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Fayat Group BOMAG BC 672 RB-4 Service Manual

Refuse compactor, soil compactor
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Service Manual
BC 672 RB-4 / BC 772 RB-4 / BC 772 RS-4 /
BC 772 EB-4
S-570-0050
S/N 101 570 04 1001> / S/N 101 570 02 1001> / S/N 101 570 03 1001> / S/N 101 570 94 1001>
Refuse compactor
Soil compactor
008 925 84
© 06/2018

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Summary of Contents for Fayat Group BOMAG BC 672 RB-4

  • Page 1 Service Manual BC 672 RB-4 / BC 772 RB-4 / BC 772 RS-4 / BC 772 EB-4 S-570-0050 S/N 101 570 04 1001> / S/N 101 570 02 1001> / S/N 101 570 03 1001> / S/N 101 570 94 1001> Refuse compactor Soil compactor 008 925 84...
  • Page 2 Find manuals at https://best-manuals.com...

  • Page 3: Table Of Contents

    Table of contents Table of contents General..............................9 1.1 Introduction..........................10 1.2 Concerning your safety......................12 1.2.1 Basic prerequisites........................12 1.2.2 Definition of responsible persons....................15 1.2.3 Fundamentals for safe operation....................16 1.2.4 Handling fuels and lubricants..................... 18 1.2.5 Loading / transporting the machine.................... 24 1.2.6 Start up procedure........................
  • Page 4 Table of contents 2.7.3 AdBlue ® /DEF..........................95 2.7.4 Coolant............................98 2.7.5 Hydraulic oil..........................99 2.7.6 Gear oil SAE 80W-140......................100 2.7.7 Lubrication grease........................100 2.8 List of fuels and lubricants...................... 101 Overview of machine........................103 3.1 Refuse compactor........................104 3.2 Soil compactor..........................
  • Page 5 Table of contents 4.7.1 Sequence of end position damping..................205 4.8 Travel system..........................209 4.9 Training of electric system....................... 210 4.10 Inspection and maintenance work..................311 4.10.1 Maintenance Table......................... 311 4.10.2 Every 500 operating hours..................... 311 4.10.3 As required..........................312 Hydraulic system..........................
  • Page 6 Table of contents 6.2.2 Repairing the oscillating articulated joint.................. 494 6.2.3 Inspection and maintenance work.................... 496 6.3 Compactor wheels and dozer blade..................497 6.3.1 Maintenance Table........................497 6.3.2 Checks prior to start up......................497 6.3.3 Every 500 operating hours....................... 498 6.3.4 As required..........................
  • Page 7 Table of contents 7.3.3 Checking the main battery switch.................... 586 7.3.4 Fuse assignment........................586 7.3.5 ESX, checking the electric power supply................. 589 7.3.6 Diagnostics concept......................... 597 7.4 Trouble shooting, diesel engine....................600 7.4.1 Engine malfunctions......................... 600 7.4.2 Starting the engine with jump leads..................603 7.4.3 Removing the reduction of engine power.................
  • Page 8 Table of contents 9.4 Measures before restarting...................... 723 Index..............................725 Appendix............................737 A Circuit diagrams.................... 741 A.1 Circuit diagram 247................... 741 A.2 Circuit diagram 274................... 798 A.3 Circuit diagram 279................... 856 A.4 Circuit diagram 332................... 913 A.5 Circuit diagram 402................... 971 A.6 Circuit diagram 402.................

  • Page 9: General

    General General BC 672 RB-4 / BC 772 RB-4 / BC 772 RS-4 / BC 772 EB-4 Find manuals at https://best-manuals.com...

  • Page 10: Introduction

    General – Introduction 1.1 Introduction............... 10 1.2 Concerning your safety..........12 1.2.1 Basic prerequisites..........12 1.2.2 Definition of responsible persons......15 1.2.3 Fundamentals for safe operation......16 1.2.4 Handling fuels and lubricants........18 1.2.5 Loading / transporting the machine......24 1.2.6 Start up procedure...........

  • Page 11: General - Introduction

    General – Introduction Index The index is a reference register that will help you to find informa- tion in this Service Manual. The index lists keywords in alphabet- ical order. Cross references (keywords related to page numbers) enable quick and convenient search/navigation. Keywords concerning the following subjects are listed in the index: Electrical operating means Plug designations...

  • Page 12: Concerning Your Safety

    General – Concerning your safety 1.2 Concerning your safety 1.2.1 Basic prerequisites 1.2.1.1 General This machine has been built in compliance with the latest technical standard and complies with the applicable regulations and tech- nical rules. However, dangers for persons and property may arise from this machine, if: it is used for purposes other than the ones it is intended for, it is operated by untrained personnel,...
  • Page 13 General – Concerning your safety CAUTION! Danger of injury if failing to comply! Sections marked accordingly indicate a dangerous situation that could lead to fatal or severe injuries, if this warning is disregarded. NOTICE! Danger of material damage if failing to comply! Sections marked accordingly indicate possible dangers for machines or components.
  • Page 14 General – Concerning your safety Safety goggles To protect the eyes against airborne particles and squirting fluids. Face protection To protect the face against airborne particles and squirting fluids. Hard hat To protect the head against falling parts and to protect against injuries.

  • Page 15: Definition Of Responsible Persons

    General – Concerning your safety 1.2.1.6 Improper use Dangers may arise from the machine when it is used for purposes other than the one it is intended for. Any danger caused by improper use is the sole responsibility of the operating company or driver/operator, the manufacturer cannot be made liable.

  • Page 16: Fundamentals For Safe Operation

    General – Concerning your safety 1.2.2.2 Expert / qualified person An expert / qualified person is a person who, based on his/her pro- fessional education and experience, has profound knowledge in the field of construction equipment and the machine in question in particular.
  • Page 17 General – Concerning your safety All persons remaining in the area of the machine must be informed about the dangers that arise from the operation of the machine. 1.2.3.2 Regular safety inspections Have the machine inspected by an expert / qualified person as required for the conditions the machine is working under, but at least once every year.

  • Page 18: Handling Fuels And Lubricants

    General – Concerning your safety 1.2.4 Handling fuels and lubricants 1.2.4.1 Preliminary remarks The operating company must ensure that all professional users have read and follow the corresponding safety data sheets for the individual fuels and lubricants. Safety data sheets provide valuable information about the following characteristics: name of substance possible dangers...
  • Page 19 General – Concerning your safety 1.2.4.2 Safety regulations and environmental protection regulations for handling diesel fuel WARNING! Danger of burning by ignited diesel fuel! – Do not allow diesel fuel to come into contact with hot components. – Smoking and open fire is prohibited! –...
  • Page 20 General – Concerning your safety 1.2.4.3 Safety regulations and environmental protection regulations for handling AdBlue ® /DEF CAUTION! Health hazard caused by ammonia vapours! – Wear your personal protective equipment (pro- tective gloves, protective clothing). – Do not inhale ammonia vapours. –...
  • Page 21 General – Concerning your safety 1.2.4.5 Safety regulations and environmental protection regulations for handling hydraulic oil WARNING! Danger of injury caused by escaping pressure fluid! – Always depressurize the hydraulic system before starting work in the hydraulic system. – Wear your personal protective equipment (pro- tective gloves, protective clothing, goggles).
  • Page 22 General – Concerning your safety 1.2.4.6 Safety regulations and environmental protection regulations for handling coolants WARNING! Danger of scalding by hot fluid! – Open the compensation tank only when the engine is cold. – Wear your personal protective equipment (pro- tective gloves, protective clothing, goggles).
  • Page 23 General – Concerning your safety 1.2.4.7 Safety regulations and environmental protection regulations for handling battery acid WARNING! Danger of cauterization with acid! – Wear your personal protective equipment (pro- tective gloves, protective clothing, goggles). – Do not allow clothes, skin or eyes to come into contact with acid.

  • Page 24: Loading / Transporting The Machine

    General – Concerning your safety Safety regulations and environmental protection regulations when handling lubrication 1.2.4.8 grease CAUTION! Health hazard caused by contact with lubrica- tion grease! – Wear your personal protective equipment (pro- tective gloves, safety goggles, protective clothing). – Avoid contact.

  • Page 25: Start Up Procedure

    General – Concerning your safety Loads must only be attached and hoisted by an expert / capable person. Lifting the machine is not permitted. For transport by ship use a flat container with collapsible front and rear walls, so that the machine can be driven onto the container. 1.2.6 Start up procedure 1.2.6.1 Prior to starting up...

  • Page 26: Driving The Machine; Working Operation

    General – Concerning your safety Do not inhale exhaust fumes, because they contain toxic sub- stances, which could cause damage to health, unconsciousness or even death. For operation in closed or partly closed rooms ensure adequate ventilation. 1.2.6.3 Starting the engine with jump leads Connect positive with positive and negative with negative (ground cable) –...
  • Page 27 General – Concerning your safety Change the travel direction only at standstill. Do not use the machine to transport persons. Do not use the dozer blade/bucket to transport persons – danger to life! Do not use the dozer blade/tilt blade to transport persons – danger to life! In case of unusual noises and development of smoke perform trouble shooting and have the fault corrected.

  • Page 28: Refuelling

    General – Concerning your safety 1.2.8 Refuelling Do not inhale any fuel fumes. Refuel only with the engine stopped and the auxiliary heater switched off. Do not refuel in closed rooms. No open fire, do not smoke. Static charges may be generated in the fuel as it passes through the filling system.

  • Page 29: Maintenance Work

    General – Concerning your safety Restart the machine only after the danger that caused the actua- tion of the emergency stop switch has been eliminated. In case of frequent use the wear on the multi-discs brakes will be very high, you should therefore never use the emergency stop switch as a service brake.
  • Page 30 General – Concerning your safety 1.2.11.2 Work on hydraulic lines Always lower the dozer blade / bucket to the ground and shut down the engine before relieving the hydraulic system. Always lower the dozer blade / tilt blade to the ground and shut down the engine before relieving the hydraulic system.
  • Page 31 General – Concerning your safety Check and change coolant only when the engine is cold. Collect coolant and dispose of it in an environmentally friendly way. 1.2.11.4 Maintenance work on electric components and battery Before starting to work on electric parts of the machine disconnect the battery and cover it with insulating material.

  • Page 32: Repair

    General – Concerning your safety 1.2.12 Repair Identify a defective machine with a warning sign. Only operate the machine after it has been repaired. Repairs must only be performed by an expert/qualified person. When replacing safety relevant components, only original spare parts must be used.
  • Page 33 General – Concerning your safety 50mm . 1.97in 50mm . 1.97in STOP Diesel B-570-0120 Fig. 8 BC 672 RB-4 / BC 772 RB-4 / BC 772 RS-4 / BC 772 EB-4...
  • Page 34 General – Concerning your safety Hydraulic Oil Engine Coolant Spec.: • MB 325.5 • Deutz DQC CC-14 Part No.: 009 940 03 (20 l) B-570-0121 Fig. 9 BC 672 RB-4 / BC 772 RB-4 / BC 772 RS-4 / BC 772 EB-4...
  • Page 35 General – Concerning your safety 50mm . 1.97in 50mm . 1.97in STOP Diesel B-570-0122 Fig. 10 BC 672 RB-4 / BC 772 RB-4 / BC 772 RS-4 / BC 772 EB-4...
  • Page 36 General – Concerning your safety Hydraulic Oil Engine Coolant Spec.: • MB 325.5 • Deutz DQC CC-14 Part No.: 009 940 03 (20 l) B-570-0121 Fig. 11 BC 672 RB-4 / BC 772 RB-4 / BC 772 RS-4 / BC 772 EB-4...
  • Page 37 General – Concerning your safety 50mm . 1.97in 50mm . 1.97in STOP Diesel B-570-0122 Fig. 12 BC 672 RB-4 / BC 772 RB-4 / BC 772 RS-4 / BC 772 EB-4...
  • Page 38 General – Concerning your safety Hydraulic Oil Engine Coolant Spec.: • MB 325.5 • Deutz DQC CC-14 Part No.: 009 940 03 (20 l) B-570-0121 Fig. 13 Warning sticker - Danger zone Fig. 14 Warning sticker - Danger of crushing Fig.
  • Page 39 General – Concerning your safety Warning sticker - Danger of being pulled in: Shut down the engine Fig. 17 Warning sticker - Follow operating instructions Fig. 18 Warning sticker - Open the radiator cap only when the engine has cooled down Fig.
  • Page 40 General – Concerning your safety Information sticker - Guaranteed sound capacity level Fig. 21 Information sticker - Filler opening for hydraulic oil Hydraulic Oil B-DEC-0214 Fig. 22 Information sticker - Hydraulic oil level Fig. 23 Information sticker - Disconnecting the battery B-DEC-0219 Fig.
  • Page 41 General – Concerning your safety Information sticker - Coolant Engine Coolant Spec.: • MB 325.5 • Deutz DQC CC-14 Part No.: 009 940 03 (20 l) B-DEC-0221 Fig. 25 Information sticker - Clean cooling module 50mm . 1.97in B-DEC-0059 Fig. 26 Information sticker - Lashing point Fig.
  • Page 42 General – Concerning your safety Information sticker - Transport of soil compactor B-DEC-0240 Fig. 29 Machine type plate (example) Fig. 30 BC 672 RB-4 / BC 772 RB-4 / BC 772 RS-4 / BC 772 EB-4...

  • Page 43: Maintenance And Repair

    General – Maintenance and repair 1.3 Maintenance and repair 1.3.1 Notes on repair 1.3.1.1 General repair instructions NOTICE! Ensure strict cleanliness when performing repair work! – No foreign objects should enter into open sys- tems. – Thoroughly clean the area around the affected components.
  • Page 44 General – Maintenance and repair Always keep battery poles and terminal clams clean to avoid high transition resistances when starting and the related devel- opment of heat. Make sure the battery is properly fastened in the vehicle. Generator Before removing the generator you must disconnect the ground cable from the minus pole of the battery while the ignition is switched off.
  • Page 45 General – Maintenance and repair 1.3.1.1.2 Repair notes for hydraulics Please note Cleanliness is of utmost importance. Dirt and other contaminations must strictly be kept out of the system. Connections and screw fittings, filler neck covers and their immediate surrounding areas must be cleaned before removal. Before loosening hoses, pipe lines etc.
  • Page 46 General – Maintenance and repair Taking into operation Bleed the hydraulic circuits. Start up the hydraulic system without load. Check the hydraulic oil level in the tank, if necessary top up with hydraulic oil as specified in the operating and maintenance instructions or drain oil off into a suitable container.
  • Page 47 General – Maintenance and repair When using steam cleaning equipment cover control unit, cable plugs, all other electrical connections and the generator beforehand and do not expose these items to the direct steam jet. Electrical plug connections must be plugged in during jet cleaning.
  • Page 48 General – Maintenance and repair Close openings on components and engine immediately with suitable plugs/caps. Plugs/caps must only be removed just before the installation. Keep plugs/caps in their original packaging, where they are protected against dust and dirt, dispose of after one time use. Take new parts out of their original packaging just before instal- lation.
  • Page 49 General – Maintenance and repair Sealing compound must be applied thin and evenly on the cor- responding surfaces; take care that the compound does not enter into oil galleries or blind threaded bores. Examine the contact faces for scratches and burrs, remove these with a fine file or an oilstone;...
  • Page 50 General – Maintenance and repair 1.3.1.1.5 Repair notes for ball and roller bearings If one bearing of a pair of bearings shows defects, we highly recommend the replacement of both bearings. Remove any lubricant residues from the bearing to be exam- ined by washing it with a suitable degreasing agent.
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This manual is also suitable for:

Bomag bc 772 rb-4Bomag bc 772 rs-4Bomag bc 772 eb-4101 570 04 1001101 570 02 1001101 570 03 1001 ... Show all

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