift the travel lever (Fig. 99) to position "0",

the machine is hydrostatically braked.

58 BOMAG BC 672/772 RB-2, BC 772 RS-2

Operation

4.13 Operating the parking brake

Fig. 103
The travel lever neutral position control light (v)
(Fig. 103) in the right instrument cluster lights up.
Fig. 101

l Relieve the drive pedal (Fig. 101).

Fig. 104

l Turn the rotary switch for parking brake (Fig.

Fig. 102
104) to position "Right".

l Shift the travel lever (Fig. 102) to position "0",

the machine is hydrostatically braked.

Fig. 105
The parking brake warning light (u) (Fig. 105) in
the right instrument cluster lights up after 4 sec-
onds.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 59

Operation

4.14 Starting and adjusting the

air conditioning

Switching on the control unit

i Note
The diesel engine is running.
If only the ignition is switched on, the evaporator
fan speed is limited to 30% of the nominal speed.
Fig. 108

i Note
The LED-display shows the stored cabin tempera-
ture (Fig. 108).

Fig. 106

l Press the On-Off-switch (Fig. 106) on the con-

trol unit.

Fig. 107

l The LED-display (Fig. 107) shows the soft-

ware version for approx. 3 seconds.

i Note
After switching on the control unit runs an approx.
20 second self-test. After this the switching out-
puts of the control unit are released.

60 BOMAG BC 672/772 RB-2, BC 772 RS-2

Operation

Activating/deactivating air condition- Changing the temperature display to

ing operation degree Celsius or degree Fahrenheit

Fig. 109 Fig. 111

l Press the On-Off-switch (Fig. 109) for opera- l In order to change from degree Celsius to de-
tion of the air conditioning system. gree Fahrenheit press and hold the circulation
air button (1) (Fig. 111) first and then press the
minus button (2).
i Note
The display changes to degree Fahrenheit.
The LED below the symbol for operation of air con-
ditioning lights up. The stored cabin temperature is
displayed.
Operation of the air conditioning starts.

Fig. 112

l In order to change from degree Fahrenheit to

degree Celsius press and hold the circulation
air button (1) (Fig. 112) first and then press the
Fig. 110
minus button (2).
l Press the On-Off-switch (Fig. 110) for opera- The display changes to degree Celsius.
tion of the air conditioning system.

i Note
The LED below the symbol for operation of air con-
ditioning goes out. Operation of the air condition-
ing system is switched off.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 61

Operation

Adjusting the desired cabin tempera- After 5 seconds this new nominal value is saved
ture and operation of the air conditioning system is
started.

i Note
Operation of the air conditioning system is
switched on.
A cabin temperature of e.g. 21 °C is desired.

Fig. 113

l Press the minus button (Fig. 113) once.

i Note
The LED-display shows the currently adjusted
cabin temperature. The LED below the symbol for
operation of air conditioning additionally lights up.

Fig. 114

l Press the minus button (Fig. 114) 3 times.

i Note
The LED-display shows 21 °C as new nominal val-
ue.

62 BOMAG BC 672/772 RB-2, BC 772 RS-2

Operation

Manual adjustment of the evaporator

fan speed

i Note
The speed of the evaporator fan can be manually
adjusted as a measure to avoid a too quick drop-
ping of the cabin temperature.

Fig. 117

l Press the minus button 6 times (Fig. 117).

i Note
The LED bar display shows only 40% evaporator
fan speed and after 5 seconds this new value will
be saved

Fig. 115 Fully automatic air conditioning operation is

switched off. The evaporator fan speed is reduced
l At present the LED bar display (Fig. 115) to 40%.
shows the evaporator fan speed with 100%
when the air conditioning works in automatic
mode.

Fig. 118

l Press the button for evaporator fan speed (Fig.

Fig. 116 118).

l For manual operation press the button for

evaporator fan speed (Fig. 116) i Note
The LED below the symbol for manual adjustment
goes out.
i Note
The LED below the symbol for manual adjustment Automatic air conditioning operation is activated
lights up. again. The evaporator fan speed is automatically
controlled.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 63

Operation

Switching off Reheat - operation

4.15 Air conditioning, switching
Reheat – operation on/off

Switching on Reheat - operation

i Note
Reheat – operation is switched on to dehumidify
the cabin air (clear steamed up windows). The ac-
tivation lasts maximum 10 minutes and is automat-
ically switched off by the control unit.
To avoid changing of the cabin temperature the
heating is automatically activated if required.
Fig. 120

l Press the Reheat button (Fig. 120).

i Note
The LED display shows the adjusted cabin tem-
perature.
The present evaporator fan speed is shown by the
LED-display.

Fig. 119

l Press the Reheat button (Fig. 119).

i Note
The LED display shows „rH“ for Reheating status.
The evaporator fan speed is set to 100% (LED bar
display).

64 BOMAG BC 672/772 RB-2, BC 772 RS-2

Operation

4.16 Air conditioning, changing i Note

The LED below the symbol for circulation air/fresh
between circulation air/ air goes out. Fresh air operation is activated.
fresh air operation

Switching on circulation air operation.

Fig. 121

l Press the circulation air/fresh air button (Fig.

121).

i Note
The LED below the symbol for circulation air/fresh
air lights up. Circulation air operation is activated.

Switching on fresh air operation .

Fig. 122

l Press the circulation air/fresh air button (Fig.

122).

BC 672/772 RB-2, BC 772 RS-2 BOMAG 65

Operation

4.17 Air conditioning, heating i Note

The LED below the symbol for manual adjustment
operation lights up.
The LED display shows „H“ for Heating.
Fully automatic heating operation The LED bar display indicates that the heating
valve is 100% open.
i Note
Heating operation starts fully automatically if the
current cabin temperature drops below the desired
nominal temperature.

Fig. 125

l Press the minus button e.g. 6 times (Fig. 125).

i Note
Fig. 123
The LED bar display indicates that the heating
valve is 40% open.
i Note
After 5 seconds the new status of the heating
The LED display shows the stored cabin tempera- valve is saved, fully automatic heating operation is
ture (Fig. 123) and the LED bar display shows an switched off.
evaporator fan speed of 100%.

Setting heating operation manually

Fig. 126

l Press the heater button (Fig. 126) once again.

Fig. 124
i Note
l Press the heater button (Fig. 124). Automatic heater operation is activated again.

66 BOMAG BC 672/772 RB-2, BC 772 RS-2

Operation

4.18 Shutting down the engine

Fig. 129
The travel lever neutral position control light (v)
(Fig. 129) in the right instrument cluster lights up.
Fig. 127

l Take back the drive pedal (Fig. 127) (throttle

control), so that the engine speed drops to idle
speed.

i Note
When releasing the drive pedal the machine is
braked.

Fig. 130

l Turn the rotary switch for parking brake (Fig.

130) to position "Right".

Fig. 128

l Shift the travel lever (Fig. 128) to position "0".

Fig. 131
The parking brake warning light (u) (Fig. 131) in
the right instrument cluster lights up after 4 sec-
onds.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 67

Operation

With engine-independent air heating systems*

allow the heating to run for another 2 minutes.

Fig. 132

l Shift the lever for dozer blade control (A) (Fig.

132) or the lever for bucket control (B) forward
Fig. 134
and lower the dozer blade/bucket slowly until it
rests on the ground. l Switch the main battery switch (Fig. 134) to
position "II" and pull it out.

Caution
!

Do not shut down the engine all of a sudden

from full load speed, but let it idle for about 2
minutes.

Fig. 133

l Turn the ignition switch (Fig. 133) to position

"0" and pull the ignition key out.

! Caution
Secure the machine against unauthorized use,
pull the ignition key out, lock the cabin door.

! Caution
Pull out the main battery switch at the earliest
40 seconds after switching off the ignition, ex-
cept in cases of emergency.
* Optional equipment

68 BOMAG BC 672/772 RB-2, BC 772 RS-2

Operation

4.19 Parking on a slope

! Danger
Danger of accident!
Always lower the dozer blade/bucket to the
ground when parking on a slope with the en-
gine running.
Apply the parking brake to prevent unintended
rolling of the machine.

Fig. 137
The parking brake warning light (u) (Fig. 137) in
the right instrument cluster lights up after 4 sec-
onds.

Fig. 135

l Shift the lever for dozer blade control (A) (Fig.

135) or the lever for bucket control (B) forward
and lower the dozer blade/bucket slowly until it
rests on the ground.

Fig. 136

l Turn the rotary switch for parking brake (Fig.

136) to position "Right".

BC 672/772 RB-2, BC 772 RS-2 BOMAG 69

Operation

4.20 Towing the machine

! Danger
Danger of accident!
Before loosening the multi-disc brake apply
appropriate measures to secure the machine
against unintended rolling.
For towing use a towing vehicle with sufficient
tractive power.

Fig. 139
Danger
!

Danger of injury! l Attach the towing device (Fig. 139) to the tow-
ing eyes.
Do not touch hot engine parts.
Releasing the brake
!Caution
Tow the machine only after releasing the park-
ing brake.
Towing speed 1 km/h, max. towing distance
500 m.

Fig. 140

l Open the access doors on the right hand tool

box.
l Unscrew the fastening screw (3) (Fig. 140).
l Set lever (2) in direction of arrow.
Fig. 138
l Operate the pump lever (1), until the multi-disc
l Shut down the engine.
brakes are relieved. The machine can be
l Remove the protective caps (1) (Fig. 138) from towed.
the eight high pressure relief valves.
l Back the socket head cap screws (2) out for Caution
!

approx. 2 turns.
Secure lever (2) with the locking screw.
Raise the dozer blade/bucket before towing.

70 BOMAG BC 672/772 RB-2, BC 772 RS-2

Operation

Raising the dozer blade/bucket and re-

lieving the brakes

Fig. 142

! Caution
Fig. 141
After towing turn the socket head cap screws
(1) (Fig. 142) back in and tighten with a torque
Danger
! of 10 Nm.
Danger of accident! Use new protective caps to secure the high
Do not step under the raised dozer blade/ pressure relief valves.
bukket.
l Set lever 2 (Fig. 141) in direction of arrow.
l Set lever (3) in direction of arrow.
l Operate pump lever (1), until the multi-disc
brakes are released and the dozer blade/
bukket is raised. The machine can be towed.

After towing

Danger
!

Before disconnecting the towing device apply

appropriate measures to secure the machine
against unintended rolling.
l Return the lever to initial position and secure
with the locking screw.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 71

Operation

143) out of its receptacle and fasten it with the

4.21 Transport of the machine bolt (2) to the eye on the front frame.
l Secure the bolt with the cotter pin (3).

! Danger
Danger of accident!
Use only stable loading ramps of sufficient
load bearing capacity. Make sure that persons
are not endangered by the machine tipping or
sliding off.
Always use shackles on the lifting points for
loading or tying the machine down.
Check all lifting and lashing points for damage
before lifting or lashing down the machine.
Lift the machine only with suitable lifting gear.
Weights: see chapter "Technical Data".
Fig. 144
Lash the machine down, so that it is secured
against rolling, sliding and turning over. l Actuate the emergency stop switch (Fig. 144).
Observe the transport height.
After transport release the articulation lock
again and store it in the receptacle.
Unlock the emergency stop switch

Danger
!

Life hazard!
During demonstration and when loading the
machine do not remain in the danger zone of
the machine.
l Lower the dozer blade/bucket onto the trans-
port vehicle. Fig. 145

l Lash the machine to the transport vehicle , use

the four lashing eyes on front and rear frame
for this purpose (Fig. 145).

Fig. 143

l After driving the machine onto the transport

vehicle swing the articulation lock (1) (Fig.

72 BOMAG BC 672/772 RB-2, BC 772 RS-2

Operation

Fig. 146 Fig. 149

l Always use access steps and hand rails to l Remove the holding rope (Fig. 149) of the air
climb onto the engine compartment cover (Fig. conditioning carrier from the snap hook.
146).

Fig. 150
Fig. 147
l Fold the air conditioning unit (Fig. 150) back.
l Step only on such areas of the engine com-
partment cover which are provided with skid-
proof covering (Fig. 147).
After transport

Fig. 151
Fig. 148
l After transport release the articulation lock
l Fold the air intake grid (Fig. 148) back.
(Fig. 151) again and store it in the receptacle.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 73

Operation

!Caution
During transport with the air conditioning fold-
ed back ROPS and air filter may be excessively
soiled.

Fig. 154

l Hook the holding rope back into the air condi-

tioning carrier (Fig. 154).
l Fold air conditioning unit and air intake grid
back to normal position and fasten, install the
Fig. 152 maintenance door.
l Remove the service door (Fig. 152).

Fig. 153

l To enter the air intake chamber use the ac-

cess steps (Fig. 153).
l Extract all accumulated dirt.

!Caution
When extracting the dirt avoid damaging of
fins on hydraulic oil cooler, intercooler and ra-
diator.

74 BOMAG BC 672/772 RB-2, BC 772 RS-2

5 Maintenance

BC 672/772 RB-2, BC 772 RS-2 BOMAG 75

Maintenance

l Drums with inside zinc lining are not suitable to

5.1 General notes on mainte- store fuel.
nance l When choosing the storage place for fuel
make sure that spilled fuel will not harm the en-
When performing maintenance work always com- vironment.
ply with the appropriate safety regulations. l Do not let the hose stir up the slurry at the bot-
Thorough maintenance of the machine guaran- tom of the drum.
tees far longer safe functioning of the machine and l The fuel drum must rest for a longer period of
prolongs the lifetime of important components. time before drawing off fuel.
The effort needed for this work is only little com-
pared with the problems that may arise when not l The rest in the drum is not suitable for the en-
observing this rule. gine and should only be used for cleaning pur-
poses.
The terms right/left correspond with travel direc-
tion forward.
Notes on the performance of the en-
l Always clean machine and engine thoroughly
before starting maintenance work.
gine
On diesel engines both combustion air and fuel in-
l For maintenance work stand the machine on
jection quantities are thoroughly adapted to each
level ground.
other and determine power, temperature level and
l Always remove the main battery switch for all exhaust gas quality of the engine.
maintenance work.
If your engine has to work permanently in "thin air"
l Perform maintenance work only with the motor (at higher altitudes) and under full load, you should
switched off. consult the customer service of BOMAG or the
l Relieve hydraulic pressures before working on customer service of the engine manufacturer.
hydraulic lines.
Notes on the cooling system
l Before working on electric parts of the ma-
chine disconnect the battery and cover it with Prepare and check coolant with highest care,
insulation material. since otherwise the engine may be damaged by
corrosion, cavitation and freezing.
l When working in the area of the articulated
joint attach the articulation lock (transport Coolant is prepared by adding an ethylene-glycol
lock). based anti-freeze agent with corrosion inhibiting
properties to the cooling water.
Mixing with cooling system protection agent is
Environment
necessary in all climatic zones. It prevents corro-
During maintenance work catch all oils and fu- sion, lowers the freezing point and raises the boil-
els and do not let them seep into the ground or ing point of the coolant.
into the sewage system. Dispose of oils and fu-
els environmentally.
Notes on the hydraulic system
Keep used filters in a separate waste container
During maintenance work on the hydraulic system
and dispose of environmentally.
cleanliness is of major importance. Make sure that
Catch biodegradable oils separately. no dirt or other contaminating substances can en-
ter into the system. Small particles can produce
Notes on the fuel system flutes in valves, cause pumps to seize, clog noz-
zles and pilot bores, thereby making expensive re-
The lifetime of the diesel engine depends to a
pairs inevitable.
great extent on the cleanliness of the fuel.
l If, during the daily inspection of the oil level the
l Keep fuel free of contaminants and water,
hydraulic oil level is found to have dropped,
since this will damage the injection elements
check all lines, hoses and components for
of the engine.
leaks.

76 BOMAG BC 672/772 RB-2, BC 772 RS-2

Maintenance

l Seal external leaks immediately. If necessary

inform the responsible customer service. 5.2 Fuels and lubricants
l Do not store drums with hydraulic oil outdoors,
or at least under a cover. Water can be drawn
Engine oil
in through the bunghole when the weather
changes. Quality
l We recommend to use the BOMAG filling and For use in DEUTZ engines the lubrication oils are
filtering unit with fine filter to fill the system. classified in DEUTZ Lubrication Oil Quality Class-
This ensures finest filtration of the hydraulic es (DQC).
oil, prolongs the lifetime of the hydraulic oil fil-
Use only oils complying with DQC III-05 or DQC
ter and protects the hydraulic system.
IV-05.
l Clean fittings, filler covers and the area around The list of approved lubrication oils is also availa-
such parts before disassembly to avoid enter- ble in the Internet under the following address:
ing of dirt.
l Do not leave the tank opening unnecessarily www.deutz.com
open, but cover it so that nothing can fall in.
de >>SERVICE >> Fuels and lubricants and
diagnostics >> DeutzQualityClass >>
Welding work on the refuse compactor DQC-Release list
l Disconnect the main battery switch en >>SERVICE >> Fuels and lubricants and
diagnostics >> DeutzQualityClass >>DQC-
l Pull the plugs off all control units, engine con- release list
trol unit (EMR), travel control (ESX) and addi-
tional control (DIOS). Consult your local service station if in doubt.
l Use winter grade engine oil for winter opera-
tion!

Oil viscosity
Since lubrication oil changes its viscosity with the
temperature, the ambient temperature at the oper-
ating location of the engine is of utmost impor-
tance when choosing the viscosity class (SAE-
class) .
Too high viscosity can cause starting difficulties,
too low ´viscosity can jeopardize the lubrication ef-
fect and result in a high lubrication oil consump-
tion.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 77

Maintenance

bient temperatures below -10°C and when us-

ing biodegradable diesel fuel the oil change
intervals must be halved.

Fuels
You should only use commercially available brand
diesel fuel with a sulphur content of less than 0.5%
and ensure strict cleanliness when filling in. A
higher sulphur content has a negative effect on the
oil change intervals.
The fuel level should always be topped up in due
time so that the fuel tank is never run dry, as oth-
erwise filter and injection lines need to be bled.

Quality
The following fuel specifications are permitted:
l EN 590
l DIN 51628
l ASTM D975 Grade-No. 1-D and 2-D.
l JIS K 2204 Grade Fuel 1 and Grade Fuel 2
with lubrication properties acc. to EN 590

Winter fuel
For winter operation use only winter diesel fuel, to
avoid clogging because of paraffin separation.
Diesel fuels suitable for temperatures down to -44
Fig. 155 °C are available for arctic climates. At very low
Optimal operating conditions can be achieved by temperatures disturbing paraffin separation can
using the oil viscosity chart (Fig. 155) as a refer- also be expected when using winter diesel fuel.
ence. The admixture of petroleum and the addition of
At ambient temperatures below -40 °C the lubrica- "flow enhancing additives" (fuel additives) is not
tion oil must be pre-heated (e.g. by parking the permitted.
machine indoors).
The viscosity is classified acc. to SAE. Multi-pur- Coolant
pose oils should generally be used. For fluid cooled engines the cooling fluid must be
prepared by admixing a cooling system protection
Oil change intervals agent to the fresh water and should be checked
The longest permissible time a lubrication oil within the specified maintenance intervals.
should remain in an engine is 1 year. If the follow- This prevents damage caused by corrosion, cavi-
ing oil change intervals are not reached over a pe- tation, freezing and overheating.
riod of 1 year, the oil change should be performed
at least once per year, irrespective of the operating Fresh water quality
hours reached. The correct quality of water is highly important
DQC III, when preparing coolant. Clear and clean water
DQC IV = 500 operating hours within the boundaries of the following analysis val-
ues should generally be used.
!Caution
When using fuels with a sulphur content of
more than 0,5% to 1% or under permanent am-

78 BOMAG BC 672/772 RB-2, BC 772 RS-2

Maintenance

If our cooling system protection agent is not avail-

able for any important reasons, you may, in excep-
Fresh water analysis values
tional cases, use products that have been
pH-value at 20 °C 6.5 - 8.5
approved by the engine manufacturer.
Chloride ion content (mg/l) (ppm) max. 100
Sulphate ion content (mg/l) max. 100 The list of approved cooling system protection
(ppm) agents can be found in the internet under
Total hardness [°dGH] 3 - 12 www.deutz.com >>SERVICE >> Fuels and lubri-
corresponds with a potash ion 0.54 - 3.56 cants and diagnostics >> Collig system protection
content (mmol/l) of >>Technical circular Cooling System Protection
Carbon hardness proportion of min. 3 Agents.
the total hardness (°d) Products of the same product group (see Deutz
corresponds with a content of min. 53.4 Technical Circular Cooling System Protection
CaCO3 (mg/l) (ppm) Agents) can be mixed with each other.

Information concerning the water quality can be The BOMAG cooling system protection agent cor-
obtained from the waterworks. responds with product group A.

If the fresh water analysis values are unknown,

these must be determined with the help of a water ! Caution
analysis. Do not mix different coolants and additives of
If the values of the analysis deviate, the water any other kind.
must be treated accordingly. Before changing the product you must clean
l pH-value too low the entire cooling system.
Adding of caustic lye of soda or caustic potash Consult your local service station if in doubt.
solution.
To ensure proper corrosion protection you must
l Total hardness or chlorides and/or sulphates use the cooling system protection agent all year
too high: around, whereby the following concentration must
Mixing with dehardened water (e.g. distilled not be fallen short of or exceeded.
water).
l Total hardness or carbonate hardness too low: Mixing ratio
Mixing with hardened water (harder water is in
Cooling sys- Fresh water Cold protec-
most cases available in the form of drinking
tem protection tion down to
water).
agent
min. 35% 65% -22 °C
Caution
! 40% 60% -28 °C
Another analysis must be made after the fresh max. 45% 55% -35 °C
water has been prepared.
Caution
!
Cooling system protection agent
A proportion of more than 45% of cooling sys-
As a protection against frost, corrosion and boiling tem protection agent causes a drop in cooling
point anti-freeze agents must be used under any power.
climatic conditions.
The use of corrosion protection oils as cooling
Coolant for fluid cooled engines is prepared by
system protection agents is not permitted.
adding an ethylene-glycol based anti-freeze agent
with corrosion inhibiting properties to the cooling
water. i Note
We therefore highly recommend our BOMAG cool- When working at temperature below -35 °C you
ing system protection agent (BOMAG part-no. 009 should consult our local service representative.
940 08)..

BC 672/772 RB-2, BC 772 RS-2 BOMAG 79

Maintenance

Environment Lubrication grease

Coolant must be disposed of environmentally. For lubrication purposes use an EP-high pressure
grease, lithium saponified (penetration 2), acc. to
Mineral oil based hydraulic oil DIN 51502 KP 2G.

The hydraulic system is operated with hydraulic oil

HV 46 (ISO) with a kinematic viscosity of
46 mm2/s at 40 °C. For topping up or for oil chang-
es use only high-quality hydraulic oil, type HVLP
according to DIN 51524, part 3, or hydraulic oils
type HV according to ISO 6743/3. The viscosity in-
dex (VI) should be at least 150 (observe informa-
tion of manufacturer).

Bio-degradable hydraulic oil

The hydraulic system can also be operated with a
synthetic ester based biodegradable hydraulic oil.
The biologically quickly degradable hydraulic oil
Panolin HLP Synth.46 meets all demands of a
mineral oil based hydraulic oil according to
DIN 51524.
In hydraulic systems filled with Panolin HLP
Synth.46 always use the same oil to top up.
When changing from mineral oil based hydraulic
oil to an ester based biologically degradable oil,
you should consult the lubrication oil service of the
oil manufacturer for details.

! Caution
Check the filter more frequently after this
change.
Perform regular oil analyses for content of wa-
ter and mineral oil.
Replace the hydraulic oil filter element every
500 operating hours.

Gear oil
Quality
For the gearboxes use only ,ulti-purpose gear oils
ISO VG 220 of API-GL5-class with a minimum vis-
cosity of 20 mm2/s at 100 °C. We recommend
BOMAG SAE 80W-140, TN 00992507.
This is a hypoid lubricant of highest quality class
for extremely loaded transmissions.
The additives in this oil ensure low wear lubrication
under all operating conditions.

80 BOMAG BC 672/772 RB-2, BC 772 RS-2

Maintenance

5.3 Table of fuels and lubri-

cants

Assembly Fuel or lubricant Quantity

Summer Winter Attention

Observe the level marks

Engine

- Engine oil DQC III or IV approx. 36 litres

SAE 10W-40 (-20 °C to +40 °C)

SAE 10W/40 (-15 °C to +40 °C)

SAE 5W-40 (-30 °C to +40 °C)

SAE 5W-30 (-30 °C to +30 °C)

- Fuel Diesel Winter diesel fuel approx. 500 litres

- Coolant Mixture of water and anti-freeze agent approx. 50 litres

(see "Fuels and Lubricants - Colant")

Hydraulic system Hydraulic oil (ISO), HV46, kinem. Viscosity approx. 350 litres
46 mm2/s at 40 °C with viscosity index (VI) >150 or
biodegradable ester based hydraulic oil

Transfer box Gear oil SAE 80W-140, API GL-5 approx. 4.5 litres

Travel gear Gear oil SAE 80W-140, API GL-5 approx. 7,7 litres each
Gear oil SAE 80W-140, API GL-5 (Bonfiglioli)
approx. 6,5 Liter each (L +
S)

Central lubrication system High pressure grease (lithium saponified) approx. 2.0 kg, automatic
lubrication

Bucket High pressure grease (lithium saponified) as required

Air conditioning system Refrigerant R134a approx. 1850 g

Cabin heater (diesel)

- Oil bath air filter SAE 15W/40 (above 0 °C) SAE 10W/30 as required
(down to approx. -10 °C )
SAE 5W/30
(down to approx. -30 °C )

BC 672/772 RB-2, BC 772 RS-2 BOMAG 81

Maintenance

5.4 Running-in instructions

The following service work must be performed

when taking new machines into operation.

! Caution
Up to approx. 250 operating hours check the
engine oil level twice every day.
Depending on the load the engine is subjected
to, the oil consumption will drop to the normal
level after approx. 100 to 250 operating hours.

After a running time of 15 minutes retighten

the V-belts for generator and air conditioning
compressor.

Maintenance after 50 operating hours

l Changing engine oil and oil filter
l Change the oil in the drive gears.
l Retighten bolted connections on intake and
exhaust tubes, oil sump and engine mounts.
l Retighten all bolted connections on the ma-
chine.

Maintenance after 500 operating hours

l Change the oil in splitter gear and oil filter.
l Change the oil in the drive gears.

Special intervals
l Switch the air conditioning on every month for
about 10 minutes.

82 BOMAG BC 672/772 RB-2, BC 772 RS-2

Maintenance

5.5 Maintenance table

every 10 operating hours, daily

every 1000 oper. hours

every 2000 oper. hours

every 4000 oper. hours

every 6000 oper. hours

every 500 oper. hours
No. Maintenance work Comment

as required
5.6 Check the engine oil level Dipstick mark X
5.7 Check the fuel level Instrument cluster X
5.8 Check the hydraulic oil level Inspection glass X
5.9 Check the coolant level Instrument cluster X
5.10 Check the oil level in the transfer box Inspection glass X
5.11 Visual inspection of the machine for X
damage and leaks
5.12 Lubricate joints and bearings on the X
bucket (RS).
5.13 Change engine oil and oil filter * min. 1x per year X
see foot note
5.14 Check, clean the water separator when the "water in fu- X
el" warning light lights
up
5.15 Service the generator V-belt X
5.16 Check the V-belt for the air condition- X
ing compressor
5.17 Service the fan V-belt X
5.18 Battery service, checking the main pole grease X
battery switch
5.19 Check the engine mounts X
5.20 Service the air conditioning X
5.21 Check the condition of radiator, inter- also if the engine tem- X
cooler and hydraulic oil cooler, clean, perature or hydraulic
clean the engine oil temperature warn-
ing lights light up

BC 672/772 RB-2, BC 772 RS-2 BOMAG 83

Maintenance

every 10 operating hours, daily

every 1000 oper. hours

every 2000 oper. hours

every 4000 oper. hours

every 6000 oper. hours

every 500 oper. hours
No. Maintenance work Comment

as required
5.22 Check the fastening of the scrapers X
5.23 Check the oil level in the travel gear X
5.24 Check the central lubrication system, X
fill up
5.25 Replace the fresh air and circulation X
air filters
5.26 Check, adjust the valve clearance Intake: 0.25 mm X
Exhaust: 0.30 mm
5.27 Replace the fuel filter cartridges X
5.28 Replacing the fuel pre-filter cartridge, X
bleed the fuel system
5.29 Check the anti-freeze concentration X
and the condition of the coolant
5.30 Intercooler, draining off oil/condensa- min. 1x per year X
tion water
5.31 Check fastening of engine/turbo X
charger/combustion air hoses
5.32 Check the crankcase pressure X
5.33 Oil change in travel gear** see foot note X
5.34 Replace the fuel filter for the cabin X
heater (diesel)
5.35 Check, clean the oil bath air filter for X
the cabin heater
5.36 Change the hydraulic oil fine filter*** see foot note X
5.37 Change hydraulic oil and breather fil- at least every 2 years X
ter ** see foot note
5.38 Changing the coolant X

84 BOMAG BC 672/772 RB-2, BC 772 RS-2

Maintenance

every 10 operating hours, daily

every 1000 oper. hours

every 2000 oper. hours

every 4000 oper. hours

every 6000 oper. hours

every 500 oper. hours
No. Maintenance work Comment

as required
5.39 Change oil and filter in the transfer see foot note X
box ****
5.40 Check condition of oscillating articu- X
lated joint
5.41 Change the injection valves only by authorized X
service personnel
5.42 Change the crankcase ventilation X
valve
5.43 Replace the coolant pump only by authorized X
service personnel
5.44 Replace the pressure retaining valve only by authorized X
on the injection pump service personnel
5.45 Replace the glow plugs only by authorized X
service personnel
5.46 Clean, change the dry air filter car- when the air filter X
tridge warning light lights up
min. 1x per year
5.47 Clean the condenser X
5.48 Adjust scrapers and edge cutters X
5.49 Replace the wheel caps X
5.50 Check the condition of the cutting X
blades, replace the cutting blades if
necessary
5.51 Fill the provision tank for the wind- X
screen washer system
5.52 Drain off dirty fluids from front and X
rear frame
5.53 Tighten all bolted connections X
5.54 Conservation X

BC 672/772 RB-2, BC 772 RS-2 BOMAG 85

Maintenance

* Running-in instructions: after 50 operating hours change the oil; oil change intervals depend on fuel quality (sulphur content); with a
fuel consumption of > 50 l/h the oil must be changed every 250 operating hours
** Running-in instructions: oil change after 50, 500 and 1000 operating hours, then every 1000 operating hours
*** also after repairs in the hydraulic system.
**** oil change after 500 and 2000 operating hours, then every 2000 operating hours

86 BOMAG BC 672/772 RB-2, BC 772 RS-2

Every 10 operating hours

Every 10 operating hou rs

5.6 Checking the engine oil lev- 5.7 Checking the fuel level
el
! Caution
! Caution Do not drive the fuel tank dry, as otherwise the
fuel system needs to be bled.
The machine must be in horizontal position.
If the engine is warm, shut it down and check
the oil level after five minutes. With a cold en-
gine the oil level can be checked immediately.
For quality of oil refer to the table of fuels and
lubricants.

Fig. 157

l Check the fuel level on the fuel gauge (j) (Fig.

157), refuel if necessary.

Refuelling
Fig. 156
Danger
!
l Pull out the dipstick (Fig. 156) and wipe it clean
with a lint-free, clean cloth. Fire hazard!

l Reinsert the oil dipstick until it bottoms and pull When working on the fuel system do not use
it out again. open fire, do not smoke, do not spill any fuel.

l The oil level must always be between the Do not refuel in closed rooms.
"MIN"- and "MAX"-marks, fill up oil if neces- Shut down the engine.
sary.
Danger
!

Health hazard!
Do not inhale any fuel fumes.

Caution
!

Monitor the entire refuelling process.

For quality and quantity of fuel refer to the "ta-
ble of fuels and lubricants".

BC 672/772 RB-2, BC 772 RS-2 BOMAG 87

Every 10 operating hours

Environment
Catch running out fuel, do not let it seep into
the ground.
l Shut down the engine.

Fig. 160

l Unlock the tank cover (Fig. 160) and take it off.

l Clean the area around the filler opening.

Fig. 158
Caution
!

Contaminated fuel can cause malfunction or

l Use access steps (Fig. 158) and
even damage of the engine.
If necessary, fill in fuel through a funnel with
screen.
l Top up with fuel (diesel or winter diesel).
l Screw the fuel tank cover back on.

Fig. 159

l hand rails (Fig. 159).

l Open the cover flap on the front frame.

88 BOMAG BC 672/772 RB-2, BC 772 RS-2

Every 10 operating hours

5.8 Check the hydraulic oil level 5.9 Check the coolant level

! Caution ! Danger
In hydraulic systems filled with Panolin HLP Danger of scalding!
Synth. 46 always use the same oil to top up.
Open the cap on the coolant compensation
With other ester based oils consult the lubrica-
tank only when the engine is cold.
tion oil service of the respective oil manufac-
turer.
! Caution
! Caution If, during the daily inspection the coolant level
is found to have dropped, check all lines, hos-
If, during the daily inspection of the oil level
es and engine for leaks.
the hydraulic oil level is found to have
dropped, check all lines, hoses and compo- Do not use radiator sealant to seal leaks.
nents for leaks. For coolant refer to the "table of fuels and lu-
bricants".

Fig. 161

l Check the oil level in the inspection glass (Fig. Fig. 162
161).
i Note
i Note A too low coolant level is indicated by the coolant
At a room temperature of approx. 20 °C the oil lev- level warning light (d) (Fig. 162) in the left instru-
el should reach approx. 1/3 way up the inspection ment cluster.
glass.
l If the oil level is too low top up hydraulic oil im-
mediately.

For quality and quantity of oil refer to the "table

of fuels and lubricants".

BC 672/772 RB-2, BC 772 RS-2 BOMAG 89

Every 10 operating hours

5.10 Checking the oil level in the

transfer box

! Caution
Check the oil level only in cold condition and
with the engine shut down.
For quality of oil refer to the "table of fuels and
lubricants".

Fig. 163

l Open the safety flap (Fig. 163).

Fig. 165

l Check the oil level in the inspection glass (Fig.

165), it must be slightly above the middle of the
inspection glass.
Fig. 164

l Unscrew the cap (Fig. 164).

l The coolant level must reach the edge of the
filler opening, top up if necessary.

Fig. 166

l Clean the area around the breather filter (Fig.

166) and unscrew the breather filter.
l Top up oil, if necessary
l Screw the breather filter back on.

90 BOMAG BC 672/772 RB-2, BC 772 RS-2

Every 10 operating hours

5.11 Visual inspection of the ma- 5.12 Lubricating the joints and
chine for damage and leaks bearings on the bucket (RS)

! Danger
Danger of injury!
Lower the bucket to the ground

Fig. 167

l Check the complete machine and all attach-

ments for good condition and completeness
(Fig. 167).
l Check all pipes and hoses for good condition
Fig. 169
and tightness.
l Clean all grease nipples (Fig. 169) and lubri-
l Have all damage repaired.
cate with approx. 5 strokes from the grease
gun.
For quality of grease refer to the table of fuels and
lubricants.

i Note
If necessary clean and lubricate once every week.

Fig. 168

l Operate the flutter valve (Fig. 168) to drain the

water off the ROPS.

i Note
After completing maintenance work reinstall all
plates, covers etc. that have been removed, close
opened service doors.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 91

Every 10 operating hours

92 BOMAG BC 672/772 RB-2, BC 772 RS-2

Every 500 operating hours

Every 500 oper ating hours

5.13 Changing engine oil and oil

filter

! Danger
Danger of scalding!
When draining off hot oil.
By hot oil when unscrewing the engine oil fil-
ter.

Caution
! Fig. 171
Drain the oil only when the engine is warm. l Loosen and unscrew the engine oil filter car-
tridge (Fig. 171) using an appropriate filter
Environment wrench.
Catch running out oil and dispose of environ- l Wipe the sealing face clean.
mentally together with the oil filter cartridge. l Cover the rubber seal of the new engine oil fil-
l Remove the rear service door. ter slightly with clean oil.
l Spin the new engine oil filter cartridge on and
tighten it hand tight.

Fig. 170

l Unscrew the safety cap (2) (Fig. 170) from the

oil drain socket (1). Fig. 172

l Take the drain hose (3) out of the right hand l Fill in new engine oil (Fig. 172) through the oil
stowage compartment and screw it on. filler neck.
l Drain off and catch the engine oil. For quality and quantity of oil refer to the "table
l Once the old oil has run out remove the drain of fuels and lubricants".
hose and screw the safety cap back on. l Screw the cap back on again.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 93

Every 500 operating hours

5.14 Checking, cleaning the wa-

ter separator

! Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke, do not spill any fuel.

Danger
!

Fig. 173 Health hazard!

l Loosen the hose (Fig. 173) on the oil collecting Do not inhale any fuel fumes.
vessel on the crankcase ventilation.
l Disassemble the oil collecting vessel and Environment
empty it. Catch running out fuel and dispose of environ-
mentally.
Environment
Dispose of old oil environmentally. i Note
l Assemble the oil collecting vessel and fasten The service intervals for the water separator de-
the hose. pend on the water content in the fuel and can
therefore not be determined precisely. After taking
the engine into operation you should therefore
check the filter bowl initially every day, later as re-
quired, for signs of water.
If a too high quantity is drained off, the filter needs
to be bled, see section "Replacing the fuel pre-
cleaner cartridge".

Fig. 174

l After a short test run check for leaks.

l Check the oil level on the dipstick (Fig. 174),
correct if necessary.

Fig. 175

! Caution
If the warning light for water in the fuel (Fig.
175) in the right dashboard lights up when

94 BOMAG BC 672/772 RB-2, BC 772 RS-2

Every 500 operating hours

starting or during operation, drain the water

from the prefilter. 5.15 Servicing the generator V-
l Open the engine compartment doors on the belt
left hand side.

! Danger
Danger of injury!
Work on the V-belt drive must only be per-
formed with the engine shut down.

Check the V-belt

Fig. 176

l Place a collecting vessel (Fig. 176) under the

drain bore.
l Slacken the drain plug for a few turns and
catch running out fuel / water .
l Drain the fuel off until there is no water left.
Close the drain plug again.
Fig. 177

i Note l Inspect the entire circumference of the V-belt

(Fig. 177) visually for damage and cracks. Re-
Once the water separator is empty the warning
place damaged or cracked V-belts.
light for water in fuel must go out.

Check the V-belt tension

i Note
A belt tension meter is required to check the V-belt
tension.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 95

Every 500 operating hours

Changing the V-belt

l Loosen screws (2) (Fig. 179).
l Loosen screw (1).
l Remove the belt and install a new one.
l Tighten the screw (1) clockwise, until the re-
quired belt tension is reached.
l Retighten screws (2).

i Note
Retighten new V-belts after a running time of 15
Fig. 178
minutes.

l Lover the indicator arm (1) (Fig. 178) into the

measuring unit.
l Rest the guide (3) on the V-belt (2) between
two belt pulleys. The stop should abut against
the side.
l Evenly press the button (4) under a right angle
to the V-belt (2), until the spring engages audi-
bly and noticeably.
l Lift the meter carefully without changing the
position of the indicator arm (1).
l Read the measuring value at the intersecting
point (arrow), scale (5) and indicator arm (1).

Retighten the V-belt

Fig. 179

l Loosen screws (2) (Fig. 179).

l Tighten the screw (1) clockwise, until the re-
quired belt tension is reached.
l Retighten screws (2).

96 BOMAG BC 672/772 RB-2, BC 772 RS-2

Every 500 operating hours

Retighten the V-belt

5.16 Servicing the air condition-
ing compressor* V-belt

Danger
!

Danger of injury!
Work on the V-belt must only be performed
with the engine shut down.

Check the V-belt

Fig. 181

l Slacken the bearing screw (2) (Fig. 181) for

the compressor bracket.
l Slightly loosen the hexagon screw (1) on the
slot for the compressor bracket.
l Loosen the counter nut (3).
l Turn down tensioning screw (4) in direction of
arrow, until the correct V-belt tension is
reached.
l Retighten all fastening screws.
Fig. 180

l Inspect the entire circumference of the V-belt Changing the V-belt

(Fig. 180) visually for damage and cracks. Re-
place damaged or cracked V-belts. l Slacken the bearing screw (2) (Fig. 181) for
the compressor bracket.
l Check with thumb pressure whether the V-belt
can be depressed more than 10 to 15 mm (0.4 l Slightly loosen the hexagon screw (1) on the
– 0.6 inches) between the V-belt pulleys, slot for the compressor bracket.
retighten if necessary. l Loosen the counter nut (3).
l Turn tensioning screw (4) in direction of arrow
to the stop.
l Take off the old V-belt and replace it with a
new one.
l Turn down tensioning screw (4) in direction of
arrow, until the correct V-belt tension is
reached.
l Retighten all fastening screws.

i Note
Retighten new V-belts after a running time of 15
minutes.

* Optional equipment

BC 672/772 RB-2, BC 772 RS-2 BOMAG 97

Every 500 operating hours

5.17 Servicing the fan V-belt

! Danger
Danger of injury!
Work on the fan V-belt must only be performed
with the engine shut down.

Checking the fan V-belt

i Note
Fig. 183
A belt tension meter is required to check the V-belt
l Press the indicator arm (a) of the tester (Fig.
tension.
183) into the gap of the measuring scale.
l Place the meter in the middle between the V-
belt pulleys on the back of the fan V-belt.

Fig. 182

l Inspect the entire circumference of the V-belt

(Fig. 182) visually for damage and cracks. Fig. 184
l Replace damaged or cracked V-belts. l Actuate the push button (b) (Fig. 184) evenly
with a finger under a right angle to the V-belt,
until the pressure spring disengages audibly
and noticeably.

i Note
The indicator arm remains in the measured posi-
tion.
l Take the measuring unit carefully off, without
moving the indicating arm.

98 BOMAG BC 672/772 RB-2, BC 772 RS-2

Every 500 operating hours

Fig. 185 Fig. 186

l Read the V-belt tension where the upper edge l Slightly loosen screws (1) and (2) (Fig. 186) as
of the indicating arm intersects with the meas- well as nut (3), so that there is still friction be-
uring scale (Fig. 185). tween the components.
First installation = approx. 1900 N l Loosen the nut (4) for a few turns.
after approx. 30 - l Turn the nut (5) clockwise and tension the V-
60 minutes run- belt.
ning-in time = approx. 1400 N
l Tighten the screw (2).
Min. 1100 N = tension to approx. 1400 N
l Measure the V-belt tension, tighten if neces-
sary.
Tensioning the fan V-belt
l Slightly slacken the nut (5).
l Tighten the nut (3).
! Caution
Do not tighten the V-belt excessively, since l Screw both nuts (4) and (5) to contact, then
this would damage the V-belt which in turn counter both nuts against each other.
could lead to damage on V-belt drive and en- l Tighten the screw (1).
gine.
Never tighten the new V-belt a second time to Change the fan V-belt
the value of 1900 N, even after only a brief en-
gine operation!
With a new V-belt check the tension after ap-
prox. 50 operating hours and tighten it to ap-
prox. 1400 N.

Fig. 187

l Slightly loosen screws (1) and (2) (Fig. 186) as

well as nut (3), so that there is still friction be-
tween the components.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 99

Every 500 operating hours

l Loosen the nut (4) for a few turns.

5.18 Battery service, checking
l Turn the nut (5) back so that the idler pulley is
able to swing back far enough. the main battery switch
l Take off the old V-belt and install a new one.
l Turn the nut (5) clockwise and tension the V- ! Danger
belt.
Danger of cauterisation ! Danger of explosion!
l Tighten the screw (2).
When working on the battery do not use open
l Start the engine for a moment or crank it once fire, do not smoke!
by hand.
The battery contains acid. Wear protective
l Measure the V-belt tension, tighten if neces- clothing! Do not let acid come in contact with
sary. skin or clothes!
Do not lay any tools on the battery!
For recharging remove the plugs from the bat-
tery to avoid the accumulation of highly explo-
sive gases.

! Caution
If a battery is defective you should always re-
place both batteries to avoid damage caused
by differing battery conditions/charge condi-
tions.

Environment
Dispose of the old batteries environmentally.

i Note
Maintenance free batteries also need care. Main-
tenance free only means that the fluid level does
not need to be checked. Each battery suffers un-
der self-discharge, which may, in not checked oc-
casionally, even cause damage to the battery as a
result of exhaustive discharge.
The following therefore applies for the service
life:
l Switch off all consumers (e.g. ignition, light, in-
side light, radio).
l Check open-circuit voltage of the battery at
regular intervals. At least once per month.
Reference values: 12.6 V = fully charged; 12.3 V =
50% discharged.
l Recharge the battery immediately after an
open-circuit voltage of 12.25 V or less is
reached. Do not perform quick charging.

100 BOMAG BC 672/772 RB-2, BC 772 RS-2

Every 500 operating hours

The open-circuit voltage of the battery occurs ap- Checking the main battery switch
prox. 10 hours after the last charging process or
one hour after the last discharge.
l After each charging process allow the battery
to rest for one hour before taking it into service.
l For resting periods of more than one month
you should always disconnect the battery. Do
not forget to perform regular open-circuit volt-
age measurements.

!Caution
Exhausted batteries (batteries with formation
of sulphate on the plates are not covered un-
der warranty!
Fig. 189

!Caution
Pull out the main battery switch at the earliest
40 seconds after switching off the ignition, ex-
cept in cases of emergency.
With engine-independent air heating systems*
allow the heating to run for another 2 minutes.
l Turn the main battery switch (Fig. 189) to po-
sition "II" and check by voltage measurement
(ignition key test) whether the batteries are
disconnected from the electric system of the
machine.
Fig. 188

l Open the access cover in the floor in front of

the cabin door (Fig. 188).
l Clean battery poles and pole clamps and
grease them with pole grease (Vaseline).
l Retighten the pole clamps.
l Check the fastening of the battery.
l On serviceable batteries check the acid level,
if necessary top up to the filling mark with dis-
tilled water.

* Optional equipment

BC 672/772 RB-2, BC 772 RS-2 BOMAG 101

Every 500 operating hours

5.19 Check the engine mounts 5.20 Servicing the air condition-
ing

The air conditioning unit is attached to the

ROPS and can be access from outside for
service work.

Caution
!

Under very dusty conditions clean every day in

order to maintain the cooling power of the air
conditioning system.

! Danger
Danger of accident!
Fig. 190

l Check all fastening screws on the engine Do not clean with a hot water jet. Heat will
mounts (Fig. 190) for tight fit, tighten if neces- cause extreme overpressure, which could
sary. cause damage or explosion of the system.

l Check condition of engine mounts, replace if

necessary.
Clean the condenser

Fig. 191

l Fold the air intake grid (Fig. 191) back.

102 BOMAG BC 672/772 RB-2, BC 772 RS-2

Every 500 operating hours

Fig. 192 Fig. 194

l Clean the condenser fins on front and back l Start operation of the air conditioning (Fig.
with compressed air or cold water (Fig. 192). 194).

!Caution
During cleaning work do not damage the cool-
ing fins and realign bent fins.

Checking the refrigerant level

l Start the engine.

Fig. 195

l Open the air outlet nozzles (Fig. 195).

l Check, whether the out flowing air is noticea-
bly cooler.

i Note
The adjusted temperature must be below the actu-
Fig. 193 al temperature inside the cabin, so that the com-
pressor will be switched on.
l Switching on the control unit (Fig. 193).

BC 672/772 RB-2, BC 772 RS-2 BOMAG 103

Every 500 operating hours

Checking the moisture level of the dry-

ing agent

Fig. 196

l Check whether the white float (Fig. 196) inside

the inspection glass of the drier/collector unit
floats right at the top. Fig. 198

l Check the moisture indication pearl (Fig. 198)

inside the inspection glass of the drier/collec-
i Note
tor unit.
The refrigerant level is correct.
orange = Drying agent o.k.
colour-
less = moisture level of drying agent too
high.
l Inform the service department. Replace drier/
collector unit, check air conditioning system.

!Caution
Have the drier/collector unit replaced by the
service department every year before the oper-
ating season.

Fig. 197
Checking the condition of the drier/col-
lector unit
l If the white float (Fig. 197) inside the inspec-
tion glass of the drier/collector unit floats at the
bottom, inform the service department. !Caution
According to the regulation for pressure reser-
voirs all pressure reservoirs must be repeated-
i Note
ly inspected by a specialist. In this sense
The refrigerant level is not correct.
repeated inspections are external examina-
l Refrigerant must be filled up, if necessary tions, normally on pressure reservoirs in oper-
check the air conditioning system for leaks. ation. In connection with this inspection the
drier/collector unit must be visually examined
twice every year. During these inspections
special attention must be paid to corrosion
and mechanical damage. If the reservoir is not
in proper condition it must be replaced for
safety reasons, as a precaution to protect op-
erators and third parties against any danger

104 BOMAG BC 672/772 RB-2, BC 772 RS-2

Every 500 operating hours

arising from the handling and operation of

pressure reservoirs. 5.21 Checking condition of radi-
ator, intercooler and hy-
! Danger draulic oil cooler, clean,
Danger of injury! cleaning the engine
In case of mechanical damage or corrosion on
this drier/collector unit this unit must be re-
placed, to avoid bursting and further damage. i Note
Dirty operating conditions, particularly lubrication
oil and fuel deposits on the cooling fins reduce the
cooling effect. You should therefore immediately
seal any oil or fuel leaks near cooling fan, cylinder
or oil cooler and subsequently clean the cooling
fins.

Danger
!

Danger of injury!
Perform cleaning work only after the engine
has cooled down and with the engine stopped!

Fig. 199

l Check the drier/collector unit (Fig. 199) for me-

chanical damage or rust.

Fig. 200

l Remove the service covers on left (Fig. 200)

and

BC 672/772 RB-2, BC 772 RS-2 BOMAG 105

Every 500 operating hours

l In case of oily contamination spray the parts

with cold cleansing agent and spray it off with
a water jet after s sufficient soaking time.
l If steam cleaning equipment is available, this
should preferably be used.

Cleaning the engine

Caution
!

After cleaning the coolers it is mandatory to

clean the engine.

Fig. 201 Cover all parts of the electrical system, do not

subject to the direct water jet.
l right hand side (Fig. 201) of the air duct hous-
ing.

!Caution
During cleaning take care not to damage the
fins on hydraulic oil cooler, intercooler and ra-
diator. Keep a safe distance with the spray
nozzle.

i Note
Clean the coolers in the correct sequence.
l Clean hydraulic oil cooler, intercooler and radi-
ator from the air duct side first.
Fig. 203

l Blow the engine dry with compressed air.

Flush lose dirt with a water jet out of the V-
shaped space between the cylinders.
l The drain bore (Fig. 203) must be free, remove
blockage if necessary.

Fig. 202

l Remove the service door (Fig. 202).

l Clean all coolers from the air intake side.
l Remove dried on dirt with a suitable brush.
l Blow the cooling air channels out with com-
pressed air.

106 BOMAG BC 672/772 RB-2, BC 772 RS-2

Every 500 operating hours

5.22 Check the fastening of the

scrapers

Fig. 204

l In case of oily contamination spray the engine

with cold cleansing agent and spray it off with
a water jet after s sufficient soaking time.
l Drain bores (Fig. 204) and (Fig. 203) must be Fig. 205
free, remove blockage if necessary.
l Check fastening screws 2 (Fig. 205) and 3
l After wet cleaning run the engine warm to (Fig. 206) on scrapers 1 (Fig. 205)
evaporate all water residues and to avoid cor-
rosion.
l Reinstall the service covers.

Fig. 206

l and on the lateral edge cutters 1 (Fig. 206) for

tight fit, retighten if necessary.

i Note
The tightening torques apply for screws covered
with OKS 240 (copper paste).
l Check the gap between scrapers 2 (Fig. 206)
and compactor wheels, it must be approx.
5 mm (0,2“).

i Note
Only this adjustment ensures effective cutting of
wires.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 107

Every 500 operating hours

At the closest point (2) (Fig. 206) there must be

metal to metal contact between the edge cutters 5.23 Checking the oil level in the
and the shell surfaces of the compactor wheels. travel gear
! Caution
Remove refuse residues, cables, ropes, wires ! Caution
etc. to prevent premature wear of the wheel Check the oil level in all four travel gears.
shell edge.
For quality of oil refer to the "table of fuels and
lubricants".

Checking the oil level (Bonfiglioli)

Fig. 207

l Check the inner sides of the compactor

wheels, remove wires, cables, ropes, etc. (Fig.
207).
Fig. 208
l Check the scraper bars 1 (Fig. 207), replace if
l Drive the machine, until the drain plug (Fig.
worn.
208) is at the deepest point.
l Clean the area around the level inspection
plug and unscrew the plug.
l Check the oil level. The oil level must reach the
bottom edge of the bore.
l If necessary fill in oil, for this purpose clean the
area around the filler plug and unscrew the
plug.
l Fill in oil through the filler bore, until it starts to
run out through the level inspection bore.
l Clean the oil filler and inspection plug and
screw it back in tightly.

108 BOMAG BC 672/772 RB-2, BC 772 RS-2

Every 500 operating hours

Checking the oil level (L + S)

5.24 Checking, filling the central
lubrication system

The following lubrication points are provided

economically and reliably with grease by the
central lubrication system.
l 2 x at the lower bearing block for the dozer
blade,
l 1 x eye of the dozer blade cylinder,
l 4 x steering cylinder eyes,
l 2 x on the articulated joint,
l 4 x on the slewing ring in the articulated joint
Fig. 209
It is differentiated between the two cycles pause
l Drive the machine, until the drain plug (Fig.
and work.
209) is at the deepest point.
Pause: Over a time period of 60 minutes there will
l Clean and unscrew filler and level control plug.
be no lubrication.
l Check the oil level. The oil level must reach the Work: Adjusted in the factory.
bottom edge of the bore, top up oil if neces-
sary.
Checking:
l Clean the oil filler and inspection plug and
screw it back in tightly.

Fig. 210

l Switch the ignition on.

l Actuate the push button (Fig. 210) for 2 sec-
onds.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 109

Every 500 operating hours

Filling with a manual grease gun

!Caution
Ensure strict cleanliness, as otherwise the dis-
tributor will be blocked.
For quality and quantity of grease refer to the
table of fuels and lubricants.

Fig. 211

l The stirring device in the transparent container

1 (Fig. 211) moves and presses the grease to
the lubrication points.

i Note
The push button must only be used to check the
system.
Fig. 212
Failure of a lubrication point l Remove both covers from the cartridge 1 (Fig.
(e.g. lubrication point blocked) 212).
l Grease emerging from the opening 3 (Fig. l Unscrew the connecting fitting from the manu-
211) indicates that one of the lubrication points al grease gun (2).
is blocked. l Pull the rod completely out.
l Eliminate the cause. l Push the cartridge with the triangular mark for-
ward into the grease gun.
Filling via the grease nipple. l Check, whether the sealing ring is correctly in-
serted in the connecting fitting.
! Caution l Screw the connecting fitting on to the manual
Ensure strict cleanliness, as otherwise the dis- grease gun.
tributor will be blocked.
Do not fill the grease container via the cover.
Fill the grease container when the grease level
has dropped down to 1/4 of the filling capacity.
l Clean the grease nipple.
l Fill the grease container via the grease nipple
(2) up to the "Max"-mark.

For quality and quantity of grease refer to the

table of fuels and lubricants.
l Switch the ignition on, press the push button
(Fig. 210) for 2 seconds, the system starts to
work.

110 BOMAG BC 672/772 RB-2, BC 772 RS-2

Every 500 operating hours

5.25 Replacing the fresh air and

circulation air filters

Fig. 213

l Clean the area around the covering cap of the

central lubrication system.
l Unscrew the covering cap from the central lu-
brication system and unscrew the plug from Fig. 214
the manual grease gun (Fig. 213).
l Unscrew the cover.
l Screw the manual grease gun on the socket of
l Take the old fresh air filter out and insert the
the central lubrication system.
new fresh air filter (Fig. 214).
l Operate the rod to press the grease into the
l Fasten the cover with screws.
transparent container.
l Screw the manual grease gun off, insert a new
cartridge and repeat the pumping action until
the transparent container is filled up to the
"Max"-mark.

!Caution
After filling the container screw the cap and
the plug back on.

Fig. 215

l remove the slotted cover from the console be-

hind the driver’s seat.
l Remove both circulation air filters and insert
the new circulation air filters (Fig. 215).
l Fasten the slotted cover to the console.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 111

Every 500 operating hours

112 BOMAG BC 672/772 RB-2, BC 772 RS-2

Every 1000 operating hours

Every 1000 operating hours

Caution
5.26 Check, adjust the valve !

This engine is equipped with an internal ex-

clearance haust recirculation system. During the intake
cycle the exhaust valve opens for a short mo-
ment.
! Caution
This must not be mistaken as overlapping of
We recommend to have this work carried out valves!
by trained personnel or our after sales service.
Before checking the valve clearance let the en-
gine cool down for at least 30 minutes. The en-
gine oil temperature must be less than 80 °C.

Fig. 218

Check the valve clearance

l Intake valves 0,25 mm
Fig. 216
l Exhaust valves 0,30 mm
l Remove all valve covers (Fig. 216).
l A feeler gauge of appropriate thickness (1)
must fit with little resistance between rocker
arm (2) (Fig. 218) and valve (3).
l If the gap is too narrow or too wide for the feel-
er gauge, the valve must be adjusted.

Adjusting the valve clearance

l Loosen counter nut (4) (Fig. 218) for 2 to 3
turns.
l Adjust the setscrew (5) with a screwdriver, un-
til the feeler gauge can be inserted and pulled
out with little resistance after retightening the
counter nut.
Fig. 217
l Repeat the adjustment procedure on each cyl-
Adjustment diagram (Fig. 217)
inder.

Valves Cylinder
overlapping A1 B3 A3 B2 A2 B1
adjustment B2 A2 B1 A1 B3 A3

l Turn the crankshaft until the valves are over-

lapping.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 113

Every 1000 operating hours

5.27 Replacing the fuel filter car-

tridges

! Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke and do not spill any fu-
el.

Danger
!
Fig. 219
Health hazard!
l Assemble all cylinder nead covers with new
gaskets (Fig. 219), tightening torque: 22 Nm. Do not inhale any fuel fumes.

Caution
! ! Caution
After a short test run check the engine for Ensure strict cleanliness! Thoroughly clean
leaks. the area around the fuel filters.
After work on the fuel system bleed the sys-
tem, perform a test run and check for leaks.
Additional bleeding of the fuel system by a 5
minute test run in idle speed or low load is
mandatory.

Environment
Catch running out fuel and dispose of environ-
mentally.
l Open the left hand engine compartment doors.

114 BOMAG BC 672/772 RB-2, BC 772 RS-2

Every 1000 operating hours

5.28 Replacing the fuel pre-filter

cartridge, bleeding the fuel
system

Danger
!

Fire hazard!
When working on the fuel system do not use
open fire, do not smoke and do not spill any fu-
el.
Fig. 220
Danger
!
l Loosen both fuel filters (Fig. 220) using a suit-
able filter wrench and screw it off. Health hazard!
l Clean the sealing face on the filter carriers Do not inhale any fuel fumes.
from any dirt.
!Caution
Caution
! Ensure strict cleanliness! Thoroughly clean
The filter cartridge must never be filled before- the area around the fuel filters.
hand. After work on the fuel system bleed the sys-
tem, perform a test run and check for leaks.
Additional bleeding of the fuel system by a 5
minute test run in idle speed or low load is
mandatory.

Environment
Catch running out fuel and dispose of environ-
mentally.

Change the fuel pre-filter cartridge

Fig. 221

l Slightly oil the rubber seal on the new filter car-

tridge (Fig. 221).
l Turn the new filter cartridge on by hand, until
the seal contacts.
l Then tighten hand-tight.
l Always bleed the fuel system after changing
the fuel pre-filter cartridge (see next chapter).
l Check for leaks after a short test run.

Fig. 222

l (1) Shut down the engine (Fig. 222).

BC 672/772 RB-2, BC 772 RS-2 BOMAG 115

Every 1000 operating hours

l (2) Pull the cable off the water separator. l Slacken the bleeding screws on the fuel pre-fil-
Loosen the bleeding screw and drain off fuel ters for 2 to 3 turns.
from the bleeding screw.
l Operate the fuel hand pump (2) manually, until
l (3) Loosen and unscrew the fuel pre-filter car- fuel flows out of the loosened bleeding screws
tridge using an appropriate filter wrench. without air bubbles.
l (4) Unscrew the water separator from the filter l Then tighten the bleeding screws while pump-
cartridge. ing.
l (5) Apply a thin coat of oil to the rubber seal of l Start the engine and run it 5 minutes with idle
the water separator. speed.
l (6) Turn the water separator on by hand, until
the seal contacts, then tighten hand-tight.
l (7) Apply a thin coat of oil to the rubber seal of
the filter element.
l (8) Turn the filter cartridge on by hand, until the
seal contacts, then tighten hand-tight. Plug the
cable of the water sensor back on.

Bleed the fuel system

i Note
Air in the fuel system causes irregular running of
the engine, a drop in engine power, stalls the en-
gine and makes starting impossible.
Therefore bleed the fuel system after changing the
fuel pre-filter or working on the fuel system.

Fig. 223

l Slacken the bleeding screw (1) (Fig. 223) on

the fuel pre-filter for 2 to 3 turns.
l Operate the fuel hand pump (2) manually, until
fuel flows out of the loosened bleeding screw
without air bubbles.
l Then tighten the bleeding screw while pump-
ing.

116 BOMAG BC 672/772 RB-2, BC 772 RS-2

Every 1000 operating hours

5.29 Checking the anti-freeze

concentration and the con-
dition of the coolant

Danger
!

Danger of scalding!
Check the anti-freeze concentration only when
the engine is cold.

!Caution Fig. 225

In order to avoid damage to the engine (e.g. by l Unscrew the radiator cap (Fig. 225) and check
corrosion, cavitation and freezing), particular the anti-freeze concentration with a conven-
attention must be paid to the inspection of the tional tester.
coolant.
For coolant quality refer to the "table of fuels Caution
!

and lubricants". The anti-freeze concentration (additive) must

Do not mix different coolants and additives, be at least 35 Vol% and maximum 45 Vol%.
see section "Fuelds and Lubricants - Coolant". l Check the condition of the coolant.
In case of lubrication oil entering into the cool-
ing system or a suspicious turbidity caused by
corrosion residues or other suspended matter,
! Caution
the coolant must be drained off and the com- If the coolant is contaminated by corrosion
plete cooling system needs to be cleaned. Lu- residues or other suspended matter, flush the
brication oil can damage the sealing materials cooling system, see section "Changing the
used in the engine. coolant".

Environment
Catch coolant and dispose of environmentally.

Fig. 224

l Open the safety flap (Fig. 224).

BC 672/772 RB-2, BC 772 RS-2 BOMAG 117

Every 1000 operating hours

5.30 Intercooler, draining off oil/ 5.31 Checking the fastening of

condensation water engine / turbo charger /
combustion air hoses
i Note
Do this work at least once every year.

Environment
Environmental damage
Catch running out fluid, do not let it seep into
the ground and dispose off environmentally.

Fig. 227

l Check charge air pipe (Fig. 227) and intercool-

er for tight fit and leaks.
l Check the exhaust gas pipe and the lubrica-
tion oil line to and from the exhaust gas turbo
charger for tight fit and leaks.
l Check the connecting sleeves for tight fit.
Fig. 226

l Unscrew the drain plug (Fig. 226) and catch

running out fluid.

Fig. 228

l Open the maintenance flap on the ROPS.

l Check the combustion air hose for tight fit and
leaks (Fig. 228).

118 BOMAG BC 672/772 RB-2, BC 772 RS-2

Every 1000 operating hours

5.32 Checking the crankcase

pressure

! Caution
Excessive pressure in the crankcase can
cause lubrication oil leaks on all seals.
This may be caused by a not correctly func-
tioning crankcase ventilation.
Moreover, too high crankcase pressure can
also cause damage to the exhaust turbocharg-
Fig. 229 er and the complete engine.
l Check combustion air tube and connecting l Pull out the oil dipstick .
sleeves for tight fit (Fig. 229).

Fig. 230

l Connect the U-pipe pressure gauge (1) (Fig.

230) to the oil dipstick opening using hose and
hose clamps.
l Make sure that the connection is tightly
sealed!
l Fill half of the U-pipe pressure gauge with wa-
ter.
l Fasten the U-pipe pressure gauge at a quiet
location (e.g. on the wall).
l Run the engine up to operating temperature.
l Run the engine at high idle or under full load.
l Read the pressure on the fine measurement or
U-pipe pressure gauge.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 119

Every 1000 operating hours

5.33 Oil change in travel gear

Nominal value

high idle speed: max. 20 mm water col-

! Danger
umn
Danger of scalding!
full load: max. 50 mm water col-
When draining off hot oil.
umn

! Caution
! Caution
Drain oil only at operating temperature.
If the pressure exceeds the permissible crank-
case pressure you should perform trouble- Perform the oil change on all four drive gears.
shooting and rectify the fault. For quality and quantity of oil refer to the "table
of fuels and lubricants".

Environment
Catch running out oil and dispose of environ-
mentally.

Oil change (Bonfiglioli)

Fig. 231

l Drive the machine, until the drain plug (Fig.

231) is at the deepest point.
l Clean the surrounding area. Clean and un-
screw filler, level control and drain plugs.
l Drain and catch all oil.
l Once all oil has run out clean the drain plug
and screw it back in fitted with a new sealing
ring.

120 BOMAG BC 672/772 RB-2, BC 772 RS-2

Every 1000 operating hours

Fig. 232 Fig. 234

l Fill in oil through the filler bore (Fig. 232), until l Fill in oil, until it reaches the bottom edge of the
it starts to run out through the level inspection bore (Fig. 234).
bore.
l Turn the filler and level control plug back in
l Clean the level control and filler plug and with a new seal ring.
screw it back in with a new seal ring.

Oil change (L + S)

Fig. 233

l Drive the machine, until the drain plug (Fig.

233) is at the deepest point.
l Clean and unscrew filler, level inspection and
drain plugs and.
l Drain and catch all oil.
l Once all oil has run out clean the drain plug
and screw it back in fitted with a new sealing
ring.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 121

Every 1000 operating hours

5.34 Changing the fuel filter for 5.35 Checking, cleaning the oil
the cabin heater (diesel) bath air filter for the cabin
heater
! Danger
Fire hazard! Caution
!

When working on the fuel system do not use During the heating period check, clean every
open fire, do not smoke, do not spill any fuel. day
Do not inhale any fuel fumes. For quality of oil refer to the "table of fuels and
lubricants".
Environment
Catch running out fuel, do not let it seep into
the ground.

Fig. 236

l Open the quick locks and take off the oil bowl
(Fig. 236). Check the oil level.
Fig. 235
l Remove all oil slurry, clean the oil bowl and fill
l Open the flap on the front frame. it with fresh oil up to the level mark.
l Pull the hoses from both sides off the fuel filter l Check the fresh air intake tube in the oil bath
(Fig. 235). air filter housing for any obstructions, clear out
l Take the fuel filter out of the bracket. if necessary.

l Insert a new fuel filter with the point of the ar-

row facing towards the pump and push both
hoses on.
l Remove the cover.

122 BOMAG BC 672/772 RB-2, BC 772 RS-2

Every 1000 operating hours

5.36 Change the hydraulic oil

fine filter

! Danger
Danger of scalding!
Danger of scalding by hot oil when unscrewing
the fine filter.

Environment
Do not let old oil seep into the ground, but dis- Fig. 238
pose off environmentally.
l Do not use the oil in the filter bowl again.
l Take out the old filter element (3) (Fig. 238),
! Caution
clean the filter bowl.
If the filter has to be changed together with the
hydraulic oil, the filter must only be changed l Clean the thread on the filter bowl.
after the oil change and after the test run. l Assemble the filter bowl with a new filter ele-
ment, check the condition of the seal rings.
i Note l Run the engine for about 3 minutes with low
Apart from the normal oil change intervals, the fil- speed, this will bleed the hydraulic system.
ter element must also be changed after major re- l Check for leaks after a short test run.
pairs in the hydraulic system.

Fig. 237

l Remove the locking wire, if present.

l Unscrew spigot nut 1 (Fig. 237).
l Remove filter bowl (2) with filter element.

! Caution
Catch running out oil.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 123

Every 1000 operating hours

124 BOMAG BC 672/772 RB-2, BC 772 RS-2

Every 2000 operating hours

Every 2000 operating hours

5.37 Changing hydraulic oil and

breather filter

i Note
See also the notes on the hydraulic system in the
chapter "General notes on maintenance".

Danger
!

Danger of scalding!
When draining off hot hydraulic oil! Fig. 239

l Unscrew the breather filter (Fig. 239) from the

Caution
! compensation tank.
The hydraulic oil must also be changed after
major repairs in the hydraulic system.
!Caution
Perform the oil change when the hydraulic oil Do not remove the filter element from the cover
is warm. of the compensation tank.
Replace the hydraulic oil filter elements with
every hydraulic oil change.
Change the filter only after the hydraulic oil
change and after the test run.
Clean the area round hydraulic oil tank, filler
opening and breather filter.
Do not start the engine after draining the hy-
draulic oil.
Do not use any detergents to clean the system.
Use only lint-free cleaning cloths.
For quality and quantity of oil refer to the "table
of fuels and lubricants".
Fig. 240
When changing from mineral oil based hydrau-
lic oil to an ester based biologically degradable l Unscrew plug (1) (Fig. 240) from drain cock
oil, you should consult the lubrication oil serv- (2).
ice of the oil manufacturer for details. l Take the drain hose (3) out of the right hand
stowage compartment, hold it into a collecting
Environment container.
Catch running out hydraulic oil and dispose of l Open drain cock (2) and let the old oil run out.
environmentally.
l Once all old oil has run out close the drain
l Remove the rear cover. cock, remove the drain hose and screw the
plug back on.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 125

Every 2000 operating hours

Cleaning the hydraulic oil tank

i Note
If the hydraulic oil tank needs to be cleaned from
inside the following work must be performed:
l Unscrew the hexagon screws (4) (Fig. 240)
and take off the cover .
l Wipe the inside of the hydraulic tank clean with
the lint-free cloth.

Caution
!

Do not use any detergents. This will contami- Fig. 242

nate the hydraulic oil! l Check the oil level in the inspection glass (Fig.
l Insert a new seal and reinstall the cover. 242) (arrows).

Fill in hydraulic oil. i Note

At a temperature of approx. 20 °C the oil level
should reach 1/2 way up the inspection glass.
With hot hydraulic oil and a too high oil level hy-
draulic oil can flow through the overflow into the
engine compartment.

Fig. 241

l Remove the filler cap (Fig. 241).

l Fill in new hydraulic oil through the screen.

i Note Fig. 243

We recommend to use the BOMAG filling and fil- l Screw the new breather filter on (Fig. 243).
tering unit with fine filter to fill the system. This en-
l Perform a test run and check the system for
sures finest filtration of the hydraulic oil, prolongs
leaks.
the lifetime of the hydraulic oil filter and protects
the hydraulic system.
Bleeding the hydraulic system
l Run the engine for about 3 minutes with low
speed, this will bleed the hydraulic system.

126 BOMAG BC 672/772 RB-2, BC 772 RS-2

Every 2000 operating hours

5.38 Change the coolant

! Danger
Danger of scalding!
Change the coolant only when the engine is
cold.

! Caution
Do not start the engine after draining off the
coolant.
Fig. 245
In case of lubrication oil entering into the cool- l Unscrew the cap (Fig. 245).
ing system or a suspicious turbidity caused by
corrosion residues or other suspended matter,
the coolant must be drained off and the com-
plete cooling system needs to be cleaned. Lu-
brication oil can damage the sealing materials
used in the engine.
When changing the coolant without any signs
of contamination, cleaning of the cooling sys-
tem is not necessary.

!Caution
For quality and quantity of coolant refer to the
"table of fuels and lubricants".
Do not mix different coolants and additives, Fig. 246
see section "Fuelds and Lubricants - Coolant". l Connect the drain hose to the drain cock (Fig.
246).
Environment l Open the drain cock and catch the running out
Catch coolant and dispose of environmentally. coolant.
l After the coolant has run out close the drain
cock, remove the drain hose.
l Check the condition of the coolant.

!Caution
Thoroughly flush the cooling system if the
coolant is contaminated by corrosion residues
or other suspended matter.
If lubrication oil has entered you must add a
cleansing agent in order to remove any resi-
dues from the system. Follow the instructions
of the manufacturer. If in doubt consult your
Fig. 244 local service station or the engine manufactur-
er.
l Open the safety flap (Fig. 244).
l Remove the thermostat.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 127

Every 2000 operating hours

l Fill in clean water.

5.39 Oil and filter change in
l Start the diesel engine and run it warm to op-
erating temperature. transfer box
l Allow the engine to cool down to approx. 50
°C.
! Danger
l Drain all water off.
Danger of scalding!
l When using a cleansing agent repeat the
flushing process twice with clear water. Danger of scalding by hot oil when unscrewing
the filter.
l Screw the plug back in once all coolant has run
out.
Caution
!
l Reinstall the thermostat .
Drain oil only at operating temperature.
The filter element must be changed with every
! Caution
oil change.
The anti-freeze concentration (additive) must
be at least 35 Vol% and maximum 45 Vol%.
Environment
Catch running out oil and dispose of environ-
mentally together with the oil filter cartridge.

Danger
!

Danger of injury!
Lower the rear bottom cover to the ground af-
ter unscrewing it, do not let it drop down.
l Remove the rear bottom cover.

Fig. 247

l Fill coolant in through the opening in the com-

pensation tank (Fig. 247) and screw tzhe cap
back on.
l Start the diesel engine and run it warm to op-
erating temperature.
l Check the coolant level again, top up if neces-
sary.

Fig. 248

l Clean the area around the breather filter (Fig.

248) and unscrew the breather filter.
l Cleaning the breather filter.

128 BOMAG BC 672/772 RB-2, BC 772 RS-2

Every 2000 operating hours

Fig. 249 Fig. 251

l Unscrew the plug (Fig. 249)from the oil drain l Fill in new oil (Fig. 251).
socket.
For quality and quantity of oil refer to the "table
l Drain off and catch transmission oil. of fuels and lubricants".
l Screw the plug back in once the oil has run
out.

Fig. 252

l Check the oil level in the inspection glass (Fig.

Fig. 250 252).
l Unscrew the spigot nut and remove filter bowl l Start the engine and run it for a short while.
with filter element (Fig. 250).
l Check the oil level again, if necessary top up
l Let the oil run out of the cooling pipe and catch oil.
it
l Check for leaks.
l Clean the filter bowl and install it with a new fil-
ter element, check the condition of the seal
rings.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 129

Every 2000 operating hours

5.40 Checking the condition of

the articulated joint

Fig. 253

l Check all fastening screws (Fig. 253) for tight

fit, tighten if necessary.
l Check the condition of the lubrication lines 1
(Fig. 253) to the bearings for the steering cyl-
inder rods.

130 BOMAG BC 672/772 RB-2, BC 772 RS-2

Every 4000 operating hours

Every 4000 operating hours

5.41 Changing the injection

valve

i Note
This work must only be performed by authorized
service personnel.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 131

Every 4000 operating hours

132 BOMAG BC 672/772 RB-2, BC 772 RS-2

Every 6000 operating hours

Every 6000 operating hours

5.42 Replacing the crankcase 5.43 Changing the coolant pump

ventilation valve
i Note
This work must only be performed by authorized
service personnel.

Fig. 254

l Replace the crankcase ventilation valve (Fig.

254).

BC 672/772 RB-2, BC 772 RS-2 BOMAG 133

Every 6000 operating hours

5.44 Changing the pressure re- 5.45 Replacing the glow plugs
taining valve on te injection
pump i Note
This work must only be performed by authorized
service personnel.
i Note
This work must only be performed by authorized
service personnel.

134 BOMAG BC 672/772 RB-2, BC 772 RS-2

As required

As r equired

5.46 Cleaning, changing the dry

air filter cartridge

! Caution
Perform cleaning, maintenance and repair
work only with the engine shut down. Do not
start the engine after removing the filter ele-
ment.

Fig. 256

l Unscrew wing nut (1) (Fig. 256) and remove

cover (2).

Fig. 255
Maintenance of the dry air filter is due when air fil-
ter control light (g) (Fig. 255) in the left instrument
cluster lights permanently, but at the latest after
one year.
Fig. 257
i Note l Unscrew hexagon nut (1) (Fig. 257) and pull
Once the air filter warning light lights up, work may safety cartridge (4) out.
be continued until the end of the day.
l The safety cartridge remains in the housing.

! Caution Cleaning the main filter element

Do not clean the safety cartridge, but replace
immediately.
!Caution
l Open the left hand engine compartment door. If necessary, the main filter element may be
cleaned up to five times. It must be renewed at
the latest after a maximum utilization period of
two years.
The number of cleaning intervals of the main
filter element can be marked on the safety ele-
ment with a ball pen or a felt pen.
Cleaning does not make sense if the main filter
cartridge is covered with a sooty deposit. Use
a new filter cartridge.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 135

As required

Incorrectly handled filter cartridges may be- Cleaning the dust bowl
come ineffective because of damage (e.g.
cracks) and cause damage to the engine.
Replace the safety cartridge if the main filter el-
ement is defective!
Additional cleaning intervals between two fil-
ter services signalized by the fault monitoring
board are not necessary.

Fig. 260

l Remove the insert (Fig. 260) from the filter

housing and clean it.
l Wipe the filter housing out with a cloth. Do not
clean with compressed air.
l Reinsert the element.
Fig. 258

l Blow the filter cartridge out from inside to out- Changing the safety filter element
side with dry compressed air (max. 5 bar) (Fig.
258), until all dust has been removed. Caution
!

The safety filter element must not be cleaned

and should not be used again after it has been
removed.
Break the seal only to replace the safety filter
element.
The safety filter element must be replaced:
l if the main filter element is defective,
l after five times cleaning of the main filter ele-
ment,
l at the latest after 2 years,
l if the air filter warning light in the instrument
cluster comes on again after the main filter el-
Fig. 259 ement has been serviced.
l Examine the filter cartridge with a torch for
cracks and holes in the paper bellows (Fig.
259).

Caution
!

Do not continue to run the machine with a

damaged main filter element. If in doubt use a
new main filter element.

136 BOMAG BC 672/772 RB-2, BC 772 RS-2

As required

5.47 Clean the condenser

! Danger
Danger of accident!
Do not clean with a hot water jet. Heat will
cause extreme overpressure, which could
cause damage or explosion of the system.

! Caution
A soiled condenser results in a considerable
Fig. 261
reduction of air conditioning power.
l Unscrew hexagon nut 1 (Fig. 261) and pull
If, during operation of the air conditioning sys-
safety cartridge (2) out.
tem, the warning buzzer sounds switch the air
l Insert a new safety cartridge and fasten it with conditioning off and clean the condenser.
a new fastening nut. Under extremely dusty conditions it may be
l Insert the element into the filter housing. necessary to clean the condenser several
times per day.
l Insert a new main filter cartridge and fasten it
with a new fastening nut. During cleaning work do not damage the cool-
ing fins and realign bent fins.
l Screw the cover on.

Fig. 262

l Always use access steps and hand rails to

climb onto the engine compartment cover (Fig.
262).

BC 672/772 RB-2, BC 772 RS-2 BOMAG 137

As required

Fig. 263 Fig. 266

l Step only on such areas of the engine com- l Fold the air conditioning unit (Fig. 266) back.
partment cover which are provided with skid-
proof covering (Fig. 263). l Clean the condenser fins with compressed air
or cold water.

Fig. 264
Fig. 267
l Fold the air intake grid (Fig. 264) back.
l Fold the air conditioning unit back (Fig. 267)
and clean the fins from above with com-
pressed air or cold water.
l Realign pressed own fins with a fin comb.

Fig. 265

l Remove the holding rope (Fig. 265) of the air

conditioning carrier from the snap hook.

138 BOMAG BC 672/772 RB-2, BC 772 RS-2

As required

Edge cutter
5.48 Adjust scrapers and edge
cutter

Scrapers

Fig. 269

l Check the condition of all edge cutters 1 (Fig.

269) on the compactor wheels, replace dam-
aged or worn edge cutters.

Fig. 268
l Check the gap (2) between edge cutters and
compactor wheels.
l Check the condition of all scrapers 1 (Fig. 268)
on the compactor wheels, replace damaged or l At the closest point (2) there must be metal to
worn scrapers. metal contact between the edge cutters and
the shell surfaces of the compactor wheels.
l Check the gap between scrapers and compac-
tor wheels, adjust the gap of the inner scrapers l For adjustment slacken the screws (3) and ad-
to 0 mm. just the edge cutters.

l Adjust the gaps of all other scrapers to 5 mm.

l For adjustment slacken screws 2 (Fig. 268)
i Note
For manufacturing reasons the shell of the com-
and adjust the scrapers to a gap of approx. 0
pactor wheels may not be absolutely round.
or 5 mm.
l Retighten the slackened screws. At the widest points the edge cutters may there-
fore have a few millimetres distance to the shell
l Tightening torque 502 Nm. surface.
l Retighten the slackened screws.
i Note
The tightening torques apply only for screws cov-
! Caution
ered with OKS 240 (copper paste).
Remove refuse residues, cables, ropes, wires
etc. to prevent premature wear of the wheel
shell edge.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 139

As required

5.49 Replacing the wheel caps

! Danger
Danger of accident!
Perform all work only with the engine shut
down and after actuating the emergency stop
switch.
Wear goggles and proper working gloves dur-
ing all work.

Fig. 270
Caution
!

This work shall only be performed by qualified l Drive out the roll pins with hydraulic hammer
specialists. (Fig. 270) and mandrel.

The caps should be replaced at the latest when

the front faces collapse.
Use only new roll pins, as otherwise caps and
pad feet may be damaged.

Required tools/materials:
l Hydraulic hammer with gun handle, tool adapt-
er 22x82 mm (approx. 12 kg)
l Power station with sufficient pressure (max
pressure min. 125 bar)
l Mandrel to drive out, BOMAG PN 570 036 37a
l Mandrel to drive in, BOMAG PN 570 036 36
l new pad foot caps Fig. 271

l new roll pins l Take off the pad foot cap and clean the base
l copper paste thoroughly (Fig. 271).

i Note
If the roll pins are completely filled with hardened
material, driving out the pins may be obstructed. In
this case the inside area of the roll pin must be
cleaned out with an 10 mm impact drill with an ef-
fective drilling length of 100 - 120 mm.

Fig. 272

l Attach the new pad foot cap.

140 BOMAG BC 672/772 RB-2, BC 772 RS-2

As required

l Grease the large roll pin (1) (Fig. 272) with

copper paste and attach it with the groove 5.50 Checking the cutting plates,
pointing up, drive it in with the mandrel. replacing the cutting plates
l Grease the smaller roll pin (2) with copper if necessary
paste and attach it with the groove pointing
down., drive it in with the mandrel.

Fig. 273

l Check the condition of the cutting plates 1

(Fig. 273) on the dozer blade/bucket. If the cut-
ting plate is worn down to the lower edge of the
dozer blade, turn the cutting plate around or
replace it.
l Lift the dozer blade/bucket up and support it
safely.

! Danger
Danger of accident!
Do not work on the lifted and unsupported doz-
er blade/bucket.
l To change the plate unscrew the hexagon
nuts (2). Take the washer (3) off, cut it of with
a torch, if required.
l Knock the hexagon screws (4) and take the
old cutting plate off.
l Before assembling the new cutting plate check
the contact face on the dozer blade, rework it
if necessary.
l Attach the cutting plate, insert the counter-
sunk screws and observe the locating recess,
install the washer and fasten the assembly.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 141

As required

5.51 Fill the provision tank for 5.52 Drain off dirty fluids from
the windscreen washer sys- front and rear frame
tem
Environment
Dispose of dirty fluids environmentally.
l Remove the cover from the front frame.

Fig. 274

l Check the fluid level in both tanks (Fig. 274),

top up if necessary.
l For winter operation fill in the appropriate Fig. 275
amount of ant-freeze agent; refer to the speci- l Unscrew the drain plugs (Fig. 275) from the
fications of the manufacturer of the ant-freeze front frame, catch running out fluids.
agent.
l Seal any leaks, clean the floor and screw the
drain plugs back in.

Fig. 276

l Remove the service door at the tail end of the

machine.
l Unscrew the drain plugs (Fig. 276) from the
rear frame. Catch running out fluids.
l Seal any leaks, clean the floor and screw the
drain plugs back in.

142 BOMAG BC 672/772 RB-2, BC 772 RS-2

As required

5.53 Retightening bolted con-

nections

Fig. 277

l Clean the area around the flutter valve (Fig.

277).
l Operate the flutter valve to drain the water off
the ROPS. Fig. 278

Fig. 279

Bolted connections with OKS 240 (copper

paste) (Fig. 278) and normal bolted connec-
tions (Fig. 279).
l Scrapers M20x1.5 = 502 Nm
l Compactor wheels – planetary drives (L+S)
M20 = 578 Nm
l Bearing blocks for dozer plate bearings M 30 x
2 = 1804 Nm * Strength class for screws with
untreated, non-lubricated surface. Screw qual-
ity designations are stamped on the screw
heads:
8.8 = 8G 10.9 = 10K 12.9 = 12K
The values result in a 90% utilization of the
screw’s yield point at a coefficient of friction μ total
= 0,14.
Compliance with the tightening torques is checked
with torque wrenches.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 143

As required

When using MoS2 lubricants the specified tighten-

ing torques do not apply. 5.54 Conservation
If the engine is to be shut down for a longer period
i Note
of time (e.g. for winter storage), we recommend
Self-locking nuts must always be replaced once the following engine conservation to avoid corro-
they have been unscrewed. sion:
l Clean the engine including the cooling system:
With cold cleansing agent and a water jet or,
even better, with steam cleaning equipment.
l Run the engine warm and shut it down.
l Drain the still warm engine oil and fill in anti-
corrosion engine oil.
l Drain the fluid from the tank, mix it well with
10% anti-corrosion oil and fill this mixture back
in. Instead of mixing anti-corrosion oil to the
fuel the tank may also be filled with injection
pump testing oil with anti-corrosion properties
(e.g. Calibration Fluid B).
l Run the engine for 10 minutes until all lines, fil-
ter, pump and nozzles are filled with the con-
serving mixture and the new engine oil is
distributed to all parts.
l After this test run remove the cylinder head
covers and the lateral cover of the injection
pump, spray the rocker chambers and the
spring chamber in the injection pump with the
mixture of 10% anti-corrosion oil and diesel fu-
el. Then reinstall the hoods and the cover.
l Crank the engine several times by hand (with-
out ignition) in order to spray all combustion
chamber.
l Take the V-belts off and spray the grooves of
the V-belt pulleys with anti-corrosion oil. Re-
move this anti-corrosion oil before taking the
machine back into operation.
l Close the air intake opening on the air filter
and the exhaust opening.

i Note
Depending on the weather condition these con-
serving measures will provide protection for ap-
prox. 6 - 12 months. Before taking the machine
back into operation the conserving mixture must
be drained off and replaced by engine oil of the

144 BOMAG BC 672/772 RB-2, BC 772 RS-2

As required

API-(MIL-) classification, see section fuels and lu-

bricants.
l For longer resting periods all blank surfaces
must be conserved. Piston rods must be pro-
tected with grease.

BC 672/772 RB-2, BC 772 RS-2 BOMAG 145

As required

146 BOMAG BC 672/772 RB-2, BC 772 RS-2

6 Trouble shooting

BC 672/772 RB-2, BC 772 RS-2 BOMAG 147

Trouble shooting

6.1 General notes on trouble

shooting

The following work must only be carried out by

qualified and trained personnel or by the
BOMAG sales service.

Please observe strictly the safety regulations

in chapter 2 of these operating and mainte-
nance instructions.
Faults occur frequently due to the fact, that the
machine has not been properly operated or serv-
iced. Therefore, whenever a fault occurs, read
through these instructions on correct operation
and maintenance. If you cannot locate the cause
of the fault or eliminate it yourself by following the
trouble shooting charts, you should contact our
customer service departments at our branch office
or dealers.

148 BOMAG BC 672/772 RB-2, BC 772 RS-2

Trouble shooting

6.2 Engine problems

Fault Possible cause Remedy

Engine does not Fuel tank empty Fill tank and bleed
start or starts
poorly Batteries not charged or not connected Tighten the terminal clamps on the batter-
ies, check all cable connections

Starter defective Have starter examined by a specialist

Fuel pre-cleaner soiled, control light for clean

water separator lights.

Fuel filter clogged, in winter due to paraf- Change the filter, use winter fuel
fin separation

Start limit temperature not reached Cold starting device (glow plug) defective

Specified valve clearance is not correct Adjusting the valve clearance

Fuel lines leaking Check all line connections for leaks and
tighten the fittings

Air in the fuel system Bleed the fuel system

Fuel lift pump defective Have fuel lift pump examined by a special-
ist

Incorrect start of commencement Have injection pump examined by a spe-

cialist

Engine solenoid not working Have examined by a specialist, replace if

necessary

Wrong engine oil for operating conditions Change oil and oil filter, use recommend-
ed type of oil

Poor starting of Battery power too low, terminal clamps Have the batteries tested, clean the termi-
engine or en- loose or oxidized causing the starter to nal clamps, tighten and cover them with
gine works irreg- turn too slowly. acid-free grease
ularly with poor
power Especially during winter: use of too vis- Use an engine oil complying with the am-
cous engine oil bient temperatures

Start limit temperature not reached Cold starting device (glow plug) defective

BC 672/772 RB-2, BC 772 RS-2 BOMAG 149

Trouble shooting

Fault Possible cause Remedy

Poor starting of Fuel supply too low, fuel system clogged Change the fuel filter, then bleed the sys-
engine or en- by paraffin separation during winter tem, clean the fuel screen in the fuel lift
gine works irreg- pump, check line connections for tight-
ularly with poor ness and tighten fittings. Use winter fuel
power under cold conditions

The specified valve clearance is not cor- Adjusting the valve clearance
rect

Injection nozzles defective Have examined by a specialist

Dry air filter cartridges soiled (engine air change

filter control light in fault monitoring board
lights)

Incorrect start of commencement Have injection pump examined by a spe-

cialist

Engine oil level too high Drain the oil down to the top dipstick mark

Air in the fuel system Bleed the fuel system

poor fuel quality Observe the fuel quality, if necessary

change the fuel

Excessive ex- Engine oil level too high Drain the oil down to the top dipstick mark
haust smoke
Dry air filter cartridges soiled (engine air change
filter control light in fault monitoring board
lights)

Poor compression due to burned or bro- Have compression rings and pistons ex-
ken compression rings or incorrect valve amined by a specialist, adjust the valve
clearance clearance

extremely slanted position of engine Avoid driving with excessive slanted posi-
tion

Start limit temperature not reached Cold starting device (glow plug) defective

Exhaust turbo charger defective Have examined by a specialist

150 BOMAG BC 672/772 RB-2, BC 772 RS-2

Trouble shooting

Fault Possible cause Remedy

Engine over- Radiator soiled Clean the cooling fins

heating, engine
is shut down by Coolant temperature too high (the coolant Clean cooling fins, check coolant level,
the engine con- temperature control light in the fault mon- check radiator fan
trol unit itoring board lights)

Coolant level too low (control light "lack of Fill up coolant, check radiator hoses,
coolant" in the fault monitoring board check radiator, missing or incorrect radia-
lights, the warning buzzer sounds). tor cap on compensation tank

Incorrect engine oil level Catch or drain off engine oil

Injection nozzles defective Have examined by a specialist

Injection pump displacement not correctly Have corrected by a specialist

adjusted

Insufficient cooling air supply to the cool- Remove any clogging from the cooling air
ing fan duct

Too high concentration of anti-freeze and/ Use correct concentration

or coolant additives

Engine oil pres- Oil level too low (engine oil pressure con- Top up oil
sure too low, en- trol light in the fault monitoring board lights
gine is shut up).
down by the en-
gine control unit Leaks in the lubrication system Check fittings on oil lines, lubrication oil fil-
ter and oil cooler for leaks, if necessary
tighten all fittings

extremely slanted position of engine Avoid driving with excessive slanted posi-
tion

The battery Generator speed too low Check the V-belt tension, if necessary re-
charge control place the V-belt
light in the fault
monitoring The generator does not charge the batter- Have examined by a specialist
board lights up ies, because of a defect generator or reg-
during operation ular

BC 672/772 RB-2, BC 772 RS-2 BOMAG 151

Trouble shooting

152 BOMAG BC 672/772 RB-2, BC 772 RS-2

Trouble shooting

6.3 General notes on diagnostic

push button and control
light

!Caution
In case of a fault make a note of the fault code
and inform the BOMAG customer service or
the customer service of the engine manufac-
turer.

Fig. 281
i Note
After 2 seconds = 2 x short flashes of 0.4 sec-
Depending on the significance of the detected fault
onds of the first digit (recogni-
the engine may keep on running, however, with
tion of the EMR* 2) (Fig. 281).
limitations (limp home), whereby the fault lamp will
continually light, or the engine will be shut down after another 2
and the fault lamp will flash. If the warning lamps seconds = 1 x long flash of 0.8 second of
for engine oil pressure control or coolant level also the second digit for the stored
light up, correct the fault (e.g. top up oil, let the en- fault
gine cool down). after another 2
Once the fault is eliminated the fault lamp will go seconds = 1 x short flash of 0,4 second of
out. the third digit for the stored
fault
The diagnostic button provides the possibility to
read out existing faults in form of flashing codes. l Write down the fault code and transmit it to the
customer service department.
Example fault code 211
After output of
fault code = 5 seconds pause, the display
by flashing and permanent
light.)
l If necessary repeat as described above to
read out the next fault code.

Fig. 280

l Press the diagnose button (Fig. 280) for ap-

prox. 1 to 3 seconds, then release the button.

* Electronic engine control

BC 672/772 RB-2, BC 772 RS-2 BOMAG 153

Trouble shooting

154 BOMAG BC 672/772 RB-2, BC 772 RS-2