BOMAG Sanitary landfill Compactor BC 672 RB / BC 672 EB / BC 772 RB RS Operation & MAINTENANCE-PDF

Operating instructions Maintenance instructions

%& 5% %& 5% %& 5% %& 56 S/N 101 570 53 1005 > (EPA) S/N 101 570 56 1001 > (EPA)

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Catalogue number

)RUHZRUG

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

Foreword

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

You should only operate the 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 Rules for the Operation of Road Rollers and Soil Compactors" and the applicable instructions for prevention of accidents.

This manual comprises: ●

safety regulations

●

operating instructions

●

maintenance instructions

●

trouble shooting

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

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

We reserve the right for technical modifications without prior notification.

Using these instructions will ●

help you become acquainted with the machine.

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

●

avoid malfunctions caused by operating errors.

You can also obtain the spare parts catalogue and the repair instructions from your BOMAG dealer against the serial number of your machine.

Compliance with the maintenance instructions will ●

increase the reliability of the machine on the waste disposal site,

●

prolong the lifetime of the machine,

●

reduce repair costs and downtimes.

BOMAG does not assume liability for the function of the machine ●

●

if the operation of the machine does not comply with the operating instructions, if the machine is used for purposes other that the ones mentioned in these instructions (refer to the safety regulations).

Information about the correct use of our machines on waste disposal sites are also available from your BOMAG dealer.

The above mentioned and following notes do not extent or replace the warranty and liability conditions mentioned in the general terms of business of BOMAG. We wish you successful work with your BOMAG machine.

BOMAG GmbH & Co. OHG Printed in Germany Copyright by BOMAG

No warranty claims can be lodged for damage resulting from ●

operating errors,

●

insufficient maintenance and

●

the use of wrong fuels and lubricants.

Please note!

These instructions were written for the operator and the service personnel on the waste disposal site.

BC 672 RB/EB,BC 772 RB/RS

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

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

Serial-number (Fig. 1 and 2) ............................

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

Engine number (Fig. 3)

L

Note

Fig. 1

Supplement the above data together with the commissioning protocol.

During commissioning our organisation will instruct you in the operation and maintenance of the machine.

Please observe strictly the safety regulations and all notes on risks and dangers!

Fig. 2

Fig. 3

6

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Table of Contents

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3.1 General notes

28

3.2 Description of indicators and control elements

28

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4.1 General notes

44

4.2 Tests before taking into operation

44

4.3 Starting the engine

45

4.4 Starting under low temperatures

48

4.5 Starting with jump leads

49

4.6 Driving the machine

49

4.7 Emergency exit

52

4.8 Actuating the emergency stop switch

53

4.9 Operating the dozer blade

53

4.10 Operating the bucket (RS)

54

4.11 Operating the service brake

56

4.12 Operating the parking brake

57

4.13 Starting and adjusting the air conditioning

58

4.14 Air conditioning, switching Reheat – operation on/off

62

4.15 Air conditioning, changing between circulation air/fresh air operation

63

4.16 Air conditioning, heating operation

64

4.17 Shutting the engine down

65

4.18 Parking on a slope

67

4.19 Towing the machine

68

4.20 Transport of the machine

70

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5.1 General notes on maintenance

74

5.2 Fuels and lubricants

75

5.3 Table of fuels and lubricants

78

5.4 Running-in instructions

79

5.5 Maintenance chart

80

5.6 Check the engine oil level

82

5.7 Checking the fuel level

82

5.8 Checking the hydraulic oil level

83

5.9 Visual inspection of the machine for damage and leaks

83

5.10 Check the coolant level

84

5.11 Check the oil level in the splitter gear

86

5.12 Checking/emptying the fuel pre-cleaner (water separator)

86

5.13 Lubricating the joints and bearings on the bucket (RS)

87

5.14 Service the air conditioning (summer operation)

88

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Table of Contents

5.15 Check the fastening of the scrapers

91

5.16 Change the engine oil

92

5.17 Changing the engine oil filter

93

5.18 Check the engine mounts

93

5.19 Checking condition of radiator, intercooler and hydraulic oil cooler, clean, cleaning the engine 94 5.20 Checking the oil level in the planetary gears

96

5.21 Checking the battery, greasing the poles, checking the battery disconnect switch 96 5.22 Checking, filling the central lubrication system

97

5.23 Checking the condition and tension of the generator V-belt, replacing the Vbelt 99 5.24 Check condition and tension of refrigerant compressor V-belt, replace the Vbelt 101 5.25 Checking the condition and tension of the fan V-belt, replacing the V-belt 102 5.26 Replacing the fresh air and circulation air filters

104

5.27 Checking the anti-freeze concentration

105

5.28 Oil change in planetary gear

106

5.29 Checking, adjusting the valve clearance

107

5.30 Changing the fuel filter cartridge

108

5.31 Changing the fuel prefilter element

109

5.32 Checking the fastening of engine / turbo charger / combustion air hoses 111

8

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

112

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

112

5.35 Changing the hydraulic oil fine filter

113

5.36 Changing hydraulic oil and breather filter

114

5.37 Change oil and filter in the splitter gear

116

5.38 Checking the condition of the articulated joint

117

5.39 Changing the injection valve

118

5.40 Check turbo charger compressor outlet, clean if necessary.

118

5.41 Changing the crankcase ventilation valve

119

5.42 Changing the coolant pump

120

5.43 Changing the pressure retaining valve on te injection pump

120

5.44 Changing the coolant, venting the cooling system

121

5.45 Adjust scrapers and edge cutter

122

5.46 Replacing the pad foot caps

123

5.47 Checking the cutting plates, replacing the cutting plates if necessary

126

5.48 Changing the dry air filter cartridge

126

5.49 Retightening bolted connections

128

5.50 Checking the preheating system. Maintenance in case of frost.

129

5.51 Fill the provision tank for the windscreen washer system

130

5.52 Drain off dirty fluids from front and rear frame

131

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Table of Contents

5.53 Conservation

132

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6.1 General notes on trouble shooting

134

6.2 Engine problems

135

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1 Technical Data

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Fig. 4

Dimensions in mm

A

B

B2

B3

D

H

H2

H4

K

L

BC 672 RB

3500

3800

3550

3775

1660

4120

3820

1950

6000

8120

BC 672 EB

3500

3800

3200

3775

1580

4120

3820

1050

600

8120

*

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

Drive system Driven compactor wheels

12

BC 672 RB

BC 672 EB

kg kg kg

32100 15300 16800

28900 14100 14800

kW rpm V

Deutz BF 6M 1015CP(EPA) Water 6 314 2100 24

Deutz BF6M 1015CP(EPA) Water 6 314 2100 24

12/180 hydrostatic 4

12/180 hydrostatic 4

V/AH

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BC 672 EB

Travel characteristics Travel speed Travel range I Travel range II Gradability (soil dependent) Steering angle Oscillation angle Inner track radius

km/h 0 to 4,5 forward, reverse 0 to 4,5 forward, reverse km/h 0 to 12 forward, reverse 0 to 12 forward, reverse % 100 100 +/- degree +/- degree mm

40 15 3090

40 15 3090

pcs. pcs. mm

60 50 1350

50 50 1350

hydrostatic mech./hydrost. mech./hydrost.

hydrostatic mech./hydrost. mech./hydrost.

Oscill.-articul. hydraulic

Oscill.-articul. hydraulic

mm

1200

1200

mm

120

120

l l l

500 350 approx. 44

500 350 approx. 44

Compactor wheels Number of teeth, front Number of teeth, rear Compaction width per wheel side Brake Service brake Parking brake Emergency brake, emergency stop Steering Type of steering Steering operation Dozer blade Height adjustment above ground level Height adjustment below ground level Filling capacities Fuel (diesel) Hydraulic oil Coolant *

The right for technical modifications remains reserved

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Fig. 5

Dimensions in mm

A

B

B2

B3

D

H

H2

H4

K

L

BC 772 RB

3500

3800

3550

3775

1620

4100

3810

1950

580

8120

BC 772 RS

3875

3800

3550

3775

1660

4120

3820

1800

600

9275

*

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

Drive system Driven compactor wheels

14

BC 772 RS

BC 772 RB

kg kg kg

36800 20500 16300

36800 17421 19379

kW rpm V

Deutz BF 6M 1015CP(EPA) Water 6 330 2100 24

Deutz BF6M 1015CP(EPA) Water 6 330 2100 24

12/180 hydrostatic 4

12/180 hydrostatic 4

V/AH

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*

BC 772 RS

BC 772 RB

Travel characteristics Travel speed Travel range I Travel range II Gradability (soil dependent) Steering angle Oscillation angle Inner track radius

km/h 0 to 4.5 forward, reverse 0 to 4.5 forward, reverse km/h 0 to 12 forward, reverse 0 to 12 forward, reverse % 75 100 +/- degree +/- degree mm

30 15 3750

40 15 3090

pcs. pcs. mm

60 50 1350

60 50 1350

hydrostatic mech./hydrost. mech./hydrost.

hydrostatic mech./hydrost. mech./hydrost.

Oscill.-articul. hydraulic

Oscill.-articul. hydraulic

mm

5350

1200

mm

50

200

l l l

750 350 approx. 44

500 350 approx. 44

Compactor wheels Number of teeth, front Number of teeth, rear Compaction width per wheel side Brake Service brake Parking brake Emergency brake, emergency stop Steering Type of steering Steering operation Dozer blade Height adjustment above ground level Height adjustment below ground level Filling capacities Fuel (diesel) Hydraulic oil Coolant *

The right for technical modifications remains reserved

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The following noise and vibration values according to the EC-directive for machines, edition (91/368/EEC) were measured at nominal engine speed.

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

Noise value The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is sound pressure level on the operator’s stand: LpA =71.4 dB(A) sound capacity level: LWA =112 dB(A) These sound values were determined according to ISO 3744 for the sound capacity level (LWA) and ISO 6081 for sound pressure level (LpA) at the place of the operator.

Vibration value The vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are: Vibration of the entire boy (driverâ&#x20AC;&#x2122;s seat) The weighted effective acceleration value determined according to ISO 2631 part 1, is <= 0,5 m/sec2.

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

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2 Safety regulations

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General notes

sional way or if it is used for purposes other than those mentioned in these instructions.

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 signature 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

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 changes to the machine Unauthorized alterations to the machine are prohibited for safety reasons.

Original parts and accessories have been specially designed for this machine. We wish to make explicitly clear that we have not tested or approved any parts or accessories not supplied by us. The installation and/or use of such products may have an adverse effect on the active and/or passive driving safety. The manufacturer explicitly excludes any liability for damage caused by the use of non-original parts or accessories.

Intended use This machine must only be used for: ●

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

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 functional safety equipment.

●

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

●

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

Safety notes in the operating and maintenance instructions:

Danger Sections marked like this point out possible dangers for persons.

Caution Sections marked like this point out possible dangers for the machine or for parts of the machine.

Unintended use Dangers may, however, arise from the machine if it is used by untrained personnel in an unprofes-

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Starting the machine

Note

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

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

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

Environment Sections marked like this highlight activities for the safe and environmental disposal of fuels and lubricants as well as replaced parts.

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

Observe all environment protection regulations.

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

●

all handrails, steps and platforms are free of grease, oils, fuels, dirt, snow and ice

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.

Loading the machine The ramp inclination must be lower than the gradability of the machine.

To climb onto the machine use steps and handrails.

Check before starting, whether: ●

the machine shows any obvious defects

Secure the machine against falling or slipping off.

●

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

all protective devices are properly secured in their place

●

steering, brakes, control elements, lighting and warning horn are in order the seat is correctly adjusted

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.

Do not start the machine if any gauges, control lights or controls are defective.

Towing the machine

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

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

Starting Start and operate the machine only from the operator’s seat

Checking the roll over protection structure (ROPS) 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.

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

To start the machine set all control levers to "neutral position".

After starting check all gauges.

Starting with jump leads 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.

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

Change the travel direction forward/reverse only at standstill.

Starting in closed rooms

Do not use the dozer blade/bucket to transport persons! Mortal danger!

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!

Moving other vehicles with the dozer blade/bucket is prohibited.

Driving the machine

In case of unusual noises and development of smoke perform trouble shooting and have the fault corrected.

Persons in the danger area

Match the speed to the working conditions.

If a machine has turned over and the cabin door is jammed, all cabin windows can be used as escape doors.

Always give way to loaded transport vehicles.

Before taking up work, also after breaks, you should always convince yourself that the danger zone is free of persons or obstructions, especially when driving in reverse.

Do not run the heating in service or storage halls.

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

Driving on inclinations and slopes Do not drive on gradients exceeding the maximum gradability of the machine.

Give warning signals, if necessary. Stop work immediately if persons remain in the danger zone, despite the warning.

On slopes drive extremely careful and always directly up or down the slope. Change to a lower gear before starting to drive.

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

Wet and loose soils considerably reduce the ground adhesion of the machine on inclinations and slopes. Higher risk of accident!

Driving In events of emergency and in case of danger actuate the emergency stop switch immediately. Do not use the emergency stop switch as service brake. Restart the machine only after the danger that caused the actuation of the emergency stop switch has been eliminated.

If the machine has contacted high-voltage power lines:

Parking the machine Park the machine on horizontal, level, firm ground.

Before leaving the machine: ●

lower the dozer blade/bucket to the ground

●

return the control lever to neutral position

●

shut the engine down, pull the ignition key off lock the cabin

●

do not leave the operator’s stand

●

●

warn others from coming close to or touching the machine

Do not jump off the machine, but use hand grips and access steps.

●

if possible drive the machine out of the danger zone

Mark machines, which could be in the way, with a clearly visible sign.

●

have the power switched off

Pull off the main battery switch.

Operate the machine only from the operator’s stand.

Filling the fuel tank

Keep the cabin doors closed.

Do not breath in fuel fumes.

Do not adjust the driver’s seat while driving.

Refuel only with engine and cabin heater shut down.

Do not climb onto or off the machine while the machine is driving.

20

Do not refuel in closed rooms.

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No open fire, do not smoke.

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

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

Drain the hydraulic oil at operating temperature – danger of scalding!

Catch running out hydraulic oil and dispose of environmentally.

Always catch and dispose of hydraulic oils separately.

Do not start the engine after draining the hydraulic oil.

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

Maintenance work Maintenance work must only be performed by qualified and authorized persons.

Comply with the maintenance work described in the operating and maintenance instructions, including the information concerning the replacement of parts.

Changing hydraulic hoses

For overhead maintenance and assembly work use the access steps and working platforms provided or other secure means. Do not use machine parts as access steps.

Hydraulic hoses must be immediately replaced if:

Hydraulic hoses must not be mixed up by mistake.

Hydraulic hoses must be visually inspected at regular intervals.

●

the outer layer is damaged down to the inlay (e.g. chafing, cuts, cracks)

●

the outer layer is brittle (formation of cracks in the hose material)

●

the hose shows deformations in pressurized and depressurized condition, which do not comply with the original shape of the hydraulic hose

●

the hose shows deformations in bends, e.g. squeezing, buckling, layer separation, formation of blisters

Lower the dozer blade/bucket to the ground.

●

parts of the hose are leaking.

Pull the key out of the ignition switch.

●

hoses are not correctly installed

Secure the articulated joint with the articulation lock.

●

the hydraulic hose has separated from the fitting

Work on hydraulic lines

●

the fitting shows corrosion that impairs both function and strength

●

fittings are damaged or deformed, whereby the function and strength of the hose - hose connection is impaired

●

expiration of storage time and utilization period

When performing maintenance work on machines used in contaminated environments, all applicable national or local safety regulations must be applied.

Keep unauthorized persons away from the machine.

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

Park the machine on level, firm ground.

In order to depressurize the hydraulic system lower the dozer blade/bucket to the ground and shut the engine down.

Relieve hydraulic pressures before working on hydraulic lines. Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury. When being injured by hydraulic oil seek medical advice immediately, as otherwise this may cause severe infections.

Do not step in front of or behind the wheels when performing adjustment work in the hydraulic system.

Only genuine BOMAG replacement hydraulic hoses ensure that the correct hose type (pressure range) is used at the right location.

Working on the engine Drain the engine oil at operating temperature – danger of scalding!

Do not change the setting of pressure relief valves.

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Working on the air conditioning

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

Faults on the air conditioning should only be fremedied by professional personnel.

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

Do not perform welding work in the vicinity of the air conditioning. Danger of explosion!

Working on the cooling system Check the coolant level only on a cold and not running engine, fill up if necessary – danger of scalding! Drain off and fill in coolant only when the engine is cold and not running. Catch coolant and dispose of environmentally.

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

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

Working on the dozer blade/bucket

Working on electric parts of the machine

Lower the dozer blade/bucket to the ground and shut the engine down.

Before starting to work on electric parts of the machine disconnect the battery and cover it with insulating material.

Cleaning work

Do not use fuses with higher ampere ratings and do not repair fuses with a piece of wire. Fire hazard!

Do not use gasoline or other easily inflammable substances for cleaning.

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

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

Do not guide the cleaning jet into the exhaust.

Do not let acid come in contact with hands or clothes! When injured by acid flush off with clear water and seek medical advice.

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

Metal objects (e.g. tools, rings, watch straps) must not come in contact with the battery poles – danger of short circuit and burning!

Repair

When recharging serviceable batteries remove all plugs, to avoid the accumulation of explosive gases.

Observe the applicable instructions when starting with an auxiliary battery.

Dispose of old batteries according to regulations.

Switch off the charging current before removing the charging clamps.

Ensure sufficient ventilation, especially if the battery is to be charged in a closed room.

Working on the fuel system Do not inhale any fuel fumes.

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

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

22

Do not perform cleaning work while the engine is running.

If the machine is defective attach a clearly visible warning tag.

Always remove the main battery switch before starting welding work on the machine.

Before pulling the connecting plugs off the control units the ignition switch must be switched to „0“.

When performing electric welding work on the refuse compactor, the plug connectors must be pulled off the control units as a measure to protect the electronics in engine control unit and ESX. Repair work must only be performed by qualified and authorized persons. Use our repair instructions for this work.

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

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3 Indicators and Controls

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Fig. 6

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1

Fuel level gauge

13 Rotary switch for speed range selection

2

Volt meter 24V

14 Travel lever (forward/0/reverse)

3

Engine revolution counter and operating hour meter

15 Rotary switch for parking brake

4

Coolant temperature gauge

17 Cigarette lighter

5

Hydraulic oil temperature gauge

18 Push button for central lubrication system

6

Ignition switch

19 Emergency stop push button

7

Fault monitoring board for engine functions

20 Control unit for air conditioning*

8

Fault monitoring board for machine functions

21 Rotary switch for cabin fresh circulation fan

9

Lever for dozer blade / bucket control control

22 Travel pedal for throttle control

16 Rotary switch for seat cushion heating

10 Warning light for engine control

23 Steering lever

11 Control light for water separator in fuel pre-filter

24 Push button for warning horn

12 Socket 24V

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25 Air distribution nozzles

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3.1

General notes

3.2

Description of indicators and control elements

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.

Fig. 7

Nr. 1 =

Fuel level gauge

shows the fuel level inside the fuel tank.

L

Note

Do not drive the fuel tank dry, as otherwise the fuel system needs to be bled.

Fig. 8

Nr. 2 =

Voltmeter 24 V

shows the on-board voltage when the ignition is on. shows that the generator charges the battery when the engine is running.

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,QGLFDWRUV DQG &RQWUROV

Coolant level too low = Control light ”7” in the fault monitoring board for machine functions no. 7 lights up, the engine is shut down after 20 seconds. Top up coolant, change if necessary, seal leakages.

Fig. 9

Nr. 3 =

Engine revolution counter and operating hour meter

The engine revolution counter shows the engine speed in revolutions per minute.

Scale value X = engine speed (scale value x 100).

The operating hour meter counts the operating hours while the engine is running.

All maintenance work must be performed according to the indicated operating hours.

Fig. 11

Nr. 5 =

Hydraulic oil temperature gauge

shows the temperature of the hydraulic oil. temperature too high = 92±3 °C, control light ”14” in the fault monitoring board for engine functions no. 8 lights up, the warning buzzer sounds and the engine is shut down after 2 minutes. Clean the hydraulic oil cooler.

Fig. 10

Nr. 4 =

Coolant temperature gauge

shows the coolant temperature in the engine cooling system. temperature too high = Control light ”6” in the fault monitoring board for engine/ hydraulic system no. 7 lights up, the warning buzzer sounds and the engine power is reduced. Clean the radiator.

Fig. 12

Nr. 6 =

Ignition switch

Position "0"

BC 672 RB/EB,BC 772 RB/RS

%20$*

= Ignition off, key can be pulled out, engine off.

29

,QGLFDWRUV DQG &RQWUROV

Position "I"

L

= Ignition on, all control lights on the fault monitoring boards light up for approx. 4 seconds.

Control lights for charge system, engine oil pressure and parking brake. Control lights for travel lever in neutral, preselected travel speed range and preheating system light up. Preheating, after approx.

30 seconds the control light will start to flash. Start the engine immediately after the control light has started flashing.

Fig. 13

Nr. 7 = Note

The ignition switch is designed with a lock to prevent repetitive starting. For a new starting attempt the ignition key must first be turned back to position "0".

Position "II", Start

= turn further against spring pressure, the engine starts, turn the ignition key back to position "I" once the engine has started. Control lights for charge system and engine oil pressure go out. Parking brake control light only goes out after releasing the parking brake.

Fault indicator, engine functions

If one of the red control lights comes on during operation, there is a problem with the engine.

Nr. 8 =

Fault indicator, machine functions

If one of the red control lights comes on during operation, there is a problem with the machine.

L

Note

When turning the ignition switch to position "I" all control lights will light up for approx. 4 seconds (function test).

Replace a defective fault indicator immediately.

Caution Run the engine warm for a short while before starting work. Do not allow the engine to run longer than 10 minutes with idle speed.

Do not shut the engine down all of the sudden from full speed, but let it idle for a while for temperature equalization.

Fig. 14

Fault monitoring board for engine functions (RB) Control light 1 (yellow)

30

%20$*

= Preheating system (cold start) flashes with ignition switch in position "I"

BC 672 RB/EB,BC 772 RB/RS

,QGLFDWRUV DQG &RQWUROV

after 30 seconds and goes out after starting.

2 (yellow)

3 (red)

= Batteries are not being charged.

Check V-belt, if necessary repair the generator. = Engine oil pressure too low, the engine control unit shuts the engine down. Check the engine oil level, if necessary have the engine repaired.

3a (red) permanent light = Fault in engine control. The engine control is switched off (emergency operation).

Fig. 15

Fault monitoring board for machine functions

3a (red) flashing = external fault, the warning buzzer sounds. The machine control has detected a fault.

4 (yellow) 5 (yellow)

L

Control light 9 (yellow)

10 (red) = Parking brake closed lights up

= Cabin dehumidifier switched on. = Air filter cartridges soiled, clean cartridges, replace.

= Position "I" of ignition switch with engien shut down, when starting the engine = after 4 seconds in position â&#x20AC;&#x17E;rightâ&#x20AC;&#x153; of the rotary switch for the parking brake

Note

Once the air filter service indicator lights up, work may be continued until the end of the day.

6 (red)

= Coolant temperature too high. The engine control unit shuts the engine down. Clean the radiator.

7 (red)

= Lack of coolant. The warning buzzer sounds, the engine is shut down after 20 seconds. Fill up coolant, change if necessary.

8 (yellow)

= Dirt sensor on the return flow filter

goes out

= after starting the engine, with the rotary switch for the parking brake in position "0"

11 (yellow) = Central lubrication system

= Failure of fresh air fan (depressed rotating speed). Clean the fresh air filter, replace if necessary, replace the fan if damaged.

flashes 1 second on 1 second off = Lubrication pump faulty flashes 0.5 seconds on 0.5 seconds off = Grease container empty flashes 0.5 seconds on 1 second off = Malfunction of the central lubrication system Permanent light approx. 45 seconds = Lubrication process 12 (yellow) = Pressure differential switch on 4 hydraulic oil filters. Replace all hydraulic oil filters, check the hydraulic system if it comes on too early.

BC 672 RB/EB,BC 772 RB/RS

%20$*

31

,QGLFDWRUV DQG &RQWUROV

Position "0" (neutral position) = no actuation, lever returns automatically to "0"-position.

13 (yellow) = Pressure differential switch on the splitter gear oil filter. Replace the oil filter, check the hydraulic system if it comes on too early.

Position "I"

= Dozer blade down

Position „I“ and push button “a“ = Dozer blade in floating position (e.g. to level the surface while driving backwards)

14 (red) = Hydraulic oil temperature 92±3 °C. The warning buzzer sounds, the engine is shut down after 2 minutes. Let the engine run at idle speed until the warning light goes out, clean the hydraulic oil cooler.

Position "II"

= Dozer blade up, float position off

15 (red) = Hydraulic oil filter, return flow. Warning buzzer sounds. Check the hydraulic system, change the return flow filter.

16 (green)

17 (green)

18 (green)

= The travel lever is in "0"-position for starting. When operated to one of the travel directions the control light goes out. = I. speed range, rotary switch for speed range selection in position turtle.

Fig. 17

= II. speed range, rotary switch for speed range selection in position rabbit.

19 (red) = Hydraulic oil level, minimum level.

The warning buzzer sounds, the engine is shut down after 20 seconds.

Seal the leak, fill up hydraulic oil.

20 (yellow) = not used.

Lever for bucket control (RS) Middle position = No actuation, lever returns automatically to middle position.

Bucket up/down Position forward

= bucket down

Position backwards = bucket up

Tipping the bucket Position left

= Tipping the bucket to fill

Position right

= Tipping the bucket to empty

Floating position Press button "a"

Fig. 16

Nr. 9 =

32

Lever for dozer blade control

= bucket in float position, e.g. to level the site surface during reverse travel

Press button "a" again = float position of bucket disabled

%20$*

BC 672 RB/EB,BC 772 RB/RS

,QGLFDWRUV DQG &RQWUROV

goes out

= if fuel is clean.

Fig. 18

Nr. 10 = Warning light for engine control

L

Fig. 20

Nr. 12 = Socket 24V

Note

Permanent current, loadable up to max. 10 A.

With the ignition switch in position â&#x20AC;&#x17E;Iâ&#x20AC;&#x153; the warning light lights for about 3 seconds (function check) Permanent light= A fault message has occurred, the refuse compactor can still be used to a limited extent. flashes

= Severe fault, the engine is shut down.

goes out

= with normal engine functions.

Fig. 21

Nr. 13 = Rotary switch for speed range selection Position left

= 1. Low working speed range, control light "17", turtle, in the fault monitoring board for machine functions no. 8 lights up.

Position right

= 2. Transport speed range, control light "18", rabbit, in the fault monitoring board for machine functions no. 8 lights up.

Fig. 19

Nr. 11 = Control light for water separator in fuel pre-filter lights up

= if the water proportion in the transparent section of the fuel filter reaches the contacts.

Environment Drain off the water proportion and other impurities and dispose of environmentally.

BC 672 RB/EB,BC 772 RB/RS

%20$*

33

,QGLFDWRUV DQG &RQWUROV

Fig. 22

Fig. 23

Nr. 14 = Travel lever (forward/reverse)

Nr. 15 = Rotary switch for parking brake

Position "0"

Position "right" = Parking brake applied, after 4 seconds control light "10" in the fault monitoring board for machine functions no. 8 lights up.

= for starting the engine, control light "16" in the fault monitoring board for machine functions no. 8 lights up.

Position "front" = forward travel, control light goes out.

Position "left"

Position "rear" = reversing, control light goes out, at the same time the warning backup alarm sounds.

= Parking brake released. The parking brake control light goes out.

Danger Danger of accident!

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

L

Note

In travel lever position "0" (neutral position) the machine is automatically braked.

Fig. 24

Nr. 16 = Rotary switch for seat heating Position"left"

= seat heating off.

Position"right" = seat heating on.

34

%20$*

BC 672 RB/EB,BC 772 RB/RS

,QGLFDWRUV DQG &RQWUROV

Fig. 25

Fig. 27

Nr. 17 = Cigarette lighter

Nr. 19 = Emergency stop switch The engine will be shut down and the brake will close immediately.

Danger Danger of accident!

Operate only in emergency situations during operation, do not use as a service brake.

The machine should only be started again after the danger, that caused the actuation of the emergency stop switch, has been removed. operate

= push the button completely down, it will automatically lock in end position.

Nr. 18 = Push button for central lubrication system

unlock

= turn the button clockwise and release it.

press 2 seconds

to drive

= move the travel lever no. 14 to "0"-position and start the engine again.

Fig. 26

= the central lubrication system starts an additional lubrication cycle.

press 1 second = to reset a malfunction. The flashing of the control light "11" on the fault monitoring board for machine functions no. 8 changes to permanent light.

Fig. 28

Nr. 20 = Control unit for air conditioning

BC 672 RB/EB,BC 772 RB/RS

%20$*

35

,QGLFDWRUV DQG &RQWUROV

a

= Push button to activate and deactivate operation of air conditioning.

always supplied with fresh air and maintains a slight overpressure in the cabin.

b

= Push button to raise the nominal value, may also be used to increase the fan speed manually.

Positions 1, 2 and 3 = various fan speeds

c

= LED with symbol for operation of air conditioning activated.

d

= LED with symbol for air circulation activated.

In case of a failure of the fresh air fan or if the fan runs under load the control light 8 on the fault monitoring board for engine functions no. 7 will light up.

e

= LED with symbol for fan speed manually adjusted.

Clean fresh air filter or replace the fan if it is defective.

f

= 4-digit LED display for room temperature, nominal value (in °F or °C), as well as fault indication for temperature sensors.

g

= Button to start REHEAT-operation.

h

= Button to activate the heating.

i

= Button to switch over circulation air/ fresh air operation.

j

= Push button for manual adjustment of the evaporator fan speed.

k

= 12 digit LED bar display for evaporator fan speed (in 10%-steps)

l

= Push button to raise the nominal value, may also be used to increase the fan speed manually.

m

L

= Push button to activate and deactivate the control unit.

Note

Fig. 30

Nr. 22 = Travel pedal for throttle control Position "0"

= Engine running at idle speed

Position "I"

= higher idle speed/full load

L

Note

The engine speed can be read on the engine speed display no. 3.

Fig. 29

Nr. 21 = Rotary switch for fresh air fan in cabin The fresh air fan for the cabin runs always when the ignition switch is turned to position "I" and wen the engine is running. It ensures that the cabin is

36

Fig. 31

Nr. 23 = Steering lever

%20$*

BC 672 RB/EB,BC 772 RB/RS

,QGLFDWRUV DQG &RQWUROV

Steering lever to the left = steering movement to the left Steering lever to the right = steering movement to the right

Fig. 34

Nr. 26 = Electric installation box The installation box is installed in the console behind the driverâ&#x20AC;&#x2122;s seat.

Fig. 32

Nr. 24 = Push button for warning horn

Fig. 35

Fuses Fig. 33

Terminal

Nr. 25 = Air distribution nozzles The air distribution nozzles are assigned to the air conditioning, coolant powered cabin heating and the cabin fresh air fan.

Adjusting the direction = turn the outside of the nozzle Regulating the air quantity = adjust, open or close by swivelling the flap

BC 672 RB/EB,BC 772 RB/RS

X1:20 (15A)

= (F50) Climatronic (option)

X1:21 (30A)

= (F89) Cigarette lighter

X1:22

= (F94) Spare, safety ventilation system

X1:23 (30A)

= (F13) Ignition switch

X1:24 (20A)

= (F34) Air conditioning

X1:25 (30A)

= (F05) Socket

X1:26 (10A)

= (F84) Processor control

X1:27 (30A)

= (F67) Power control

X1:28

= (F123) Spare, safety ventilation system

X1:29 (15A)

= (F24) Instruments

X1:30 (10A)

= (F16) Lubrication system

%20$*

37

,QGLFDWRUV DQG &RQWUROV

X1:31 (15A)

= (F29) Driveryâ&#x20AC;&#x2122;s seat

X1:32 (10A)

= (F122) Control EMR

X1:33 (20A)

= (F31) Cabin ventilator

X1:34 (15A)

= (F23) Warning horns

X1:35 (10A)

= (F25) Driving and braking

X1:36 (10A)

= (F33) Climatronic (option)

L

Note

Additionally switch on the toggle switch in the cabin dashboard

Fig. 38

Nr. 28 = Air circulation nozzle for cabin heater *

Adjusting the direction = turn the outside of the nozzle

Fig. 36

Main fuse, battery 250A

L

=

(F00)

Regulating the air quantity = adjust, open or close by swivelling the flap

Note

The main fuse is located in the battery compartment.

Caution This air circulation nozzle must always be completely open when running the cabin heater. Otherwise malfunction of the cabin heater.

Fig. 37

Nr. 27 = Cabin light switch on

= turn lamp glass clockwise

switch off

= turn lamp glass anti-clockwise

Fig. 39

Nr. 29 = Timer for cabin heating a

= Memory display

b

= Weekday or preselected day

*

38

%20$*

Optional equipment

BC 672 RB/EB,BC 772 RB/RS

,QGLFDWRUV DQG &RQWUROV

c

= Symbol for radio remote control

Fuse box F2

d

= Current time or preselected time

(1) 10A = Spare

e

= Temperature display

(2) 10A = (F125) Pre-fuse, reversing camera

f

= Operating display

(3) 10A = (F98) Mirror heater

g

= Temperature preselection – control range 10°C ...30°C

(4) 10A = (F41) Flashing beacon

h

= Push button extend time

(6) 5A

i

= Push button shorten time

(7) 25A = (F40) Cabin heater

j

= Push button to switch heater on/off

(8) 10A = (F49) Transformer for radio

k

= Push button select, activate, deactivate memory

l

= Push button to set time and weekday

(5) 10A = (F42) cabin light = (F90) Timer for cabin heater

Fig. 41

Nr. 31 = Dashboard, cabin a

= Toggle switch for front windscreen wipers

b

= Toggle switch for front washer

c

= Toggle switch/push button for rear windscreen wiper/washer

d

= Toggle switch for interior lights

Do not use fuses with higher ampere ratings and do not bridge fuses.

e

= Toggle switch for front working head lights

Fuse box F1

f

(1) 10A = (F27) Windscreen wiper, washer, front

= Toggle switch for working head lights, sides

g

(2) 10A = (F28) Windscreen wiper, washer, rear

= Toggle switch for working head lights, rear

h

= Toggle switch for rear view mirror heatings

(4) 20A = (F85) Working headlights, front

i

= Toggle switch for flashing beacon

(5) 15A = (F86) Working headlights, rear

j

= Toggle switch for engine compartment light

Fig. 40

Nr. 30 = Fuse boxes, cabin Danger Fire hazard!

(3) 10A = Spare

(6) 10A = (F02) Fresh air fan (7) 15A = (F99)2 headlight, engine compartment light (8) 15A = (F66) 2 working headlights left, right

BC 672 RB/EB,BC 772 RB/RS

%20$*

39

,QGLFDWRUV DQG &RQWUROV

gine compartment and as a protection against unauthorized use.

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

Fig. 42

Nr. 32 = Comfort seat a

= Lever, seat inclination

b

= Lever, seat enlargement

c

= Rotary button, arm rest adjustment

d

= Rotary button, backrest curvature (Drehknopf, Lehnenwölbung (support for intervertebral disc)

e

= Lever, backrest inclination

Fig. 44

f

= Lever, length adjustment

Reversing camera*

g

= Foldable lever, horizontal suspension

h

= Lever, adjustment of vertical suspension, seat height

with the monitor connected it enables the driver to check the working range behind the machine without direct vision.

i

= Snap-in lever to turn the seat

Angle of vision = 110° horizontal, 75° vertical

j

= Rotary button to displace the arm rest

Fig. 45

Monitor for reversing camera**

Fig. 43

Main battery switch Position "I"

= normal position, operation

Position "II"

= disconnects the battery from the vehicle electrics, in case of fire in the wiring or in the en-

40

With the reversing camera connected the driver is able to check the working area behind the machine without having a direct view. * **

%20$*

Optional equipment Optional equipment

BC 672 RB/EB,BC 772 RB/RS

,QGLFDWRUV DQG &RQWUROV

a

= Selector switch for permanent or automatic operation

B

= distance point approx. 1 m (1.1 yard)

b

= Adjusting the contrast

C

c

= Adjusting the brightness

= distance point approx. 3m (3.3 yards)

d

= Switching the brightness for day or night operation

D

= distance point approx. 5m (5.5 yards)

Distance mark on monitor

Fig. 46

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

L

Note

Distance marks should always be rubbed on by the operator himself, so that he will have a feeling for the distances in the travel range behind the machine.

The following text explains how to rub marks for distances,

Fig. 47

A

= tail edge and maximum width

BC 672 RB/EB,BC 772 RB/RS

%20$*

41

,QGLFDWRUV DQG &RQWUROV

42

%20$*

BC 672 RB/EB,BC 772 RB/RS

4 Operation

BC 672 RB/EB,BC 772 RB/RS

%20$*

43

2SHUDWLRQ

4.1

General notes

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.

4.2

Tests before taking into operation

Please observe strictly the safety regulations in these operating and maintenance instructions.

Before each working day: ●

Check the engine oil level

●

Check the hydraulic oil level

L

Note

In hydraulic systems filled with Panolin HLP Synth.

46 always use the same oil to top up. With other ester based oils consult the lubrication oil service of the respective oil manufacturer. ●

Check the coolant level

●

Check the oil level in the splitter gear

Danger Fire hazard!

Do not refuel in closed rooms ●

Check the fuel level

●

Drain the water from the fuel pre-cleaner (if required)

●

Check fuel tank and fuel lines for leaks

●

Inspect engine and machine visually

●

Check bolted connections for tight fit

●

Check function of brakes. Do not use the emergency stop to check

●

Check function of steering

●

Check the scrapers on the compactor wheels

●

Check the edge cutters for the compactor wheels

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

44

●

Check the provision tank for the windscreen washer system

●

Check the mirror adjustment.

%20$*

BC 672 RB/EB,BC 772 RB/RS

2SHUDWLRQ

L

Note

4.3

Clean windscreens and mirrors if required. ●

Check inner sides of compactor wheels, remove wires, cables, ropes, etc.

Refer also to the maintenance instructions in this manual.

Top up missing lubricants according to the maintenance instructions.

Starting the engine

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

Fig. 49 Fig. 48 ●

Set the main battery switch (Fig. 48) to position ”I”.

●

Adjust the comfort seat (Fig. 49).

Danger Danger of accident!

Always wear your seat belt.

Fig. 50 ●

BC 672 RB/EB,BC 772 RB/RS

%20$*

Fasten your seat belt (Fig. 50).

45

2SHUDWLRQ

Fig. 51 ●

Check, whether the emergency stop switch (Fig. 51) is unlocked.

Fig. 54

Shift the travel lever (Fig. 54) to position "0".

●

L

Note

Do not press the drive pedal before and during starting.

Fig. 52 ●

Shift the dozer blade control lever (Fig. 52) to position ”0” (RB).

Fig. 55 ●

Turn the ignition key (Fig. 55) to position "I".

Fig. 53 ●

46

Set the bucket control level (Fig. 53) to middle position (RS).

%20$*

BC 672 RB/EB,BC 772 RB/RS

2SHUDWLRQ

Fig. 56

Fig. 57

All congtrol lights in the fault monitoring baord for engine functions 7 (Fig. 56) and machine functions (8) light up for approx. 4 seconds (test function).

â&#x2014;?

Turn the ignition key (Fig. 57) to position "II", the starter will crank the engine.

â&#x2014;?

As soon as the engine ignites return the ignition key to position "I".

The engine control warning light lights for approx.

3 seconds (test function).

Control lights for battery charging, engine oil pressure and parking brake as well as control light for travel lever in "0" position, control light for travel speed range and preheating control light continue to light.

Caution Perform the starting process for maximum 20 seconds without interruption and pause for a minute between starting attempts.

Control lights for charge system, engine oil pressure and preheating system go out.

Caution Run the engine warm for a short while, but do not run with idle speed for more than 10 minutes.

If the engine has not started after two attempts perform trouble shooting.

BC 672 RB/EB,BC 772 RB/RS

%20$*

47

2SHUDWLRQ

4.4

Starting under low temperatures

Before starting perform all work described in section 4.2.

●

L

Note

Do not actuate the travel pedal.

Fig. 60 ●

Turn the ignition key (Fig. 60) to position "II", the starter will crank the engine.

●

As soon as the engine ignites return the ignition key to position "I".

Control lights for charge system, engine oil pressure and preheating system go out.

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

Fig. 58 ●

Turn the ignition key (Fig. 58) to position "I" and hold it,

At extreme minus temperatures the hydraulic oil filter control light in the monitoring board may light up, but should go out again after approx. 15 minutes.

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

Fig. 59 ●

48

until preheating control light 1 (Fig. 59) in the fault monitoring board for engine functions stops flashing.

%20$*

BC 672 RB/EB,BC 772 RB/RS

2SHUDWLRQ

4.5

Starting with jump leads

4.6

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

Wrong connection will cause severe damage in the electric system.

Driving the machine

Danger Danger of accident!

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

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

Before starting to drive make sure that the drive range is absolutely safe.

Always wear the seat belt when driving.

Keep the cabin door closed.

Fig. 61 ●

When starting with external batteries connect the plus poles (Fig. 61) and the minus poles (earth cable) after.

●

Perform all steps as described in the previous section.

●

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

Fig. 62 ●

Turn the rotary switch for travel speed ranges (Fig. 62) to the desired speed range.

Position "left"

= 1. speed range, working speed

Position „right“ = 2. speed range, transport speed

BC 672 RB/EB,BC 772 RB/RS

%20$*

49

2SHUDWLRQ

Fig. 63

Fig. 65

Control light, symbol turtle 17 (Fig. 63) for 1st speed range, control light rabbit for 2nd speed range in the fault monitoring board for machine functions lights up.

●

Pull the bucket control lever (Fig. 65) back and raise the bucket (RS).

Fig. 66 ●

Fig. 64 ●

Pull the dozer blade control lever (Fig. 64) back to position "II" and raise the dozer blade (RB).

Shift the travel lever (Fig. 66) to the desired travel direction.

Position "I"

= Forward

Position "II"

= Backwards

In position "II" the backup alarm sounds.

50

%20$*

BC 672 RB/EB,BC 772 RB/RS

2SHUDWLRQ

Danger Danger of accident!

Before starting to drive make sure that the drive range is absolutely safe.

During travel the cabin door must be kept closed.

Fig. 67

The control light for neutral position of travel lever 16 (Fig. 67) in the fault monitoring board for machine functions goes out.

Fig. 70

Actuate the throttle pedal (Fig. 70).

●

L

Note

When reversing the backup alarm sounds.

When releasing the travel pedal the machine is automatically braked.

Fig. 68 ●

Turn the rotary switch for parking brake (Fig. 68) to position „left“. Parking brake released.

Fig. 71 ●

Read the engine speed on the RPM-meter (Fig. 71).

Fig. 69

The parking brake control light 10 (Fig. 69) in the machine functions monitoring board goes out.

BC 672 RB/EB,BC 772 RB/RS

%20$*

51

2SHUDWLRQ

4.7

Emergency exit

If the machine should turn over and the cabin door is closed, all cabin window can be used as an emergency exits.

Fig. 72 â&#x2014;?

Steer the machine with the steering lever (Fig. 72) to the desired direction.

Fig. 73 â&#x2014;?

Take the emergency hammer (Fig. 73) out of the bracket and destroy the window most suitable as emergency exit.

Danger Danger of injury!

Risk of injury by glass splinters.

52

%20$*

BC 672 RB/EB,BC 772 RB/RS

2SHUDWLRQ

4.8

Actuating the emergency stop switch

4.9

Danger Mortal danger!

Danger 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. 74

L

Do not use the dozer blade to transport persons.

Moving other vehicles with the dozer blade is prohibited!

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

Fig. 75

Press the button of the emergency stop switch (Fig. 74) down, it locks in pressed position.

●

Operating the dozer blade

●

Pull the lever for dozer blade control (Fig. 75) back to position "II" and raise the dozer blade.

Note

The engine is shut down.

Caution 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

●

Return the travel lever to "0"-position and start the engine again.

Fig. 76 ●

BC 672 RB/EB,BC 772 RB/RS

%20$*

Push the lever for dozer blade control (Fig. 76) forward to position "I" and lower the dozer blade.

53

2SHUDWLRQ

4.10 Operating the bucket (RS)

Danger Mortal danger!

Do not use the bucket to transport persons.

Moving other vehicles with the bucket is prohibited!

Always lower the bucket to the ground before shutting the engine down.

Fig. 77 ●

Press button a (Fig. 77).

●

Shift the dozer blade control lever to float position "I".

Fig. 79 ●

Pull the bucket control lever (Fig. 79) back and raise the bucket.

Fig. 78 ●

Shift the lever to position "II" to switch off float position.

Fig. 80 ●

54

%20$*

Shift the bucket control lever (Fig. 80) forward and lower the bucket to the ground.

BC 672 RB/EB,BC 772 RB/RS

2SHUDWLRQ

Fig. 81

Fig. 83

●

Press push button a (Fig. 81) in the lever. The bucket changes to float position.

●

Press the push button again to disable the float position.

Shift the bucket control lever (Fig. 83) to the left to fill the bucket. The bucket tips back.

●

L

Note

When releasing the bucket control lever, it will automatically return to middle position.

Fig. 82 ●

Shift the bucket control lever (Fig. 82) to the right to empty the bucket. The bucket tips forward.

BC 672 RB/EB,BC 772 RB/RS

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55

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4.11 Operating the service brake

Fig. 86

Fig. 84 â&#x2014;?

The control light for neutral position of travel lever 16 (Fig. 86) in the fault monitoring board for machine functions flashes.

Relieve the drive pedal (Fig. 84).

Fig. 85 â&#x2014;?

56

Shift the travel lever (Fig. 85) to position "0", the machine is hydrostatically braked.

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4.12 Operating the parking brake

Fig. 89

Fig. 87 ●

The control light for neutral position of travel lever 16 (Fig. 89) in the fault monitoring board for machine functions flashes.

Relieve the drive pedal (Fig. 87).

Fig. 90 Fig. 88 ●

●

Shift the travel lever (Fig. 88) to position "0", the machine is hydrostatically braked.

Turn the rotary switch for parking brake (Fig. 90) to position „right“.

Fig. 91

The parking brake control light 10 (Fig. 91) in the fault monitoring board for machine functions lights up after 4 seconds.

BC 672 RB/EB,BC 772 RB/RS

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57

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4.13 Starting and adjusting the air conditioning Switching on the control unit

L

Note

The diesel engine is running.

If only the ignition is switched on, the evaporator fan speed is limited to 30% of the nominal speed.

Fig. 94

L

Note

The LED-display shows the stored cabin temperature (Fig. 94).

Fig. 92

Press the On-Off-switch (Fig. 92) on the control unit.

â&#x2014;?

Fig. 93

The LED-display (Fig. 93) shows the software version for approx. 3 seconds.

â&#x2014;?

L

Note

After switching on the control unit runs an approx.

20 second self-test. After this the switching outputs of the control unit are released.

58

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Activating/deactivating air conditioning operation

Changing the temperature display to degree Celsius or degree Fahrenheit

Fig. 95

Fig. 97

Press the On-Off-switch (Fig. 95) for operation of the air conditioning system.

●

L

●

Note

In order to change from degree Celsius to degree Fahrenheit press and hold the circulation air button 1 (Fig. 97) first and then press the minus button (2). The display changes to degree Fahrenheit.

The LED below the symbol for operation of air conditioning lights up. The stored cabin temperature is displayed.

Operation of the air conditioning starts.

Fig. 98 ●

Fig. 96

Press the On-Off-switch (Fig. 96) for operation of the air conditioning system.

●

L

In order to change from degree Fahrenheit to degree Celsius press and hold the circulation air button 1 (Fig. 98) first and then press the minus button (2). The display changes to degree Celsius.

Note

The LED below the symbol for operation of air conditioning goes out. Operation of the air conditioning system is switched off.

BC 672 RB/EB,BC 772 RB/RS

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59

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After 5 seconds this new nominal value is saved and operation of the air conditioning system is started.

Adjusting the desired cabin temperature

L

Note

Operation of the air conditioning system is switched on.

A cabin temperature of e.g. 21°C is desired.

Fig. 99

Press the minus button (Fig. 99) once.

●

L

Note

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

Fig. 100

Press the minus button (Fig. 100) 3 times.

●

L

Note

The LED-display shows 21 °C as new nominal value.

60

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Manual adjustment of the evaporator fan speed

L

Note

The speed of the evaporator fan can be manually adjusted as a measure to avoid a too quick dropping of the cabin temperature.

Fig. 103

Press the minus button 6 times (Fig. 103).

●

L

Note

The LED bar display shows only 40% evaporator fan speed and after 5 seconds this new value will be saved Fully automatic air conditioning operation is switched off. The evaporator fan speed is reduced to 40%.

Fig. 101

At present the LED bar display (Fig. 101) shows the evaporator fan speed with 100% when the air conditioning works in automatic mode.

●

Fig. 104

Press the button for evaporator fan speed (Fig. 104).

●

Fig. 102

For manual operation press the button for evaporator fan speed (Fig. 102)

●

L

L

The LED below the symbol for manual adjustment goes out.

Note

The LED below the symbol for manual adjustment lights up.

BC 672 RB/EB,BC 772 RB/RS

Note

Automatic air conditioning operation is activated again. The evaporator fan speed is automatically controlled.

%20$*

61

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Switching off Reheat - operation

4.14 Air conditioning, switching Reheat – operation on/off Switching on Reheat - operation

L

Note

Reheat – operation is switched on to dehumidify the cabin air (clear steamed up windows). The activation lasts maximum 10 minutes and is automatically switched off by the control unit.

To avoid changing of the cabin temperature the heating is automatically activated if required.

Fig. 106

Press the Reheat button (Fig. 106).

●

L

Note

The LED display shows the adjusted cabin temperature.

The present evaporator fan speed is shown by the LED-display.

Fig. 105

Press the Reheat button (Fig. 105).

●

L

Note

The LED display shows „rH“ for Reheating status.

The evaporator fan speed is set to 100% (LED bar display).

62

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L

4.15 Air conditioning, changing between circulation air/ fresh air operation

Note

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

Switching on circulation air operation.

Fig. 107

Press the circulation air/fresh air button (Fig. 107).

â&#x2014;?

L

Note

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

Switching on fresh air operation .

Fig. 108 â&#x2014;?

Press the circulation air/fresh air button (Fig. 108).

BC 672 RB/EB,BC 772 RB/RS

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63

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L

4.16 Air conditioning, heating operation

Note

The LED below the symbol for manual adjustment lights up.

The LED display shows „H“ for Heating.

Fully automatic heating operation

L

The LED bar display indicates that the heating valve is 100% open.

Note

Heating operation starts fully automatically if the current cabin temperature drops below the desired nominal temperature.

Fig. 111

Press the minus button e.g. 6 times (Fig. 111).

●

L

Fig. 109

L

Note

The LED bar display indicates that the heating valve is 40% open.

Note

The LED display shows the stored cabin temperature (Fig. 109) and the LED bar display shows an evaporator fan speed of 100%.

After 5 seconds the new status of the heating valve is saved, fully automatic heating operation is switched off.

Setting heating operation manually

Fig. 112

Press the heater button (Fig. 112) once again.

●

Fig. 110 ●

64

Press the heater button (Fig. 110).

L

Note

Automatic heater operation is activated again.

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4.17 Shutting the engine down

Fig. 115

The control light for neutral position of travel lever 16 (Fig. 115) in the fault monitoring board for machine functions flashes.

Fig. 113

Release the drive pedal (Fig. 113) (throttle control), so that the engine speed rops to idle speed.

●

L

Note

When releasing the drive pedal the machine is braked.

Fig. 116 ●

Turn the rotary switch for parking brake (Fig. 116) to position „right“.

Fig. 114 ●

Shift the travel lever (Fig. 114) to position "0".

BC 672 RB/EB,BC 772 RB/RS

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65

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Fig. 117

Fig. 119

The parking brake control light 10 (Fig. 117) in the fault monitoring board for machine functions lights up after 4 seconds.

●

Shift the bucket control lever (Fig. 119) (RS) forward and rest the bucket on the ground.

Caution Do not shut the engine down all of the sudden from full speed, but let it idle for approx. 3 to 5 minutes for temperature equalization.

Fig. 118 ●

Shift lever (Fig. 118) for dozer blade control (RB) forward to position "I" and lower the dozer blade slowly until it rests on the ground.

Fig. 120

Turn the ignition switch (Fig. 120) to position "0" and pull the ignition key out.

●

Caution Secure the machine against unauthorized use, pull the ignition key out, lock the cabin door, switch of the main battery switch and remove the key.

66

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4.18 Parking on a slope

Danger Danger of accident!

Parking on a slope with the engine running.

Lower the dozer blade/bucket to the ground.

Apply the parking brake to prevent unintended rolling of the machine.

Fig. 123 ●

Turn the rotary switch for parking brake (Fig. 123) to position „right“.

Fig. 121 ●

Shift the dozer blade control lever (Fig. 121) forward to position „I“ and lower the dozer blade slowly until it rests on the ground.

Fig. 124

The parking brake control light 10 (Fig. 124) in the fault monitoring board for machine functions lights up after 4 seconds.

Fig. 122 ●

Shift the bucket control lever (Fig. 122) (RS) forward and rest the bucket on the ground.

BC 672 RB/EB,BC 772 RB/RS

%20$*

67

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4.19 Towing the machine

Fig. 127

Fig. 125

●

Remove the safety caps from the eight high pressure relief valves (Fig. 127).

●

Back the inner hexagon screws (1) out for approx. 2 turns.

Rear towing hooks (Fig. 125).

●

Fig. 126

Danger Danger of accident!

Fig. 128

L

You should always use a tow bar. ●

68

Note

After towing turn the inner hexagon screws 1 (Fig. 128) back in and tighten to a torque of 10 Nm.

Attach the tow bar (Fig. 126) to the towing eyes.

%20$*

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Release the brake

Raise the dozer blade/bucket before towing.

Raising the dozer blade/bucket and relieving the brakes

Fig. 129

Danger Danger of accident!

Fig. 130

Before releasing the multi-disc brakes secure the machine against unintended rolling.

Danger Danger of accident!

Open the access door on the right hand tool box.

●

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

●

Unscrew the locking bolt 3 (Fig. 129).

●

Set lever (2) in direction of arrow.

●

Operate the pump lever (1), until the multi-disc brakes are relieved. The machine can be towed.

Do not step under the raised dozer blade/bucket. ●

Set lever 2 (Fig. 130) in direction of arrow.

●

Set lever (3) in direction of arrow.

●

Operate the pump lever (1), until the multi-disc brakes are relieved and the dozer blade/bucket is raised. The machine can be towed.

Caution Secure lever (2) with the locking screw.

BC 672 RB/EB,BC 772 RB/RS

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4.20 Transport of the machine

Danger Danger of accident!

Use only stable loading ramps of sufficient load bearing capacity. Make sure that persons are not endangered by the machine tipping or sliding off.

Always use shackles on the lifting points for loading or tying the machine down.

Lift the machine only with suitable lifting gear.

Weights: See technical data.

Fig. 132 ●

Actuate the emergency stop switch (Fig. 132).

Lash the machine down, so that it is secured against rolling, sliding and turning over.

After transport release the articulation lock again and store it in the receptacle.

Unlock the emergency stop switch

Danger Mortal danger!

During demonstration and when loading the machine do not remain in the danger zone of the machine. ●

Lower the dozer blade/bucket onto the transport vehicle.

Fig. 133 ●

Tie the machine to the transport vehicle, use the four lifting hooks (Fig. 133) ....

Fig. 131 ●

70

After driving the machine onto the transport vehicle swing the articulation lock 1 (Fig. 131) out of its receptacle and fasten it with the bolt (2) to the eye on the front frame. Secure the bolt with the cotter pin (3).

Fig. 134 ●

%20$*

and (Fig. 134) on front and rear frames.

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Caution Observe the transport height.

Fig. 137 ●

Fold the air intake grid (Fig. 137) back.

Fig. 135 ●

Always use access steps and hand rails to climb onto the engine compartment cover (Fig. 135).

Fig. 138 ●

Remove the holding rope (Fig. 138) of the air conditioning carrier from the des snap hook and

Fig. 136 ●

Step only on such areas of the engine compartment cover which are provided with skidproof covering (Fig. 136).

Fig. 139 ●

BC 672 RB/EB,BC 772 RB/RS

%20$*

fold the air conditioning unit (Fig. 139) back.

71

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After transport

Fig. 142 ●

To enter the air intake chamber use the access step (Fig. 142).

●

Extract all accumulated dirt.

Fig. 140

After transport release the articulation lock (Fig. 140) again and store it in the receptacle.

●

Caution During transport with the air conditioning folded back ROPS and air filter may be excessively soiled.

Caution When extracting the dirt avoid damaging of fins on hydraulic oil cooler, intercooler and radiator.

Fig. 143 Fig. 141 ●

72

●

Hook the holding rope back into the air conditioning carrier (Fig. 143).

●

Fold air conditioning unit and air intake grid back to normal position and fasten, install the maintenance door.

Remove the service door (Fig. 141).

%20$*

BC 672 RB/EB,BC 772 RB/RS

5 Maintenance

BC 672 RB/EB,BC 772 RB/RS

%20$*

73

0DLQWHQDQFH

5.1

Notes on the fuel system

General notes on maintenance

The lifetime of the diesel engine depends to a great extent on the cleanliness of the fuel.

When performing maintenance work always comply with the appropriate safety regulations.

Thorough maintenance of the machine guarantees far longer safe functioning of the machine and prolongs the lifetime of important components.

The effort needed for this work is only little compared with the problems that may arise when not observing this rule.

●

Keep fuel free of contaminants and water, since this will damage the injection elements of the engine.

●

When choosing the storage place for fuel make sure that spilled fuel will not harm the environment.

●

Do not let the hose stir up the slurry at the bottom of the drum.

●

Always clean machine and engine thoroughly before starting maintenance work.

●

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

●

For maintenance work stand the machine on level ground.

●

Fuel residues in the drum are not suitable for the engine.

●

Always remove the main battery switch for all maintenance work.

●

Perform maintenance work only with the engine shut down.

●

Relieve hydraulic pressures before working on hydraulic lines.

●

Before working on electric parts of the machine disconnect the battery and cover it with insulation material.

Notes on the performance of the engine On diesel engines both combustion air and fuel injection quantities are thoroughly adapted to each other and determine power, temperature level and exhaust gas quality of the engine.

If your engine has to work permanently in "thin air" (at higher altitudes) and under full load, you should consult the customer service of BOMAG or the customer service of the engine manufacturer.

The terms right/left correspond with travel direction forward. ●

Notes on the hydraulic system

When working in the area of the articulated joint attach the articulation lock (transport lock).

●

During maintenance work catch all oils and fuels and do not let them seep into the ground or into the sewage system. Dispose of oils and fuels environmentally.

●

Catch and dispose of biodegradable oils separately.

During maintenance work on the hydraulic system cleanliness is of major importance. Make sure that no dirt or other contaminating substances can enter into the system. Small particles can produce flutes in valves, cause pumps to seize, clog nozzles and pilot bores, thereby making expensive repairs inevitable. ●

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

●

Seal external leaks immediately. If necessary inform the responsible customer service.

●

Clean fittings, filler covers and the area around such parts before disassembly to avoid entering of dirt.

●

Do not leave the tank opening unnecessarily open, but cover it so that nothing can fall in.

Frequent causes of faults ●

Operating errors

●

Incorrect, insufficient maintenance

If you cannot locate the cause of a fault or rectify it yourself by following the trouble shooting chart, you should contact the service departments at our branch offices or dealers.

74

%20$*

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0DLQWHQDQFH

Welding work on the refuse compactor ●

Disconnect the main battery switch

●

Pull the plugs off all control units, engine control unit (EMR), travel control (ESX) and additional control (DIOS).

5.2

Fuels and lubricants

Engine oil ●

Use winter grade engine oil for winter operation!

In order to assure perfect cold starting it is import to chose the viscosity (SAE-class) of the engine oil according to the ambient temperature.

For winter operation below -10 °C the oil change intervals must be shortened.

Fig. 144

Lubrication oil with a too high viscosity index causes starting difficulties. The temperature when starting the engine is therefore of highest importance when choosing the viscosity of engine oil for winter operation.

Oil viscosity Since lubrication oil changes its viscosity with the temperature, the ambient temperature at the operating location of the engine is of utmost importance when choosing the viscosity class (SAEclass) (see diagram).

BC 672 RB/EB,BC 772 RB/RS

%20$*

75

0DLQWHQDQFH

Occasional falling short of the temperature limit (e.g. use of SAE 15W/40 down to -15 °C) may effect the cold starting ability of the engine, but will not cause any engine damage.

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

Regular lubrication oil changes The longest permissible time a lubrication oil should remain in an engine is 1 year. If the following oil change intervals are not reached over a period of 1 year, the oil change should be performed at least once per year, irrespective of the operating hours reached.

Oil quality Preferably use oils of ACEA-classification E3-96 / E4-98. This enables utilization of the longest oil change intervals.

Permitted ACEA-oils = 250 operating hours

E3-96

= 500 operating hours

E4-98

= 500 operating hours

The oil manufacturer is solely responsible for assigning a product to a certain quality class.

L

Note

When changing to a higher alloyed oil quality after a longer period of operation, it is recommended to perform the first oil change of the higher quality oil already after 20 operating hours. The lubrication oil filter cartridge must be changed at the same time.

You should only use commercially available brand diesel fuel with a sulphur content below 0.5% and ensure strict cleanliness when filling in. A higher sulphur content has a negative effect on the oil change intervals. Use only winter-grade diesel fuel under low ambient temperatures. The fuel level should always be topped up in due time so that the fuel tank is never run dry, as otherwise filter and injection lines need to be bled.

Oil change intervals with oil quality

E2-96

The ACEA- and the API-classifications are used to classify the oil quality.

Quality

Lubrication oil change intervals

= 250 operating hours

Lubrication oil quality classes

Fuels

Oils of API-quality class CG-4/CH-4 may also be used.

E1-96

When using oils with a sulphur content of more than 1% by weight and a permament operating oil temperature below 60°C consult the service department of the engine manufacturer.

The following fuel specifications are permitted: DIN 51601; Nato Codes: F-54, F-75; BS 2869: A1 and A2; ASTM D 975-78: 1-D and 2-D; VV-F-800 a: DF-A, DF-1 and DF-2.

Permitted API-oils CF/CF-4 = 250 operating hours CG-4

= 500 operating hours

Winter fuel

CH-4

= 500 operating hours

For winter operation use only winter diesel fuel, to avoid clogging because of paraffin separation. At very low temperatures disturbing paraffin separation can also be expected when using winter diesel fuel.

Caution These intervals apply only when using a diesel fuel with maximum 0.5 % sulphur by weight and for ambient temperatures higher than 10 °C.

When using fuels with a sulphur content of more than 0,5% to 1% or under ambient temperatures below -10 °C (10°C) the oil change intervals specified in the table must be halved.

76

In most cases a sufficient cold resistance can also be achieved by adding flow enhancing fuel additives. Consult the engine manufacturer.

%20$*

BC 672 RB/EB,BC 772 RB/RS

0DLQWHQDQFH

Mineral oil based hydraulic oil The hydraulic system is operated with hydraulic oil HV 46 (ISO) with a kinematic viscosity of 46 mm2/s at 40 °C. For topping up or for oil changes use only high-quality hydraulic oil, type HVLP according to DIN 51524, part 3, or hydraulic oils type HV according to ISO 6743/3. The viscosity index (VI) must be at least 150. (Observe the information of the manufacturer).

Bio-degradable hydraulic oil The hydraulic system can also be operated with a synthetic ester based biodegradable hydraulic oil.

The biologically quickly degradable hydraulic oil Panolin HLP Synth.46 meets all demands of a mineral oil based hydraulic oil according to DIN 51524.

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

Lubrication grease For lubrication purposes use an EP-high pressure grease, calcium and/or lithium saponified (penetration 2), acc. to DIN 51502 KP 2G. Coolant High performance diesel engines require a well balanced coolant mixture of water, anti-freeze and supplementary coolant additives.

For coolant mixtures use only soft tap water with a water hardness between 3 and 20 °dGH. The water should not contain more than 100 mg/dm3 of chlorine and sulphate.

Prepare and check coolant with highest care, since otherwise the engine may be damaged by corrosion, cavitation and freezing.

In hydraulic systems filled with Panolin HLP Synth.46 always use the same oil to top up.

When changing from mineral oil based hydraulic oil to an ester based biologically degradable oil, you should consult the lubrication oil service of the oil manufacturer for details.

Check the filter more frequently after this change.

Splitter gear oil / planetary gear oil Quality

As a protection against frost and boiling point antifreeze agents must be used under any climatic conditions.

Mixing of coolant water and cooling system protection agent must be performed at a concentration level of the cooling system protection agent of minimum 35% and maximum 45%.

Caution Do not mix different coolants and additives of any other kind.

For splitter gear and planetary gears use only multi-purpose gear oils of API-GL4- and API-GL5class, SAE 85W-90.

However, these oils must comply with the following viscosity:

Environment Cooling system protection agents must be disposed of environmentally.

175 cSt - 250 cSt at 40°C min. 16.5 cSt at 100°C This is a hypoid lubricant of highest quality class for extremely loaded transmissions.

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

Planetary gear oil BC 672 EB Quality For planetary gears use only gear oil CLP HC of viscosity class ISO VG 320 at 40°C mm²/s (cSt) acc. to DIN 51519.

This is a hypoid lubricant of highest quality class for extremely loaded transmissions.

BC 672 RB/EB,BC 772 RB/RS

%20$*

77

0DLQWHQDQFH

5.3

Table of fuels and lubricants

Assembly

Fuel or lubricant Summer

Quantity approx.

Winter

Attention Observe the level marks

Engine

Engine oils see table of fuels and lubricants

approx. 34 litres without filter change, approx. 36 litres with filter change

SAE 15W/40 (-10 째C to +40 째C) Coolant

approx. 44 litres

Mixture of water and anti-freeze agent Fuel

Diesel

Winter diesel fuel* (down 500 litres to -12 째C)

Hydraulic system

Hydraulic oil (ISO), HV46, with viscosity index 150 or 350 litres ester based biodegradable hydraulic oil

Splitter gear

SAE 85W-90 EP, API GL5

approx. 4.5 litres

Planetary drives (Lohmann + Stolterfoht)

SAE 85W-90 EP, API GL5

approx. 7 litres

BC 672 EB, Planetary drives (Lohmann + Stolterfoht)

CLP HC

approx. 7 litres

Central lubrication system High pressure grease (calcium and/or lithium saponi- 2.0 kg automatic lubricafied) tion Bucket

High pressure grease (calcium and/or lithium saponi- approx. 1.9 kg fied)

Air conditioning system Cabin heater (diesel) - Oil bath air filter

78

Refrigerant R 134 A as engine oil

approx. 1.9 kg

down to approx. -30 째C use SAE 5W/30

%20$*

as required

BC 672 RB/EB,BC 772 RB/RS

0DLQWHQDQFH

5.4

Running-in instructions

The following service work must be performed when taking new machines into operation.

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

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

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

Maintenance after 50 operating hours ●

Change the oil in the L + S planetary drives.

●

Retighten bolted connections on intake and exhaust tubes, oil sump and engine mounts.

●

Retighten all bolted connections on the machine.

Maintenance after 500 operating hours ●

Change the oil in splitter gear and oil filter.

●

Change the oil in the planetary gear.

Special intervals ●

Switch the heating system on every month for about 10 minutes.

●

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

Caution After the installation of a new or a service exchange engine and after repair work on the cylinder head the valves clearance must be checked after 50 operating hours.

After the installation of new or service exchange gearboxes the specified service intervals start again from the beginning.

BC 672 RB/EB,BC 772 RB/RS

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79

0DLQWHQDQFH

5.5

Maintenance chart

With all maintenance intervals perform also the work for shorter preceding service intervals.

No.

Designation

Note

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

Check the engine oil level Check the fuel level Check the hydraulic oil level Visual inspection of the machine for damage and leaks Check the coolant level Check the oil level in the splitter gear Check/empty the fuel pre-cleaner (water separator) Lubricate joints and bearings on the bucket

Every 500 operating hours 5.14 5.15 5.16

Service the air conditioning Check the fastening of the scrapers Change the engine oil

5.17 5.18 5.19

Change the engine oil filter Check the engine mounts Check condition of radiator, intercooler and hydraulic oil cooler, clean, clean the engine Check the oil level in the planetary gears Check the battery condition, greasing the poles Check the central lubrication system, topping up Check condition and tension of generator V-belt, replacing the V-belt Check the V-belt for refrigerant compressor, tighten, replace the V-belt Check, tighten the fan V-belt Replace the fresh air and circulation air filters Check the anti-freeze concentration

5.20 5.21 5.22 5.23 5.24 5.25 5.26 5.27

80

summer operation 628 Nm (463 ft lb) min. 1x per year at a fuel consumtion of >50l/h the oil change must be performed every 250 operating hours

%20$*

BC 672 RB/EB,BC 772 RB/RS

0DLQWHQDQFH

No.

Designation

Note

Every 1000 operating hours 5.28 5.29

Oil change in planetary gear Check, adjust the valve clearance

5.30 5.31 5.32

Change the fuel filter cartridge Change the fuel prefilter element Check fastening of engine / turbocharger / combustion air hoses Replace the fuel filter for the cabin heater (diesel) Check, clean oil bath air filter for cabin heater (diesel) Change the hydraulic oil fine filter

5.33 5.34 5.35

Inlet valve 0.25 mm (0.009 inch) exhaust valve 0.3 mm (0.012 inch) replace also before winter operation

Every 2000 operating hours 5.36

Change the hydraulic oil**

at least every 2 years, only quality stage HV 46 VI150

5.37 5.38

Change oil and filter in the splitter gear Check the condition of the oscillating articulated joint

Every 4000 operating hours 5.39 5.40 5.41

Change the injection valve only by authorized service personnel Check turbo charger compressor outlet, clean if nec- only by authorized service personnel essary.

Change the crankcase ventilation valve only by authorized service personnel

Every 6000 operating hours 5.42 5.43

Change the coolant pump Change the pressure retaining valve on te injection pump

only by authorized service personnel only by authorized service personnel

As required 5.44 5.45 5.46 5.47 5.48 5.49 5.50 5.51 5.52 5.53

Change the coolant/vent the cooling system at least every 2 years Adjust scrapers and edge cutter Change the wheel caps Check the condition of cutters, replacing the cutters if necessary Change the dry air filter cartridge at least every 2 years or when the indicator lights up Retighten bolted connections Check the preheating system, maintenance in case of frost Fill the provision tank for the windscreen washer system Drain off dirty fluids from front and rear frame Conservation

BC 672 RB/EB,BC 772 RB/RS

%20$*

81

(YHU\ RSHUDWLQJ KRXUV

Every 10 operating hours

5.6

L

Check the engine oil level

5.7

Note

Checking the fuel level

Danger Fire hazard!

The machine must be in horizontal position. Just before testing run the engine approx. 2 minutes with idle speed. Shut the engine down.

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

Do not refuel in closed rooms Do not inhale any fuel fumes. ●

Open the flap on the front frame.

●

Unlock the filler cap and take it off.

Fig. 145 ●

Pull the dipstick (Fig. 145) out, wipe it off with a lint-free, clean cloth and reinsert it until it bottoms.

●

Pull the dipstick back out again.

●

The oil level must be near the ”Max”-mark.

Fig. 146

●

If the oil level is too low top up oil immediately.

●

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

Clean the area around the filler opening and fill in fuel (Fig. 146).

Caution 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.

82

%20$*

BC 672 RB/EB,BC 772 RB/RS

(YHU\ RSHUDWLQJ KRXUV

5.8

Checking the hydraulic oil level

5.9

Fig. 147 ●

L

Visual inspection of the machine for damage and leaks

Fig. 148

Check the oil level in the inspection glass (Fig. 147) (arrow).

●

Check the complete machine and all attachments for good condition and completeness (Fig. 148).

Note

●

Check all pipes and hoses for good condition and tightness.

●

Have all damage repaired.

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

L

Note

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 must be refilled with the same oil.

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

Fig. 149

Operate the flutter valve (Fig. 149) to drain the water off the ROPS.

●

L

Note

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

BC 672 RB/EB,BC 772 RB/RS

%20$*

83

(YHU\ RSHUDWLQJ KRXUV

5.10 Check the coolant level

Drain bore on water pump carrier

L Danger Danger of scalding!

Check the coolant level only when the engine is cold.

Note

In case of leaks on the mechanical seal the leaking coolant is discharged to the outside. Entering into the lubrication oil area of the crankcase is thereby avoided.

Caution The drain bore must not be closed under any circumstances.

Fig. 150 ●

Open the safety flap (Fig. 150).

Fig. 152

If coolant frlows out of the drain bore (Fig. 152) the coolant pump must be replaced.

●

Checking the condition of the coolant Caution In case of lubrication oil entering into the cooling system or a suspicious turbidity caused by corrosion residues or other suspended matter, the coolant must be drained off and the complete cooling system needs to be cleaned. Lubrication oil can damage the sealing materials used in the engine.

Fig. 151 ●

Unscrew the cap (Fig. 151).

●

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

For specified coolant refer to the table of fuels, lubricants and filling capacities. ●

84

Screw the cap back on and close the safety flap.

Environment Environmental damage!

Do not let engine coolant and cleansing fluid seep into the ground, but dispose of environmentally.

%20$*

BC 672 RB/EB,BC 772 RB/RS

(YHU\ RSHUDWLQJ KRXUV

Cooling system soiled by corrosion residues or other suspended matter (no contamination by lubrication oil)

●

Maintain this temperature for about 5 minutes.

●

Shut the engine down and let the water cool down to a temperature of approx. 50 °C.

●

Drain all coolant off, see section ”changing coolant”.

●

Drain all cleansing mixture off.

●

●

Fill in clean water

●

Start the engine and flush the cooling system out for a short while

Fill the cooling system 2x after each other with clear water and flush for about 5 minutes with the engine running.

●

Drain all water off.

●

Drain all water off

●

Reinstall the thermostat (Fig. 153).

●

Fill the cooling system with coolant.

●

Fill the cooling system with coolant.

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

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

Soiled cooling system with proportions of lubrication oil (oil film on coolant) ●

Drain all coolant off, see section ”changing coolant”.

●

Prepare a cleaning mixture of clean water and cleansing agent P3 Standard or P3T 5124.

Mixing ratio: 50 gramms cleansing agent for 1 litre of water.

Caution Stir the cleansing mixture well.

Fig. 153 ●

Remove thermostat cover 2 (Fig. 153) and disassemble thermostat (1).

●

Reassemble the thermostat cover.

●

Fill the cooling system with cleansing mixture.

●

Start the engine and run it until a water temperature of approx. 90 °C is reached.

BC 672 RB/EB,BC 772 RB/RS

%20$*

85

(YHU\ RSHUDWLQJ KRXUV

5.11 Check the oil level in the splitter gear

5.12 Checking/emptying the fuel pre-cleaner (water separator) Danger Fire hazard!

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

Environment Catch running out fuel and dispose of environmentally.

L

Fig. 154 ●

Check the oil level in the inspection glass (Fig. 154) with the engine at standstill, it must be slightly above the middle of the inspection glass.

Note

The service intervals for the water separator depend on the water content in the fuel and can therefore not be determined precisely. After taking the engine into operation you should therefore check the filter bowl initially every day, later as required, for signs of water.

Fig. 155 ●

Clean the area around the breather filter (Fig. 155) and unscrew the breather filter.

●

Top up oil, if necessary

Fig. 156

If the water separator control light (Fig. 156) on the right hand side of the dashboard lights up during starting or operation, drain the water from the prefilter.

●

For quality of oil refer to the table of fuels, lubricants and filling capacities. ●

Clean the oil breather filter and screw it back on.

L

Note

Open the engine compartment doors on the left hand side.

86

%20$*

BC 672 RB/EB,BC 772 RB/RS

(YHU\ RSHUDWLQJ KRXUV

5.13 Lubricating the joints and bearings on the bucket (RS) Danger Danger of injury!

Lower the bucket to the ground

Fig. 157 ●

Place a collecting vessel (Fig. 157) under the drain opening.

●

Open the drain cock.

Fig. 159

Clean all grease nipples (Fig. 159) and lubricate with approx. 5 strokes from the grease gun.

●

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

L

Fig. 158

If necessary clean and lubricate once every week.

Drain the fuel off until there is no water left (Fig. 158). Close the drain cock.

●

L

Note

Note

Once the water separator is empty the control light must go out.

BC 672 RB/EB,BC 772 RB/RS

%20$*

87

(YHU\ RSHUDWLQJ KRXUV

Every 500 operating hours

5.14 Service the air conditioning (summer operation) The air conditioning unit is attached to the ROPS and can be access from outside for service work.

Caution Under very dusty conditions clean every day in order to maintain the cooling power of the air conditioning system.

Fig. 161

Danger Danger of accident!

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

Cleaning the condenser

Clean the condenser fins on front and back with compressed air or cold water (Fig. 161).

●

Caution During cleaning work do not damage the cooling fins and realign bent fins.

Checking the refrigerant level ●

Start the engine.

Fig. 160 ●

Fold the air intake grid (Fig. 160) back.

Fig. 162 ●

88

%20$*

Switching on the control unit (Fig. 162).

BC 672 RB/EB,BC 772 RB/RS

(YHU\ RSHUDWLQJ KRXUV

Fig. 163

Fig. 165

Start operation of the air conditioning (Fig. 163).

●

Check whether the white float (Fig. 165) inside the inspection glass of the drier/collector unit floats right at the top.

●

L

Note

The refrigerant level is correct.

Fig. 164 ●

Open the air outlet nozzles (Fig. 164).

●

Check, whether the outflowing air is noticeably cooler.

Fig. 166

L

Note

If the white float (Fig. 166) inside the inspection glass of the drier/collector unit floats at the bottom, inform the service department.

●

The adjusted temperature must be below the actual temperature inside the cabin, so that the compressor will be switched on.

L

Note

The refrigerant level is not correct. ●

BC 672 RB/EB,BC 772 RB/RS

%20$*

Refrigerant must be filled up, if necessary check the air conditioning system for leaks.

89

(YHU\ RSHUDWLQJ KRXUV

Checking the moisture level of the drying agent

arising from the handling and operation of pressure reservoirs.

Danger Danger of injury!

In case of mechanical damage or corrosion on this drier/collector unit this unit must be replaced, to avoid bursting and further damage.

Fig. 167

Check the moisture indication pearl (Fig. 167) inside the inspection glass of the drier/collector unit.

â&#x2014;?

blue

= drying agent o.k.

purple

= moisture level of drying agent too high.

Fig. 168 â&#x2014;?

Inform the service department. Replace drier/ collector unit, check air conditioning system.

â&#x2014;?

Check the drier/collector unit (Fig. 168) for mechanical damage or rust.

Caution Have the drier/collector unit replaced by the service department every year before the operating season.

Checking the condition of the drier/collector unit Caution According to the regulation for pressure reservoirs all pressure reservoirs must be repeatedly inspected by a specialist. In this sense repeated inspections are external examinations, normally on pressure reservoirs in operation. In connection with this inspection the drier/collector unit must be visually examined twice every year. During these inspections special attention must be paid to corrosion and mechanical damage. If the reservoir is not in proper condition it must be replaced for safety reasons, as a precaution to protect operators and third parties against any danger

90

%20$*

BC 672 RB/EB,BC 772 RB/RS

(YHU\ RSHUDWLQJ KRXUV

At the closest point (2) (Fig. 170) there must be metal to metal contact between the edge cutters and the shell surfaces of the compactor wheels.

5.15 Check the fastening of the scrapers

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

Fig. 169

Check fastening screws 2 (Fig. 169) and 3 (Fig. 170) on scrapers 1 (Fig. 169)

●

Fig. 171 ●

Check the inner sides of the compactor wheels, remove wires, cables, ropes, etc. (Fig. 171).

●

Check the scraper bars 1 (Fig. 171), replace if worn.

Fig. 170

and on the lateral edge cutters 1 (Fig. 170) for tight fit, retighten if necessary.

●

L

Note

The tightening torques apply for screws covered with OKS 240 (copper paste).

Check the gap between scrapers 2 (Fig. 170) and compactor wheels, it must be approx.

5 mm (0,2“).

●

L

Note

Only this adjustment ensures effective cutting of wires.

BC 672 RB/EB,BC 772 RB/RS

%20$*

91

(YHU\ RSHUDWLQJ KRXUV

5.16 Change the engine oil

L

●

Unscrew the safety cap 2 (Fig. 172) from the oil drain socket (1).

●

Take the oil drain hose (3) out of the right hand storage compartment and screw it on, drain the engine oil off and collect it.

●

Once the old oil has run out remove the drain hose and screw the safety cap back on.

Note

Drain the engine oil only when the engine is warm.

Preferably use oils of ACEA-classification E3-96 / E4-98. This enables utilization of the longest oil change intervals. Oils of API-quality class CG-4 / CH-4 may also be used.

Oil change intervals (operating hours) for ACEA qualities E1-96

= 250 operating hours

E2-96

= 250 operating hours

E3-96

= 500 operating hours

E4-98

= 500 operating hours

Oil change intervals (operating hours) for API qualities CF-4

= 250 operating hours

CG-4

= 500 operating hours

CH-4

= 500 operating hours

Fig. 173 ●

Fill in new engine oil (Fig. 173) through the oil filler neck.

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

Danger Danger of scalding!

●

Screw the cap back on again.

Danger of scalding when draining off hot oil!

Environment Environmental damage!

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

Fig. 174 ●

After a short test run check the oil level on the dipstick (Fig. 174), if necessary top up to the top mark ("Max").

Fig. 172 ●

92

Remove the rear service door. %20$*

BC 672 RB/EB,BC 772 RB/RS

(YHU\ RSHUDWLQJ KRXUV

5.17 Changing the engine oil filter

5.18 Check the engine mounts

Danger Danger of scalding!

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

Environment Environmental hazard!

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

Fig. 176 ●

Check all fastening screws on the engine mounts for tight fit, tighten if necessary (Fig. 176).

Fig. 175 ●

Loosen the engine oil filter (Fig. 175) with a suitable filter wrench and screw it off.

●

Wipe the sealing face clean.

●

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

●

Screw the new engine oil filter on hand-tight.

●

Perform a short test run, inspect the engine for leaks and check the oil level, top up oil if necessary.

BC 672 RB/EB,BC 772 RB/RS

%20$*

93

(YHU\ RSHUDWLQJ KRXUV

5.19 Checking condition of radiator, intercooler and hydraulic oil cooler, clean, cleaning the engine

L

Note

Dirty operating conditions, particularly lubrication oil and fuel deposits on the cooling fins reduce the cooling effect. You should therefore immediately seal any oil or fuel leaks near cooling fan, cylinder or oil cooler and subsequently clean the cooling fins.

Fig. 178

right hand side (Fig. 178) of the air duct housing.

●

Danger Danger of injury!

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

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

L

Note

Clean the coolers in the correct sequence. ●

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

Fig. 177 ●

Remove the service covers on left (Fig. 177) and

Fig. 179

94

●

Remove the service door (Fig. 179).

●

Clean all coolers from the air intake side.

●

Remove dried on dirt with a suitable brush.

●

Blow the cooling air channels out with compressed air.

%20$*

BC 672 RB/EB,BC 772 RB/RS

(YHU\ RSHUDWLQJ KRXUV

●

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

●

If steam cleaning equipment is available, this should preferably be used.

Cleaning the engine Caution After cleaning the coolers it is mandatory to clean the engine.

Cover all parts of the electrical system, do not subject to the direct water jet.

Fig. 181 ●

In case of oily contamination spray the engine with cold cleansing agent and spray it off with a water jet after s sufficient soaking time.

●

Drain bores (Fig. 181) and (Fig. 180) must be free, remove blockage if necessary.

●

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

●

Reinstall the service covers.

Fig. 180 ●

Blow the engine dry with compressed air.

Flush lose dirt with a water jet out of the Vshaped space between the cylinders.

●

The drain bore (Fig. 180) must be free, remove blockage if necessary.

BC 672 RB/EB,BC 772 RB/RS

%20$*

95

(YHU\ RSHUDWLQJ KRXUV

5.20 Checking the oil level in the planetary gears

L

5.21 Checking the battery, greasing the poles, checking the battery disconnect switch

Note

Check the oil level in all four planetary drives.

Danger 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.

Environment Dispose of old batteries environmentally.

Fig. 182 ●

Move the machine, until the drain plug (Fig. 182) is in bottom position.

●

Clean and unscrew filler and level control plug.

●

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

For quality of oil refer to the table of fuels, lubricants and filling capacities. ●

Clean the filler and level control plug and screw it back in.

Fig. 183 ●

Open the access door in the floor in front of the cabin door (Fig. 183).

Non-maintenance free batteries: ●

Clean battery and battery compartment (Fig. 183).

●

Clean the water drain bores

●

Open the plugs and check the acid level.

With control inserts Check, whether the acid level reaches the lower end of the control inserts.

96

%20$*

BC 672 RB/EB,BC 772 RB/RS

(YHU\ RSHUDWLQJ KRXUV

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).

●

5.22 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

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.

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.

Checking the main battery disconnect switch

Checking:

Fig. 185

Fig. 184 ●

Actuate the switch (Fig. 184) and check with a voltmeter (ignition key test), whether the battery has been disconnected from the electrical system of the machine.

●

Switch the ignition on.

●

Actuate the push button (Fig. 185) for 2 seconds.

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

BC 672 RB/EB,BC 772 RB/RS

%20$*

97

(YHU\ RSHUDWLQJ KRXUV

Filling with a manual grease gun

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

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

Fig. 186

The stirring device in the transparent container 1 (Fig. 186) moves and presses the grease to the lubrication points.

●

L

Note

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

Fig. 187

Failure of a lubrication point

●

Remove both covers from the cartridge 1 (Fig. 187).

●

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.

●

Check, whether the sealing ring is correctly inserted in the connecting fitting.

●

Screw the connecting fitting on to the manual grease gun.

(e.g. lubrication point blocked) ●

Grease emerging from the opening 3 (Fig. 186) indicates that one of the lubrication points is blocked.

●

Eliminate the cause.

Filling via the grease nipple.

Caution 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 quantity of grease refer to the table of fuels and lubricants. ●

98

Switch the ignition on, press the push button (Fig. 185) for 2 seconds, the system starts to work.

%20$*

BC 672 RB/EB,BC 772 RB/RS

(YHU\ RSHUDWLQJ KRXUV

5.23 Checking the condition and tension of the generator Vbelt, replacing the V-belt Danger Danger of injury!

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

Checking the V-belt

Fig. 188 ●

Clean the area around the covering cap of the central lubrication system.

●

Unscrew the covering cap from the central lubrication system and unscrew the plug from the manual grease gun (Fig. 188).

●

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.

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

Fig. 189 ●

Inspect the entire circumference of the V-belt (Fig. 189) visually for damage and cracks. Replace damaged or cracked V-belts.

●

Check with thumb pressure whether the V-belt can be depressed more than 5 to 10 mm between the V-belt pulleys, retighten if necessary.

BC 672 RB/EB,BC 772 RB/RS

%20$*

99

(YHU\ RSHUDWLQJ KRXUV

Retightening the V-belt

●

Fit the new V-belt to the V-belt pulleys.

●

Tension the V-belt as previously described.

●

Reinstall and tension the fan drive V-belt.

L

Note

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

Fig. 190 ●

Slacken the fastening screws 3 and 4 (Fig. 190) slightly.

●

Loosen the counter nut (2).

●

Turn down tensioning screw (1) in direction of arrow, until the correct V-belt tension is reached.

●

Retighten hexagon screws and counter nut.

Changing the V-belt ●

Remove the V-belt of the fan drive.

Fig. 191 ●

Slacken the fastening screws 3 and 4 (Fig. 191) slightly.

●

Loosen the counter nut (2).

●

Turn tensioning screw (1) in direction of arrow to the stop.

●

Take the old V-belt off the V-belt pulley.

100

%20$*

BC 672 RB/EB,BC 772 RB/RS

(YHU\ RSHUDWLQJ KRXUV

5.24 Check condition and tension of refrigerant compressor V-belt, replace the V-belt

Retightening the V-belt

Danger Danger of injury!

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

Checking the V-belt Fig. 193 ●

Slacken the bearing screw 2 (Fig. 193) for the compressor bracket.

●

Slightly loosen the hexagon screw (1) on the slot for the compressor bracket.

●

Loosen the counter nut (3).

●

Turn down tensioning screw (4) in direction of arrow, until the correct V-belt tension is reached.

●

Retighten screws and counter nut.

Changing the V-belt

Fig. 192 ●

Inspect the entire circumference of the V-belt (Fig. 192) visually for damage and cracks. Replace damaged or cracked V-belts.

●

Check with thumb pressure whether the V-belt can be depressed more than 10 to 15 mm (0.4 – 0.6 inches) between the V-belt pulleys, retighten if necessary.

Fig. 194

BC 672 RB/EB,BC 772 RB/RS

●

Remove the V-belt of the fan drive.

●

Slacken the bearing screw 2 (Fig. 194) for the compressor bracket.

●

Slightly loosen the hexagon screw (1) on the slot for the compressor bracket.

●

Loosen the counter nut (3).

%20$*

101

(YHU\ RSHUDWLQJ KRXUV

●

Turn tensioning screw (4) in direction of arrow to the stop.

●

Take the old V-belt off the V-belt pulley.

●

Fit the new V-belt to the V-belt pulleys.

●

Tension the V-belt as previously described.

●

Reinstall and tension the fan drive V-belt.

L

Note

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

5.25 Checking the condition and tension of the fan V-belt, replacing the V-belt Danger Danger of injury!

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

Checking the fan V-belt

Fig. 195 ●

Inspect the entire circumference of the V-belt (Fig. 195) visually for damage and cracks. Replace damaged or cracked V-belts.

Fig. 196

102

●

Press the indicator arm of the tester a (Fig. 196) into the gap of the measuring scale.

●

Lay the measuring unit loosely onto the back of the fan V-belt.

%20$*

BC 672 RB/EB,BC 772 RB/RS

(YHU\ RSHUDWLQJ KRXUV

L

at minimum 1100N

Note

To measure the V-belt tension a free length of at least 200 mm is required.

= tension to approx. 1400N

Tensioning the fan V-belt

Fig. 197

Operate measuring unit b (Fig. 197) with a finger (I or II or II), until the pressure sping disengages audibly or noticeably.

●

L

Fig. 199 ●

Slightly slacken three hexagon screws (Fig. 199) on the bracket of the reversing pulley.

Note

The indicator arm remains in the measured position. ●

take the measuring unit carefully off, without moving the indicating arm.

Fig. 200

Fig. 198 ●

●

Attach the spanner to the fastening screw for the reversing pulley (Fig. 200) and pull the reversing pulley down with power.

●

During this process retighten the hexagon screws on the bracket for the reversing pulley.

●

Measure the V-belt tension, tighten if necessary.

Read the V-belt tension where the upper edge of the indicating arm intersects with the measuring scale (Fig. 198).

First installation = approx. 1,900N after 20 minutes of operation = approx. 1,400N

BC 672 RB/EB,BC 772 RB/RS

%20$*

103

(YHU\ RSHUDWLQJ KRXUV

Changing the fan V-belt

5.26 Replacing the fresh air and circulation air filters

Fig. 201

Slightly slacken three hexagon screws (Fig. 201) on the bracket of the reversing pulley.

●

Fig. 203 ●

Unscrew the cover.

●

Take the old fresh air filter out and insert the new fresh air filter (Fig. 203).

●

Fasten the cover with screws.

Fig. 202 ●

Attach the spanner to the fastening screw for the reversing pulley (Fig. 202) and press the reversing pulley inwards.

●

Take the old V-belt off the V-belt pulley.

●

Lay the new V-belt onto the V-belt pulleys and tighten it as described above.

L

Note

Retighten the new fan V-belt after a running time of 20 minutes.

104

Fig. 204 ●

remove the slotted cover from the console behind the driver’s seat.

●

Remove both circulation air filters and insert the new circulation air filters (Fig. 204).

●

Fasten the slotted cover to the console.

%20$*

BC 672 RB/EB,BC 772 RB/RS

(YHU\ RSHUDWLQJ KRXUV

5.27 Checking the anti-freeze concentration Caution In order to avoid damage to the engine e.g. by corrosion, cavitation and freezing, particular attention must be paid to the inspection of the coolant.

Danger Danger of scalding!

Check the anti-freeze concentration only when the engine is cold. â&#x2014;?

Perform the inspection with conventional test equipment.

â&#x2014;?

The anti-freeze concentration (additive) must be at least 35 Vol% and maximum 45 Vol%.

Danger Health hazard!

The mixing of nitrite based anti-freeze agents with amine based agents results in the formation of health affecting nitrosamines.

Environment Catch all anti-freeze agent and dispose of environmentally.

BC 672 RB/EB,BC 772 RB/RS

%20$*

105

(YHU\ RSHUDWLQJ KRXUV

Every 1000 operating hours

5.28 Oil change in planetary gear

L

Note

Drain oil only at operating temperature. Perform the oil change on all four planetary drives.

Danger Danger of scalding!

Danger of scalding when draining off hot engine oil!

Fig. 206 ●

Environment Environmental damage!

Catch old oil and dispose of environmentally.

Fill in oil, until it reaches the bottom edge of the bore (Fig. 206).

For quality and quantity of oil refer to the table of fuels, lubricants and filling capacities. ●

Clean filler and level plug (1) and screw it back in tightly fitted with a new sealing ring.

Fig. 205 ●

Move the machine, until the drain plug (Fig. 205) is in bottom position.

●

Clean and unscrew filler, level inspection and drain plugs and.

●

Drain and catch all oil.

●

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

106

%20$*

BC 672 RB/EB,BC 772 RB/RS

(YHU\ RSHUDWLQJ KRXUV

"overlapping" (i.e. the exhaust valve is not yet closed, the inlet valve starts to open) (Fig. 208) , starting with cylinder A1.

5.29 Checking, adjusting the valve clearance

L

Note

The valve clearance must be ●

0,25 mm for inlet valves,

●

0,3 mm for exhaust valves.

Check and adjust the valve clearance only when the engine is cold.

Perform a short test run and check the engine for leaks.

Fig. 209 ●

Adjust only the valves marked black (Fig. 209).

Fig. 207

remove all cylinder head covers (Fig. 207).

●

L

Note

Fig. 210

Check the gasket, use a new one if necessary.

Checking the valve clearance ●

Inlet valve 0,25 mm,

●

Exhaust valve 0,3 mm.

●

A feeler gauge of appropriate thickness 1 (Fig. 210) must fit through the gap between rocker arm (2) and valve (3) with only little resistance.

●

If the gap is too wide or too narrow for the feeler gauge, the valve clearance must be adjusted.

Adjusting the valve clearance Fig. 208 ●

●

Crank the engine by hand or with the starter, until the valves on the respective cylinder are

BC 672 RB/EB,BC 772 RB/RS

%20$*

Loosen the counter nut 4 (Fig. 210) for 2 to 3 turns. regulate the adjustment screw (5) with a screwdriver so that the feeler gauge fits

107

(YHU\ RSHUDWLQJ KRXUV

through the gap with little resistance after retightening the counter nut. ●

5.30 Changing the fuel filter cartridge

Check and adjust all other adjustable valves.

For control purposes mark each adjusted valve with chalk.

Danger Fire hazard!

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

Do not inhale any fuel fumes.

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

Open the left hand engine compartment doors.

Fig. 211 ●

Turn the crankshaft one revolution (360 degrees) further (for this purpose mark e.g. the flywheel or the V-belt pulley with chalk), see "crankshaft adjustment 2" (Fig. 211). The valves on cylinder A2 are overlapping.

●

Check and adjust all other valves according to (Fig. 211). Assembly must be performed in reverse order.

Fig. 212

108

●

Loosen both fuel filters (Fig. 212) using a suitable filter wrench and screw it off.

●

Clean the sealing face on the filter carriers from any dirt.

%20$*

BC 672 RB/EB,BC 772 RB/RS

(YHU\ RSHUDWLQJ KRXUV

5.31 Changing the fuel prefilter element Danger Fire hazard!

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

Do not inhale any fuel fumes.

Fig. 213 ●

Slightly oil the rubber seal on the new filter cartridge (Fig. 213).

●

Fill the filter cartridge with clean diesel fuel.

●

Turn the new filter cartridge on by hand, until the seal contacts.

●

Then tighten hand-tight.

●

Check for leaks after a short test run.

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

Fig. 214

BC 672 RB/EB,BC 772 RB/RS

●

Unscrew the hexagon screws (Fig. 214) from the filter cover and take the cover off.

●

Take the filter element out of the filter housing.

●

Insert the new filter element into the filter housing.

●

Check the seal of the filter cover, replace if necessary.

●

Install the filter cover with seal and tighten the hexagon screws crosswise.

%20$*

109

(YHU\ RSHUDWLQJ KRXUV

Fig. 215 ●

Place a collecting vessel (Fig. 215) under the drain opening.

●

Open the drain cock.

●

Drain off fuel, water and dirt, then close the drain cock.

Fig. 217 ●

Operate the hand pump (Fig. 217) manually, until fuel flows out of the slackened bleeding screw (Fig. 216) without air bubbles.

●

Then tighten the bleeding screw while pumping.

Bleeding the fuel prefilter

L

Note

Air in the fuel system causes irregular running of the engine, a drop in engine power, stalls the engine and makes starting impossible.

Therefore bleed the fuel system after changing the fuel prefilter.

Fig. 216 ●

110

Slacken the bleeding screw (Fig. 216) on the fuel prefilter for 2 to 3 turns.

%20$*

BC 672 RB/EB,BC 772 RB/RS

(YHU\ RSHUDWLQJ KRXUV

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

Fig. 220 ●

Check combustion air tube and connecting sleeves for tight fit (Fig. 220).

Fig. 218 ●

Check charge air pipe (Fig. 218) and intercooler for tight fit and leaks.

●

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

●

Check the connecting sleeves for tight fit.

Fig. 219 ●

Open the maintenance flap on the ROPS.

●

Check the combustion air hose for tight fit and leaks (Fig. 219).

BC 672 RB/EB,BC 772 RB/RS

%20$*

111

(YHU\ RSHUDWLQJ KRXUV

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)

Danger 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.

L

Note

Check, clean every day during the heating period.

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

Fig. 222

Fig. 221 ●

Open the flap on the front frame.

●

Pull the hoses from both sides off the fuel filter (Fig. 221).

●

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.

●

112

Remove the cover.

●

Loosen the quick locks and take the oil bowl (Fig. 222) 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.

L

Note

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.

%20$*

BC 672 RB/EB,BC 772 RB/RS

(YHU\ RSHUDWLQJ KRXUV

5.35 Changing the hydraulic oil fine filter Danger Danger of scalding!

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

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

Caution 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.

L

Note

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

Fig. 224

Caution Catch oil running out.

●

Do not use the oil in the filter bowl.

●

Take the old filter element 3 (Fig. 224) 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. 223 ●

Remove the locking wire, if present.

●

Unscrew the spigot nut 1 (Fig. 223).

●

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

BC 672 RB/EB,BC 772 RB/RS

%20$*

113

(YHU\ RSHUDWLQJ KRXUV

Every 2000 operating hours

5.36 Changing hydraulic oil and breather filter See also notes on the hydraulic system. ●

Perform the oil change when the hydraulic oil is warm.

●

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

●

Do not run the pumps without oil.

●

Do not use any detergents to clean the system.

Fig. 225

Use only lint-free cleaning cloths.

●

●

Caution Replace the hydraulic oil filter element with every hydraulic oil change.

L

Unscrew the breather filter (Fig. 225) from the compensation tank.

Caution Do not remove the filter element from the cover of the compensation tank.

Note

Generally replace the hydraulic oil filter after the test run. ●

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

●

The system must be bled again after the filter change.

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

When changing from mineral oil based hydraulic oil to an ester based biologically degradable oil, you should consult the lubrication oil service of the oil manufacturer for details.

Environment Catch old oil and dispose of environmentally. ●

114

Remove the rear cover.

Fig. 226

Danger Danger of scalding!

Danger of scalding when draining off hot hydraulic oil! ●

Unscrew plug 1 (Fig. 226) from drain cock (2), take the drain hose (3) out of the right hand storage compartment and connect it.

●

Guide the drain hose into a vessel of appropriate size.

%20$*

BC 672 RB/EB,BC 772 RB/RS

(YHU\ RSHUDWLQJ KRXUV

●

Open drain cock (2) and let the old oil run out.

●

Once all old oil has run out close the drain cock, remove the drain hose and screw the plug back on.

Cleaning the hydraulic oil tank

L

Note

If the hydraulic oil tank needs to be cleaned from inside the following work must be performed: Unscrew the hexagon screws and take off the cover (4).

●

Wipe the inside of the hydraulic tank clean with the lint-free cloth.

●

Fig. 228

L

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

Note

At a temperature of approx. 20 °C the oil level should be at 1/3 of the inspection glass.

Insert a new seal and reinstall the cover.

●

Check the oil level in the inspection glass (Fig. 228) (arrows).

●

With hot hydraulic oil and a too high oil level hydraulic oil can flow through the overflow into the engine compartment.

Fill in hydraulic oil.

●

Screw the new breather filter on.

●

Perform a test run and check the system for leaks.

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

●

Run the machine until operating temperature is achieved, then shut the engine.

Environment Catch running out oil and dispose of environmentally.

Fig. 227

L

●

Note

We recommend to use the filling and filtering unit (BOMAG part-no. 079 930 35) with fine filter to fill the hydraulic system. This ensures finest filtration of the hydraulic oil, prolongs the lifetime of the hydraulic oil filter and protects the hydraulic system. ●

Fill in new hydraulic oil through the screen (Fig. 227).

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

BC 672 RB/EB,BC 772 RB/RS

%20$*

115

(YHU\ RSHUDWLQJ KRXUV

5.37 Change oil and filter in the splitter gear

L

Note

Drain oil only at operating temperature.

The filter element must be changed with every oil change

Danger Danger of scalding!

Danger of scalding when draining off hot oil!

Environment Environmental damage!

Fig. 230 ●

Unscrew the plug from the oil drain socket (Fig. 230).

●

Drain off and catch transmission oil.

●

Screw the plug back in once the oil has run out.

Catch old oil and dispose of environmentally.

Danger Danger of injury!

Lower the rear bottom cover to the ground after unscrewing it, do not let it drop down. ●

Remove the rear bottom cover.

Fig. 231 ●

Unscrew the spigot nut and remove filter bowl with filter element (Fig. 231).

●

Let the oil run out of the cooling pipe and catch it

●

Clean the filter bowl and install it with a new filter element, check the condition of the seal rings.

Fig. 229 ●

Clean the area around the breather filter (Fig. 229) and unscrew the breather filter.

●

Cleaning the breather filter.

116

%20$*

BC 672 RB/EB,BC 772 RB/RS

(YHU\ RSHUDWLQJ KRXUV

5.38 Checking the condition of the articulated joint

Fig. 232 ●

Fill in new oil (Fig. 232).

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

Fig. 234 ●

Check all fastening screws (Fig. 234) for tight fit, tighten if necessary.

●

Check the condition of the lubrication lines 1 (Fig. 234) to the bearings for the steering cylinder rods.

Fig. 233 ●

Check the oil level in the inspection glass (Fig. 233).

●

Start the engine and run it for a short while.

●

Check the oil level again, if necessary top up oil.

BC 672 RB/EB,BC 772 RB/RS

%20$*

117

(YHU\ RSHUDWLQJ KRXUV

Every 4000 operating hours

5.39 Changing the injection valve

L

Note

This work must only be performed by authorized service personnel.

118

5.40 Check turbo charger compressor outlet, clean if necessary.

L

Note

This work must only be performed by authorized service personnel.

%20$*

BC 672 RB/EB,BC 772 RB/RS

(YHU\ RSHUDWLQJ KRXUV

5.41 Changing the crankcase ventilation valve

L

Note

This work must only be performed by authorized service personnel.

BC 672 RB/EB,BC 772 RB/RS

%20$*

119

(YHU\ RSHUDWLQJ KRXUV

Every 6000 operating hours

5.42 Changing the coolant pump

L

Note

5.43 Changing the pressure retaining valve on te injection pump

This work must only be performed by authorized service personnel.

L

Note

This work must only be performed by authorized service personnel.

120

%20$*

BC 672 RB/EB,BC 772 RB/RS

$V UHTXLUHG

As required

5.44 Changing the coolant, venting the cooling system Danger Danger of scalding!

Change the coolant only when the engine is cold.

Caution Do not start the engine after draining off the coolant.

Fig. 236 ●

Unscrew the cap (Fig. 236).

When changing the coolant without any signs of contamination, cleaning of the cooling system is not necessary.

Environment Catch coolant and dispose of environmentally.

Fig. 237 ●

Connect the drain hose to the drain cock (Fig. 237).

●

Guide the drain hose into a vessel of appropriate size.

●

Open the drain cock and let the coolant run out.

●

Once all coolant has run out close the drain cock, remove the drain hose and screw the plug back on.

Fig. 235 ●

Open the safety flap (Fig. 235).

BC 672 RB/EB,BC 772 RB/RS

%20$*

121

$V UHTXLUHG

5.45 Adjust scrapers and edge cutter Scrapers

Fig. 238 ●

Fill coolant in through the opening in the compensation tank (Fig. 238).

For coolant quantity refer to the table of fuels, lubricants and filling capacities. ●

●

Close the compensation tank. For bleeding start the engine and run it warm.

Fig. 239

Check the coolant level, top up if necessary.

●

Check the condition of all scrapers 1 (Fig. 239) on the compactor wheels, replace damaged or worn scrapers.

●

Check the gap between scrapers and compactor wheels, adjust the gap of the inner scrapers to 0 mm.

●

Adjust the gaps of all other scrapers to 5 mm.

●

For adjustment slacken screws 2 (Fig. 239) and adjust the scrapers to a gap of approx. 0 or 5 mm.

●

Retighten the slackened screws.

●

Tightening torque 502 Nm.

L

Note

The tightening torques apply only for screws covered with OKS 240 (copper paste).

122

%20$*

BC 672 RB/EB,BC 772 RB/RS

$V UHTXLUHG

Edge cutter

5.46 Replacing the pad foot caps

L

Note

This work shall only be performed by qualified specialists.

The caps should be replaced at the latest when the front faces collapse.

Danger Danger of accident!

Fig. 240

Check the condition of all edge cutters 1 (Fig. 240) on the compactor wheels, replace damaged or worn edge cutters.

●

●

Check the gap (2) between edge cutters and compactor wheels.

●

At the closest point (2) there must be metal to metal contact between the edge cutters and the shell surfaces of the compactor wheels.

●

For adjustment slacken the screws (3) and adjust the edge cutters.

L

Perform all work only with the engine shut down and after actuating the emergency stop switch.

Wear goggles and proper working gloves during all work.

Note

For manufacturing reasons the shell of the compactor wheels may not be absolutely round.

At the widest points the edge cutters may therefore have a few millimetres distance to the shell surface. ●

Retighten the slackened screws.

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

BC 672 RB/EB,BC 772 RB/RS

Fig. 241

Spare parts (Fig. 241) 1

= Cap BOMAG part-no. 311 661 91

2

= Roll pin BOMAG part-no. 311 623 79

Quantity per machine: 220 pcs.

Caution When changing the caps use only new roll pins, as otherwise caps and pad feet may be damaged.

%20$*

123

$V UHTXLUHG

Fig. 242

Fig. 244

Special tools (Fig. 242)

●

3

= BOSCH hammer (220 V) BOMAG part-no. 079 940 08

4

= Disassembly mandrel BOMAG partno. 570 032 96

5

= Assembly mandrel BOMAG part-no.

570 030 82

6

= Driving mandrel BOMAG part-no.

570 032 95

Clean the tamper foot thoroughly with a steel wire brush (Fig. 244).

Fig. 245 ●

Attach a new cap 1 (Fig. 245) to the foot. Dip a new roll pin (2) with the bevelled end into lubrication grease.

Fig. 243

Fit BOSCH hammer 3 (Fig. 243) with the disassembly mandrel (4) and drive the roll pin out in one go with the BOSCH hammer.

●

L

Note

Ensure correct contact between disassembly mandrel and roll pin.

Fig. 246 ●

124

%20$*

Slide roll pin 2 (Fig. 246) over the assembly mandrel (5) and insert it into the cap bore.

BC 672 RB/EB,BC 772 RB/RS

$V UHTXLUHG

L

Note

Chamfer 2.1 (Fig. 246) rests against the assembly mandrel.

Danger Danger of injury!

When knocked through, the assembly mandrel flies out at very high speed.

Catch the assembly mandrel e.g. with a bundle of cloths.

Fig. 248

Assembly of caps on the inner segment side is performed below the edge of the frame (Fig. 248), as otherwise the assembly mandrel will not drop out. Drive the roll pin in from outside to inside (2).

●

L

Note

When assembling the wheel caps move the machine as required.

Fig. 247

Fit BOSCH hammer 3 (Fig. 247) with the driving mandrel (4) and drive the roll pin in quickly with the BOSCH hammer until the roll pin is flush with the cap.

●

L

Note

The roll pin 2 (Fig. 248) may also be driven in using an approx. 1 – 2 kg hammer.

In case of very high pretension a 5 kg hammer should be used.

BC 672 RB/EB,BC 772 RB/RS

%20$*

125

$V UHTXLUHG

5.47 Checking the cutting plates, replacing the cutting plates if necessary

5.48 Changing the dry air filter cartridge Caution Always replace both dry air filter cartridges.

Fig. 249

Check the condition of the cutting plates 1 (Fig. 249) 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.

●

Fig. 250

The dry air filter needs to be serviced if control light 5 (Fig. 250) “air filter dirty” lights up, but at the latest after 2 years.

Caution Do not clean the dry air filter, but replace it immediately, this applies also for the safety cartridge.

Danger 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 countersunk screws and observe the locating recess, install the washer and fasten the assembly.

Fig. 251 ●

126

%20$*

Unscrew wing nut 1 (Fig. 251), remove cover (2).

BC 672 RB/EB,BC 772 RB/RS

$V UHTXLUHG

●

Wipe the filter housing out with a cloth. Do not clean with compressed air.

●

Install new safety cartridge and dry air filter, do not clean.

●

Install the cover.

Fig. 252 ●

Unscrew hexagon nut 1 (Fig. 252) and pull dry air filter (2) out.

Fig. 253 ●

Unscrew hexagon nut 1 (Fig. 253) and pull safety cartridge (2) out.

Fig. 254 ●

Remove the insert (Fig. 254) from the filter housing and clean it.

BC 672 RB/EB,BC 772 RB/RS

%20$*

127

$V UHTXLUHG

When using MoS2 lubricants the specified tightening torques do not apply.

5.49 Retightening bolted connections

L

Note

Self-locking nuts must always be replaced once they have been unscrewed.

Fig. 255

Fig. 256

Bolted connections with MIT OKS 240 (copper paste) (Fig. 255) and normal bolted connections (Fig. 256). ●

Scrapers M20x1.5 = 502 Nm

●

Compactor wheels – planetary drives (L+S) M20 = 578 Nm

●

Bearing blocks for dozer plate bearings M 30 x 2 = 1804 Nm * Strength class for screws with untreated, non-lubricated surface. Screw quality designations are stamped on the screw heads:

8.8 = 8G 10.9 = 10K 12.9 = 12K The values result in a 90% utilization of the screw’s yield point at a coefficient of friction µ total = 0,14.

Compliance with the tightening torques is checked with torque wrenches.

128

%20$*

BC 672 RB/EB,BC 772 RB/RS

$V UHTXLUHG

Test step 1

5.50 Checking the preheating system. Maintenance in case of frost.

Danger Fire hazard!

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

Environment Catch running out fuel.

Fig. 258 ●

Turn the ignition key to position "I", the control light "preheating" 1 (Fig. 258) mus flash.

Otherwise the glow plug is defective or the line is interrupted.

Test step 2

Danger Danger of injury!

Keep clear of rotating parts. ●

Fig. 257

L

Loosen the pipe fitting (2) on the glow plug for a few turns.

Note

If the system works correctly suction pipe 3 (Fig. 257) must become hand-warm near the glow plug (1) during preheating. Otherwise perform the test in the following sequence:

Fig. 259

BC 672 RB/EB,BC 772 RB/RS

●

Press the button of the emergency stop switch in (Fig. 259).

●

Hold the ignition key in position „I“, until the „preheating“ control light goeas out.

%20$*

129

$V UHTXLUHG

●

Turn the ignition key further to position "II" against the resistance and crank the engine with the starter.

●

Fuel must run out of the loosened pipe fitting.

Otherwise have the system (solenoid valve) checked.

5.51 Fill the provision tank for the windscreen washer system

Test step 3 ●

Remove the glow plug and connect the fuel line.

●

Crank the engine with the starter, see test step 2.

●

Fuel must run out of the glow plug. Otherwise replace the clogged glow plug.

●

Reinstall the disassembled parts.

Fig. 260

130

●

Check the fluid level in both tanks (Fig. 260), top up if necessary.

●

For winter operation fill in the appropriate amount of ant-freeze agent; refer to the specifications of the manufacturer of the ant-freeze agent.

%20$*

BC 672 RB/EB,BC 772 RB/RS

$V UHTXLUHG

5.52 Drain off dirty fluids from front and rear frame Environment Dispose of dirty fluids environmentally. ●

Remove the cover from the front frame.

Fig. 263 ●

Clean the area around the flutter valve (Fig. 263).

●

Operate the flutter valve to drain the water off the ROPS.

Fig. 261 ●

Unscrew the drain plugs (Fig. 261) from the front frame, catch running out fluids.

●

Seal any leaks, clean the floor and screw the drain plugs back in.

Fig. 262 ●

Remove the service door at the tail end of the machine.

●

Unscrew the drain plugs (Fig. 262) from the rear frame. Catch running out fluids.

●

Seal any leaks, clean the floor and screw the drain plugs back in.

BC 672 RB/EB,BC 772 RB/RS

%20$*

131

$V UHTXLUHG

API-(MIL-) classification, see section fuels and lubricants.

5.53 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 anti-corrosion oil to the fuel the tank may also be filled with injection pump testing oil with anti-corrosion properties (e.g. Calibration Fluid B).

●

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.

L

For longer resting periods all blank surfaces must be conserved. Piston rods must be protected with grease.

Note

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

132

%20$*

BC 672 RB/EB,BC 772 RB/RS

6 Trouble shooting

BC 672 RB/EB,BC 772 RB/RS

%20$*

133

7URXEOH VKRRWLQJ

6.1

General notes on trouble shooting

The following work must only be carried out by qualified and trained personnel or by the BOMAG sales service.

Please observe strictly the safety regulations in chapter 2 of these operating and 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.

134

%20$*

BC 672 RB/EB,BC 772 RB/RS

7URXEOH VKRRWLQJ

6.2

Engine problems

Fault

Possible cause

Remedy

Engine does not start or starts poorly

Fuel tank empty

Fill tank and bleed

Batteries not charged or not connected

Tighten the terminal clamps on the batteries, check all cable connections

Starter defective

Have starter examined by a specialist

Fuel pre-cleaner soiled, control light for water separator lights.

clean

Fuel filter clogged, in winter due to paraffin separation

Change the filter, use winter fuel

Start limit temperature not reached

Cold starting device (glow plug) defective

Specified valve clearance is not correct

Adjusting the valve clearance

Fuel lines leaking

Check all line connections for leaks and tighten the fittings

Air in the fuel system

Bleed the fuel system

Fuel lift pump defective

Have fuel lift pump examined by a specialist

Incorrect start of commencement

Have injection pump examined by a specialist

Engine solenoid not working

Have examined by a specialist, replace if necessary

Wrong engine oil for operating conditions

Change oil and oil filter, use recommended type of oil

Battery power too low, terminal clamps loose or oxidized causing the starter to turn too slowly.

Have the batteries tested, clean the terminal clamps, tighten and cover them with acid-free grease

Especially during winter: use of too viscous engine oil

Use an engine oil complying with the ambient temperatures

Start limit temperature not reached

Cold starting device (glow plug) defective

Poor starting of engine or engine works irregularly with poor power

BC 672 RB/EB,BC 772 RB/RS

%20$*

135

7URXEOH VKRRWLQJ

Fault

Possible cause

Remedy

Poor starting of engine or engine works irregularly with poor power

Fuel supply too low, fuel system clogged by paraffin separation during winter

Change the fuel filter, then bleed the system, clean the fuel screen in the fuel lift pump, check line connections for tightness and tighten fittings. Use winter fuel under cold conditions

The specified valve clearance is not correct

Adjusting the valve clearance

Injection nozzles defective

Have examined by a specialist

Dry air filter cartridges soiled (engine air filter control light in fault monitoring board lights)

change

Incorrect start of commencement

Have injection pump examined by a specialist

Engine oil level too high

Drain the oil down to the top dipstick mark

Air in the fuel system

Bleed the fuel system

poor fuel quality

Observe the fuel quality, if necessary change the fuel

Engine oil level too high

Drain the oil down to the top dipstick mark

Dry air filter cartridges soiled (engine air filter control light in fault monitoring board lights)

change

Poor compression due to burned or broken compression rings or incorrect valve clearance

Have compression rings and pistons examined by a specialist, adjust the valve clearance

extremely slanted position of engine

Avoid driving with excessive slanted position

Start limit temperature not reached

Cold starting device (glow plug) defective

Exhaust turbo charger defective

Have examined by a specialist

Excessive exhaust smoke

136

%20$*

BC 672 RB/EB,BC 772 RB/RS

7URXEOH VKRRWLQJ

Fault

Possible cause

Remedy

Engine overheating, engine is shut down by the engine control unit

Radiator soiled

Clean the cooling fins

Coolant temperature too high (the coolant temperature control light in the fault monitoring board lights)

Clean cooling fins, check coolant level, check radiator fan

Coolant level too low (control light "lack of coolant" in the fault monitoring board lights, the warning buzzer sounds).

Fill up coolant, check radiator hoses, check radiator, missing or incorrect radiator cap on compensation tank

Incorrect engine oil level

Catch or drain off engine oil

Injection nozzles defective

Have examined by a specialist

Injection pump displacement not correctly adjusted

Have corrected by a specialist

Insufficient cooling air supply to the cooling fan

Remove any clogging from the cooling air duct

Too high concentration of anti-freeze and/ or coolant additives

Use correct concentration

Oil level too low (engine oil pressure control light in the fault monitoring board lights up).

Top up oil

Leaks in the lubrication system

Check fittings on oil lines, lubrication oil filter and oil cooler for leaks, if necessary tighten all fittings

extremely slanted position of engine

Avoid driving with excessive slanted position

Generator speed too low

Check the V-belt tension, if necessary replace the V-belt

The generator does not charge the batteries, because of a defect generator or regular

Have examined by a specialist

Engine oil pressure too low, engine is shut down by the engine control unit

The battery charge control light in the fault monitoring board lights up during operation

BC 672 RB/EB,BC 772 RB/RS

%20$*

137

7URXEOH VKRRWLQJ

138

%20$*

BC 672 RB/EB,BC 772 RB/RS