Bomag BC 670 RB Refuse Compactor Operating instructions Maintenance instructions Manual 00816061 PDF

Operating instructions Maintenance instructions

BC 670 RB S/N 101 570 40 .... › S/N 101 570 41 .... ›

Cummins LTA 10-C352 Cummins MTA11-C350

Refuse Compactor Catalogue number

008 160 61

03/1997

Foreword BOMAG machines are products from the wide product range of BOMAG compaction equipment.

The vast experience of BOMAG as well as modern production and testing methods such as lifetime tests of all important components and most stringent quality demands ensure highest reliability of the machine.

These instructions comprise:

You should only operate this machine after you have been instructed and by observing these instructions.

Please observe strictly the safety regulations.

Please observe also the guidelines of the civil engineering liability association "safety regulations for the operation of road rollers and soil compactors" as well as the relevant accident prevention regulations.

• Safety regulations • Operating instructions • Maintenance instructions • Trouble shooting

For your own safety you should only use genuine BOMAG spare parts.

Using these instructions will

These operating and maintenance instructions are also available in other languages.

We reserve the right for technical modifications without prior notification.

• help to become acquainted with the machine.

• avoid malfunctions caused by unprofessional operation.

Compliance with the maintenance instructions will

• increase the reliability of the machine on the sanitary landfill site,

The spare parts catalogue and the repair instructions are available from your BOMAG dealer against the serial number of your machine.

You can also obtain information about the correct use of our machines on the landfill site from your BOMAG dealer.

The afore mentioned or following notes do not constitute an extension or replacement of the general terms of business of BOMAG.

• prolong the lifetime of the machine, • reduce repair costs and downtimes.

BOMAG will not assume liability for the correct function of the machine

• if the operation is not in accordance with the operating instructions,

We wish you successful work with your BOMAG machine.

BOMAG GmbH & Co. OHG Boppard

• if it is used for purposes other than the ones it is determined for (see safety regulations).

No warranty claims can be lodged for damage resulting from

• operating errors, • insufficient maintenance and • the use of wrong fuels and lubricants.

Please note!

This manual was written for the operator and the service personnel on the landfill site.

Always keep this manual close at hand, e.g. in the tool compartment of the machine or in the container provided for this purpose. The operating and maintenance instruction manual is part of the machine.

BC 670 RB

Printed in Germany Copyright by BOMAG

BOMAG

V

Foreword Please fill in ............................

Machine type (Fig. 1) ............................

Serial No. (Fig. 1 and 2) ............................

Engine type (Fig. 3) ............................

Engine No. (Fig. 3) Fig. 1

Fill in the above listed data when receiving the machine.

Upon receipt of the machine our organization will instruct you about correct operation and maintenance.

Please observe strictly all safety regulations and notes on potential dangers!

Fig. 2

Fig. 3

VI

BOMAG

BC 670 RB

Table of Contents

1 Technical Data

2

2 Safety regulations

6

3 Indicators and control elements

3.1

4 Operation

4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10

5 Maintenance

BC 670 RB

Description of indicators and control elements

16

Tests before starting to operate Starting the engine Driving the machine Emergency exit Operating the dozer blade Schaufel betätigen Dozer blade, emergency control Operating the service brake Shutting the engine down Operating the hydraulic system emergency switch 4.11 Parking on a slope 4.12 Towing the machine 4.13 Transport of machine

28 29 32 33 34 35 36 37 37

5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15

46 47 50 51 52 54 54 55 55 56 57 57 58 59

General notes on maintenance Fuels and lubricants Table of fuels and lubricants Running-in instructions Maintenance chart Checking the engine oil level Checking the coolant level Draining the water separator in the fuel system Checking the V-belt Checking the fuel level Checking the hydraulic oil level Lubricating the dozer blade Checking the machine for damage and leaks Changing engine oil and oil filter cartridge Checking the concentration of anti-freeze agent and the coolant additive 5.16 Changing the coolant filter 5.17 Changing the fuel filter cartridges 5.18 Checking the fastening of the scrapers 5.19 Checking the oil level in the splitter gear 5.20 Checking the oil level in the planetary drives 5.21 Checking the engine fasteners 5.22 Checking, cleaning the radiator and the hydraulic oil cooler 5.23 Servicing the battery, checking the main batBOMAG

39 39 40 41

61 61 63 65 66 66 67 67

VII

Table of Contents tery diconnect switch 5.24 Checking, filling the central lubrication system 5.25 Changing the lubrication cartridge on the dozer blade cylinder 5.26 Greasing hinges on doors and maintenance flaps 5.27 Servicing the air conditioning (summer operation) 5.28 Checking the condition and tension of the generator V-belt, changing the V-belt 5.29 Checking the condition and tension of the refrigerant compressor V-belt, changing the V-belt 5.30 Checking the condition and tension of the blower V-belt, changing the V-belt 5.31 Checking, adjusting the injection valves and the valve clearance 5.32 Checking the fastening of engine / turbo charger / combustion air hoses 5.33 Changing the fuel filter for the cabin heater (diesel) 5.34 Checking, cleaning the oil bath air filter for the cabin heater (diesel) 5.35 Changing the oil in the planetary drive 5.36 Changing the oil in the splitter gear 5.37 Changing the hydraulic oil fine filter 5.38 Checking the coolant pump 5.39 Changing the hydraulic oil 5.40 Changing the coolant 5.41 Draining the fuel tank sludge 5.42 Checking the condition of the articulated joint 5.43 Maintenance work, which has to be performed every 6000 operating hours by a specialist workshop 5.44 Servicing the combustion air filter 5.45 Cleaning the condenser (air conditioning unit) 5.46 Adjusting scrapers and edge cutters 5.47 Replacing the wheel caps 5.48 Checking the cutting plates, replace the cutting plates if necessary 5.49 Tightening the bolted connections 5.50 Checking, changing the starting aid container (ether) 5.51 Checking the provision container of the windscreen washer system

VIII

BOMAG

68 70 72 72 73 76

78 79 81 87 88 89 89 90 91 92 93 95 98 99

99 100 101 102 103 105 106 106 107

BC 670 RB

Table of Contents

6 Trouble Shooting

BC 670 RB

5.52 Conservation

107

6.1 6.2

110 111

General notes Engine

BOMAG

IX

1 Technical Data

BC 670 RB

BOMAG

1

Technical Data

Dim. mm (inch) BC 670 RB

A B B2 B3 3500 3884 3550 3775 (137.8) (152.9) (139.8) (148.6) (3800 (149.6) without edge cutters)

Weights Operating weight CECE Front axle load CECE Rear axle load CECE Drive Engine manufacturer Type Cooling Number of cylinders Rated power ISO 9249 Rated speed Electric equipment, operating voltage Battery, 2 pcs.

Drive system Driven compacting wheels

2

D 1620 (63.8)

H H2 4100 3810 (161.4) (149.9)

H4 1950 (76.8)

K 580 (22.8)

L 8120 (319.7)

kg(lbs) kg(lbs) kg(lbs)

32000(70560) 15283(33699) 16717(36860)

kW rpm V

LTA-10-C325 water 6 231 2100 24

Cummins MTA 11-C350 water 6 252 2100 24

12/180 hydrostatic 4

12/180 hydrostatic 4

V/Ah

BOMAG

BC 670 RB

Technical Data Travel performance data Travel speed Speed range I Speed range II Gradability (depending on soil) Steering angle Oscillation angle Inner track radius Compacting wheels Number of teeth, front Number of teeth, rear Compaction width per wheel side

km/h km/h %

0 ... 4,5 forward, reverse 0 ... 12 forward, reverse 100

+/- degree +/- degree mm(in)

40 15 3090(121.7)

pcs. pcs. mm(in)

60 50 1350(53.1)

Brake Service brake Parking brake Emergency brake

hydrostatic mech./hydrostatic mech./hydrostatic

Steering Type of steering Steering operation

Oscill.-articul. hydraulic

Dozer blade/bucket Height adjustment above ground Height adjustment below ground level Filling capacities Fuel (diesel) Hydraulic oil Engine oil Coolant

BC 670 RB

mm(in)

1200(47.2)

mm

200(7.87)

l(USgal) l(USgal) l(USgal) l(USgal)

500(132.1) 350(92.47)

BOMAG

ca. 36,6(9.670) ca. 44(11.625)

3

Technical Data The following noise and vibration values according to the EC-machine regulation edition (91/368/EEC) were determined at nominal speed of the diesel engine.

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

Noise values The sound level according to enclosure 1, paragraph 1.7.4.f of the EEC-machine regulation is Sound pressure level at the operator’s platformSchalldruckpegel am Bedienerplatz: LpA = 70 dB(A) sound capacity level: LWA = 104 dB(A) These values were determined according to ISO 3744 for the sound capacity level (LWA) or ISO 6081 for the sound pressure level (LpA) at the operator’s stand.

Vibration values The vibration values according to enclosure 1, paragraph 3.6.3 a of the EC-machine regulation are: Vibration effecting the whole body (operator’s seat) The weighted effective value for the acceleration determined according to ISO 2631 part 1 is 0,5 m/sec2.

Hand-arm vibration values The weighted effective acceleration value according to ISO 8662 Part 1 is 2,5 m/sec2.

Technical modifications reserved

4

BOMAG

BC 670 RB

BC 670 RB

BOMAG

5

Safety regulations This BOMAG machine is built in accordance with the latest technical standard and the valid technical rules and regulations. There is, however, a risk of danger for persons and property if:

• the machine is used for purposes other than those it is intended for

• the machine is operated by untrained personnel • the machine is modified or converted in an unprofessional way

• the applicable safety regulations are not observed.

Each person involved in the operation, maintenance and repair of the machine must carefully read and apply these instructions. If necessary, this should be confirmed by obtaining the signiture of the customer.

Furthermore the following regulations and instructions are obviously also valid:

• applicable accident prevention instructions • generally acknowledged safety and road traffic regulations

• country specific regulations

Unintended use Dangers may, however, arise from the machine if it is used by untrained personnel in an unprofessional way or if it is used for purposes other than those mentioned in these instructions.

Starting and operation of the machine in an explosive environment is prohibited.

Who is allowed to work with the machine?

The machine must only be operated by trained and authorized persons which are at least 18 years of age. The responsibilities for the operation of the machine must be clearly specified and complied with.

Persons who are under the influence of alcohol, medication or drugs must not operate, service or repair the machine.

Maintenance and repair tasks require specific knowledge and must therefore only be carried out by trained and qualified personnel.

Conversions and alterations to the machine Unauthorized conversions to the machine are prohibited for safety reasons.

Intended use This machine must only be used for:

• compaction and distribution of refuse on sanitary landfill sites.

Any other use of the machine counts as unintended use and may cause danger for persons or damage to the machine.

• The machine must only be operated with fully

Original parts and accessories have been specially designed for this machine. We would like to point out, that any parts and accessories not supplied by us have not been approved by us. The installation and/or use of such products may impair the active and/or passive driving safety.

The manufacturer expressly excludes any liability for damage resulting from the use of non-original parts or accessories.

functional safety equipment.

• The machine should be checked by an expert once every year.

Safety notes in the operating and maintenance instructions:

• Machines which are used in a contaminated environment (with hazardous effects on environment and/or health) must have special protection equipment.

6

Sections marked like this highlight possible dangers for persons.

BOMAG

BC 670 RB

Safety regulations Starting the machine Sections marked like this highlight possible dangers for machines or parts of the machine.

Before starting Use only machines which have been properly serviced at regular intervals.

Become acquainted with the equippment, the control elements, the working mode of the machine and the area you will be working in.

Sections marked like this provide technical information concerning the optimal economical use of the machine.

Use your personal protective outfit (hard hat, safety boots etc.).

Safety stickers on the machine Do not damage safety stickers (see spare parts catalogue), keep them legible and observe their meaning.

Replace damaged or illegible safety stickers.

Check before mounting the machine if:

• there are persons or obstructions beside or under the machine

• the machine is free of any oily and combustible material

Loading the machine

• all handrails, steps and platforms are free of

Use only strong and stable loading ramps. The ramp inclination must be lower than the gradability of the machine.

grease, oils, fuels, dirt, snow and ice To climb onto the machine use steps and handrails.

Secure the machine against falling or slipping off.

Check before starting, whether:

On the transport vehicle secure the machine against rolling off, slipping about or turning over.

• the machine shows any obvious defects • all protective devices are properly secured in their place

Persons are highly endangered when

• they step or stand under loads being lifted, • they remain in the danger zone of the machine during an ongoing demonstration or during loading.

Towing the machine When releasing the multi-disc brake secure the machine against unintended rolling.

Checking the roll over protection structure (ROPS)

warning horn are in order

• the seat is correctly adjusted Do not start the machine if any gauges, control lights or controls are defective.

Do not take any loose objects with you or fasten them to the machine.

On machines with ROPS you shoul always wear your seat belt!

Starting

In the area of the ROPS fastening the frame must not be distorted, bent or cracked.

The ROPS must not show any signs of rust, damage, hairline cracks or open fractures.

Neither must any additional parts be welded or bolted on nor must any holes be drilled without the permission of the manufacturer, since this would impair the strength of the structure.

BC 670 RB

• steering, brakes, control elements, lighting and

Start and operate the machine only from the operator’s seat To start the machine set all control levers to "neutral position".

After starting check all gauges.

BOMAG

7

Safety regulations Starting with jump leads

• have the power shut off.

Connect plus with plus and minus with minus (earth cable) - always connect the earth cable last and disconnect it first! Wrong connection will cause severe damage in the electric system.

Operate the machine only from the operator’s seat.

Never start the engine by bridging the electrical connections on the starter, because the machine would probably start to move immediately.

Do not climb onto or off the machine while driving.

Starting in closed rooms

Do not use the machine to transport persons.

Exhaust fumes are highly dangerous! When starting or operating the cabin heater in closed rooms you should therefore ensure an adequate supply of fresh air!

Do not use the dozer blade to transport persons!

Danger to life!

Driving the machine

Stop the machine if you notice unusual noises or the development of smoke. Investigate the cause and have the fault corrected.

Persons in the endangered area If the machine has turned over and the cabin door is jammed, the rear window may be used as an emergency exit. To do so pull the rip cord of the rubber seal and push the window pane out.

Before starting or resuming work and especially when driving backwards, check that there are no persons or obstructions in the endangered area.

If necessary give warning signals. Stop work immediately if persons remain in the danger area despite the warning.

Do not step or stand in the articulation area of the machine when the engine is running. Risk of squashing!

Driving In events of emergency or in case of danger actuate the emergency stop switch immediately.

Do not use the emergency stop switch as a service brake. Only restart the machine after the danger, that has caused the actuation of the emergency stop, has been eliminated.

Keep the cabin doors closed.

Do not adjust the seat while driving.

Select the travel directions forward/reverse only while the machine is standing.

Moving other vehicles with the dozer blade is prohibited.

Match the speed of the machine to the working conditions.

Always allow loaded transport vehicles to pass.

Switch the lights on when the visibility is poor. Keep away from edges and embankments.

Do not use the cabin heater in service workshops and parking halls.

Driving on slopes and gradients Do not drive up and down gradients, which exceed the max. gradability of the machine. when driving on slopes drive carefully straight up or down the slope. Change to the lower speed range before approaching the slope.

Wet and loose ground reduces the ground adhesion of the machine on inclinations and slopes.

Higher risk of accident!

Parking the machine Park the machine on level and firm ground.

If the machine has come in contact with highvoltage power lines:

Before leaving the machine:

• do not leave the operator’s stand • warn others from coming too close to the ma-

• lower the dozer blade to the ground • return the travel lever to neutral position • shut the engine down and pull the ignition key

chine or touching it

• if possible drive the machine out of the danger

out.

zone 8

BOMAG

BC 670 RB

Safety regulations • lock the cabin Do not jump off the machine, use access steps and hand rails.

Always secure parked machines, which could be in the way, with appropriate measures.

Keep unauthorized persons away from the machine.

Do not perform maintenance work with the machine driving or the engine running.

Park the machine on level and firm ground.

Lower the dozer blade to the ground.

Pull the main battry switch off.

Pull the key out of the ignition switch.

Parking on slopes and gradients

Lock the articulated joint with the articulation lock.

Secure the wheels with metal chocks.

Working on hydraulic lines

Filling the fuel tank Do not breath in fuel fumes.

Refuel only with engine and cabin heater shut down.

Do not refuel in closed rooms.

No open fire, do not smoke.

Do not spill any fuel. Catch running out fuel, do not let it seep into the ground.

Mix diesel fuel and gasoline (no supergrade gasoline) only inside the tank. Fill in the necessary quantity of gasoline, then add the diesel fuel.

Gasoline - diesel mixes are as inflammable as gasoline!

Fire protection measures Become acquainted with the location and the handling of fire extinguishers. Observe all fire alarm and fire fighting possibilities.

Maintenance Maintenance work must only be carried out by qualified and authorized personnel.

Observe the maintenance tasks described in the operating and maintenance instructions, including the exchange of parts.

For overhead service and assembly work use the provided acess installations or any other safe access ladders and work platforms. Do not use machine parts as access steps.

For machines, which have been used in contaminated environments, observe the relevant national or local safety instructions when carrying out service work.

BC 670 RB

To depressurize the hydraulic system lower the dozer blade to the ground and shut the engine down.

Depressurize the hydraulic system before starting to work. Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury. In case of injuries caused by high pressure oil immediately consult a doctor, as otherwise severe infections may result.

Do not stand in front of or behind the wheels during adjustment work in the hydraulic system.

Do not change the setting of high pressure relief valves.

Drain hydraulic oil at operating temperature danger of scalding!

Catch running out hydraulic oil and dispose of environmentally Always catch and dispose of biological hydraulic oils separately Do not start the engine after draining off the hydraulic oil.

Once all work is completed (the system still depressurized!) check all connections and fittings for leaks.

Changing hydraulic hoses Hydraulic hoses must not be mixed up by mistake.

All hydraulic hoses must be inspected visually at regular intervals.

Hydraulic hoses must be immediately replaced if:

• the outer layer is worn down to the metal lining

BOMAG

(e.g. chafing, cuts, cracks)

9

Safety regulations • embrittlement of the outer layer (development of cracks in the hose material)

• deformation in pressureless and pressurized condition, which is not in accordance with the original shape of the hose

• deformation in bends, e.g. squeezing, sharp

Working on components of the electrical equipment Before working on electrical equipment disconnect the battery and cover it with insulating material.

Do not use fuses with higher Ampere ratings and do not use wire to repair a fuse. Fire hazard!

bends, layer separation, development of blisters

• leakages • installation faults • separation of the hydraulic hose from the fitting • corrosion of the fitting, which impairs the function and the strength

• damage or deformation of the fitting, which impairs the function and strength of the hose/hose connection

• expiration of the storage and utilization period Only genuine BOMAG hydraulic hoses ensure that the correct type of hose (pressure range) is used at the right place Working on the engine

Working on the battery When working on the battery do not smoke, do not use open fire.

Do not let hands or clothes come in contact with acid. In case of injuries caused by acid flush of with clear water and consult a doctor.

Metal objects (e.g. tools, rings, wrist watches) must not contact the battery poles - danger of short circuit and burns!When recharging maintenance free batteries remove the plugs to avoid the accumulation of explosive gases.

When using an external battery to start the machine follow the respective instructions.

Dispose of old batteries environmentally.

Drain the engine oil at operating temperature danger of scalding!

Wipe off spilled oil, catch running out oil and dispose of environmentally.

Switch the charging current off before removing the charge clamps.

Ensure good ventilation, especially when charging the battery in a closed room.

Store used filters and other oily materials in a separate, specially marked container and dispose of environmentally.

Working on the fuel system

Working on the cooling system

No open fire, do not smoke, do not spill any fuel.

Check the coolant level or top up coolant only if the engine has cooled down and is not in operation danger of scalding! Only when the engine is stopped and has cooled down you may drain the coolant off and fill in new coolant. Catch the coolant and dispose of environmentally.

Catch running out fuel, do not let it seep into the ground and dispose of environmentally.

Working on the cold start system (if installed)

Faults on the air conditioning system must only be repaired by specialized personnel.

Starting fluid /ether) is easily inflammable.

Do not burn or damage used up or apparently empty starting aid cans, but dispose of environmentally.

Do not inhale any fuel fumes.

Working on the air conditioning system When working on the air conditioning system or the ventilation secure yourself with a safety belt.

Do not weld near or on the air conditioning system.

Danger of explosion!

Do not clean the air conditioning system with a hot water jet. Danger of explosion!

Do not let refrigerant escape into the atmosphere, but dispose of environmentally.

10

BOMAG

BC 670 RB

Safety regulations Working on the dozer blade Lower the dozer blade to the ground and shut the engine down.

Do not open the grease cartridge on the dozer blade, after use it will still be pressurized for some time. In case of damage caustic fluid may run out.

Wash off immediately with lots of clean water.

Cleaning Do not clean the machine while the engine is running.

Do not use gasoline or other combustible substances for cleaning purposes.

When using high pressure steam cleaning equipment do not subject electric components to the direct water jet or cover them before hand.

Do not guide the cleaning jet into the exhaust pipe.

After maintenance work Reinstall all protective devices after completing the maintenance work.

Repair Attach a warning tag to the steering wheel if the machine is defective.

In case of welding work on the machine remove the main battery switch.

Repairs must only be carried out by qualified and authorized persons. Use our repair instructions.

Test Depending on the type of applicational and the operating conditions vibratory equipment has to be examined by a specialist whenever required, but at least once every year.

BC 670 RB

BOMAG

11

3 Indicators and Controls

Please read this section thoroughly before operating 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 descriptions of the individual operating steps.

BC 670 RB

BOMAG

13

Indicators and control elements

Fig. 1

14

BOMAG

BC 670 RB

Indicators and control elements

1 Fuel level gauge 2 Hydraulic oil temperature gauge 3 Operating hour meter 4 Socket, 24V 5 Socket, 24V 6 General warning light 7 Coolant temperature gauge 8 RPM-meter 9 Control light, speed range I 10 Control light, travel speed range 11 Control light, travel lever "0"-position 12 Push button cold start system with control light 13 Ignition switch 14 Brake warning light 15 Rotary switch, front working head lights 16 Rotary switch, rear working head lights 17 Rotary switch, front windscreen wiper 18 Push button, front windscreen washer system

19 Rotary switch, rear windscreen wiper 20 Push button, rear windscreen washer system 21 Push button central lubrication system with control light 22 Rotary switch for seat heating 23 Rotary switch for cabin heater 24 Emergency stop switch, hydraulic system 25 Monitoring board 26 Lever for fresh air opening 27 not used 28 Rotary switch for speed ranges 29 Travel lever (forward/reverse) 30 Lever for dozer blade control 31 Lever for bucket control* 32 Drive pedal 33 Brake pedal/service brake 34 Warning horn 35 Steering wheel adjustment lever 36 Air distribution nozzle

* Option

BC 670 RB

BOMAG

15

Indicators and control elements

3.1 Description of indicators and control elements

Shut the engine down immediately!

No. 1 = Fuel level gauge shows the filling level in the fuel tank

If the engine is not shut, an automatic monitoring system will shut it down after approx. 20 seconds.

No. 8 = RPM-meter shows the engine speed.

Scale value x 100 = engine speed in revolutions per minute

Never drive the fuel tank empty, because this would required bleeding of the entire fuel system.

No. 2 = Hydraulic oil temperature gauge shows the temperature of the hydraulic oil, the operating temperature is approx. 70...80˚C No. 3 = Operating hour meter counts the operating hours when the engine is running, all maintenance work must be performed according to the operating hours of the machine.

No. 4 = Socket, 24V Permanent current

No. 9 = Control light, speed range I lights up = with the rotary speed range switch (28) in position "I" No. 10 = Control light II travel speed range lights up = with the rotary speed range switch (28) in position "II" No. 11 = Control light, travel lever "0"-position lights up = with the travel lever (29) in position "0" goes out = when actuating the travel lever to any direction

No. 5 = Socket, 24V Permanent current No. 6 = General warning light lights up = before and during starting the engine or in case of a fault during operation, shut the engine down.

To detect the fault, check the monitoring board.

No. 7 = Coolant temperature gauge green sector = normal coolant temperature red sector = the general warning light 6 (Fig. 1) lights up, the warning horn sounds. The coolant control light in the monitoring board lights up.

16

BOMAG

BC 670 RB

Indicators and control elements light, cold start system control light as well as engine oil pressure control light and charge control light in the monitoring board go out immediately. The brake warning light goes out when charge pressure is available. The control lights for speed ranges I and II and the control light for "0"-position of travel lever stay on.

Fig. 2

Before starting to work run the engine warm for a short while.

Do not run the engine at idling speed for longer than 10 minutes.

No. 12 = Push button cold start system with control light

When actuating this push button, an exactly dosed quantity of liquid starting aid is injected during the starting process. The cold start system is electronically released at low temperatures. lights up = with the ignition switch in position "II", when operating the push button

Actuate the push button only once during a starting process. goes out = after starting, after releasing the push button No. 13 = Ignition switch Position "0" = ignition off, pull the key out, engine stop Position "I" = ignition on; general warning light (6), speed range indicator light (9 or 10), control light for travel lever in "0"-position (11), cold start system control light (12), brake warning light (14) as well as charge control light (g) and engine oil pressure control light (j) in the monitoring board light up.

Position "II" = turn further against spring pressure, operate the starter until the engine starts, release the ignition key. General warning BC 670 RB

No. 14 = Brake warning light lights up = with the ignition switch in position ’I’ and the engine stopped, when starting the engine, when actuating the emergency stop switch for the hydraulic system, when operating the brake pedal for longer than 3 seconds. goes out = after starting the engine, after unlocking the emergency stop switch No. 15 = Rotary switch, front working head lights Position "0" = lights off Position "symbol" = working lights on

The front working lights can be switched on and off without the ignition key.

No. 16 = Rotary switch, rear working head lights Position "0" = lights off Position "symbol" = ignition switch position "I", working lights on

BOMAG

17

Indicators and control elements No. 17 = Rotary switch, front windscreen wiper Position "0" = windscreen wiper off Position "symbol" = ignition switch position "I", windscreen wipers on No. 18 = Push button, front windscreen washer system Actuate = ignition switch position "I", the front windscreen will be sprayed with water as long as the push button is actuated.

No. 19 = Rotary switch, rear windscreen wiper Position "0" = windscreen wiper off Position "symbol" = ignition switch position "I", windscreen wipers on No. 20 = Push button, rear windscreen washer system Actuate = ignition switch position "I", the rear windscreen will be sprayed with water as long as the push button is actuated.

depress 1 second

lights 2 seconds flashes 1 second on 1 seconds off flashes 0,5 seconds on 0,5 seconds off flashes 0,5 seconds on 1 second off goes out after 2 seconds

= to reset a malfunction.

The flashing of the control light changes to a permanent light. = with the ignition switch in position "I".

= malfunction of the lubricant pump

= grease container empty

= malfunction of the central lubrication system

= central lubrication working correctly with ignition switch in position "I".

No. 22 = Rotary switch for seat heating Position "I" = heating switched off Position "II" = heating switched on

Fig. 3

No. 21 = Push button central lubrication system with control light depress 2 seconds = the central lubrication system starts an additional lubrication cycle.

18

BOMAG

BC 670 RB

Indicators and control elements operate

Deactivate/ unlock

= push the button completely down, it will automatically lock in end position. The brake warning light 14 lights up. = turn the button to the right and release it.

After unlocking the emergency stop switch move the travel direction switch to "0"-position and select the travel direction again.

Fig. 4

No. 23 = Rotary switch for cabin heater

The air conditioning blower or the ventilation system must always run at least with lowest speed, to make sure, that there is a slight overpressure in the cabin.

Position "0" = cabin heater switched off Position "I" (blue) = blower switched on (cold air) Position "II" (red) = cabin heater switched on, heat regulation of the air flow by turning in direction of arrow (step 1 to 4).

The green light in the rotary switch lights up.

In case of overheating the green light in the rotary switch flashes at regular intervals. Eliminate the cause and switch the cabin heater back on.

No. 24 = Emergency stop switch, hydraulic system

Fig. 5

No. 25 = Monitoring board • In case of a fault a red control light in the monitoring board and the general warning light no. 6 light up.

Control light a = not used b = hydraulic oil filter, (charge oil filter) change the hydraulic oil filter, check the hydraulic system if it lights up too early. c = hydraulic oil level, Top up hydraulic oil, examine the machine for leakages and seal all hydraulic leaks.

Actuation only in events of emergency during operation.

Do not use as service brake. The braking deceleration is very high.

BC 670 RB

BOMAG

19

Indicators and control elements d

= hydraulic oil return flow filter, filter dirty.

Do not continue to operate the machine, as this may cause damage in the hydraulic system.

Inform the after sales service of BOMAG. e = engine air filter clean or change the air filter element f = malfunction of the hydraulic system Fig. 6

Do not continue to operate the machine, as this may cause damage in the hydraulic system.

Inform the after sales service of BOMAG. g = charge control light battery is not being charged check the V-belt h = coolant level too low top up with coolant check the coolant circuit for leakages. i = hydraulic oil temperatur ›92 ˚C, Run the diesel engine at idling speed until the warning light goes out, clean the hydraulic oil cooler j = engine oil pressure, check the engine oil level; top up engine oil, if the engine oil pressure warning light stays on do not continue to operate the machine, as this may damage the diesel engine.

Inform the after sales service of BOMAG k = hydraulic oil level (minimum level), seal all leakages, top up hydraulic oil. l = Coolant temperature, clean the radiator, if necessary change or top up coolant.

20

If one of the control lights b to g lights up, the general warning light no. 6 will also light.

Fig. 7

If one of the control lights h and i lights up, the general warning light no. 6 will also light and the warning horn will sound.

BOMAG

BC 670 RB

Indicators and control elements

Fig. 8

Fig. 10

If one of the control lights j, k and l lights up, the general warning light no. 6 will also light, the warning buzzer will sound and the engine will be automatically shut down after 20 seconds.

No. 28 = Rotary switch I. and II. travel speed range Position "I" = 1. range, working speed, the control light (9) lights up.

Position "II" = 2. range, transport speed range, the control light (10) lights up, e.g. to drive to and from the place of use and for light work.

Fig. 9

No. 26 = Lever for fresh air opening • if the windows are steamed up and the heating is switched on keep the lever in "front" position until the windows are clear. Then shift the lever "back", to close the fresh air supply.

No. 27 = not used

No. 29 = Travel lever (forward/reverse) Position "0" = to start the engine, the control light (11) lights up Position "I" = forward travel, the control light goes out.

Position "II" = reverse travel, at the same time the reversing warning horn will sound and the control light will go out.

Danger of accident!

Before setting off in reverse direction make sure that the travel area behind the machine is save to drive.

When the travel lever is set to "0"-position (neutral position) the machine is braked automatically.

BC 670 RB

BOMAG

21

Indicators and control elements Position "III" = bucket down Position "IV" = bucket up Float position = press button (a), at the same tome press the lever (e.g. to level the area during reversing)

Fig. 11

No. 30 = Lever for dozer blade control Position "0" (Neutral position) = no actuation, the lever returns automatically to "0"-position Position "I" = dozer blade down Position "II" = pull the locking disc (a), shift the lever forward and lock it. Dozer blade, float position (e.g. to level the site surface during reverse travel) Position "III" = to lift the dozer blade

Fig. 13

No. 32 = Drive pedal (throttle control): Position "0" = engine running at idling speed Position "I" = high idle/full load

When taking the drive pedal back, the machine will automatically be braked.

Fig. 12

No. 31 = Lever for bucket control * Position "0" (Neutral position) = no actuation, the lever returns automatically to "0"-position Position "I" = tipping of bucket for filling Position "II" = tipping of bucket for emptying * Option

22

BOMAG

BC 670 RB

Indicators and control elements

Fig. 14

Fig. 15

No. 33 = Brake pedal, service brake Position "I" braking = kick the brake pedal down Position "II" release = release the brake pedal

Fuses in the electric junction box, right hand side outside the cabin Capacity of fuse as stated on the old fuse

When the travel lever is set to "0"-position (neutral position) the machine is braked automatically.

No. 34 = Warning horn No. 35 = Steering wheel adjustment lever

Danger of accident!

Do not adjust during travel To adjust the position • loosen the screw • adjust the steering wheel accordingly • tighten the screw No. 36 = Air distribution nozzle

Fire hazard!

Do not use fuses with a higher Ampere rating and do not repair a fuse with a piece of wire.

Fuses (1) 40A (2) 30A (3) 25A (4) 10A (5) 20A (6) 20A (7) (8) (9) 25A (10) 25A (11) (12) (13) 10A (14) 10A (15) (16) 15A (17) 15A (18) 10A

BC 670 RB

BOMAG

= F01 main fuse = F05 sockets = F40 cabin heater = F42 cabin light = F18 prefuse for front working head lights = F22 rear working head lights = spare = spare = F33 air conditioning unit = F34 circuit breaker for air conditioning unit = spare = spare = F16 central lubrication system = F52 dozer blade = spare = F19 working head lights front left = F20 working head lights front right = F21 dash board light

23

Indicators and control elements

Fig. 16

Fig. 17

Main battery switch Position ’I’ = normal position, operation Position ’II’ = disconnects the battery from the machine electrics in case of cable burns, fire in the engine compartment and as a protection against unauthorized use.

Adjusting the seat • Lever 1 (Fig. 17), back rest adjustment • Push button (2), height adjustment

Except in events of emergency the after running period of the heating of 2 minutes must be taken into consideration.

Pneumatically operated with a compressor. The seat can be raised with the ignition switch in position "I".

• Lever (3), for removal and installation (seat + arm rest console) • Lever (4), seat adjustment forward/backward (seat without arm rest console) • Rotary knob (5), adjustment of arm rest inclination • Seat belt (6)

Danger of accident!

Do not adjust the seat belt while driving.

24

BOMAG

BC 670 RB

Indicators and control elements air outlet nozzles (3) to the desired direction. Once the cabin has cooled down switch the blower to lowest range.

If no cooling effect can be noticed with the air conditioning ventilation switched on, set the toggle switch to "Off".

Perform trouble shooting. switch off = turn the rotary switch (1) to "0", set the toggle switch (2) to "Off".

Fig. 18

Air conditioning* If the warning buzzer sounds continuously when the air conditioning unit is in operation, switch the air conditioning unit off and clean the condenser.

Switch the air conditioning unit on at least once every month with the engine running (approx. 10 minutes) (even during winter).

The air conditioning system works with filtered fesh air and circulation air.

The high proportion of fresh air produces a slight overpressure in the cabin, which keeps dust and dirt out.

Keep cabin door and windows closed while the air conditioning system is working.

Ventilation switch on

= turn the rotary switch 1 (Fig. 18) to blower range 1 to 3

Blower range 4 is not connected switch off = turn rotary switch (1) to position "0" Air conditioning ventilation switch on = start the engine, operate the toggle switch (2) so that the red dot is visible, set the rotary switch to the desired blower range 1 to 3, turn the slewable

Fig. 19

Ventilation system switch off = turn rotary switch to position "0" switch on = rotary switch position "I", lowest power, rotary switch position "II", medium power, rotary switzch position "III", full power.

Always run the ventilation at lowest range to generate an overpressure in the cabin.

* Option

BC 670 RB

BOMAG

25

Indicators and control elements

Fig. 20

Fig. 21

Coolant heating in the cabin switch off = set the control thermostat 3 (Fig. 20) to position "0", turn the rotary switch for the blower (2) to the left to position "Off". switch on = adjust the desired cabin temperature on the control thermostat (3) (heat regulation, open the circulation opening (4) (cabin air) or the fresh air opening with the control cable (1), switch the rotary switch for the blower (2) to the right to range 1or range 2.

Main fuse, battery 250A = (F00)

The main fuse is located in the battery compartment.

If the cabin windows are steamed up pull the control cable (1) to open the fresh air supply.

When working with the refuse compactor keep the circulation opening open.

26

BOMAG

BC 670 RB

4 Operation

Please read section 3 Indicators and Control Elements thoroughly before operating the machine if you are not yet fully familiar with the indicators and control elements of the machine.

All indicators and control elements are described in detail in this chapter.

BC 670 RB

BOMAG

27

Operation • Check the inner sides of the compactor wheels,

4.1 Tests before starting to operate Please observe the safety regulations in these operating and maintenance instructions.

Before each working day: • Check the engine oil level • Check the hydraulic oil level

remove wires, cables, ropes etc.

Refer also to the maintenance instructions in this manual.

Top up missing lubricants according to the maintenance instructions.

Hydraulic systems, which are filled with Panolin HLP Synth. 46 must be refilled with the same oil.

For any other ester based oils consult the lubrication oil experts of the respective oil manufacturer.

• Check the coolant level • Check the oil level in the splitter gear

Fig. 1

Fire hazard!

Do not refuel in closed rooms.

• Check the fuel level.

• Drain the water from the fuel prefilter (as required) • Check fuel tank and lines for leaks.

• Inspect engine and machine visually.

• Check screw connections for tight fit.

• Check the function of the brake.

Do not use the emergency stop for this purpose.

• Check the function of the steering system • Check the scrapers for the compactor wheels • Check the scrapers for the compactor wheels

• Turn the main battery switch (Fig. 1) to position "I".

Remove refuse, cables, ropes, wires etc. to avoid premature wear of the wheel shell edges.

• Check the provision container of the windscreen washer system.

• Check the adjustment of the mirrors.

Clean windows and mirrors as required.

28

BOMAG

BC 670 RB

Operation

4.2 Starting the engine

In this section it is assumed that the operator is fully acquainted with the functions of the various control elements on the machine.

Danger of accident!

Always wear the seat belt and adjust it correctly.

Fig. 2

• Check, whether the emergency stop switch 24 (Fig. 2) is unlocked.

Do not operate the drive pedal before and during starting.

Fig. 1

• Set the control levers 31 and 29 (Fig. 1) to position "0".

Fig. 3

• Turn the ignition switch 13 (Fig. 3) to position ’I’.

• With the ignition switch in position ’I’ the following control lights light up:

BC 670 RB

BOMAG

29

Operation • The brake warning light goes out when charge pressure is available. The control lights for speed ranges I and II and the control light for "0"-position of travel lever stay on.

Before starting to work run the engine warm for a short while.

Do not run the engine at idling speed for longer than 10 minutes.

Fig. 4

• General warning light 6 (Fig. 4), indicator light for speed range ’I’ or ’II’ (9) and (10), control light for travel lever in "0"-position (11) and brake warning light (14) as well as the following control lights in the monitoring board:

Starting at low temperatures • Set the control levers 31 and 29 (Fig. 1) to position "0".

• Check, whether the emergency stop switch 24 (Fig. 2) is unlocked.

Do not operate the drive pedal during cold starting.

Fig. 5

• Charge control light g (Fig. 5) and engine oil pressure control light j light up.

• Turn the ignition switch to position ’II’, the engine will start.

Fig. 6

• Turn the ignition key 13 (Fig. 6) through position Operate the starter for max. 20 seconds. If the engine does not start, repeat the starting procedure after a pause of one minute.

• Once the engine ignites turn the ignition switch back to position "I".

• General warning light as well as engine oil pressure control light and charge control light in the monitoring board go out immediately.

30

’I’ to position "II". The engine will start.

• During this process press the push button (12) of the cold start system.

Actuate the push button only once during a starting process.

BOMAG

BC 670 RB

Operation • Set the control levers 31 and 29 (Fig. 1) to The cold start system is electronically released at low temperatures.

When actuating this push button, an exactly dosed quantity of liquid starting aid is injected during the starting process.

position "0".

• Check, whether the emergency stop switch 24 (Fig. 2) is unlocked.

• Turn the ignition switch to position ’II’. The engine will start.

• After starting disconnect the minus poles (earth cable) first and the plus poles last.

Do not drive with full engine speed before the operating temperature is reached.

At extremely low temperaturesthe hydraulic oil filter control light in the monitoring board may light up, but must go out again after approx. 15 minutes.

When this control light lights up, drive the machine with half power until it goes out.

Starting with jump leads

For jump starting two external batteries are required, one for each main battery.

Fig. 7

• When starting with external batteries connect the plus poles (Fig. 7) and the minus poles (earth cable) after.

Wrong connection will cause severe damage to the electrical system.

BC 670 RB

BOMAG

31

Operation

4.3 Driving the machine

Danger of accident!

Wet and loose soils reduce the ground adhesion of the machine on gradients considerably.

Soil conditions and weather influences impair the gradability of the machine.

Before setting off make sure that the travel area is save to drive.

Drive only with the seat belt on.

• Adjust the steering wheel to the driver and lock it in the required position.

Fig. 2

• Move the travel lever 29 (Fig. 2) to the desired travel direction.

Position ’I’ = forward Position ’II’ = reverse

The control light for travel lever in ’0’-position goes out in position ’I’ and ’II’.

Fig. 1

• Switch the speed range selector switch 28 (Fig. 1) to the desired speed range.

Position ’I’ = working speed Position ’II’ = fast speed, e.g. to drive to the work place Fig. 3

• Pull the lever 31 (Fig. 3) for the dozer blade control back to position ’III’ and lift the dozer blade slowly off the ground.

Symbol tortoise, speed range ’I’ (9) or symbol rabbit, speed range ’II’ (10) llight up.

Danger of accident!

Before setting off make sure that the travel area is save to drive.

During travel the cabin door must be kept tightly closed.

32

BOMAG

BC 670 RB

Operation

4.4 Emergency exit If the machine has turned over and the cabin door is jammed up, the right hand front cabin window can be used as an emergency exit.

Fig. 4

• Operate the drive pedal for the engine speed control 32 (Fig. 4).

During reverse travel a warning signal will sound.

When taking the drive pedal back, the machine will automatically be braked.

Fig. 1

• Pull the rip cord (Fig. 1), push the window pane out of the rubber seal and climb out through the opening.

BC 670 RB

BOMAG

33

Operation

4.5 Operating the dozer blade

Danger of accident!

Do not use the dozer blade to transport persons.

Moving other vehicles with the dozer blade is not permitted!

Fig. 2

• Move the dozer blade lever 31 (Fig. 2) to float position "II", to do so lift the locking disc (a) up and shift the lever through position "I" to position "II" and lock it.

• To disable the float position lift the locking disc up and return the lever to position "0".

The lever returns automatically to ’0’-position.

Fig. 1

• Lever 31 (Fig. 1) for dozer blade up and down.

Positon ’0’

Position "I" Position "III"

= neutral position, the lever returns automatically to ’0’-position = dozer blade down = to lift the dozer blade

Always lower the dozer blade to the ground before shutting the engine down.

34

BOMAG

BC 670 RB

Operation

4.6 Schaufel betätigen*

Danger of accident!

Do not use the dozer blade to transport persons.

Moving other vehicles with the dozer blade is not permitted!

Always lower the dozer blade to the ground before shutting the engine down.

Fig. 3

• Press the button (arrow) and move the lever 31 (Fig. 3) forward to reach the float position for the bucket.

Fig. 1

• Move the lever 31 (Fig. 1) to left or right to opeb or close the bucket.

Fig. 4

• To disable the float position shift the lever 31 (Fig. 4) to position "0".

Fig. 2

• Move the lever 31 (Fig. 2) to the front or the rear to lower or raise the bucket.

* Option

BC 670 RB

BOMAG

35

Operation

4.7 Dozer blade, emergency control

down

= press the valve with a screw driver or a punch to position "II" .

After operation the lever returns automatically to middle position.

In case of a malfunction in the electronic system for the dozer blade control the blade can be manually lifted and lowered when the engine is running.

The electrical control PVEH has an integrated fault monitoring system. The light emitting diode above the plug lights green during normal operation and changes to red in case of a fault.

Taking into service after a fault: Before taking the system into operation the voltage supply must be interrupted.

In case of a fault the valve block can be operated manually.

In case of a fault shut the engine down and start it again.

If the fault is still there operate the dozer blade manually on the valve block.

Danger of accident!

In case of a malfunction in the dozer blade control drive the machine immediately to the workshop, paerform trouble shooting and have the fault repaired. Do not continue to work with the machine!

• Remove the lower rear maintenance door.

Fig. 1

For the dozer blade up = press the valve with a screw driver or a punch to position "I" (Fig. 1).

36

BOMAG

BC 670 RB

Operation

4.8 Operating the service brake

4.9 Shutting the engine down

Fig. 1

Fig. 1

• Kick the brake pedal 33 (Fig. 1) down. The

• Take the drive pedal 32 (Fig. 1) (throttle control)

machine is braked hydrostatically and the multidisc brakes will close with a short delay.

If the brake pedal is actuated longer than 3 seconds, the brake warning light will light and the multi-disc brake will close.

back to decelerate the engine to idling speed.

Releasing the drive pedal has a braking effect on the machine.

Fig. 2

• Set the travel lever 29 (Fig. 2) (forward/reverse) to ’0’ (neutral position). The control light for 0-position of the travel lever (11) lights up.

BC 670 RB

BOMAG

37

Operation

Fig. 3

Fig. 5

• Set the rotary speed range selector switch 28

• Turn the ignition switch 13 (Fig. 5) to position ’0’

(Fig. 3) to position ’I’ or ’II’.

(’Engine Stop’ position). The ignition is switched off.

Secure the machine against unauthorized use, pull the ignition key off, lock the cabin doors, switch the main battery switch off and pull the key out.

Fig. 4

• Shift the lever 31 (Fig. 4) for the dozer blade control forward to position ’I’ and lower the dozer blade slowly to the ground.

Do not shut down the engine suddenly from full load, but let it idle for at least 3 to 5 minutes for temperature equalization.

38

BOMAG

BC 670 RB

Operation

4.10 Operating the hydraulic system emergency switch

4.11 Parking on a slope

When parking on a gradient with the engine running, actuate the emergency stop to avoid unintended rolling.

Danger of accident In events of emergency and in case of danger the emergency stop switch must be actuated immediately. Only unlock the emergency stop switch after the danger, that has caused the actuation, has been eliminated.

Fig. 1

• Press the button of the emergency stop switch 24 (Fig. 1) down, it locks in depressed position.

The brake warning light lights up and the brake is closed.

Do not use the emergency stop switch as service brake. The braking deceleration is very high. If the brake is used very often, the discs of the multi-disc brakes will wear off.

• Unlock the button by turning it clockwise • Reselect the travel direction

BC 670 RB

BOMAG

39

Operation

4.12 Towing the machine

Fig. 3

• Rear towing hooks (Fig. 3/arrow) Fig. 1

• Slacken all eight high pressure relief valves on

Hang the not needed towing ropes on the top hangers.

the travel pumps for approx. one turn (Fig. 1).

Turn only the larger hexagon (Fig. 1/arrow).

Do not deadjust the pressure adjustment screw, as otherwise the high pressure relief setting has to be readjusted.

Releasing the brake

Fig. 4

Fig. 2

After towing retighten all eight high pressure relief valves with a tightening torque of 10010 Nm.

40

Danger of accident When releasing the multi disc brakes secure the machine against unintended rolling.

• Open the access doors on the right hand tool compartment.

• Unscrew the locking screw 3 (Fig. 4).

• Move the lever (2) in direction of arrow.

BOMAG

BC 670 RB

Operation • Operate the pump lever (1) until the multi disc

4.13 Transport of machine

brakes are released. The machine can now be towed.

Danger of accident Use only strong and stable loading ramps.

Make sure that no persons are endangered if the machine should turn over or slip off.

Always use shackles on the lifting points to load or lash down the machine.

Use only suitable lifting gear to lift the machine.

Weights: see technical data Lash the machine down so that it is properly secured against rolling off, slipping and turning over.

After the transport release the articulation lock and fix it in the receptacle.

Unlock the emergency stop switch.

Secure the lever (2) with the locking screw.

Lift the dozer blade off the ground before towing.

Lifting the dozer blade and releasing the brake

Fig. 5

Danger of accident When releasing the multi disc brakes secure the machine against unintended rolling.

Do not step under the lifted dozer blade.

• Move the lever (2) in direction of arrow.

• Move the lever (3) in direction of arrow.

• Operate the pump lever (1) until the multi disc brales are released and the dozer blade is lifted off the ground. The machine can now be towed.

BC 670 RB

Fig. 1

Danger to life Do not stand in the travel range of the machine during a demonstration or during loading.

• Lower the dozer blade to the transport vehicle.

• After driving the machine on the transport vehicle swing the articulation lock 1 (Fig. 1) out of its receptacle to the front and fasten it with the pin (2) to the eye on the front frame. Secure the pin with a safety cotter pin (3).

BOMAG

41

Operation After the transport

Fig. 2

• Operate the emergency stop switch 24 (Fig. 2).

Fig. 5

• After the transport release the articulation lock (Fig. 5) and fix it in its receptacle.

Fig. 3

• Lash the machine to the transport vehicle, fasten the lashing gear to the four lifting eyes (Fig. 3 and 4) on front and rear frame.

Fig. 6

When transporting the machine with the air intake screen (Fig. 6) folded down, ROPS and air filter may be excessively soiled.

Fig. 4

42

BOMAG

BC 670 RB

Operation

Fig. 7

• Remove the maintenance flap (Fig. 7).

• Remove all dirt.

When sucking the dirt off make sure not to damage the fins on hydraulic oil cooler and radiator.

• If necessary clean the air filter, see chapter "maintenance as required".

BC 670 RB

BOMAG

43

5 Maintenance

BC 670 RB

BOMAG

45

Maintenance Notes on the fuel system

5.1 General notes on maintenance When servicing the machine pay careful attention to all applicable safety instructions.

Thorough maintenance of the machine ensures maximum reliability and prolongs the lifetime of important components. The effort required for these activities is small when being compared with the problems which may arise, if these instructions are not observed.

• Clean machine and engine thoroughly before starting maintenance work.

• For maintenance work park the machine on level ground.

• Remove the main battery switch during all maintenance work.

• Maintenance work must generally be carried out with the engine shut down.

• Depressurize hydraulic lines before working on them.

• Disconnect the battery and cover it with insulation material before starting to work on electrical components.

The terms left/right are always related to travel direction forward.

• Always attach the articulation lock (transport lock) before starting to work in the articulation area of the machine.

• Collect oils and fuel environmentally and do not let them seep into the ground or into the sewage system. Dispose of oils and fuel environmentally.

• Always catch and dispose of biodegradable oils separately.

Frequent causes of failures • Operating errors • Incorrect, inadequate maintenance If you cannot identify the cause of a fault by following the trouble shooting chart or cannot eliminate a fault yourself, you should contact one of our service stations at our branch offices or dealers.

46

The lifetime of the diesel engine depends mainly on the cleanliness of the fuel.

• Keep the engine free of dirt and water as this could damage the injection elements of the engine.

• When choosing the storage place for fuel it must be ensured that spilled fuel will not harm the environment.

• Do not let the suction hose disturb the sludge on the bottom of the drum.

• Do not draw off fuel from near the bottom of the fuel drum.

• The rest in the fuel drum is not suitable for the engine.

Notes on the engine performance Combustion air and fuel injection rates of the diesel engine have been carefully adjusted and determine the engine’s performance and temperature level as well as the quality of the exhaust gas.

If your machine has to operate permanently in "thin air" (at high altitudes) and with full power, you should consult the after sales service of BOMAG or the service department of the engine manufacturer.

Notes on the hydraulic system When servicing the hydraulic system cleanliness is of utmost importance. Make sure, that no dirt or other contaminating substances enter into the system. Small particles can flute valves, cause pumps to seize and block restrictors and pilot bores, thereby causing costly repairs.

• If, during the daily oil level check the oil level is found to have dropped, check all lines, hoses and components for leakages.

• Seal external leakages immediately. If necessary inform the after sales service of BOMAG. • Clean fittings, filler caps and their immediate surrounding area before removing them, so that no dirt can fall in.

• Do not leave the tank opening unnecessarily open, cover it so that no dirt can fall in.

BOMAG

BC 670 RB

Maintenance Oil quality

5.2 Fuels and lubricants Engine oil The use of high quality HD brand engine oils in connection with the specified filter and oil change intervals guarantee a long lifetime and a good performance of the engine.

Do not use running-in oil for new or overhauled engines.

Oil viscosity CUMMINS recommends to use preferably oils of the viscosity class SAE 15W-40.

To ensure perfect cold starting it is important to choose the viscosity (SAE grade) of the engine oil with respect to the ambient temperature (Fig. 1).

Lubrication oils are differentiated according to their performance abilities and their quality class. The specifications according to API (American Petroleum Institute) are commonly used.

A limit of 1.0 % by weight for sulphated ash is considered optimal.

The sulphated ash must not exceed 1.8 % by weight Permitted API oils API = CG-4/CF-4 must, however not exceed 1.8 percent of mass.

If oil of the quality class CG-4/CF-4 is not available, please consult your local Cummins dealer.

Lubrication oil change intervals The longest permissible utilization time for the lubrication oil in the engine is 6 months. If the following oil change intervals are not reached within a year, the oil must be changed at least once every 6 months, irrespective of the operating hours CG-4/CF-4 = 250 operating hours

Fuels

Fig. 1

Lubrication oil with a too high viscosity index will cause starting difficulties. The temperature when starting the engine is therefore decisive for selecting the correct viscosity for winter operation.

Although cold stating abilities may be impaired if the temperature occasionally drops below the limit (e.g. use of SAE 15W/40 down to -15 ˚C), this will not cause any damage to the engine.

Temperature related lubrication oil changes can be avoided when using multi-purpose oils. The following oil change intervals apply also for multi-purpose oils.

Quality You should only use commercially available brand diesel fuel with a low sulphur content.

Ensure cleanliness when filling in fuel.

Under low ambient temperatures use only winter grade diesel fuel.

Always fill the fuel tank up in due time so that the tank does not run empty, as otherwise filter and injection lines must be bled.

The following fuel specifications are permitted: ASTM D 975-78: 2-D.

Oil quality

BC 670 RB

BOMAG

47

Maintenance Winter fuel

The additives in this oil ensure a low wear lubrication under all operating conditions.

Danger of explosion!

Do not mix diesel fuel with gasoline or alcohol.

For winter operation use only winter-grade diesel fuel to avoid clogging caused by paraffin separation. Under very low temperatures such separations can be expected even with winter-grade diesel fuel.

Lubrication grease For lubrication purposes use an EP-high pressure grease, lithium saponified (penetration 2) according to DIN 51502 KP 2G.

Coolant Anti-feeze agents must be used under any climatic conditions as a protection against freezing, corrosion and boiling.

Mineral oil based hydraulic oil The hydraulic system works with hydraulic oil HV 46 (ISO) with a kinematic viscosity of 46 mm2/s at 40˚C. For topping up or changing the hydraulic oil use only quality hydraulic oil type HVLP according to DIN 51524, part 3, or hydraulic oil type HV according to ISO 6743/3. The viscosity index (VI) should be at least 150. (refer to the specifications of the manufacturer).

Biodegradable hydraulic oil The hydraulic system can also be filled with ester based biodegradable hydraulic oil.

This biodegradable hydraulic oil Panolin HLP Synth. 46 meets the requirements of a mineral oil based hydraulic oil according to DIN 51524.

Always use the same oil for topping up if the system is filled with Panolin HLP Synth. 46.

When changing from a mineral oil based hydraulic oil to a bio-degradable synthetic ester based hydraulic oil consult the lubrication oil service department of your oil supplier.

Check the filter more frequently after changing to the new oil.

Do not mix different coolants and additives.

Do not mix in more than 50% anti-freeze agent, except when a lower frost protection is required.

Under no circumstances must the proportion of anti-freeze agent exceed 68%. The frost protection effect drops again when raising the concentration.

For the coolant mixture use only soft tap water (drinking water).

The water must not contain more than 170 ppm hardening agent and/or 100 ppm sulphate or 40 ppm chloride.

The cooling system must be permanently monitored. Apart from the inspection of the coolant level this includes also the inspection of the concentration of anti-freeze agent and DCA. The anti-freeze agent concentration must be checked with a refractometer (Fleetguard Part No. CC2800) or with the BOMAG test kit (BOMAG part-no. 317 026 02). Other measuring equipment is not suitable for high performance diesel engine.

The coolant must be changed every two years or 6000 operating hours.

Oil for splitter gear / planetary gears Quality For the splitter gear and the planetary drives use only multi-purpose gear oil of API-GL5-class, SAE 90.

This is a hypoid oil of highest performance class for heavy-duty transmissions.

48

Anti-freeze agents must be disposed of environmentally.

Anti-freeze agent specification TMC RP 329 or TMC RP 330 Anti-freeze concentrations Ethylene Glycol 40 % = -23 ˚C (-10 ˚F)

BOMAG

BC 670 RB

Maintenance 50 % = -34 ˚C (-34 ˚F) 60 % = -54 ˚C (-65 ˚F) 68 % = -71 ˚C (-90 ˚F) Propylene Glycol 40 % = -21 ˚C (-6 ˚F) 50 % = -33 ˚C (-27 ˚F) 60 % = -49 ˚C (-56 ˚F) 68 % = -63 ˚C (-82 ˚F) Coolant additives Coolant additives (SCA, Supplement Coolant Additive) are recommended for all Cummins - cooling systems. Anti-freeze agents on their own do not provide sufficient corrosion protection for high performance diesel engines.

The recommended coolant additive concentration of DCA4 (Diesel Coolant Additive) is 0,4 to 0,5 units per litre coolant.

Coolant additives are normally consumed while the engine is in operation. Cummins therefore recommends to replace the DCA4-coolant filter every 250 operating hours or every 6 months.

To check the DCA4-concentration you should e.g. use the BOMAG test kit (BOMAG part-no. 317 026 02). When changing the coolant you may either: • add 1,5 litres liquid DCA4 to the coolant and use a service filter (4 DCA4-units), • or do not add any DCA4-units to the coolant, but use a filter with a high DCA-concentration (23 DCA4-units).

In case of coolant losses, liquid DCA4 must be added according to the refilling quantity of coolant, in order to achieve the correct DCA4-concentration.

BC 670 RB

BOMAG

49

Maintenance

5.3 Table of fuels and lubricants

Assemblies

Fuels, Lubricants Summer

Engine

Winter

Engine oil API: CG-4/CF-4

Approx. quantity Attention Observe level marks 36,6 Litres* (9.670 USgal)

SAE 15W/40 (-10 ˚C (14 ˚F) to +40 ˚C (104 ˚F)) Fuel

Coolant

Diesel

winter diesel fuel (down approx. 500 litres to -12 ˚C) (10 ˚F)) (132.1 USgal)

Mixture of water, ant-freeze agent and DCA4

approx. 44 Litres (11.625 USgal)

Hydraulic oil (ISO), HV46, with viscosity index ’150’ or bio-degradable synthetic ester based hydraulic oil

approx. 350 Litres (92.47 USgal)

Splitter gear

SAE 90 EP, API GL5

approx. 6 Litres (1.585 USgal)

Planetary drive

SAE 90 EP, API GL5

approx. 7 Litres (1.849 USgal)

Central lubrication system

High pressure grease (calcium- and/or lithium saponified) DIN 51 502 KP 2G

approx. 2,0 kg (4.410 lbs) automatic lubrication

Cylinder/dozer blade

Grease cartridge (see manufacturer)

automatic lubrication

Hydraulic system

Air conditioning Cabin heater (diesel) - oil bath air filter

*

50

Refrigerant R 134 A like engine oil

up to approx. -30 ˚C (-22 ˚F) use SAE 5W/30

approx. 2,0 kg as required

with engine oil filter

BOMAG

BC 670 RB

Maintenance

5.4 Running-in instructions When taking new machines into operation the following maintenance work must be performed.

Up to approx. 250 operating hours check the engine oil level twice every day.

Depending on the engine load the oil consumption will drop to its normal level after approx. 100 to 250 operating hours.

After a running time of 15 minutes retighten the V-belts for generator and compressor.

Maintenance after 50 operating hours

• Change the oil in the splitter gear.

• Change the oil in the L + S planetary gears.

• Retighten all screw connections on the machine.

Maintenance after 500 operating hours

• Change the oil in the splitter gear.

• Change the oil in the L + S planetary gears.

Special intervals

• Run the heating every month for about 10 minutes.

• Run the air conditioning every month for about 10 minutes.

After the installation of new or service exchange gearboxes the specified service intervals must be started again from the beginning.

BC 670 RB

BOMAG

51

Maintenance

5.5 Maintenance chart With each maintenance interval you should also perform the work for shorter, preceding intervals.

Pos. No.

Description

Note

Every 10 operating hours (daily) 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13

Check the engine oil level Check the coolant level Drain the water separator in the fuel system Check the V-belt Check the fuel level Check the hydraulic oil level Lubricating the dozer blade Check the visually for damage and leaks

Every 250 operating hours 5.14 5.15 5.16 5.17

Change engine oil and engine oil filter cartridge Check the anti-freeze concentration and the coolant additive Change the coolant filter Change the fuel filter cartridges

at least every 6 months at least every 6 months

Every 500 operating hours 5.18 5.19 5.20 5.21 5.22 5.23 5.24 5.25 5.26 5.27 5.28 5.29 5.30

52

Check the fastening of the scrapers Check the oil level in the splitter gear Check the oil level in the planetary drives Check the engine fasteners Check, clean the radiator and the hydraulic oil cooler Service the battery, check the main battery diconnect switch Check, fill the central lubrication system Change the lubrication cartridge on the dozer blade cylinder Grease hinges on doors and maintenance flaps Service the air conditioning (summer operation) Check the condition and tension of the generator V-belt, change the V-belt Check the condition and tension of the refrigerant compressor V-belt, change the V-belt Check the condition and tension of the blower V-belt, change the V-belt

BOMAG

628 Nm (463 ftlb)

BC 670 RB

Maintenance

Pos. No.

Description

Note

Every 1000 operating hours 5.31 5.32 5.33 5.34 5.35 5.36 5.37 5.38

Check, adjust the injection valves and the valve clearance Check the fastening of engine / turbo charger / combustion air hoses Change the fuel filter for the cabin heater (diesel) Check/clean the oil bath air filter for the cabin heater (diesel) Change the oil in the planetary drive Change the oil in the splitter gear Change the hydraulic oil fine filter* Check the coolant pump

only every 1500 operating hours

Every 2000 operating hours 5.39 5.40 5.41 5.42 5.43

Change the hydraulic oil Change the coolant Drain the fuel tank sludge Check the condition of the articulated joint Maintenance work, which has to be performed every 6000 operating hours by a specialist workshop

at least every 2 years every 2 years or 6000 operating hours

As required 5.44

Combustion air filter service

5.45 5.46 5.47 5.48

Clean the condenser (air conditioning unit) Adjust scrapers and edge cutters Replace the wheel caps Check the cutting plates, replace the cutting plates if necessary Tighten the bolted connections Change the cold start bottle (ether) Fill the provision container of the windscreen washer system Conservation

5.49 5.50 5.51 5.52

(at least every 2 years or if the control light lights up.) (summer operation)

* Also in case of major repairs in the hydraulic system.

BC 670 RB

BOMAG

53

Every 10 operating hours

5.6 Checking the engine oil level

5.7 Checking the coolant level

The machine must be in horizontal position.

The engine must not be started if the oil level is below the "MIN"-mark or above the "MAX"-mark.

After shutting the engine down wait for at least 5 minutes before checking the oil level, to allow all oil to run down into the oil sump.

• Shut the engine down and wait for at least 5 minutes.

Danger of scalding!

Do not remove the radiator cap when the engine is hot.

Never fill cold coolant into a hot engine.

If coolant has to be topped up, use only specially prepared coolant. See chapter 5.2, table of fuels and lubricants.

Fig. 1 Fig. 2

• Pull the oil dipstick (Fig. 1) out, wipe it clean

• Unscrew the radiator cap (Fig. 2).

• The coolant must reach into the filler neck, top

with a lint-free cloth and reinsert it until it bottoms.

• Pull the oil dipstick out again.

• The oil level must reach the "MAX"-mark, top up oil if necessary.

Filling quantity between "MIN" and "MAX"-mark approx. 2 litres.

up if necessary.

For quality and quantity of oil refer to the table of fuels and lubricants.

54

BOMAG

BC 670 RB

Every 10 operating hours

5.8 Draining the water separator in the fuel system

5.9 Checking the V-belt

Fire hazard!

When working on the fuel system do not use open fire, do not smoke.

Do not inhale any fuel fumes.

Dirty fuel can cause malfunction or even damage to the engine.

Fig. 4

• Check the condition of the V-belt (Fig. 4).

Catch running out fuel, do not let it seep into the ground and dispose of environmentally.

Small cracks in longitudinal direction are permitted.

Big cracks in longitudinal direction are not permitted.

Change the V-belt if material is broken out, if there are crossing cuts in longitudinal and transverse directions or any signs of fraying.

Fig. 3

• Open the drain valve (Fig. 3) on the fuel filter for 1-1/4 to 2 turns.

• Drain the fuel-water mixture off and catch it, until clear fuel starts to run out.

Do not overtighten the drain valve to avoid damage to the thread.

• Retighten the drain valve and check for leaks, replace the sealing ring if necessary.

BC 670 RB

BOMAG

55

Every 10 operating hours

5.10 Checking the fuel level

Fire hazard!

When working on the fuel system do not use open fire, do not smoke.

Do not refuel in closed rooms

Fig. 6

• Clean the area around the filler opening and fill in fuel (Fig. 6).

Fig. 5

Dirty fuel can cause malfunction or even damage to the engine.

If necessary fill in fuel through a screen or use a petrol gun.

For quality of fuel refer to the table of fuels and lubricants.

Danger of injury!

When filling the fuel tank use the step on the scraper and the grip on the front frame (Fig. 5).

Do not inhale any fuel fumes.

• Open the flap on the front frame.

• Unlock the filler cap and take it off.

56

BOMAG

BC 670 RB

Every 10 operating hours

5.11 Checking the hydraulic oil level

5.12 Lubricating the dozer blade*

Fig. 7

Fig. 8

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

• Clean the grease nipples (Fig. 8) (7 pieces) and

7) (arrow).

lubricate with approx. 5 strokes from the grease gun.

At room temperature of approx. 20 ˚C the oil level should reach up to about 1/3 of the sight glass.

• Top up hydraulic oil if the oil level is too low.

For quality of grease refer to the table of fuels and lubricants.

For quality and quantity of oil refer to the table of fuels and lubricants.

If, during the daily oil level check the oil level is found to have dropped, check all lines, hoses and components for leakages.

Hydraulic systems, which are filled with Panolin HLP Synth. 46 should only be topped up with the same oil. For any other ester based oils consult the lubrication oil experts of the respective oil manufacturer.

* Option

BC 670 RB

BOMAG

57

Every 10 operating hours

5.13 Checking the machine for damage and leaks

Fig. 9

• Check the entire machine (Fig. 9) and the attachments for condition and completeness.

• Check all tubes and hoses for condition and leaks.

• Repair any damages or have them repaired.

Once all maintenance work is completed reinstall all plates, covers etc. and close all open maintenance flaps.

58

BOMAG

BC 670 RB

Every 250 operating hours • Disconnect the drain hose and screw the pro-

5.14 Changing engine oil and oil filter cartridge

tection cap on after all oil has run out.

The oil change at 250 operating hours applies only when using oils of the quality class API CG-4/SF-4.

If these operating hours are not reached within half a year, the engine oil must be changed despite the operating hours.

Drain the engine oil only when the engine is warm.

Fig. 2

Danger of scalding!

When draining hot oil.

By hot oil when unscrewing the engine oil filter.

• Unscrew the filter cartridge (Fig. 2) with a suitable filter wrench.

• Clean the sealing faces on the filter carrier from all dirt.

Catch running out oil and dispose of environmentally together with the engine oil filter cartridge.

• Unscrew the cover from the oil filler neck.

• Remove the rear maintenance flap.

Fig. 3

• Fill the filter cartridge (Fig. 3) with new engine oil.

• Apply a thin film of oil to the rubber seal on the new filter cartridge.

Fig. 1

• Unscrew the protection cap 2 (Fig. 1) from the oil drain plug (1).

• Take the oil drain hose (3) from the right hand storage compartment and screw it on, drain the engine oil off and catch it.

BC 670 RB

BOMAG

59

Every 250 operating hours

Fig. 4

Fig. 6

• Tighten the filter cartridge (Fig. 4) according to

• Check the oil level again (Fig. 6), if necessary

the specification of the manufacturer.

top up to the "Max."-mark.

Fig. 5

• Fill in new engine oil through the oil filler neck (Fig. 5).

For quality and quantity of oil refer to the table of fuels and lubricants.

• Screw the cover back on.

• Perform a short test run and check the filter cartridge and the drain plug for leaks.

• Shut the engine down and wait for approx. 5 minutes to allow the oil to run back down into the oil sump.

60

BOMAG

BC 670 RB

Every 250 operating hours

5.15 Checking the concentration of anti-freeze agent and the coolant additive

5.16 Changing the coolant filter

If the DCA4-value is higher than 0,8 units per litre coolant, do not change the coolant until the specified value (0,4 to 0,5 units per litre) is reached again.

The inspection of the coolant is of utmost importance to avoid damage to the engine, e.g. corrosion, cavitation and freezing.

Danger of scalding!

Check the anti-freeze concentration only when the engine is cold.

• Perform this test with the testing kit (BOMAG part-no. 317 026 02).

Danger of scalding!

Change the coolant only when the engine is cold.

Nominal value: Concentration of anti-freeze agent 40 Vol% to 60 Vol%.

DCA4 - content 0,4 to 0,5 units per litre Analysis of measurement: If the DCA4-value is higher than 0,8 units per litre coolant, do not change the coolant until the specified value is reached again.

If the DCA4-value is lower than 0,3 units per litre coolant top up the required quantity of liquid DCA4 additive and change the water filter.

Fig. 7

• Unscrew the cover from the compensation tank (Fig. 7).

See chapter 5.2 table of fuels and lubricants and the operating instructions for the testing kit.

Fig. 8

• Turn the coolant shut-off valve (Fig. 8) counterclockwise to position "OFF".

BC 670 RB

BOMAG

61

Every 250 operating hours

Fig. 9

Fig. 11

• Slacken the coolant filter (Fig. 9) and screw it

• Turn the coolant shut-off valve (Fig. 11) in

off.

clockwise direction to position "ON".

• Perform a short test run and check the coolant filter for leaks.

Catch and dispose of all coolant environmentally together with the coolant filter.

• Wipe the sealing face clean.

• Apply a thin film of clean oil to the rubber seal of the new coolant filter.

Make sure that no oil enters into the coolant filter, since this would have a negative effect on the coolant.

Fig. 10

• Screw the new coolant filter (Fig. 10) on and tighten it as specified by the manufacturer.

62

BOMAG

BC 670 RB

Every 250 operating hours

5.17 Changing the fuel filter cartridges

Fire hazard!

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

Do not inhale any fuel fumes.

Fig. 13

Catch running out fuel, do not let it seep into the ground.

During installation to not mix the filter cartridges (Fig. 13) up by mistake!

Filter "A" = secondary filter Filter "B" = primary filter with water separator

Fig. 12

• Unscrew both fuel filter cartridges (Fig. 12) with a suitable filter wrench.

• Clean the sealing faces on the filter carrier from all dirt.

Fig. 14

• Fill the new filter cartridges (Fig. 14) with clean fuel as specified in the table of fuels and lubricants.

• Apply some oil to the sealing ring.

BC 670 RB

BOMAG

63

Every 250 operating hours

Fig. 15

• Screw the filter cartridges (Fig. 15) on by hand and tighten them as specified by the manufacturer.

64

BOMAG

BC 670 RB

Every 500 operating hours

5.18 Checking the fastening of the scrapers

Remove refuse, cables, ropes, wires etc. to avoid premature wear of the wheel shell edges.

Fig. 1

• Check the gap between scraper 1 (Fig. 1) and compacting wheels, it should be approx. 5 mm (0,2’).

• Check the fastening screws (2) on the scrapers for tight fit, if necessary tighten.

Fig. 3

• Check the inner sides of the compactor wheels (Fig. 3), remove wires, cables, ropes etc.

• Check the scraper bars (1), have renewed if worn.

Fig. 2

• Check the lateral edge cutters 1 (Fig. 2) for tight fit, if necessary tighten.

There must be a metal to metal contact at the tightes point between edge cutters und drum shells (2).

Wires can only be effectly cut off in this adjustment.

BC 670 RB

BOMAG

65

Every 500 operating hours

5.19 Checking the oil level in the splitter gear

5.20 Checking the oil level in the planetary drives

Check the oil level in all four planetary drives.

Fig. 4

• Check the oil level in the inspection glass (Fig. 4) with the engine shut down, the oil level must reach slightly above the middle of the inspection glass.

Fig. 6

• Move the machine until the drain plug 2 (Fig. 6) has reached its lowest position.

• Clean and unscrew the filler and level plug (1).

• Check the oil level The oil level must reach the lower edge of the bore, if necessary top up oil.

For quality of oil refer to the table of fuels and lubricants.

• Screw the filler and level plug tightly back in.

Fig. 5

• Clean the area around the breather filter (Fig. 5) and screw the breather filter out.

• If necessary top up oil.

For quality of oil refer to the table of fuels and lubricants.

• Clean the breather filter and screw it back in.

66

BOMAG

BC 670 RB

Every 500 operating hours

5.21 Checking the engine fasteners

5.22 Checking, cleaning the radiator and the hydraulic oil cooler

Dirty operational conditions and especially lubrication oil and fuel deposits on the cooling fins of the hydraulic oil cooler reduce the cooling power considerably. You should therefore immediately seal any oil or fuel leaks near the cooling blower, the cylinders or the oil cooler and clean the cooling fins after.

Fig. 7

• Check all fastening screws on the engine mounting brackets (Fig. 7) for tight fit, if necessary tighten.

Danger of injury!

Cleaning is only permitted with the engine stopped and cooled down!

Fig. 8

• Open the maintenance covers (Fig. 8) on both sides of the radiator covering.

During cleaning take care to avoid damage to the hydraulic oil cooler and the radiator. Keep a safe distance with the spray jet.

Clean the coolers in the correct sequence.

• Clean the hydraulic oil cooler and the radiator first from the air duct side.

BC 670 RB

BOMAG

67

Every 500 operating hours

5.23 Servicing the battery, checking the main battery diconnect switch

Fig. 9

• Remove the maintenance flap (Fig. 9).

• Clean both coolers from the air intake side.

• Remove dried on dirt with a suitable brush.

• Blow the cooling air passages out with pressure air.

• In case of oily dirt spray the parts with a cold cleansing agent and clean it off with a water jet after a sufficient soaking time.

• If steam cleaning equipment is available, this should be preferably used instead of any other cleaning method.

Cauterization!

When working on the battery do not use open fire, do not smoke!

Do not let skin and clothes come in contact with acid!

Wear your protective outfit!

Do not lay any tools on the battery!

Before recharging the battery remove all plugs to avoid the accumulation of highly explosive gases.

Dispose of old batteries environmentally.

After cleaning the coolers, it is absolutely necessary to clean the engine.

Cover all parts of the electric equipment, do not subject them to the direct water jet.

• After wet cleaning run the engine warm to evaporate all water and to avoid corrosion.

• Reassemble the maintenance cover.

Fig. 10

• Open the access door in the floor in front of the cabin door.

Non-maintenance free batteries: • Clean battery and battery compartment (Fig. 10) • Clean the water drain bores • Open the plugs and check the acid level.

68

BOMAG

BC 670 RB

Every 500 operating hours With control inserts Check, whether the acid level reaches the lower end of the control inserts.

If necessary bear in mind that the heating will continue to run for another 2 minutes.

Without control inserts Measure the acid level with a clean wooden stick approx. 10 to 15 mm above the upper edge of the lead plates.

• Use only distilled water to top up missing liquid.

• Clean the battery poles and pole clamps and cover them with acid free grease (vaseline).

• Check the fastening of the batteries.

With transparent battery housing • Check if the acid level reaches the level mark on the housing.

Maintenance free batteries • Clean the battery.

• Clean and grease the poles.

• Tighten the terminal clamps.

Checking the main battery disconnect switch

Fig. 11

• Actuate the switch (Fig. 11) and check with a voltmeter (ignition key test), whether the battery has been disconnected from the electrical system of the machine.

BC 670 RB

BOMAG

69

Every 500 operating hours

5.24 Checking, filling the central lubrication system The following lubrication points are provided economically and reliably with grease by the central lubrication system.

• 2 x at the lower bearing block for the dozer blade, • 1 x eye of the dozer blade cylinder, • 4 x steering cylinder eyes, • 2 x on the articulated joint, • 4 x on the slewing ring in the articulated joint It is differentiated between the two cycles pause and work.

Pause: Over a time period of 60 minutes there will be no lubrication.

Work: Adjusted in the factory.

Fig. 13

• The stirring device in the transparent container 1 (Fig. 13) moves and presses the grease to the lubrication points.

The push button must only be used to check the system.

Checking: • Switch the ignition on.

Failure of a lubrication point (e.g. lubrication point blocked) • Grease emerging from the opening (3) means that one of the lubrication points is blocked.

• Eliminate the cause.

Filling via the grease nipple.

Fig. 12

• Actuate the push button 21 (Fig. 12) for 2 seconds.

Ensure strict cleanliness, as otherwise the distributor 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.

• Clean the grease nipple.

• Fill the grease container via the grease nipple (2) up to the "Max"-mark.

For quality and quality of grease refer to the table of fuels and lubricants.

• Switch the ignition on.

70

BOMAG

BC 670 RB

Every 500 operating hours • Check, whether the sealing ring is correctly inserted in the connecting fitting.

• Screw the connecting fitting on to the manual grease gun.

Fig. 14

• Actuate the push button 21 (Fig. 14) for 2 seconds.

The system will start to work.

Fig. 16

• Clean the area around the covering cap of the

Filling with a manual grease gun

central lubrication system.

• Unscrew the covering cap from the central lubrication system and unscrew the plug from the manual grease gun (Fig. 16).

• Screw the manual grease gun on the socket of the central lubrication system.

• Operate the rod to press the grease into the transparent container.

• 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.

Ensure strict cleanliness, as otherwise the distributor will be blocked.

For quality and quantity of grease refer to the table of fuels and lubricants.

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

Fig. 15

• Remove both covers from the cartridge 1 (Fig. 15).

• Unscrew the connecting fitting from the manual grease gun (2).

• Pull the rod completely out.

• Push the cartridge with the triangular mark forward into the grease gun.

BC 670 RB

BOMAG

71

Every 500 operating hours

5.25 Changing the lubrication cartridge on the dozer blade cylinder

5.26 Greasing hinges on doors and maintenance flaps

Danger of injury!

Do not open the grease cartridge on the dozer blade, after use it will still be pressurized for some time.

In case of damage caustic fluid may run out, wash off immediately with lots of water!

Fig. 18

• Clean all grease nipples (Fig. 18) and grease them with high pressure grease from the grease gun.

• Lubricate all other hinges with an oil can.

For quality of grease refer to the table of fuels and lubricants.

Fig. 17

• Remove the guard plate 2 (Fig. 17).

• Unscrew the spigot nut (3) from the connection on the grease cartridge.

• Open the retaining clamp (5) and take the old grease cartridge (4) off.

• For installation unscrew the plug from the thread on the grease cartridge.

• Screw the spigot nut on the connection of the grease cartridge and tighten it.

• Insert the new grease cartridge and fasten it with the retaining clamp.

• Turn the screw with the seal (1) in until the ring breaks off.

• Install the guard.

72

BOMAG

BC 670 RB

Every 500 operating hours Changing the charcoal filter*

5.27 Servicing the air conditioning (summer operation) The air conditioning unit is installed in the cabin roof and can be accessed from outside for service work.

In case of stronger smells the charcoal filters should be changed more frequently. .

Under very dusty conditions the filter elements must be cleaned at shorter intervals.

Switch the air conditioning unit on at least once every month for a short while (approx. 10 minutes).

Danger of accident!

When working on the air conditioning system or the ventilation secure yourself with a safety belt because of the height.

Fig. 20

• Open the locks 1 (Fig. 20) on both sides and fold the filter boxes (2) down.

Fig. 19

• Hang the ladder into the openings in the roll over protection structure (Fig. 19).

Ladder BOMAG part-no. 007 610 06 • Fasten the safety belt to the ROPS.

Fig. 21

• Change two charcoal filters (Fig. 21) on both sides.

• Close the filter boxes again.

* Option

BC 670 RB

BOMAG

73

Every 500 operating hours • Clean the filter elements with a brush, by shak-

Cleaning the filter elements

ing or blowing the filter mats out.

Closing the cabin doors quickly and with force with the ventilation switched off causes a short term overpressure in the cabin. This has a certain self cleaning effect on the air filter mats.

The sliding windows and the fresh air inlet openings must be closed.

Do not clean the filter mats with any fluids.

• Insert the filter elements in such a way, that the paper ribs are arranged in vertical direction, as shown in the illustration/arrows.

Cleaning the condenser

A soiled condenser impairs the efficiency of the air conditioning system considerably.

Under severe conditions (extreme dust) clean the condenser several times.

If the warning buzzer sounds continuously when the air conditioning unit is in operation, switch the air conditioning unit off and clean the condenser.

Fig. 22

• Open the locks 1 (Fig. 22) on both sides and take the filter boxes (2) off.

Fig. 24

• Detach the rubber straps or open the quick locks, open the flap 1 (Fig. 24) and fold it back.

Fig. 23

• Take the filter elements 1 (Fig. 23) out of the filter boxes.

• Check the filter elements, replace damaged parts.

• Replace the filter elements at the latest after 500 operating hours.

74

BOMAG

BC 670 RB

Every 500 operating hours • Blow the condenser fins (2) out with pressure air or clean it with a cold water jet.

Danger of accident!

Do not clean with a hot water jet. Heat causes an extreme overpressure which can damage the system or cause explosion of the air conditioning system.

• Close the flap.

Fig. 26

Changing the air filter of the condenser fan • Open the front part of the housing.

• Unscrew the fastening nuts 1 (Fig. 26) and take the frame off the fan.

• Take the filter (2) off and insert a new filter.

The slot in the filter must take the power supply cable. Place the three recesses in the filter over the fastening studs.

• Replace the filter for the second blower in the same way.

Replacing the drier in the air conditioning system • Have the drier replaced by the After Sales Service once every year just before the operating period.

Fig. 25

• Loosen the clamps of the ventilator frame (Fig. 25) and take the fan off.

The drier is installed in the refrigerant container and can only be exchanged completely with the refrigerant container.

If the inspection glass shows a brown deposit, the system must be additionally flushed and the oil in the system must be changed.

BC 670 RB

BOMAG

75

Every 500 operating hours Checking the function of the air conditioning system

5.28 Checking the condition and tension of the generator Vbelt, changing the V-belt

Danger of injury!

Work on the generator V-belt must only be performed with the engine shut down.

Checking the V-belt

Fig. 27

• With the engine running and the air conditioning system switched on, the air coming from the air conditioning unit (Fig. 27) must be colder than the surrounding air.

• If this is not the case, inform BOMAG’s After Sales Service.

Fig. 28

• Examine the entire circumference of the V-belt (Fig. 28) for damage and cracks. Replace damaged or cracked V-belts.

Fig. 29

• Check the V-belt tension (Fig. 29).

76

BOMAG

BC 670 RB

Every 500 operating hours We recommend to use the Cummins V-belt tension tester Part. No. ST-1293.

Changing the V-belt:

A V-belt is considered used after it has been in use for more than 10 minutes.

Specified value with 5 ribs: V-belt old 270 to 530 N (60 to 120 lbf) V-belt new 670 N (150 lbf)

Tensioning the V-belt: Fig. 31

• Slacken the hexagon screws 1, 2 and 3 (Fig. 31).

• Turn the tensioning screw (4) counter-clockwise to the end stop.

• Take the old V-belt off the V-belt pulleys.

• Place the new V-belt on the V-belt pulleys.

• Tension the V-belt as previously described.

If necessary, retighten the new V-belt after a running time of 15 minutes.

Fig. 30

• Slacken the hexagon screws 1, 2 and 3 (Fig. 30).

• Turn the tensioning screw (4) clockwise until the correct V-belt tension is reached.

• Retighten the hexagon screws.

BC 670 RB

BOMAG

77

Every 500 operating hours Tensioning the V-belt:

5.29 Checking the condition and tension of the refrigerant compressor V-belt, changing the V-belt

Danger of injury!

This work must only be performed with the engine shut down.

Checking the V-belt Fig. 33

• Slightly loosen the screws for the compressor bracket 3 (Fig. 33).

• Slacken the hexagon nut (2) on the tensioning screw (1).

• Turn the tensioning screw clockwise until the correct V-belt tension is reached.

• Retighten screws and nut.

Changing the V-belt: Fig. 32

• Examine the entire circumference of the V-belt (Fig. 32) for damage and cracks. Replace damaged or cracked V-belts.

• Check by thumb pressure that the V-belt cannot be depressed more than 10 to 15 mm (0.4 to 0.6 in) between the V-belt pulleys, retension if necessary.

Fig. 34

• Slightly loosen the screws for the compressor bracket 3 (Fig. 34).

• Slacken the hexagon nut (2) on the tensioning screw (1).

• Turn the tensioning screw counter-clockwise.

• Take the old V-belt off the V-belt pulleys.

• Place the new V-belt on the V-belt pulleys.

78

BOMAG

BC 670 RB

Every 500 operating hours • Tension the V-belt as previously described.

If necessary, retighten the new V-belt after a running time of 15 minutes.

5.30 Checking the condition and tension of the blower V-belt, changing the V-belt

Danger of injury!

This work must only be performed with the engine shut down.

Checking the V-belt

Fig. 35

• Examine the entire circumference of the V-belt (Fig. 35) for damage and cracks. Replace damaged or cracked V-belts.

Fig. 36

• Check the V-belt tension (Fig. 36).

BC 670 RB

BOMAG

79

Every 500 operating hours We recommend to use the Cummins V-belt tension tester Part. No. ST-1293.

Changing the V-belt:

A V-belt is considered used after it has been in use for more than 10 minutes.

Specified value with 12 ribs: V-belt old 530 to 1070 N (120 to 240 lbf) V-belt new 1330 N (300 lbf)

Tensioning the V-belt: Fig. 38

• Slacken the nut 2 (Fig. 38).

• Turn the tensioning screw (1) counter-clockwise.

Fig. 37

• Slacken the nut 2 (Fig. 37).

• Turn the tensioning screw (1) clockwise until the correct V-belt tension is reached.1 • Retighten the nut.

Fig. 39

• Open the maintenance flap (Fig. 39) and disassemble the blower.

• Take the old V-belt off the V-belt pulleys and take it out over the blower hub.

• Move the new V-belt over the blower hub and place it on the V-belt pulleys.

• Tension the V-belt as described before.

If necessary, retighten the new V-belt after a running time of 15 minutes.

80

BOMAG

BC 670 RB

Every 1000 operating hours

5.31 Checking, adjusting the injection valves and the valve clearance

Valves and injection valves must be checked and adjusted at the latest every 1500 operating hours or once every year.

The tightening torque for the injection valve adjustment screws is 0,6 to 0,7 Nm (5 to 6 in-lb).

The valve clearance for • the inlet valves = 0,36 mm (0.014 in) • the exhaust valves = 0,69 mm (0.027 in)

Fig. 2

• Remove the crankcase ventilation tube (Fig. 2).

• Unscrew the valve cover fastening screws and take the cover off.

Fig. 1 Fig. 3

The valve clearance and the injection valves must be checked and adjusted when the engine is cold (Fig. 1).

Coolant temperature › 60 ˚C

BC 670 RB

Each of the cylinders (Fig. 3) has three rocker arms: • The long rocker arm (E) is the arm for the exhaust valve (EXHAUST), • the middle rocker arm is the arm for the injection valve, • the short rocker arm (I) is the arm for the inlet valve (INLET).

BOMAG

81

Every 1000 operating hours

Fig. 4

The sense of rotation of the crankshaft is clockwise when looking at the engine from the front.

The ignition sequence (Fig. 4) is 1-5-3-6-2-4.

Fig. 6

Do not use the blower to turn the crankshaft.

You will find the valve adjustment marks on the V-belt pulley of the auxiliary output.

Use the auxiliary output (Fig. 6) to turn the crankshaft.

Fig. 5

At an index mark the valve clearance and the injection valve of different cylinders (Fig. 5) are adjusted.

At an index mark a valve pair and one injection valve are adjusted, before the V-belt pulley is turned further to the next index mark.

For the adjustment of all valves and injection valves the crankshaft must be turned for two revolutions.

82

Fig. 7

The checking and adjustment procedure can be started at any position of the index mark. The following example starts with the index mark "A".

• Turn the auxiliary output clockwise until the index mark "A" matches the mark (Fig. 7) on the housing.

BOMAG

BC 670 RB

Every 1000 operating hours

Fig. 8

Fig. 10

When the "A"-mark is correctly set, the inlet and exhaust valves on cylinder 5 must be closed and the injection valve on cylinder 3 can be adjusted.

• Slacken the adjustment screw (Fig. 10) so far,

If this condition is not reached, cylinder 2 is ready for adjustment of the valve clearance and cylinder 4 for adjustment of the injection valve!

Both valves are closed when both rocker arms have clearance (Fig. 8) and can be moved to the side.

that the rocker arm pad still touches the plunger of the injection valve.

The adjustment screw must be slackened so far, that the injection valve is completely unloaded.

This is reached when the rocker arm can just be moved.

Fig. 11

• Insert the cam adjustment tool (CUMMINS Part No.: 3823348) into the top injection cap (Fig. 11).

Fig. 9

• Slacken the counter nut (Fig. 9) of the injection valve adjustment screw on cylinder 3.

• Turn the adjustment screw in until all clearance is eliminated.

• Turn the adjustment screw in another turn.

BC 670 RB

Guide the adjustment tool, around the cap until the pin engages in one of the four bores.

BOMAG

83

Every 1000 operating hours

Fig. 12

Fig. 14

• Apply thumb pressure (Fig. 12) to the handle of

• Hold the adjustment screw in this position (Fig.

the adjustment tool to lift the injection cam up.

Use only as much force as required to keep the injection cam in this position.

If too much force is applied, the pin on the adjustment tool may snap off.

14) and tighten the counter nut.

Tightening torque: 61 Nm (45 in-lb) without adapter spanner 47 Nm (35 in-lb) with adapter spanner

Fig. 15

• Remove the adjustment tool (Fig. 15) before Fig. 13

• Hold the injection cam in top position (Fig. 13) and tighten the adjustment screw with the torque wrench (CUMMINS Part No.: 3376592).

turning the engine crankshaft.

• Check, whether the push rod can be turned by hand.

If this is not the case the adjustment is too tight.

Tightening torque: 0,6 to 0,7 Nm (5 to 6 in-lb)

Excessive tightening of the adjustment screw can damage the engine!

84

BOMAG

BC 670 RB

Every 1000 operating hours

Fig. 16

Fig. 18

• Check or adjust the valve clearance according

Torque method • Slacken the counter nut on the adjustment screw and tighten the adjustment screw (Fig. 18) with the torque wrench.

to (Fig. 16) before advancing the crankshaft to the next index mark.

Tightening torque: 0,7 Nm (6 in-lb) Pull-through method • Tighten the adjustment screw until a slight resistance can be noticed when pulling the feeler gauge through.

Fig. 17

• Choose the correct feeler gauge (Fig. 17) for the valve clearance adjustment.

Valve clearance Inlet valve 0,36 mm (0.014 in) Exhaust valve 0,69 mm (0.027 in) • Insert the appropriate feeler gauge between valve stem and cross-head.

Fig. 19

• Hold the adjustment screw in this position (Fig. 19) and tighten the counter nut.

There are two possible ways to adjust the valve clearance. The best method is by means of the torque wrench. This ensures uniform adjustment values.

BC 670 RB

Tightening torque: 61 Nm (45 in-lb) without adapter spanner 47 Nm (35 in-lb) with adapter spanner

BOMAG

85

Every 1000 operating hours

Fig. 20

Fig. 22

• After tightening the counter nut check the valve

• Once the adjustment of the valve clearance and

clearance again with the feeler gauge (Fig. 20), correct it if necessary.

the injection valves on this cylinder is completed turn the auxiliary output further, until the index mark "B" (Fig. 22) matches with the mark on the housing.

Fig. 21

• If the valve clearance was adjusted with the pull-through method, choose a feeler gauge which is 0,03 mm (0.001 in) thicker than the specified valve clearance.

If this feeler gauge (Fig. 21) fits through the gap, the valve clearance is not correct.

86

Fig. 23

• Check and adjust all other valve clearances and injection valves according to the table (Fig. 23).

• Once all valves and injection valves are correctly adjusted, check the tightening torques of all counter nuts and adjustment screws.

BOMAG

BC 670 RB

Every 1000 operating hours

5.32 Checking the fastening of engine / turbo charger / combustion air hoses

Fig. 24

• Check the valve cover gasket (Fig. 24), replace if necessary.

Fig. 26

• Check charge air line (Fig. 26) and intercooler for tight fit and leaks.

• Check the exhaust pipe and lubrication line to and from the exhaust turbo charger for tight fit and leaks.

• Check the connecting sleeves for tight fit.

Fig. 25

• Install the valve cover to the rocker chamber.

• Tighten the screws in the sequence shown in (Fig. 25).

Tightening torque: 15 Nm (130 in-lb)

Fig. 27

• Open the maintenance flap on the ROPS. • Check the combustion air hose (Fig. 27) for tight fit and leaks.

BC 670 RB

BOMAG

87

Every 1000 operating hours

5.33 Changing the fuel filter for the cabin heater (diesel)

Fire hazard!

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

Do not inhale any fuel fumes.

Fig. 28

• Check combustion air tube and connecting

Catch running out fuel, do not let it seep into the ground.

sleeves (Fig. 28) for tight fit.

Fig. 29

• Open the flap on the front frame.

• Pull the hoses from both sides off the fuel filter (Fig. 29).

• Take the fuel filter out of the bracket.

• Insert a new fuel filter with the point of the arrow facing towards the pump and push both hoses on.

• Remove the cover.

88

BOMAG

BC 670 RB

Every 1000 operating hours

5.34 Checking, cleaning the oil bath air filter for the cabin heater (diesel)

5.35 Changing the oil in the planetary drive

Check, clean every day during the heating period.

Change the oil only at operating temperature.

Change the oil in all four planetary drives.

Danger of scalding!

There is a danger of scalding when draining hot engine oil!

Catch the old oil and dispose of environmentally. Environmental hazard!

Fig. 30

• Loosen the quick locks and take the oil bowl 1 (Fig. 30) off. Check the oil level.

• Remove the oil sludge, clean the oil bowl and fill the bowl with fresh oil.

For quality of oil refer to the section about fuels, lubricants and filling capacities.

At temperatures down to approx. 0 ˚C use SAE 15W/40, for temperatures down to approx. -10 ˚C use SAE 10W/30, for temperatures down to approx. -30 ˚C use SAE 5W/30 or thin spindle oils.

• Observe the dipstick mark.

• Check the fresh air intake tube in the oil bath filter housing for free flow, clean if necessary.

Fig. 31

• Move the machine until the drain plug 2 (Fig. 31) has reached its lowest position.

• Clean the plugs (1) and (2) and screw them out.

• Drain the oil off and catch it.

• Once all old oil has run out clean the plug (2) and screw it back in with a new sealing ring.

• Fill in oil until the oil level reaches the lower edge of the bore (1).

For quality and quantity of oil refer to the section about fuels, lubricants and filling capacitie.

• Clean the plug (1) and screw it tightly back in with a new sealing ring.

BC 670 RB

BOMAG

89

Every 1000 operating hours

5.36 Changing the oil in the splitter gear

Change the oil only at operating temperature.

Danger of scalding!

There is a danger of scalding when draining hot oil!

Fig. 33

• Unscrew the oil drain plug (Fig. 33), catch Catch the old oil and dispose of environmentally.

running out oil.

• Once all old oil has run out clean the plug and screw it back in with a new sealing ring.

Danger of injury!

After unscrewing place the rear lower cover on the ground, do not let it drop.

• Remove the rear lower cover.

Fig. 34

• Fill in new oil (Fig. 34).

For quality and quantity of oil refer to the table of fuels and lubricants.

• Check the oil level in the inspection glass.

Fig. 32

• Clean the area around the breather filter (Fig. 32) and screw the breather filter out.

90

BOMAG

BC 670 RB

Every 1000 operating hours

5.37 Changing the hydraulic oil fine filter

Danger of scalding!

There is a danger of scalding by hot oil when unscrewing the fine filter.

Fig. 35

• Clean the breather filter and screw it back in (Fig. 35).

• Remove the cover.

Do not let old oil seep into the ground, but dispose of environmentally.

If the filter has to be changed together with the hydraulic oil, the filter should in any case be changed after the oil change and the test run.

The filter elements must be changed with every hydraulic oil change or after major repairs in the hydraulic system.

Fig. 36

• Remove the locking wire, if present.

• Unscrew the spigot nut 1 (Fig. 36).

• Take the filter bowl (2) with the filter element off.

BC 670 RB

BOMAG

91

Every 1000 operating hours

5.38 Checking the coolant pump

The gasket of the coolant pump needs a coolant film for lubrication and cooling. A deposit of chemicals or the formation of striae on the drain bore is therefore normal.

Fig. 37

Catch oil running out.

• Do not use the oil in the filter bowl.

• Take the old filter element 3 (Fig. 37) out, clean the filter bowl.

• Clean the thread on the filter bowl.

• Install the filter bowl with a new filter element, observe the condition of the sealing rings (4).

• Run the engine for max. 3 minutes at low speed, this bleeds the hydraulic system.

• After a short test run check for leaks.

Fig. 38

• Check if coolant is permanently running out of the drain bore (Fig. 38).

In case of a permanent leak it is necessary to replace the coolant pump.

Fig. 39

• Check if the drain bore (Fig. 39) is free.

92

BOMAG

BC 670 RB

Every 2000 operating hours

5.39 Changing the hydraulic oil See also the section ’notes on the hydraulic system’.

• Change the hydraulic oil only at operating temperature.

• Clean the area around the hydraulic oil tank, the filler opening and the breather filter.

• Do not run the pumps without oil.

• Do not use any detergents to clean the system.

• Use only lint-free cloths.

Fig. 1

• Unscrew the breather filter (Fig. 1) from the compensation container.

Change the hydraulic oil filter element with every hydraulic oil change.

Do not remove the filter element from the cover on the compensation container.

Change the hydraulic oil filter element generally after the test run.

• Run the diesel engine for max. 3 minutes at low engine speed.

• Bleed the system again after changing the filter.

Do not start the engine after draining off the hydraulic oil.

When changing from a mineral oil based hydraulic oil to an ester based biodegradable hydraulic oil consult the lubrication oil service department of the oil manufacturer.

Catch running out oil and dispose of environmentally.

• Remove the rear lower cover.

BC 670 RB

Fig. 2

Danger of scalding!

There is a danger of scalding when draining hot hydraulic oil!

• Unscrew the plug 1 (Fig. 2) from the drain valve (2), take the drain hose (3) out of the right hand storage compartment and connect it.

• Hold the drain hose into a suitable container.

• Open the drain valve (2) and drain the old oil off.

• Close the drain valve once all oil has run out, remove the drain hose and screw the plug back in.

BOMAG

93

Every 2000 operating hours Cleaning the hydraulic oil tank

The following work has to be carried out if the hydraulic oil tank is to be cleaned from inside.

• Loosen the hexagon screws and take the cover (4) off.

• Clean the inside of the hydraulic oil tank with a lint-free cloth.

Fig. 4

Do not use any detergents. This will contaminate the hydraulic oil!

• Insert a new seal and reattach the cover.

• Check the oil level in the inspection glass (Fig. 4) (arrow).

At approx. 20 ˚C the oil level should reach up to approx. 1/3 of the sight glass.

If the hydraulic oil is hot and the oil level is too high hydraulic oil may run out into the engine compartment.

• Screw the new breather filter in.

• Perform a test run and check the system for leakages.

Filling in hydraulic oil

Bleeding the hydraulic system • Run the diesel engine for approx. 3 minutes at low engine speed.

• Drive the machine until operating temperature is reached and shut the engine down.

Fig. 3

Catch running out oil and dispose of environmentally.

For filling we recommend to use the filling and filtering unit (BOMAG part-no. 079 930 35) with fine filter. This filters the hydraulic oil , prolongs the utilization time of the hydraulic oil filter and protects the hydraulic system.

• Fill in the new hydraulic oil through the screen (Fig. 3).

For quality and quantity of oil refer to the table of fuels and lubricants.

94

BOMAG

BC 670 RB

Every 2000 operating hours

5.40 Changing the coolant

The coolant must be changed at the latest after 2 years or after 6000 operating hours have been reached within 2 years.

Danger of scalding!

Change the coolant only when the engine is cold.

Fig. 5

• Connect the pressure test hose to the test port (Fig. 5) and let the air escape from the hydraulic oil cooler.

Do not start the engine after draining off the coolant.

If no oil escapes from the pressure test port screw the test port off and fill the hydraulic oil cooler with an oil can.

Catch running out coolant and dispose of environmentally.

Draining off the coolant

Fig. 6

• Open the cover (Fig. 6) and fold it down.

BC 670 RB

BOMAG

95

Every 2000 operating hours Flushing the cooling system

The engine cooling lines must be bled during filling.

The coolant must be filled in slowly, to avoid trapping of air.

Wait some minutes until all air has escaped, then fill up with coolant to the Max-mark.

Fig. 7

• Unscrew the cap (Fig. 7).

Fig. 9

• The cooling system must be filled with a mixture of sodium carbonate and water (Fig. 9) (or a commercially available coolant (e.g. RESTORE).

Fig. 8

• Unscrew the plug from the drain valve (Fig. 8) and connect the drain hose.

• Hold the drain hose into a container of suitable size.

• Open the drain valve and let the coolant run out.

• Close the drain valve after all coolant has run out.

96

0,5 kg sodium carbonate for 23 litres of water.

Do not close the cap for the compensation container.

• Run the engine for approx. 5 minutes with a coolant temperature of 80 ˚C. • Shut the engine down and let the flushing fluid cool down.

• Drain the flushing fluid off.

BOMAG

BC 670 RB

Every 2000 operating hours

Fig. 10

Fig. 11

• Fill the cooling system with clear water (Fig.

• Mix the anti-freeze mixture (Fig. 11) before

10).

filling it in and fill the system slowly.

For preparation of the coolant refer to section 5.2, fuels and lubricants.

Open the breather valves but do not close the cap.

• Run the engine for approx. 5 minutes with a coolant temperature of 80 ˚C. • Shut the engine down and let the flushing water cool down.

• Drain the flushing water off.

For quantity of coolant refer to the table of fuels and lubricants.

When choosing the coolant filter check if liquid ACA4 has been filled in.

• Close the compensation tank. Run the engine warm and check the coolant level again, if necessary top up with coolant.

If the drained off water is still dirty, flushing must be continued until the water is clear.

• Close all drain and bleeding valves.

Filling the cooling system

Do not use pure water as coolant, since this may cause damage to the engine by corrosion.

When using the service-coolant filter (4 DCA4-units), a proportion of 1.5 litres of liquid DCA4 must be added to the coolant.

When using the filter element with 23 DCA4-units (pre charge element), do not add any liquid DCA4.

BC 670 RB

BOMAG

97

Every 2000 operating hours

5.41 Draining the fuel tank sludge

Fire hazard!

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

• Unscrew the plug (1) and push the drain hose on immediately.

Catch running out fuel.

• For cleaning purposes it is quite sufficient to drain off approx. 5 l (1.32 US gal.) of fuel. Pull the hose off, screw the plug in immediately and tighten it.

Catch running out fuel, do not let it seep into the ground.

• Open the flap on the front frame.

Fig. 14

Fig. 12

• Unscrew the plug 3 (Fig. 12) inside the front frame.

To drain off water, fuel, sludge etc. from inside the front frame unscrew the drain plugs 1 and 2 (Fig. 14) from both sides, let the fluid run out, catch it and dispose of environmentally.

• Screw all plugs back in.

• reinstall the cover.

Fig. 13

• Guide the drain hose 2 (Fig. 13) through the open bore in the front frame and hold it into a suitable container outside the machine.

98

BOMAG

BC 670 RB

Every 2000 operating hours

5.42 Checking the condition of the articulated joint

5.43 Maintenance work, which has to be performed every 6000 operating hours by a specialist workshop • Check the bearings of the V-belt idler pulley • Check the bearing of the blower hub • Clean, calibrate the fuel pump • Clean, calibrate the injection valves • Check the turbo charger • Check the vibration dampers

Fig. 15

• Check all fastening screws (Fig. 15) for tight fit, tighten if necessary.

• Check the condition of the lubrication lines (1) to the bearings for the steering cylinder rods.

BC 670 RB

BOMAG

99

As required

5.44 Servicing the combustion air filter

Fig. 3

• Unscrew the hexagon nut 1 (Fig. 3) and take the safety cartridge (2) out.

Fig. 1

Maintenance of the dry air filter is due if the control light in the monitoring board e (Fig. 1) and the general warning light continue to light up, but at the latest after 2 years.

Do not clean the dry air filter, but replace immediately. This applies also for the safety cartridge.

Fig. 4

• Take the element 1 (Fig. 4) out of the filter housing and clean it.

• Wipe the filter housing out with a cloth. Do not clean with pressure air.

• Install the new safety cartridge and the dry air filter, do not clean.

• Reinstall the cover.

Fig. 2

• Unscrew the wing nut 1 (Fig. 2), take the cover (2) off.

• Unscrew the hexagon nut (3) and pull the dry air filter (4) out.

100

BOMAG

BC 670 RB

As required

5.45 Cleaning the condenser (air conditioning unit)

A soiled condenser impairs the efficiency of the air conditioning system considerably.

Under severe conditions (extreme dust) clean the condenser several times.

If the warning buzzer sounds continuously when the air conditioning unit is in operation, switch the air conditioning unit off and clean the condenser.

Fig. 6

• Keep the drain tube (Fig. 6) for drainage of the roof empty.

Fig. 5

• Unhook the rubber straps and open the flap 1 (Fig. 5).

• Blow the condenser fins (2) out with pressure air or clean it with a cold water jet.

Danger of accident!

Do not clean with a hot water jet. Heat causes an extreme overpressure which can damage the system or cause explosion of the air conditioning system.

• Straighten deformed fins with a fin comb.

• Close the flap.

BC 670 RB

BOMAG

101

As required Edge cutter

5.46 Adjusting scrapers and edge cutters

Scrapers

Fig. 8

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

Fig. 7

• Check the condition of all scrapers 1 (Fig. 7) on the compacting wheels, replace damaged or worn scrapers.

• Check the gap between scrapers and compacting wheels, the gap for the inner scrapers should be adjusted to 0 mm.

• Adjust all other scrapers to 5 mm.

• To adjust the scraper slacken the screws (2) and adjust the scraper to a distance of approx.

0 resp. 5 mm.

• Retighten the slackened screws.

• Tightening torque 628 Nm (463 ft lb).

8) on the compacting wheels, replace damaged or worn edge cutters.

• Check the distance (2) between edge cutter and compacting wheels.

• There must be metal to metal contact at the tightest point between edge cutters and drum shells (2).

• To adjust the edge cutters slacken the screws (3) and adjust the cutters accordingly.

Due to manufacturing reasons it is not possible to produce an absolutely round drum shell for the compacting wheels.

At the widest points the gap between the edge cutters and the drum shells may therefore be up to a few millimetres.

• Retighten the slackened screws.

Remove refuse, cables, ropes, wires etc. to avoid premature wear of the wheel shell edges.

102

BOMAG

BC 670 RB

As required

5.47 Replacing the wheel caps

This work should only be performed by specialists.

Replace the caps at the latest when the front face breaks through.

Danger of accident!

Perform all work only with the engine shut down and the emergency stop switch engaged.

Wear protective goggles and proper working gloves.

Fig. 10

Tools (Fig. 10) 3 = BOSCH hammer (220 V) BOMAG part-no. 079 940 05 4 = disassembly mandrel BOMAG part-no. 570 030 83 5 = assembly mandrel BOMAG part-no. 570 030 82 6 = assembly mandrel BOMAG part-no. 570 030 98

Fig. 9

Spare parts (Fig. 9) 1 = wheel cap BOMAG part. no. 311 661 91 2 = dowel pin BOMAG part-no. 311 623 79 Quantity per machine: 220 pieces

Fig. 11

• Fit the disassembly mandrel 4 (Fig. 11) to the BOSCH hammer (3) and force the dowel pin out with the BOSCH hammer.

When changing the wheel caps use only new dowel pins, as the old pins may cause damage the caps and the pad feet.

BC 670 RB

Make sure that the disassembly mandrel sits perfectly on the dowel pin.

BOMAG

103

As required

Fig. 12

Fig. 14

• Clean the pad foot thoroughly with a wire brush

• Slide the dowel pin 2 (Fig. 14) on the assembly

(Fig. 12).

mandrel (5) and insert it into the bore in the cap.

The chamfer (2.1) rests against the assembly mandrel.

Danger of injury!

When the dowel pin is knocked through, the assembly mandrel will fly off with high speed.

Catch the mandrel e.g. with a bundle of cloths.

Fig. 13

• Place the new cap 1 (Fig. 13) on the pad foot.

Dip the new dowel pin (2) with the chamfer into lubrication grease.

Fig. 15

• Fit the assembly mandrel 4 (Fig. 15) to the BOSCH hammer (3) and drive the dowel pin in with the BOSCH hammer until the dowel pin is flush with the cap.

104

BOMAG

BC 670 RB

As required

5.48 Checking the cutting plates, replace the cutting plates if necessary

The dowel pin 2 (Fig. 12) can also be knocked in with an approx. 1-2 kg hammer.

If the pretension is very high, a 5 kg hammer should be used.

Fig. 17

• Check the condition of the cutting plates 1 (Fig.

Fig. 16

• The caps on the inner segment side can only be assembled from under the edge of the frame (Fig. 16), as otherwise the assembly mandrel will not fall out.

Knock the dowel pin in from outside to inside (2).

When assembling the caps move the machine accordingly.

BC 670 RB

17) on the dozer blade/bucket. If the cutting plate is worn down to the lower edge of the dozer blade, turn the cutting plate around or replace it.

• Lift the dozer blade/bucket up and support it safely.

Danger of accident!

Do not work on the lifted and unsupported dozer blade/bucket.

• To change the plate unscrew the hexagon nuts (2). Take the washer (3) off, cut it of with a torch, if required.

• Knock the hexagon screws (4) and take the old cutting plate off.

• Before assembling the new cutting plate check the contact face on the dozer blade, rework it if necessary.

• Attach the cutting plate, insert the counter-sunk screws and observe the locating recess, install the washer and fasten the assembly.

BOMAG

105

As required

5.49 Tightening the bolted connections

Bolted connections • Transverse beam, cabin top M20 = 200 Nm • Scraper M20x1,5 = 628 Nm • Compacting wheels - planetary drives (L+S) M20 = 578 Nm • Pillow blocks for dozer blade M 30 x 2 = 1760 Nm * Strength class for screws with untreated, non-lubricated surface. The screw quality is stamped on the screw heads: 8.8 = 8G 10.9 = 10K 12.9 = 12K These values result in a 90% utilization of the screw’s yield point at a coefficient of friction of · total = 0,14.

The tightening torques are checked with torque wrenches.

The stated tightening torques become invalid when using MoS2 lubricants.

Self-locking nuts must be generally exchanged if they have been unscrewed.

106

5.50 Checking, changing the starting aid container (ether)

Fire and health hazard!

Starting fluid (ether) is easily inflammable and highly toxic.

Service work and trouble shooting should only be performed in well ventilated rooms or in an open environment.

Keep away from heaters, open fire or sparks.

Protect eyes and skin against contact with starting liquid.

Do not burn or damage used up or apparently empty starting aid cans, but dispose of environmentally.

• Open the right hand lateral box on the rear frame.

Fig. 18

• Unscrew both wing nuts from the bracket (Fig. 18).

• Unscrew the starting aid container from the valve body.

• Shake the starting aid container lightly to detect the filling level, if necessary dispose of the empty container environmentally and screw the new one in hand tight.

BOMAG

BC 670 RB

As required

5.51 Checking the provision container of the windscreen washer system

Fig. 19

• Check the filling level in both containers (Fig. 19), if necessary fill up.

• For winter operation fill in the required quantity of anti-freeze agent; refer to the information of the anti-freeze agent manufacturer.

5.52 Conservation If the engine is to be shut down for a longer period of time (e.g. for winter storage), we recommend the following engine conservation to avoid corrosion: • Clean the engine including the cooling system: With cold cleansing agent and a water jet or, even better, with steam cleaning equipment.

• Run the engine warm and shut it down.

• Drain the still warm engine oil and fill in anticorrosion engine oil.

• Drain the fluid from the tank, mix it well with 10% anti-corrosion oil and fill this mixture back in. Instead of mixing of anti-corrosion oil to the fuel, the tan may also be filled with injection pump testing oil with anti-corrosive properties (e.g. Calibration Fluid B).

• Run the engine for 10 minutes until all lines, filter, pump and nozzles are filled with the conserving mixture and the new engine oil is distributed to all parts.

• 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 fuel. Then reinstall the hoods and the cover.

• Crank the engine several times by hand (without ignition) in order to spray all combustion chamber.

• Take the V-belts off and spray the grooves of the V-belt pulleys with anti-corrosion oil. Remove this anti-corrosion oil before taking the machine back into operation.

• Close the air intake opening on the air filter and the exhaust opening.

Depending on the weather condition these conserving measures will provide protection for approx. 6 - 12 months.

Before taking the machine back into operation the conserving mixture must be drained off and replaced by engine oil of the API-(MIL-) classification, see section fuels and lubricants.

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107

As required

• For longer resting periods all blank surfaces must be conserved.

Piston rods must be protected with grease.

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BC 670 RB

6 Trouble shooting

The following work must only be carried out by qualified and trained personnel or by the BOMAG sales service.

BC 670 RB

BOMAG

109

Trouble Shooting

6.1 General notes Please observe strictly the safety regulations in chapter 2 of these operating and maintenance instructions.

Faults occur frequently due to the fact, that the machine has not been properly operated or serviced. 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.

Danger of injury!

Keep away from rotating parts of the engine.

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Trouble Shooting

6.2 Engine Faults

Possible cause

Remedy

The engine does not run or runs too slowly

Battery cable or terminal loose, broken or corroded

Check for wear. Clean and tighhten if necessary.

Battery too weak

Check level of electrolyte and specific density. Charge/change the battery.

Nominal power of battery too low

Use a battery with correct nominal power.

Incorrect oil for the operating conditions

Change oil and filter. Use specified type of oil (15W-40).

Oil temperature too low

Install an oil sump heating or drain the oil off and fill with warm oil.

Fuel tank empty

Fill in fuel.

Shut-off valve closed

Have the fuel shut-off solenoid checked by a specialist.

Incorrect starting

Start correctly

Starting aid required at low temperatures

Use, check the cold starting aid

Fuel filter clogged

Change the fuel filter

Air in the fuel system

Bleed the fuel system, tighten the fuel connections

Fuel supply restricted, fueel system clogged due to paraffin separation in winter

Change the fuel filter, bleed the fuel system, check line connections for leakages and tighten the fittings Use winter fuel in the cold season.

The engine turns, but does not start. (No exhaust fumes)

Engine difficult to start or does not start at all (exhaust fumes visible)

Engine starts, but goes out again

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BOMAG

111

Trouble Shooting

Faults

Possible cause

Remedy

Engine starts, but goes out again

Vacuum in the fuel suction line

Check the fuel line for vacuum

Fuel contaminated

Run the engine with fuel from a spare tank and check the operation

Poor fuel quality

Run the engine with good fuel from a spare tank and check the operation

Incorrect valve clearance

Adjust the valve clearance

Injection nozzles defective

Have examined by a specialist

Excessive load for nominal engine power

Reduce the load or change to a lower speed range

RPM-meter not working correctly

Check with an external speedometer

Excessive play in the throttle pedal

Adjust the lever system, change if necessary

Vacuum in the fuel suction line

Check the fuel inlet for vacuum

Engine oil level too high

Drain the engine oil down to the upper dipstick mark

Engine oil level too high

Drain the oil to the upper dipstick mark

Dry air filter cartridge dirty (the control light "engine air filter" in the monitoring board and the general warning light light up.

change

Poor compression due to burned or broken compression rings or incorrect valve clearance

Have compression rings and pistons examined by a specialist, correct the valve clearance

Excessive inclination of the engine

Avoid driving along excessive slopes

White exhaust fumes or unregular idle speed (after warming up)

The engine does not run at nominal speed when under load

Excessive exhaust fumes under load

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BOMAG

BC 670 RB

Trouble Shooting

Faults

Possible cause

Remedy

Excessive exhaust fumes under load

The turbo charger fan is rubbing

Check the turbo charger. Repair or replace the turbo charger.

Leakages in the air intake area between turbo charger and cylinder head

Check for air leaks

Incorrect fuel quality

Check the fuel specification

Vacuum in the fuel drain line

Check the fuel drain line for chafing, sharp bends or squeezing.

Excessive load at nominal power of the engine

Reduce the load

Low power due to the high altitude

Have the engine readjusted when working in altitudes of more than 3600 m

Engine oil level too high

Drain the engine oil down to the top dispstick mark

Cacuum in the fuel suction line or in the fuel filter

Check the fuel line for vacuum, change the fuel filter

Vacuum in the intake and exhaust system

Check intake and exhaust system for vacuum

Air in the fuel symptom: spongy acceleration Incorrect fuel quality

Tighten fuel connections and fuel filter

Oil level too low (the control light "engine oil pressure" in the monitoring board and the general warning light light up. The warning buzzer sounds).

Top up oil, observe the top dipstick mark.

Leakages in the lubrication system

Check fittings on oil lines, lubrication oil filter for leaks, tighten the fittings if necessary.

Excessive inclination of the engine

Avoid driving along to steep inclines

Oil pressure gauge faulty

Check the oil pressure gauge

Low engine output power

Engine oil pressure too low, shut down immediately

BC 670 RB

BOMAG

Check the fuel specification

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Trouble Shooting

Faults

Possible cause

Remedy

Engine oil pressure too low, shut down immediately

Engine oil mixed with fuel

Change the engine oil; if it mixes again with fuel inform the after sales service of BOMAG.

Incorrect engine oil

Change the engine oil and observe the specification

Engine oil temperature too high

Check the coolant level and the radiator

Radiator dirty

Clean the cooling fins

Coolant temperature too high (the control light "coolant temperature" in the monitoring board and the general warning light light up. The warning buzzer sounds).

Clean the cooling fins on the radiator, check the coolant level. Check the blower V-belt

Coolant level too low (the control light "coolant level too low" in the monitoring board and the general warning light light up, the warning buzzer sounds).

Incorrect engine oil level

Top up coolant, check the coolant hoses, check the radiator, radiator cap on compensation tank missing or incorrect

Blower V-belt cracked or loose

Tighten and/or change the V-belt

Concentration of anti-freeze agent and or coolant additives too high

Use the correct concentration

The manual control on the fuel pump is open

The manual control screw must be turned out as far as possible.

The fuel pump shut-off valve is tight

Check the function of the fuel shut-off solenoid

Fuel tank ventilation clogged

clean or replace

Vacuum in the fuel drain line

Check the fuel drain line for chafing, sharp bends or squeezing.

Engine overheating, shut the engine down immediately

The engine will not shut down

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BOMAG

Top up or drain off engine oil

BC 670 RB

Trouble Shooting

Faults

Possible cause

Remedy

The "charge control light" in the monitoring board and the general waring light light up during operation.

Generator speed too low

Check the V-belt tension, change the V-belt if necessary

The generator does not charge the battery, because either generator or regulator is defective

Have examined by a specialist

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BOMAG

115

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