Operating instructions

Maintenance instructions

 
  


BC 572 RB-2
S/N 101 570 64 1032>

Sanitary landfill compactor

Catalogue No.
008 061 01 01/2009

These BOMAG machines are products from
F oreword
the wide product range of BOMAG machines
for earth and asphalt construction, refuse
compaction and stabilizing/recycling.
BOMAG’s vast experience in connection with
state-of-the-art production and testing meth-
ods, such as lifetime tests of all important
components and highest quality demands
guarantee maximum reliability of your ma-
chine.
This manual comprises:
● Safety regulations
● Operating instructions
● Maintenance instructions
● Trouble shooting
Using these instructions will
● help you to become familiar with the machine.
● avoid malfunctions caused by unprofessional
operation.
Compliance with the maintenance instructions will
● enhance the reliability of the machine on con-
struction sites,
● prolong the lifetime of the machine,
● reduce repair costs and downtimes.
BOMAG will not assume liability for the function of
the machine
● if it is handled in a way not complying with the
usual modes of use,
● if it is used for purposes other than those men-
tioned in these instructions.
No warranty claims can be lodged in case of dam-
age resulting from
● operating errors,
● insufficient maintenance and
● wrong fuels and lubricants.
Please note!
This manual was written for operators and mainte-
nance personnel on landfill sites.
Always keep this manual close at hand, e.g. in the
tool compartment of the machine or in a specially
BC 572 RB-2


provided container. These operating and mainte-
nance instructions are part of the machine.
You should only operate the machine after you
have been instructed and in compliance with these
instructions.
Strictly observe the safety regulations.
Please observe also the guidelines of the Civil En-
gineering Liability Association ”Safety Rules for
the Operation of Road Rollers and Soil Compac-
tors” and all relevant accident prevention regula-
tions.
For your own personal safety you should only
use original spare parts from BOMAG.
In the course of technical development we re-
serve the right for technical modifications
without prior notification.
These operating and maintenance instructions are
also available in other languages.
Furthermore, the spare parts catalogue is availa-
ble from your BOMAG dealer against the serial
number of your machine.
Your BOMAG dealer will also supply you with in-
formation about the correct use of our machines
on landfill sites.
The above notes do not constitute an extension of
the warranty and liability conditions specified in the
general terms of business of BOMAG.
We wish you successful work with your BOMAG
machine.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG



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

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

Fig. 2

Fig. 3

  BC 572 RB-2

 Table of Contents

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BC 572 RB-2
 
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BC 572 RB-2
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Table of Contents

Y  BC 572 RB-2

 1 Technical Data

BC 572 RB-2
 Z
 opqrsptu vtwt

Fig. 4

Dimensions in A B B2 B3 D H H2 H4 K L
mm
BC 572 RB-2 3500 3800 3550 3425 1660 4120 3820 1950 600 8120

* BC 572 RB-2

Weights
Operating weight (CECE) kg 28600
Front axle load (CECE) kg 14150
Rear axle load (CECE) kg 14450

Travel characteristics
Travel speed range I (forward/reverse) km/h 0 - 4,5
Travel speed range II (forward/reverse) km/h 0 - 12
Max. gradability (depending on soil) % 100

Engine
Engine manufacturer Deutz
Type TCD 2013 L06 4V
Cooling Water
Number of cylinders 6
Rated power ISO 9249 kW 227
Rated power acc. to SAE J 1349 hp 304
Rated speed rpm 2200
Electric equipment, operating voltage V 24
Drive system hydrostatic
Driven compactor wheels 4

6I  BC 572 RB-2

 opqrsptu vtwt

* BC 572 RB-2
Compactor wheels
Width, front mm 1175
Width, rear mm 1125
Number of teeth, front 50
Number of teeth, rear 50

Brake
Service brake hydrostatic
Parking brake mechanical
Emergency brake hydro-mechanical

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

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

Filling capacities
Fuel (diesel) l 500
Engine oil l 21,5
Hydraulic oil l 350
Coolant l approx. 44
* Subject to technical alterations, technical data may deviate for optional equipment

BC 572 RB-2
 66
opqrsptu vtwt

The following noise and vibration data acc. to

- EC Machine Regulation edition 98/37/EC and

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

- Vibration Protection Regulation 2002/44/EC

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

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

Noise value
Sound pressure level on the place of the operator:
LpA = 75 dB(A), determined acc. to ISO 11204 and EN 500

Guaranteed sound power level:

LWA = 108 dB(A), determined acc. to ISO 3744 and EN 500

Vibration value
Vibration of the entire body (driver’s seat)
The weighted effective acceleration value determined according to ISO 7096 is ≤0.5 m/sec 2.

Hand-arm vibration values

The weighted effective acceleration value determined according to EN 500/ISO 5349 is ≤2.5 m/sec2.

6@  BC 572 RB-2

 2 Safety regulations

BC 572 RB-2
 6
xtywz {|utwsr}
General
This BOMAG machine has been built in com-
pliance with the latest technical standard and
complies with the applicable regulations and
technical 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,
● it is changed or converted in an unprofessional
way,
● the safety instructions are not observed.
Each person involved in the operation, mainte-
nance and repair of the machine must there-
fore read and comply with these safety
regulations. If necessary, this must be con-
firmed by obtaining the signature of the cus-
tomer.
Furthermore, the following obviously also applies:
● applicable accident prevention instructions,
● generally accepted safety and road traffic reg-
ulations,
● country specific safety regulations. It is the
duty of the operator to be acquainted with
these instructions and to apply these accord-
ingly. This applies also for local regulations
concerning different types of handling work.
Should the recommendations in these instruc-
tions be different from the regulations valid in
your country, you must comply with the safety
regulations valid in your country.
Intended use
This machine must only be used for:
● compaction and distribution of refuse on sani-
tary landfill sites.
Any other use of the machine counts as unintend-
ed use and may cause danger for persons or dam-
age 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 envi-
6
ronment and/or health) must have special pro-
tection equipment.
Unintended use
Dangers may, however, arise from the machine if
it is used by untrained personnel in an unprofes-
sional way or if it is used for purposes other than
those mentioned in these instructions.
Starting and operation of the machine in an explo-
sive environment is prohibited.
Who is allowed to work with the ma-
chine?
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 com-
plied 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 ma-
chine
Unauthorized alterations to the machine are pro-
hibited for safety reasons.
Original parts and accessories have been special-
ly designed for this machine. We wish to make ex-
plicitly 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 ex-
cludes any liability for damage caused by the use
of non-original parts or accessories.
Safety notes in the operating and main-
tenance instructions:
~
Danger
Sections marked like this point out possible
dangers for persons.
 BC 572 RB-2


Caution
Sections marked like this point out possible
dangers for the machine or for parts of the ma-
chine.
i Note
Sections marked like this provide technical infor-
mation concerning the optimal economical use of
the machine.
Environment
Sections marked like this highlight activities
for the safe and environmental disposal of fu-
els and lubricants as well as replaced parts.
Observe all environment protection regula-
tions.
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 inclina-
tion must be lower than the gradability
of the machine.
Secure the machine against falling or slipping off.
On the transport vehicle secure the machine
against rolling off, slipping about or turning over.
Persons are highly endangered when
● they step or stand under loads being lifted
● they remain in the danger zone of the machine
during an ongoing demonstration or during
loading.
Towing the machine
You should generally use a tow bar.
Max. towing speed 1 km/h (1.6 mph), max. towing
distance 500 m (1640 ft.).
Before releasing the multi-disc brakes secure the
machine properly against unintended rolling.
BC 572 RB-2

xtywz {|utwsr}
Checking the Roll Over Protective
Structure (ROPS)
The frame of the machine must not be warped,
bent or cracked in the area of the ROPS fastening.
The ROPS must not show any rust, damage, hair-
line cracks or open fractures.
The ROPS must not rattle about when driving.
This would indicate that it is not properly fastened.
All bolted connections must comply with the spec-
ifications and should be absolutely tight (observe
the tightening torques). Screw and nuts must not
be damaged, bent or deformed.
No accessories may be welded or bolted on and
no additional holes must be drilled without the con-
sent of the manufacturer, since this will impair the
strength of the unit.
Starting the machine
Before starting
Use only machines which have been properly
serviced at regular intervals.
Become acquainted with the equipment, the con-
trol elements, the working mode of the machine
and the area you will be working in.
Use your personal protective outfit (hard hat, safe-
ty boots etc.).
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
To climb onto the machine use steps and hand-
rails.
Check before starting, whether:
● the machine shows any obvious defects
● 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
Do not start the machine if any gauges, control
lights or controls are defective.
6
xtywz {|utwsr}
Do not take any loose objects with you or fasten
them to the machine.
On machines with ROPS you should always wear
your seat belt!
Starting
Start and operate the machine only from the oper-
ator's seat
To start the machine set all control levers to "neu-
tral 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.
Never start the engine by bridging the electrical
connections on the starter, because the machine
would probably start to move immediately.
Starting in closed rooms
Exhaust fumes are highly dangerous! When start-
ing or operating the cabin heater in closed rooms
you should therefore ensure an adequate supply
of fresh air!
Driving the machine
Persons in the danger area
If a machine has turned over and the cabin door is
jammed, all cabin windows can be used as escape
doors.
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.
Give warning signals, if necessary. Stop work im-
mediately if persons remain in the danger zone,
despite the warning.
Do not step or stand in the articulation area of the
machine when the engine is running. Danger of
squashing!
Driving
In events of emergency and in case of danger ac-
tuate the emergency stop switch immediately. Do
not use the emergency stop switch as service
brake. Restart the machine only after the danger
6S
that caused the actuation of the emergency stop
switch has been eliminated.
If the machine has contacted high-voltage power
lines:
● do not leave the operator’s stand
● warn others from coming close to or touching
the machine
● if possible drive the machine out of the danger
zone
● have the power switched off
Operate the machine only from the operator’s
stand.
Keep the cabin doors closed.
Do not adjust the driver’s seat while driving.
Do not climb onto or off the machine while the ma-
chine is driving.
Change the travel direction forward/reverse only
at standstill.
Do not use the machine to transport persons.
Do not use the dozer blade to transport persons!
Mortal danger!
Moving other vehicles with the dozer blade is pro-
hibited.
In case of unusual noises and development of
smoke perform trouble shooting and have the fault
corrected.
Match the speed to the working conditions.
Always give way to loaded transport vehicles.
Switch the lights on if the visibility is poor. Keep
away from edges and embankments.
Do not run the heating in service or storage halls.
Driving on inclinations and slopes
Do not drive on gradients exceeding the maximum
gradability of the machine.
On slopes drive extremely careful and always di-
rectly up or down the slope. Change to a lower
gear before starting to drive.
Wet and loose soils considerably reduce the
ground adhesion of the machine on inclinations
and slopes. Higher risk of accident!
Parking the machine
Park the machine on horizontal, level, firm ground.
Before leaving the machine:
 BC 572 RB-2

● lower the dozer blade to the ground.
● return the control lever to neutral position
● shut the engine down, pull the ignition key off
● lock the cabin
Do not jump off the machine, but use hand grips
and access steps.
Mark machines, which could be in the way, with a
clearly visible sign.
Pull off the main battery switch.
Filling the fuel tank
Do not inhale fuel fumes.
Refuel only after shutting the engine and the aux-
iliary heater down.
Do not refuel in closed rooms.
No open fire, do not smoke.
Do not spill any fuel. Catch running out fuel, do not
let it seep into the ground.
Wipe off spilled fuel. Keep fuel free of dirt and wa-
ter.
Leaking fuel tanks can cause explosions. Ensure
tight fit of the fuel tank filling cover, replace it if nec-
essary.
Fire protection measures
Make yourself acquainted with the location and the
operation of fire extinguishers. Observe fire warn-
ing and fire fighting installations.
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, in-
cluding the information concerning the replace-
ment of parts.
For overhead maintenance and assembly work
use the access steps and working platforms pro-
vided or other secure means. Do not use machine
parts as access steps.
When performing maintenance work on machines
used in contaminated environments, all applicable
national or local safety regulations must be ap-
plied.
Keep unauthorized persons away from the ma-
chine.
BC 572 RB-2

xtywz {|utwsr}
Do not perform maintenance work while the ma-
chine is driving or the engine is running.
Park the machine on level, firm ground.
Lower the dozer blade to the ground.
Pull the key out of the ignition switch.
Secure the articulated joint with the articulation
lock.
Work on hydraulic lines
In order to depressurize the hydraulic system low-
er the dozer blade to the ground and shut the en-
gine down.
Relieve hydraulic pressures before working on hy-
draulic lines. Hydraulic oil escaping under pres-
sure 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 sys-
tem.
Do not change the setting of pressure relief valves.
Drain the hydraulic oil at operating temperature –
danger of scalding!
Catch running out hydraulic oil and dispose of en-
vironmentally.
Always catch and dispose of hydraulic oils sepa-
rately.
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.
Changing hydraulic hoses
Hydraulic hoses must be visually inspected at reg-
ular intervals.
Hydraulic hoses must be immediately replaced if:
● the outer layer is damaged down to the inlay
(e.g. chafing, cuts or 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 genuine shape of the hydrau-
lic hose
6U
xtywz {|utwsr}
● the hose shows deformations in bends, e.g.
squeezing, buckling, layer separation, forma-
tion of blisters,
● parts of the hose are leaking.
● hoses are not correctly installed
● the hydraulic hose has separated from the fit-
ting
● 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.
Only genuine BOMAG replacement hydraulic hos-
es ensure that the correct hose type (pressure
range) is used at the right location.
● Do not mix up hoses by mistake
Working on the engine
Drain the engine oil at operating temperature –
danger of scalding!
Wipe off spilled oil, catch running out oil and dis-
pose of environmentally.
Store used filters and other oil contaminated ma-
terials in a separate, specially marked container
and dispose of environmentally.
Working on the cooling system
Check the coolant level only with the engine shut
down, 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.
Working on electric parts of the machine
Before starting to work on electric parts of the ma-
chine disconnect the battery and cover it with insu-
lating material.
Do not use fuses with higher ampere ratings and
do not repair fuses with a piece of wire. Fire haz-
ard!
Working on the battery
When working on the battery do not smoke, do not
use open fire!
Do not let acid come in contact with hands or
clothes! When injured by acid flush off with clear
water and seek medical advice.
6Y
Metal objects (e.g. tools, rings, watch straps) must
not come in contact with the battery poles – dan-
ger of short circuit and burning!
When recharging non-serviceable batteries re-
move all plugs, to avoid the accumulation of explo-
sive 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 bat-
tery is to be charged in a closed room.
Working on the fuel system
Do not inhale any fuel fumes.
Avoid 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.
Working on the air conditioning
Secure yourself with a safety harness when work-
ing on the air conditioning.
Faults on the air conditioning should only be rem-
edied by professional personnel.
Do not perform welding work in the vicinity of the
air conditioning. Danger of explosion!
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
Lower the dozer blade to the ground and shut the
engine down.
Cleaning work
Do not perform cleaning work while the motor is
running.
Do not use gasoline or other easily inflammable
substances for cleaning.
When using a steam cleaner for cleaning do not
subject electrical parts and insulation material to
the direct jet or cover these items beforehand.
Do not guide the cleaning jet into the exhaust.
 BC 572 RB-2
 xtywz {|utwsr}

After maintenance work

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

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

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

BC 572 RB-2
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@I  BC 572 RB-2

 3 Indicators and Controls

BC 572 RB-2
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Fig. 5

@@  BC 572 RB-2


1 Instrument cluster, left
2 Instrument cluster, right
3 Ignition switch
4 Air distribution nozzles
5 Lever for dozer blade control
6 Warning light and diagnostic push button for
engine control
7 Warning light water in fuel filter
8 Utility socket 24V
9 Rotary switch for travel ranges
10 Travel lever
11 Rotary switch for parking brake
12 Rotary switch for seat cushion heating
13 Cigarette lighter
BC 572 RB-2

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14 Push button for central lubrication system
15 Control unit for air conditioning*
16 Rotary switch for cabin fan
17 Potentiometer for throttle control*
18 Rotary switch to activate rotary speed pre-se-
lection/deceleration pedal with indicator light*
19 Emergency stop push button
20 Travel pedal for throttle control
21 Deceleration pedal with emergency braking
kick-down*
22 Steering lever
23 Push button for warning horn
* Optional equipment
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3.1 General notes 3.2 Description of indicators

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

Fig. 6
No. 1 = Instrument cluster, left

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

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

BC 572 RB-2
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 €rsptw} tr rwu}
Fig. 7
No. 2 = Instrument cluster, right
i Note
With the ignition switch in position "I" all gauges
and instruments are switched on for a moment.
m yellow = Control light for central lubrication
system
Flashes with 1 second on, 1 second
off in case of a fault in the lubricant
pump.
Flashes with 0.5 seconds on, 0.5
seconds off when the grease contain-
er is empty.
Flashes with 0,5 second on, 1 sec-
ond off in case of a malfunction.
Permanent light for about 45 seconds
during the lubrication process
n red = Warning light for hydraulic oil return
flow filter
Lights, if the hydraulic oil return flow
filter is blocked
Change the hydraulic oil return flow
filter.
o yellow = Differential pressure switch 2 on hy-
draulic oil filter.
Replace the rear hydraulic oil filter,
check the hydraulic system if it
comes on too early.
@S
p yellow = Differential pressure switch 1 on hy-
draulic oil filter.
Replace the front hydraulic oil filter,
check the hydraulic system if it
comes on too early.
q red = Hydraulic oil temperature warning
light
Lights if the hydraulic oil temperature
is too high, the warning buzzer
sounds, the engine is shut down after
2 minutes.
Clean the hydraulic oil cooler if nec-
essary.
r red = Hydraulic oil level warning light
Flashes when the hydraulic oil level
is too low, the warning buzzer
sounds, the engine is shut down after
20 seconds.
Check the hydraulic oil level, check
the hydraulic system for leaks, repair
if necessary.
s green = Control light speed range II
Lights when the rotary travel speed
range switch is in position "Right".
t green = Control light speed range I
Lights when the rotary travel speed
range switch is in position "Left".
u yellow = Parking brake warning light
Lights when the parking brake is ap-
plied
v green = Control light for neutral position of
travel lever
Lights when the travel lever is in neu-
tral position Goes out when the travel
lever is actuated.
w yellow = Contamination sensor warning light
Lights when the contamination sen-
sor is soiled, the warning buzzer
sounds
x = Voltmeter
y = Coolant temperature gauge
z = Hydraulic oil temperature gauge
 BC 572 RB-2
 €rsptw} tr rwu}

Fig. 8 Fig. 9
No. 3 = Ignition switch No. 4 = Air distribution nozzles
Position "0" = Ignition off, key can be pulled Adjusting the di-
out rection = turn the outside of the nozzle
Position "I" = Ignition on, all control and Regulating the air
warning lights in the instru- quantity = open or close by swivelling the
ment clusters light up for 3 flap
seconds (test function).
Fault warning light, parking
brake warning light, charge
control light and travel lever
neutral position control light
stay on.

i Note
The ignition switch is designed with a re-start lock.
For a new starting attempt the ignition key must
first be turned back to position "0".
Position "II" = Turn further against spring
pressure, the engine starts,
turn the ignition key back to Fig. 10
position "I" once the engine No. 5 = Lever for dozer blade control
has started. Charge control
Position "0" (neu-
light and fault warning light go
tral position) = no actuation, lever returns au-
out. The parking brake warn-
tomatically to "0"-position.
ing light goes out when the
parking brake is released. Position "I" = Dozer blade down
Position "I" and
 Caution
push button "a" = Dozer blade in floating position
(e.g. to level the surface while
Run the engine warm for a short while before driving backwards)
starting work. Do not rev up a cold engine to
high idle speed/full load speed. Position "II" = Dozer blade up, float position
off
Do not shut down the engine all of a sudden
from full load speed, but let it idle for about 2
minutes.

BC 572 RB-2
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i Note
The diesel engine with EMR (Electronic Engine
Control) has some protective functions for the en-
gine.
Depending on the severity of the detected fault the
engine may continue operation with limitations
(limp home), whereby the warning light will perma-
nently be on.
With flashing warning light the engine is shut
down. If the fault indicators for engine oil pressure,
engine temperature or coolant level, light up as
well, eliminate the fault.
Fig. 11
When the fault is eliminated the control light will go
Lever for bucket control* out.
Middle position = No actuation, lever returns au- The diagnostic button provides the possibility to
tomatically to middle position read out existing faults in form of flashing codes.
Position front = Bucket down With the ignition switch in position "I" the control
light lights for about 2 seconds (function check)
Position rear = Bucket up
permanent light = A fault message is present, the
Position left = Tipping bucket to fill
engine can be started and the
Position right = Tipping bucket to empty vehicle is still operable with
Press button limitations. Inform the service
(a). = Bucket in floating position (e.g. department.
to level the surface while driv- the control light
ing backwards) flashes after 2
Press button (a) seconds = Severe fault, the engine can-
again = Bucket float position deactivat- not be started, inform the serv-
ed ice department.
goes out after 2
seconds = The engine function is free of
faults.
does not light = Start the engine, press the di-
agnostic push button for 3 sec-
onds. Control light flashes 2x.
EMR-control ok.

Caution
In case of a fault make a note of the fault code
and inform the BOMAG customer service or
the customer service of the engine manufac-
turer.
Fig. 12
See chapter "Trouble shooting".
No. 6 = Warning light and diagnostic push
button for engine control

* Optional equipment

@Y  BC 572 RB-2

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Fig. 13 Fig. 15
No. 7 = Warning light water in fuel filter No. 9 = Rotary switch for travel ranges
lights = Lights when the water content Position "left" = Speed range I, slow working
in the fuel pre-cleaner reaches speed range
the sensor contacts. The control light for travel
stage I in the right instrument
cluster lights.
Environment
Position "right" = Speed range II, transport
Drain off the water and other impurities and
speed
dispose of environmentally.
The control light for travel
goes out = if fuel is clean. stage II in the right instrument
cluster lights up.

Fig. 14
No. 8 = Socket 24V Fig. 16

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

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

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Position "rear" = Backwards travel

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

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

i Note
Fig. 18
In travel lever position "0" (neutral position) the
No. 12 = Rotary switch for seat heating
machine is automatically braked.
Position"left" = seat heating off.
Position"right" = seat heating on.

Fig. 17
No. 11 = Rotary switch for parking brake
Fig. 19
Position "left" = Parking brake released
The parking brake warning No. 13 = Cigarette lighter
light in the right instrument
cluster goes out.
Position "right" = Parking brake operated
The parking brake warning
light in the right instrument
cluster lights up after 4 sec-
onds.

Fig. 20
No. 14 = Push button for central lubrication
system

I  BC 572 RB-2

 €rsptw} tr rwu}

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

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

Fig. 22
No. 16 = Rotary switch for cabin fan
Fig. 21 The cabin fan is forced to run with the ignition
No. 15 = Control unit for air conditioning * switch in position "I" and when the engine is run-
ning. It permanently supplies fresh air to the cabin
a = Push button to activate and deacti- and thereby creates a slight overpressure in the
vate operation of air conditioning. cab.
b = Push button to raise the nominal val- Position "1", "2"
ue, may also be used to increase the and "3" = Fan stages of different
fan speed manually. strengths
c = LED with symbol for operation of air
conditioning activated.
i Note
d = LED with symbol for air circulation In case of a cabin fan fault or a soiled cabin filter
activated. the cabin filter warning light in the left instrument
e = LED with symbol for fan speed man- cluster lights up.
ually adjusted.
Clean the cabin filter or use a new one, repair or
f = 4-digit LED display for room temper- replace a defective cabin fan.
ature, nominal value (in °F
or °C), as well as fault indication for
temperature sensors.
g = Button to start REHEAT-operation.
h = Button to activate the heating.
i = Button to switch over circulation air/
fresh air operation.
j = Push button for manual adjustment of
the evaporator fan speed.

* Optional equipment

BC 572 RB-2
 6
 €rsptw} tr rwu}

on. The indicator light in the ro-

tary switch lights up.

Fig. 23
No. 17 = Potentiometer for throttle control*
Infinite adjustment of engine speed with rotary Fig. 25
speed pre-selection/deceleration pedal* enabled
No. 19 = Emergency stop push button
between "MIN" and "MAX".
Turn anti-clock-
wise = to reduce the engine speed.
‚ Danger
Turn clockwise = to increase the engine speed. Danger of accident!
Use only in events of emergency during oper-
ation.
Do not use as parking brake.
Restart the machine only after the danger that
caused the actuation of the emergency stop
switch has been eliminated.
The machine is braked immediately, the engine
is shut down.
actuate = press the button completely
down, it automatically locks in
fully pressed position.
switch off/un-
Fig. 24
lock = Turn button clockwise. Re-
start the engine.
No. 18 = Rotary switch to activate rotary speed
pre-selection/deceleration pedal with
indicator light*
The rotary switch has the function to switch the ro-
tary speed pre-selection and the deceleration ped-
al* on and off.
Position "left" = Rotary speed pre-selection/
deceleration pedal switched
off. The indicator light in the ro-
tary switch does not light. Posi-
tion to start the engine
Position "right" = Rotary speed pre-selection/
deceleration pedal switched
* Optional equipment

@  BC 572 RB-2

 €rsptw} tr rwu}

Fig. 26 Fig. 28
No. 20 = Travel pedal for throttle control No. 22 = Steering lever
Position "0" = Engine running at idle speed Steering lever to
Position "I" = higher idle speed/full load the left = steering movement to the left
Steering lever to
the right = steering movement to the right
i Note
The engine speed is displayed by the engine rpm-
meter in the left instrument cluster

Fig. 29
No. 23 = Push button for warning horn
Fig. 27
No. 21 = Deceleration pedal* with emergency
braking kick-down
Normal brake = Do not push down the deceler-
ation pedal all the way to kick-
down and hold it in this posi-
tion.
Emergency
brake = Push the deceleration pedal all
the way down to kick-down po-
sition.

Fig. 30

* Optional equipment
No. 24 = Air distribution nozzles

BC 572 RB-2
 
 €rsptw} tr rwu}

The air distribution nozzles are assigned to the air

conditioning, coolant powered cabin heating and
the cabin fresh air fan.
Adjusting the di-
rection = turn the outside of the nozzle
Regulating the air
quantity = adjust, open or close by swiv-
elling the flap

Fig. 31
No. 25 = Electric installation box
The installation box is installed in the console be-
hind the driver’s seat. Fig. 32

Fuses

Terminal
X1:20 (15A) = (F50) Climatronic*
X1:21 (30A) = (F89) Cigarette lighter
X1:22 = (F94) Spare, safety ventilation
system
X1:23 (30A) = (F13) Ignition switch
X1:24 (25A) = (F93) EDC 7 Control, potential
30
X1:25 (30A) = (F05) Socket
X1:26 (10A) = (F84) Processor control
X1:27 (30A) = (F67) Power control
X1:28 = (F123) Spare, safety ventila-
tion system
X1:29 (15A) = (F24) Instruments
X1:30 (10A) = (F16) Central lubrication sys-
tem
X1:31 (15A) = (F29) Driver’s seat

* Optional equipment

  BC 572 RB-2

 €rsptw} tr rwu}

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

Fig. 35
No. 27 = Air circulation nozzle for cabin heater
*

Fig. 33
Adjusting the di-
Main fuses for battery rection = turn the outside of the nozzle
(1) 250A = (F00) main fuse for battery Regulating the air
quantity = adjust, open or close by swiv-
(2) 100A = (F48) Main fuse for pre-heating sys- elling the flap
tem
Caution
i Note
This air circulation nozzle must always be
The batteries with the main fuses are located in-
completely open when running the cabin heat-
side the battery compartment under the cover in
er. Otherwise malfunction of the cabin heater.
front of the driver's door.

Fig. 36
Fig. 34
No. 28 = Timer for cabin heating
No. 26 = Cabin light
a = Memory display
switch on = turn lamp glass clockwise
* Optional equipment

BC 572 RB-2
 
 €rsptw} tr rwu}

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

Fig. 38
No. 30 = Dashboard, cabin
Fig. 37 a = Toggle switch for front windscreen
wipers
No. 29 = Fuse boxes, cabin
b = Toggle switch for front washer
‚ Danger c = Toggle switch/push button for rear
windscreen wiper/washer
Fire hazard!
d = Toggle switch for interior lights
Do not use fuses with higher ampere ratings
and do not bridge fuses. e = Toggle switch for front working head
lights
Fuse box F1 (top) f = Toggle switch for working head
(1) 10A = (F27) Windscreen wiper, washer, lights, sides
front g = Toggle switch for working head
(2) 10A = (F28) Windscreen wiper, washer, lights, rear
rear h = Toggle switch for rear view mirror
(3) 10A = Spare heatings
(4) 20A = (F85) 4 working headlights, front i = Toggle switch for flashing beacon
(5) 15A = (F86) 2 working headlights, rear j = Toggle switch for engine compart-
(6) 10A = (F02) Fresh air fan ment light

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

ment light
* Optional equipment

S  BC 572 RB-2

 €rsptw} tr rwu}

compartment as well as pro-

tection against unauthorized
use.

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

Fig. 39
No. 31 = Comfort seat
a = Lever, seat inclination
b = Lever, seat enlargement
c = Rotary button, arm rest adjustment
d = Rotary button, backrest curvature
(Drehknopf, Lehnenwölbung (sup-
port for intervertebral disc)
e = Lever, backrest inclination
f = Lever, length adjustment
Fig. 41
g = Foldable lever, horizontal suspension
h = Lever, adjustment of vertical suspen- Reversing camera**
sion, seat height with the monitor connected it enables the driver to
i = Snap-in lever to turn the seat check the working range behind the machine with-
out direct vision.
j = Lever to displace the arm rest
Angle of vision = 110° horizontal, 75° vertical

Fig. 40

Main battery switch

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

BC 572 RB-2
 U
 €rsptw} tr rwu}

for the distances in the travel range behind the ma-

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

Fig. 42

Monitor for reversing camera*

With the reversing camera connected the driver is
able to check the working area behind the ma-
chine without having a direct view. Fig. 44
a = Selector switch for permanent or au- A = tail edge and maximum width
tomatic operation
B = distance point approx. 1 m
b = Adjusting the contrast (1.1 yard)
c = Adjusting the brightness C = distance point approx. 3m
d = Switching the brightness for day or (3.3 yards)
night operation D = distance point approx. 5m
(5.5 yards)
Distance mark on monitor

Fig. 43
Rubbing on distance marks A (Fig. 43) onto the
screen of tghe monitor enables a rough estimation
of the travel range behind the machine.

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

* Optional equipment

Y  BC 572 RB-2

 4 Operation

BC 572 RB-2
 Z
ƒ„twsr
4.1 General
If you are not yet acquainted with the controls
and indicating elements on this machine you
should thoroughly read chapter 3 “Indicators
and control elements” before starting work.
All indicators and control elements are de-
scribed in detail in this chapter.
I
4.2 Tests before taking into op-
eration
Before the everyday use or before a longer work-
ing period the following tests and inspections must
be performed.
‚ Danger
Danger of accident!
Please observe strictly the safety regulations
in chapter 2 of this instruction manual!
● Park the machine on ground as level as possi-
ble.
Check:
● fuel tank and fuel lines for leaks
● screw joints for tight fit
● function of steering
● function of brakes
● hydraulic oil tank and lines for leaks
● Presence of the appropriate operating and
maintenance instructions
● proper maintenance of the machine
● service doors closed and locked
● Scrapers for compactor wheels
● Edge cutter for compactor wheels
● Check inner sides of compactor wheels, re-
move wires, cables, ropes, etc.
Caution
Remove refuse residues, cables, ropes, wires
etc. to prevent premature wear of the wheel
shell edge.
i Note
For a description of the following tasks refer to the
chapter "maintenance every 10 operating hours".
● Engine oil level, top up if necessary
● Fuel level, top up if necessary.
● Hydraulic oil level, top up if necessary.
● Coolant level, top up if necessary
● Transfer case oil level, change if necessary
 BC 572 RB-2
 ƒ„twsr

● Check machine for damage and leak tightness

4.3 Starting the engine
● Lubricate joints and bearings on the bucket*

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

Fig. 45

● Turn the main battery switch (Fig. 45) to posi-

tion "I".

‚
Danger
Danger of accident!
Always wear your seat belt.

Fig. 46

● Fasten your seat belt (Fig. 46).

* Optional equipment

BC 572 RB-2
 6
 ƒ„twsr

Fig. 47 Fig. 50

● Check, whether the emergency stop switch ● Shift the travel lever (Fig. 50) to position "0".
(Fig. 47) is unlocked.

Fig. 51
Fig. 48 ● Turn the rotary switch for activation of manual
● Shift the dozer blade control lever (Fig. 48) to throttle/deceleration pedal** (Fig. 51) anti-
position ”0”. clockwise to position "0".

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

Fig. 49

● Set the bucket control level * (Fig. 49) to mid-

dle position.
* Optional equipment ** Optional equipment

@  BC 572 RB-2

 ƒ„twsr

Fig. 52 Fig. 54

● Turn the ignition key (Fig. 52) to position "I". The engine control warning light (EMR) (Fig. 54)
lights for approx. 2 seconds (test function).

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

i Note
The ignition switch is designed with a re-start lock.
For a new starting attempt the ignition key must
Fig. 53 first be turned back to position "0".
All control and warning lights in the instrument
clusters (Fig. 53) are switched on for a moment.
Charge control light (e), fault warning light (h),
parking brake warning light (u) and travel lever
neutral position control light (v) stay on.

Fig. 55

● Turn the ignition key (Fig. 55) to position "II",

the starter will crank the engine.
● As soon as the engine ignites return the igni-
tion key to position "I".
The fault warning light and the charge control light
go out.

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Caution
4.4 Starting under low tempera-
Run the engine warm for a short while before
starting work. Do not rev up a cold engine to tures
high idle speed/full load speed.
● Perform all work prior to starting, as described
in the section "Starting the engine".

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

Fig. 56

● Turn the ignition key (Fig. 56) to position "I".

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

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The fault warning light and the charge control light

go out.

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

Fig. 58
The engine control warning light (EMR) (Fig. 58)
lights for approx. 2 seconds (test function).

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

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

Fig. 59

● Once the preheating control light (a) (Fig. 57)

has gone out, turn the ignition switch (Fig. 59)
to position "II", the starter will crank the engine.
● As soon as the engine ignites return the igni-
tion key to position "I".

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● After starting disconnect the negative poles

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

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

Fig. 60

Caution
A wrong connection will cause severe damage
in the electric system.
● When starting with external batteries connect
the positive poles (Fig. 60) first and the nega-
tive poles (ground cable) after.
● Start as described under "Starting the engine".

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

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

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4.6 Driving the machine

‚ Danger
Danger of accident!
Wet and loose soils considerably reduce the
ground adhesion of the machine on inclina-
tions and slopes.
Soil conditions and weather influences impair
the gradability of the machine.
Before starting to drive make sure that the
drive range is absolutely safe. Fig. 62

Always wear the seat belt when driving. The control lights for travel stage I (t) or travel
stage II (s) (Fig. 62) in the right instrument cluster
Keep the cabin door closed. light up.

Fig. 61
Fig. 63
● Turn the rotary switch for travel speed ranges ● Pull the lever for dozer blade control (Fig. 63)
(Fig. 61) to the desired speed range. back to position "II" and raise the dozer blade.
Position "left" = Speed range I, slow working
speed range
Position "right" = Speed range II, transport
speed

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Fig. 64 Fig. 66

● Pull the bucket control lever * (Fig. 64) back The travel lever neutral position control light (v)
and raise the bucket. (Fig. 66) in the right instrument cluster goes out.

Fig. 65 Fig. 67

● Shift the travel lever (Fig. 65) to the desired ● Turn the rotary switch for parking brake (Fig.
travel direction. 67) to position "left".

Position "I" = Forward travel

Position "II" = Reverse travel
In position "II" the backup alarm sounds.

Fig. 68
The parking brake warning light (u) (Fig. 68) in the
right instrument cluster goes out.

* Optional equipment

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‚
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. 71

● Steer the machine with the steering lever (Fig.

71) to the desired direction.

Fig. 69

● Actuate the throttle pedal (Fig. 69).

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

Fig. 70

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

(Fig. 70) in the left instrument cluster.

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4.7 Driving the machine with ro-

tary speed pre-selection/de-
celeration pedal*

‚
Danger
Danger of accident!
Wet and loose soils considerably reduce the
ground adhesion of the machine on inclina-
tions and slopes.
Soil conditions and weather influences impair Fig. 73
the gradability of the machine. Push the deceleration pedal (Fig. 73) all the way
Before starting to drive make sure that the down to kick-down position and hold it.
drive range is absolutely safe.
Always wear the seat belt when driving.
Keep the cabin door closed.

Fig. 74

● Turn the rotary switch for activation of speed

pre-selection/deceleration pedal (Fig. 74)
Fig. 72
clockwise to position "Right".

● Shift the travel lever (Fig. 72) to position "0".

i Note
The light in the rotary switch lights up.

* Optional equipment

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Fig. 75 Fig. 77
● Release the deceleration pedal (Fig. 75) from ● Release the deceleration pedal (Fig. 77).
kick-down position, but hold it actuated.

i Note
The machine starts off and the engine revs up to
the pre-selected speed (1600...2100 min-1).

Fig. 76

● Shift the travel lever (Fig. 76) to the desired

travel direction.
Position "I" = Forward travel Fig. 78
Position "II" = Reverse travel ● Turn the potentiometer for engine speed con-
trol (Fig. 78) clockwise to increase the engine
i Note speed and anti-clockwise to reduce the engine
speed.
In position "II" the backup alarm sounds.

‚
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.

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Fig. 79
● Read the engine speed on the RPM-meter (k)
(Fig. 79) in the left instrument cluster.
Fig. 80
● Actuate the throttle pedal (Fig. 80).
i Note
When reversing the backup alarm sounds.
With the drive pedal you may reach a higher travel
speed, but you cannot reduce the travel speed
lower than the pre-adjusted speed.
@
Fig. 81
● Steer the machine with the steering lever (Fig.
81) to the desired direction.
Change in travel direction
Fig. 82
● Do not push down the deceleration pedal (Fig.
82) all the way to kick-down and hold it in this
position.
i Note
The machine decelerates slowly until it comes to a
halt.
● Select the new travel direction and release the
deceleration pedal. The machine travels to the
new direction with the pre-selected speed.
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Emergency brake function

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

Fig. 83

● Push the deceleration pedal (Fig. 83) once all

the way down to kick-down position.

i Note Fig. 84
The machine decelerates excessively. ● Do not push down the deceleration pedal (Fig.
84) all the way to kick-down and hold it in this
When holding the deceleration pedal approx. 4
position.
seconds in kick-down position, the parking brake
warning light in the instrument cluster will addition-
ally light up. i Note
● To continue driving you must first return the The machine decelerates slowly until it comes to a
travel lever to neutral position. Then select the halt.
new travel direction.

Fig. 85

● Shift the travel lever (Fig. 85) to position "0"

and release the deceleration pedal.

‚
Danger
Danger of accident!

* Optional equipment

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If the travel lever is now unintentionally moved

to any travel direction the machine will imme- 4.9 Emergency exit
diately start to drive.
Always switch off the rotary speed pre-selec-
tion/deceleration pedal before leaving the driv- i Note
er’s seat. If a machine has turned over and the cabin door is
jammed, all cabin windows can be used as escape
doors.

Fig. 86

● Set the throttle control potentiometer (Fig. 86)

to the left to minimum engine speed. Fig. 88

● Take the emergency hammer (Fig. 88) out of

its holder and smash the cabin window need-
ed to escape.

‚
Danger
Danger of injury by glass splinters!
Turn your face away when smashing the win-
dow.

Fig. 87

● Turn the rotary switch for activation of rotary

speed pre-selection/deceleration pedal (Fig.
87) anti-clockwise to position "0".

i Note
Normal driving of the machine is possible again.

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4.10 Actuating the emergency 4.11 Operating the dozer blade

stop switch
‚ Danger
‚ Danger Life hazard!
Danger of accident! Do not use the dozer blade to transport per-
sons.
In events of emergency and in case of danger
the emergency stop switch must be actuated Moving other vehicles with the dozer blade is
immediately. Only unlock the emergency stop prohibited!
switch after the danger, that has caused the Always lower the dozer blade to the ground be-
actuation, has been eliminated. fore shutting the engine down.

Fig. 89 Fig. 90
● Press the button of the emergency stop switch ● Pull the lever for dozer blade control (Fig. 90)
(Fig. 89) down, it locks in pressed position. back to position "II" and raise the dozer blade.

i Note
The engine is shut down.

† Caution
Do not use the emergency stop switch as serv-
ice 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. 91

● Push the lever for dozer blade control (Fig. 91)

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

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4.12 Operating the bucket*

‚
Danger
Life hazard!
Do not use the bucket to transport persons.
Moving other vehicles with the bucket is pro-
hibited!
Always lower the bucket to the ground before
Fig. 92 shutting the engine down.
● Press button a (Fig. 92).
● Shift the dozer blade control lever to float posi-
tion "I".

Fig. 94

● Pull the bucket control lever (Fig. 94) back and

raise the bucket.
Fig. 93

● Shift the lever (Fig. 93) to position "II" to switch

off float position.

Fig. 95

● Shift the bucket control lever (Fig. 95) forward

and lower the bucket to the ground.

* Optional equipment

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Fig. 96 Fig. 98

● Press push button a (Fig. 96) 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. 98) to the
left to fill the bucket. The bucket tips back.
i Note
When releasing the bucket control lever, it will au-
tomatically return to middle position.

Fig. 97

● Shift the bucket control lever (Fig. 97) to the

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

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4.13 Operating the service brake

Fig. 101
The travel lever neutral position control light (v)
(Fig. 101) in the right instrument cluster lights up.
Fig. 99

● Relieve the drive pedal (Fig. 99).

Fig. 100

● Shift the travel lever (Fig. 100) to position "0",

the machine is hydrostatically braked.

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4.14 Operating the parking brake

Fig. 104
The travel lever neutral position control light (v)
(Fig. 104) in the right instrument cluster lights up.
Fig. 102

● Relieve the drive pedal (Fig. 102).

Fig. 105

● Turn the rotary switch for parking brake (Fig.

Fig. 103
105) to position "Right".

● Shift the travel lever (Fig. 103) to position "0",

the machine is hydrostatically braked.

Fig. 106
The parking brake warning light (u) (Fig. 106) in
the right instrument cluster lights up after 4 sec-
onds.

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4.15 Starting and adjusting the

air conditioning

Switching on the control unit

i Note
The diesel engine is running.
If only the ignition is switched on, the evaporator
fan speed is limited to 30% of the nominal speed.
Fig. 109

i Note
The LED-display shows the stored cabin tempera-
ture (Fig. 109).

Fig. 107

● Press the On-Off-switch (Fig. 107) on the con-

trol unit.

Fig. 108

● The LED-display (Fig. 108) shows the soft-

ware version for approx. 3 seconds.

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

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Activating/deactivating air condition- Changing the temperature display to

ing operation degree Celsius or degree Fahrenheit

Fig. 110 Fig. 112

● Press the On-Off-switch (Fig. 110) for opera- ● In order to change from degree Celsius to de-
tion of the air conditioning system. gree Fahrenheit press and hold the circulation
air button (1) (Fig. 112) first and then press the
minus button (2).
i Note
The display changes to degree Fahrenheit.
The LED below the symbol for operation of air con-
ditioning lights up. The stored cabin temperature is
displayed.
Operation of the air conditioning starts.

Fig. 113

● In order to change from degree Fahrenheit to

Fig. 111
● Press the On-Off-switch (Fig. 111) for opera-
tion of the air conditioning system.
degree Celsius press and hold the circulation
air button (1) (Fig. 113) first and then press the
minus button (2).
The display changes to degree Celsius.

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

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

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

Fig. 114

● Press the minus button (Fig. 114) once.

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

Fig. 115

● Press the minus button (Fig. 115) 3 times.

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

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Manual adjustment of the evaporator

fan speed

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

Fig. 118

● Press the minus button 6 times (Fig. 118).

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

Fig. 116 Fully automatic air conditioning operation is

switched off. The evaporator fan speed is reduced
● At present the LED bar display (Fig. 116) to 40%.
shows the evaporator fan speed with 100%
when the air conditioning works in automatic
mode.

Fig. 119

● Press the button for evaporator fan speed (Fig.

Fig. 117 119).

● For manual operation press the button for

evaporator fan speed (Fig. 117) i Note
The LED below the symbol for manual adjustment
goes out.
i Note
The LED below the symbol for manual adjustment Automatic air conditioning operation is activated
lights up. again. The evaporator fan speed is automatically
controlled.

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Switching off Reheat - operation

4.16 Air conditioning, switching
Reheat – operation on/off

Switching on Reheat - operation

i Note
Reheat – operation is switched on to dehumidify
the cabin air (clear steamed up windows). The ac-
tivation lasts maximum 10 minutes and is automat-
ically switched off by the control unit.
To avoid changing of the cabin temperature the
heating is automatically activated if required.
Fig. 121

● Press the Reheat button (Fig. 121).

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

Fig. 120

● Press the Reheat button (Fig. 120).

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

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4.17 Air conditioning, changing i Note

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

Switching on circulation air operation.

Fig. 122

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

122).

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

Switching on fresh air operation .

Fig. 123

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

123).

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4.18 Air conditioning, heating i Note

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

Fig. 126

● Press the minus button e.g. 6 times (Fig. 126).

Fig. 124
i Note
The LED display shows the stored cabin tempera-
ture (Fig. 124) and the LED bar display shows an
evaporator fan speed of 100%.
i Note
The LED bar display indicates that the heating
valve is 40% open.
After 5 seconds the new status of the heating
valve is saved, fully automatic heating operation is
switched off.

Setting heating operation manually

Fig. 127

● Press the heater button (Fig. 127) once again.

Fig. 125
i Note
● Press the heater button (Fig. 125). Automatic heater operation is activated again.

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4.19 Shut down the engine

Fig. 130
The travel lever neutral position control light (v)
(Fig. 130) in the right instrument cluster lights up.
Fig. 128

● Take back the drive pedal (Fig. 128) (throttle

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

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

Fig. 131

● Turn the rotary switch for parking brake (Fig.

131) to position "Right".

Fig. 129

● Shift the travel lever (Fig. 129) to position "0".

Fig. 132
The parking brake warning light (u) (Fig. 132) in
the right instrument cluster lights up after 4 sec-
onds.

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Fig. 133 Fig. 135

● Shift the dozer blade control lever (Fig. 133)
forward to position "I" and lower the dozer
blade slowly until it rests on the ground.
● Turn the ignition switch (Fig. 135) to position
"0" and pull the ignition key out.
‡
Caution
Secure the machine against unauthorized use,
pull the ignition key out, lock the cabin door.

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

Fig. 134

● Shift the bucket control lever (Fig. 134) *for-

ward and rest the bucket on the ground.

‡
Caution
Do not shut down the engine all of a sudden
from full load speed, but let it idle for about 2
minutes.

Fig. 136

● Switch the main battery switch (Fig. 136) to

position "II" and pull it out.

* Optional equipment ** Optional equipment

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4.20 Parking on a slope

ˆ Danger
Danger of accident!
Parking on a slope with the engine running.
Lower the dozer blade to the ground.
Apply the parking brake to prevent unintended
rolling of the machine.

Fig. 139

● Turn the rotary switch for parking brake (Fig.

139) to position "Right".

Fig. 137

● Shift the dozer blade control lever (Fig. 137)

forward to position "I" and lower the dozer
blade slowly until it rests on the ground.

Fig. 140
The parking brake warning light (u) (Fig. 140) in
the right instrument cluster lights up after 4 sec-
onds.

Fig. 138

● Shift the bucket control lever * (Fig. 138) for-

ward and rest the bucket on the ground.

* Optional equipment

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4.21 Towing the machine

Fig. 143

● Remove the safety caps from the eight high

pressure relief valves (Fig. 143).
Fig. 141
● Back the inner hexagon screws (1) out for ap-
● Rear towing hooks (Fig. 141) . prox. 2 turns.

Fig. 142 Fig. 144

ˆ
Danger i Note
Danger of accident! After towing turn the Allen screws 1 (Fig. 144)
back in and tighten to a torque of 10 Nm.
You should always use a tow bar.
● Attach the tow bar (Fig. 142) to the towing
eyes.

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Releasing the brake Raise the dozer blade/bucket before towing.

Raising the dozer blade/bucket and re-

lieving the brakes

Fig. 145

ˆ Danger
Danger of accident! Fig. 146

Before releasing the multi-disc brakes secure

the machine against unintended rolling.
ˆ
Danger
● Open the access door on the right hand tool Danger of accident!
box. Before releasing the multi-disc brake secure
● Unscrew the locking bolt 3 (Fig. 145). the machine against unintended rolling.

● 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/buck-
et.
● Set lever 2 (Fig. 146) in direction of arrow.
● Set lever (3) in direction of arrow.

‰
Caution
● Operate the pump lever (1), until the multi-disc
brakes are relieved and the dozer blade/buck-
Secure lever (2) with the locking screw. et is raised. The machine can be towed.

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4.22 Transport of the machine

ˆ 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. Fig. 148
Weights: See technical data. ● Actuate the emergency stop switch (Fig. 148).
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

ˆ
Danger
Mortal danger!
During demonstration and when loading the
machine do not remain in the danger zone of
the machine.
● Lower the dozer blade onto the transport vehi-
Fig. 149
cle.
● Tie the machine to the transport vehicle, use
the four lifting hooks (Fig. 149) ....

Fig. 147

● After driving the machine onto the transport

Fig. 150
vehicle swing the articulation lock 1 (Fig. 147)
out of its receptacle and fasten it with the bolt ● and (Fig. 150) on front and rear frames.
(2) to the eye on the front frame. Secure the
bolt with the cotter pin (3).

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‰
Caution
Observe the transport height.

Fig. 153

● Fold the air intake grid (Fig. 153) back.

Fig. 151

● Always use access steps and hand rails to

climb onto the engine compartment cover (Fig.
151).

Fig. 154

● Remove the holding rope (Fig. 154) of the air

conditioning carrier from the des snap hook
and

Fig. 152

● Step only on such areas of the engine com-

partment cover which are provided with skid-
proof covering (Fig. 152).

Fig. 155

● fold the air conditioning unit (Fig. 155) back.

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After transport

Fig. 158

● To enter the air intake chamber use the ac-

Fig. 156 cess step (Fig. 158).
● After transport release the articulation lock ● Extract all accumulated dirt.
(Fig. 156) again and store it in the receptacle.
‰
‰Caution
Caution
When extracting the dirt avoid damaging of
During transport with the air conditioning fold- fins on hydraulic oil cooler, intercooler and ra-
ed back ROPS and air filter may be excessively diator.
soiled.

Fig. 159
Fig. 157 ● Hook the holding rope back into the air condi-
● Remove the service door (Fig. 157). tioning carrier (Fig. 159).
● Fold air conditioning unit and air intake grid
back to normal position and fasten, install the
maintenance door.

U  BC 572 RB-2

 5 Maintenance

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5.1 General notes on mainte-
nance
When performing maintenance work always com-
ply with the appropriate safety regulations.
Thorough maintenance of the machine guaran-
tees far longer safe functioning of the machine and
prolongs the lifetime of important components.
The effort needed for this work is only little com-
pared with the problems that may arise when not
observing this rule.
● Always clean machine and engine thoroughly
before starting maintenance work.
● For maintenance work stand the machine on
level ground.
● Always remove the main battery switch for all
maintenance work.
● Perform maintenance work only with the en-
gine shut down.
● Relieve hydraulic pressures before working on
hydraulic lines.
● Before working on electric parts of the ma-
chine disconnect the battery and cover it with
insulation material.
The terms right/left correspond with travel direc-
tion forward.
● When working in the area of the articulated
joint attach the articulation lock (transport
lock).
Environment
During maintenance work catch all oils and fu-
els and do not let them seep into the ground or
into the sewage system. Dispose of oils and fu-
els environmentally.
Catch and dispose of biodegradable oils sepa-
rately.
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.
US
Notes on the fuel system
The lifetime of the diesel engine depends to a
great extent on the cleanliness of the fuel.
● 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 en-
vironment.
● Do not let the hose stir up the slurry at the bot-
tom of the drum.
● Do not draw off fuel from near the bottom of
the drum.
● Fuel residues in the drum are not suitable for
the engine.
Notes on the performance of the en-
gine
On diesel engines both combustion air and fuel in-
jection 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.
Notes on the hydraulic system
During maintenance work on the hydraulic system
cleanliness is of major importance. Make sure that
no dirt or other contaminating substances can en-
ter into the system. Small particles can produce
flutes in valves, cause pumps to seize, clog noz-
zles and pilot bores, thereby making expensive re-
pairs 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 enter-
ing of dirt.
● Do not leave the tank opening unnecessarily
open, but cover it so that nothing can fall in.
 BC 572 RB-2

Welding work on the refuse compactor
● Disconnect the main battery switch
● Pull the plugs off all control units, engine con-
trol unit (EMR), travel control (ESX) and addi-
tional control (DIOS).
BC 572 RB-2

Štsrwrtrp
5.2 Fuels and lubricants
Engine oil
Quality
For use in DEUTZ engines the lubrication oils are
classified in DEUTZ Lubrication Oil Quality Class-
es (DQC).
Use only oils complying with DQC III-05 or DQC
IV-05.
Engines with open crankcase ventilation may al-
ternatively be operated with oils complying with
the following classification:
● ACEA: E4-99 and E6-04
● API: CI-4 and CJ-4
The list of approved lubrication oils can be found
in the internet under www.deutz.com >>SERVICE
>> Fuels and lubricants and diagnostics >> Deut-
zQualityClass >>DQC-release list.
Consult your local service station if in doubt.
● Use winter grade engine oil for winter opera-
tion!
Oil viscosity
Multi-purpose oils should be generally used.
Since lubrication oil changes its viscosity with the
temperature, the ambient temperature at the oper-
ating location of the engine is of utmost impor-
tance when choosing the viscosity class (SAE-
class) .
Optimal operating conditions can be achieved by
using the opposite oil viscosity chart (Fig. 160) as
a reference.
Occasionally falling short of the temperature limits
will impair the cold starting ability, but will not
cause any engine damage. In order to keep the
occurring wear as low as possible, occasional ex-
ceeding of the limits should not happen over a
longer period of time.
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.
UU
 Štsrwrtrp
Fig. 160
With their better temperature and oxidation stabil-
ity synthetic lubrication oils offer quite a few bene-
fits.
Oil change intervals
The longest permissible time a lubrication oil
should remain in an engine is 1 year. If the follow-
ing oil change intervals are not reached over a pe-
riod of 1 year, the oil change should be performed
at least once per year, irrespective of the operating
hours reached.
DQC III,
DQC IV = 500 operating hours
‰ 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 tem-
peratures below -10 ¯C (-10°C) the oil change
intervals specified in the table must be halved.
When using oils with a sulphur content of
more than 1% by weight and a permanent op-
erating oil temperature below 60°C consult the
UY
service department of the engine manufactur-
er.
Fuels
Quality
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 in-
jection lines need to be bled.
The following fuel specifications are permitted:
● DIN EN 590
● ASTM D975 Grade-No. 1-D and 2-D.
● JIS K 2204 Grade Fuel 1 and Grade Fuel 2
with lubrication properties acc. to EN 590
Winter fuel
For winter operation use only winter diesel fuel, to
avoid clogging because of paraffin separation. At
very low temperatures disturbing paraffin separa-
tion can also be expected when using winter diesel
fuel.
In most cases a sufficient cold resistance can also
be achieved by adding flow enhancing fuel addi-
tives. Consult the engine manufacturer.
Coolant
The correct quality of water is highly important
when preparing coolant. Clear and clean water
within the boundaries of the following analysis val-
ues should generally be used.
Water quality
Analysis values min. max.
pH-value at 20 °C 6,5 8,5
Chloride ion content [mg/dm3] - 100
Sulphate ion content [mg/dm3] - 100
Total hardness* [°dGH] ] 3 12
* Proportion of carbonate hardness on the total
hardness min. 3 dGH
Information concerning the water quality can be
obtained from the waterworks.
 BC 572 RB-2
 Štsrwrtrp

A test case for checking the water quality can be
ordered from the engine manufacturer.
If the values of the analysis deviate, the water
must be treated accordingly.
● pH-value too low
Adding of caustic lye of soda or caustic potash
solution.
● Total hardness too high:
Mixing with dehardened water.
● Total hardness or carbonate hardness too low:
Mixing with harder water.
● Chlorides and/or sulphates too high:
Mixing with dehardened water.
As a protection against frost, corrosion and boiling
point anti-freeze agents must be used under any
climatic conditions.
The proportion of anti-freeze agent must be be-
tween min. 35% and max. 45% to the water.
The biologically quickly degradable hydraulic oil
Panolin HLP Synth.46 meets all demands of a
mineral oil based hydraulic oil according to DIN
51524.
In hydraulic systems filled with Panolin HLP
Synth.46 always use the same oil to top up.
When changing from mineral oil based hydraulic
oil to an ester based biologically degradable oil,
you should consult the lubrication oil service of the
oil manufacturer for details.
Check the filter more frequently after this change.
Transfer case oil/travel gear oil
Quality
For transfer box and travel gear use only multi-pur-
pose gear oils of API-GL5-class, SAE 90.
This is a hypoid lubricant of highest quality class
for extremely loaded transmissions.

‰
The additives in this oil ensure low wear lubrication
Caution under all operating conditions.
Do not mix different coolants and additives of
any other kind. Lubrication grease
For lubrication purposes use an EP-high pressure
ˆ Danger grease, calcium and/or lithium saponified (pene-
tration 2), acc. to DIN 51502 KP 2G.
Health hazard!
The mixing of nitrite based anti-freeze agents
with amine based agents results in the forma-
tion of health affecting nitrosamines.

Environment
Coolant must be disposed of environmentally.

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 accord-
ing 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.

BC 572 RB-2
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5.3 Table of fuels and lubri-

cants

Assembly Fuel or lubricant Quantity approx.

Summer Winter Attention

Observe the level marks

Engine Engine oils see table of fuels and lubricants aoorix. 21,5 litres with fil-
ter change

SAE 10W/40

(-20 °C to +40 °C)

Coolant approx. 44 litres

Mixture of water and anti-freeze agent

Fuel Diesel Winter diesel fuel* (down 500 litres

to -12 °C)

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

Transfer box SAE 90, API GL5 approx. 4,5 litres

Travel gear SAE 90, API GL5 approx. 5,4 litres

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

Air conditioning system Refrigerant R 134 A approx. 1,9 kg

Cabin heater (diesel) as engine oil down to approx. -30 °C as required

use SAE 5W/30

- Oil bath air filter

YI  BC 572 RB-2

 Štsrwrtrp

5.4 Running-in instructions

The following service work must be performed

when taking new machines into operation.

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

After a running time of 15 minutes retighten

the V-belts for generator and air conditioning
compressor.

Maintenance after 50 operating hours

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

Maintenance after 500 operating hours

● Change the oil in splitter gear and oil filter.
● Change the oil in the drive gears.
● Check, adjust the valve clearance.

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

BC 572 RB-2
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5.5 Maintenance table

every 10 operating hours, daily

every 1000 oper. hours

every 2000 oper. hours

every 3000 oper. hours

every 6000 oper. hours

every 500 oper. hours
No. Maintenance work Comment

as required
5.6 Check the engine oil level Dipstick mark X
5.7 Check the fuel level Instrument cluster X
5.8 Check the hydraulic oil level Inspection glass X
5.9 Check the coolant level Instrument cluster, X
sight glass
5.10 Check the oil level in the transfer box Inspection glass X
5.11 Visual inspection of the machine for X
damage and leaks
5.12 Lubricate joints and bearings on the X
bucket
5.13 Change engine oil and oil filter car- min. 1x per year X
tridge* see foot note
5.14 Check, clean the water separator when the "water in fu- X
el" warning light lights
up
5.15 Check the anti-freeze concentration X
and the condition of the coolant
5.16 Check the condition and tension of X
the ribbed V-belt.
5.17 Battery service, check the main bat- pole grease X
tery switch
5.18 Check the engine mounts X
5.19 Service the air conditioning X

Y@  BC 572 RB-2

 Štsrwrtrp

every 10 operating hours, daily

every 1000 oper. hours

every 2000 oper. hours

every 3000 oper. hours

every 6000 oper. hours

every 500 oper. hours
No. Maintenance work Comment

as required
5.20 Check the condition of radiator, inter- also if the engine tem- X
cooler and hydraulic oil cooler, clean, perature or hydraulic
clean the engine oil temperature warn-
ing lights light up
5.21 Check the fastening of the scrapers X
5.22 Check the oil level in the travel gear X
5.23 Check the central lubrication system, X
fill up
5.24 Replace the fresh air and circulation X
air filters
5.25 Check, adjust the valve clearance** Intake: 0,35 ± 0.05 X
mm or 75°
Exhaust: 0.45 ± 0.05
mm or 105°
5.26 Replace the fuel filter cartridges X
5.27 Replace the fuel pre-filter cartridge, X
bleed the fuel system
5.28 Check fastening of engine/turbo X
charger/combustion air hoses
5.29 Check the crankcase ventilation valve X
5.30 Oil change in travel gear *** see foot note X
5.31 Replace the fuel filter for the cabin X
heater (diesel)
5.32 Check, clean the oil bath air filter for X
the cabin heater (diesel)
5.33 Change the hydraulic oil fine filter**** see foot note X
5.34 Oil change in transfer box ***** see foot note X
5.35 Change hydraulic oil and breather fil- at least every 2 years X
ter ** see foot note

BC 572 RB-2
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every 10 operating hours, daily

every 1000 oper. hours

every 2000 oper. hours

every 3000 oper. hours

every 6000 oper. hours

every 500 oper. hours
No. Maintenance work Comment

as required
5.36 Check/change the coolant X
5.37 Check condition of oscillating articu- X
lated joint
5.38 Replace the ribbed V-belt and the at least every 2 years X
idler pulley
5.39 Check exhaust gas recirculation, con- only by authorized X
trol lever and valve service personnel
5.40 Change the crankcase ventilation X
valve
5.41 Electronic injector test EMR only by authorized X
service personnel
5.42 Replace the glow plugs only by authorized X
service personnel
5.43 Change the injection valves only by authorized X
service personnel
5.44 Clean, change the dry air filter car- when the air filter X
tridge warning light lights up
min. 1x per year
5.45 Clean the condenser X
5.46 Adjust scrapers and edge cutters X
5.47 Check the condition of the cutting X
blades, replace the cutting blades if
necessary
5.48 Fill the provision tank for the wind- X
screen washer system
5.49 Drain off dirty fluids from front and X
rear frame
5.50 Tighten all bolted connections X
5.51 Conservation X

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* Running-in instructions: oil change after 50, 500 and 500 operating hours, then every 1000 operating hours
** Running-in instructions: oil change after 500 and 1000 operating hours, then every 1000 operating hours
*** Running-in instructions: oil change after 50, 500 and 1000 operating hours, then every 1000 operating hours
**** also after repairs in the hydraulic system.
*****Running-in instructions: oil change after 500 and 1000 operating hours, then every 1000 operating hours

BC 572 RB-2
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YS  BC 572 RB-2

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Every 10 operating hou rs

5.6 Check the engine oil level 5.7 Checking the fuel level

i Note ‰Caution
The machine must be in horizontal position. If the Do not drive the fuel tank dry, as otherwise the
engine is warm, shut it down and check the oil lev- fuel system needs to be bled.
el after five minutes. With a cold engine the oil lev-
el can be checked immediately.

Fig. 162

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

Fig. 161 162), refuel if necessary.
● Pull out the dipstick (Fig. 161) and wipe it clean
with a lint-free, clean cloth. Filling in fuel


● Reinsert the oil dipstick until it bottoms and pull
it out again. Danger
● The oil level must always be between the Fire hazard!
"MIN"- and "MAX"-marks, fill up oil if neces-
sary. When working on the fuel system do not use
open fire, do not smoke, do not spill any fuel.
For quality of oil refer to the table of fuels and Do not refuel in closed rooms.
lubricants.
Shut down the engine.

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

BC 572 RB-2
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‰
Caution
Contaminated fuel can cause malfunction or
even damage of the engine.
If necessary, fill in fuel through a funnel with
screen.
● Top up with fuel (diesel or winter diesel).

For quality and quantity of fuel refer to the "ta-

ble of fuels and lubricants".
● Screw the fuel tank cover back on.

Fig. 163

● Use access steps (Fig. 163) and

Fig. 164

● hand rails (Fig. 164).

● Open the cover flap on the front frame.

Fig. 165

● Unlock the tank cover (Fig. 165) and take it off.

● Clean the area around the filler opening.

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5.8 Check the hydraulic oil level 5.9 Check the coolant level

‰Caution
In hydraulic systems filled with Panolin HLP
Synth. 46 always use the same oil to top up.
With other ester based oils consult the lubrica-
tion oil service of the respective oil manufac-
turer.

‰ Caution
If, during the daily inspection of the oil level
the hydraulic oil level is found to have
dropped, check all lines, hoses and compo-
nents for leaks.
Fig. 167

i Note
A too low coolant level is indicated by the coolant
level warning light (d) (Fig. 167) in the left instru-
ment cluster.


Danger
Danger of scalding!
Open the cap on the coolant compensation
tank only when the engine is cold.

Fig. 166

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

166).

i Note
At a room temperature of approx. 20 °C the oil lev-
el should reach approx. 1/3 way up the inspection
glass.
● If the oil level is too low top up hydraulic oil im-
mediately.

For quality and quantity of oil refer to the "table Fig. 168
of fuels and lubricants". ● Open the safety flap (Fig. 168).

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5.10 Check the oil level in the

transfer box

i Note
Check the oil level only in cold condition and with
the engine shut down.

Fig. 169

● Unscrew the cap (Fig. 169).

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

For coolant refer to the "table of fuels and lu-

bricants".

‰ Caution
Fig. 170
If, during the daily inspection the coolant level
is found to have dropped, check all lines, hos- ● Check the oil level in the inspection glass (Fig.
es and engine for leaks. 170), it must be slightly above the middle of the
inspection glass.
Do not use radiator sealant to seal leaks.

Fig. 171

● Clean the area around the breather filter (Fig.

171) and unscrew the breather filter.
● Top up oil, if necessary

For quality and quantity of oil refer to the "table

of fuels and lubricants".
● Clean the oil breather filter and screw it back
on.

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5.11 Visual inspection of the ma- 5.12 Lubricate joints and bear-
chine for damage and leaks ings on the bucket*

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

Fig. 172

● Check the complete machine and all attach-

ments for good condition and completeness
(Fig. 172).
● Check all pipes and hoses for good condition
and tightness. Fig. 174

● Have all damage repaired. ● Clean the grease nipples (Fig. 174) and lubri-
cate with approx. 5 shots from the grease gun.

For quality of grease refer to the "table of fuels

and lubricants".

i Note
If necessary clean and grease every week.

Fig. 173

● Operate the flutter valve (Fig. 173) to drain the

water off the ROPS.

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

* Optional equipment

BC 572 RB-2
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Z@  BC 572 RB-2

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Every 500 oper ating hours

5.13 Changing engine oil and oil

filter

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

‘
Caution
Drain the oil only when the engine is warm.
Environment
Catch running out oil and dispose of environ-
mentally together with the oil filter cartridge.
● Remove the rear service door.
Fig. 176
● Turn the engine oil filter cover (Fig. 176) two to
three turns anti-clockwise and wait for approx.
30 seconds.
● Screw the engine oil filter cover with the paper
cartridge completely off.
● Carefully pull the paper filter cartridge up and
out of its guide in the housing.

Fig. 175
Fig. 177
● Unscrew the safety cap (2) (Fig. 175) from the
oil drain socket (1). ● Catch dripping off oil residues (Fig. 177).

● Take the drain hose (3) out of the right hand

stowage compartment and screw it on.
● Drain off and catch the engine oil.
● Once the old oil has run out remove the drain
hose and screw the safety cap back on.

BC 572 RB-2
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Fig. 178 Fig. 180

● Move the paper filter cartridge lightly to and ● Press the new paper filter cartridge carefully
fro, until it is separated from the engine oil filter into the engine oil filter cover (Fig. 180).
cover (Fig. 178).
● Clean the sealing faces on engine oil filter
housing and engine oil filter cover from dirt.
● Clean the guide inside the engine oil filter
housing from dirt.

Fig. 181

● Insert the engine oil filter cover with the engine

oil filter cartridge carefully into the guide in the
engine oil filter housing (Fig. 181).
● Screw the engine oil filter cover in clockwise
Fig. 179 and tighten it with a tightening torque of 40 +10
● Replace the O-ring (Fig. 179) and apply a thin Nm.
coat of oil.

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Fig. 182 Fig. 184

● Fill in new engine oil (Fig. 182) through the oil ● After a short test run check for leaks.
filler neck. ● Check the oil level on the dipstick (Fig. 184),
correct if necessary.
For quality and quantity of oil refer to the "table
of fuels and lubricants".
● Screw the cap back on again.

Fig. 183

● Loosen the hose (Fig. 183) on the oil collecting

vessel on the crankcase ventilation.
● Disassemble the oil collecting vessel and
empty it.

Environment
Dispose of old oil environmentally.
● Assemble the oil collecting vessel and fasten
the hose.

BC 572 RB-2
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starting or during operation, drain the water

5.14 Checking, cleaning the wa- from the prefilter.
ter separator ● Open the engine compartment doors on the
left hand side.
 Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke, do not spill any fuel.

Danger
Health hazard!
Do not inhale any fuel fumes.

Environment
Catch running out fuel and dispose of environ-
mentally.
i Note
The service intervals for the water separator de-
pend on the water content in the fuel and can
therefore not be determined precisely. After taking
the engine into operation you should therefore
check the filter bowl initially every day, later as re-
quired, for signs of water.
If a too high quantity is drained off, the filter needs
to be bled, see section "Replacing the fuel pre-
cleaner cartridge".
Fig. 186
● Place a collecting vessel (Fig. 186) under the
drain bore.
● Slacken the drain plug for a few turns and
catch running out fuel / water .
● Drain the fuel off until there is no water left.
Close the drain plug again.
i Note
Once the water separator is empty the warning
light for water in fuel must go out.

Fig. 185

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

ZS  BC 572 RB-2

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5.15 Check the anti-freeze con-

centration and the condition
of the coolant

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

‘Caution Fig. 188

In order to avoid damage to the engine (e.g. by ● Unscrew the cap (Fig. 188).
corrosion, cavitation and freezing), particular ● Check the anti-freeze concentration with a
attention must be paid to the inspection of the conventional tester.
coolant.
In case of lubrication oil entering into the cool- ‘ Caution
ing system or a suspicious turbidity caused by
corrosion residues or other suspended matter, The anti-freeze concentration (additive) must
the coolant must be drained off and the com- be at least 35 Vol% and maximum 45 Vol%.
plete cooling system needs to be cleaned. Lu-
brication oil can damage the sealing materials 
Danger
used in the engine.
Health hazard!

‘
Caution
The mixing of nitrite based anti-freeze agents
with amine based agents results in the forma-
Do not mix different coolants and additives of tion of health affecting nitrosamines.
any other kind.
● Check the condition of the coolant.
● If the coolant is contaminated by corrosion res-
Environment
idues or other suspended matter, drain the
Catch coolant and dispose of environmentally. coolant off completely, see section "Checking/
changing the coolant".
● Fill in clean water.
● Start the engine and flush the cooling system
out for a short while.
● Drain all water off.
● Fill the cooling system with coolant.

For quality and quantity of coolant refer to the

"table of fuels and lubricants".

Fig. 187

● Open the safety flap (Fig. 187).

BC 572 RB-2
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5.16 Checking the condition and 5.17 Battery service, check the
tension of the ribbed V-belt. main battery switch

 Danger
 Danger
Danger of injury! Danger of cauterisation ! Danger of explosion!
Work on the V-belt must only be performed When working on the battery do not use open
with the engine shut down. fire, do not smoke!
The battery contains acid. Do not let acid come
in contact with skin or clothes!
Wear protective clothing!
Do not lay any tools on the battery!
For recharging remove the plugs from the bat-
tery to avoid the accumulation of highly explo-
sive gases.

Environment
Dispose of the old batteries environmentally.

Fig. 189
● Inspect the entire circumference of the ribbed
V-belt (Fig. 189) visually for damage and
cracks. Replace damaged or cracked ribbed
V-belts.
i Note
Maintenance free batteries also need care. Main-
tenance free only means that the fluid level does
not need to be checked. Each battery suffers un-
der self-discharge, which may, in not checked oc-
casionally, even cause damage to the battery as a
result of exhaustive discharge.

The following therefore applies for the service

life:
● Switch off all consumers (e.g. ignition, light, in-
side light, radio).
● Check open-circuit voltage of the battery at
regular intervals. At least once per month.
Reference values: 12.6 V = fully charged; 12.3 V =
50% discharged.
● Recharge the battery immediately after an
open-circuit voltage of 12.25 V or less is
reached. Do not perform quick charging.
Fig. 190
The open-circuit voltage of the battery occurs ap-
● Check the distance between the tongue of the
prox. 10 hours after the last charging process or
moveable tensioner arm and the stop on the
one hour after the last discharge.
fixed tensioner housing .
● After each charging process allow the battery
● If the distance "a" (Fig. 190) is smaller than 3
to rest for one hour before taking it into service.
mm, replace the ribbed V-belt.
● For resting periods of more than one month
you should always disconnect the battery. Do

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not forget to perform regular open-circuit volt- Checking the main battery switch
age measurements.

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

Charging voltage recommendation

Fig. 193

‘Caution
Pull out the main battery switch at the earliest
40 seconds after switching off the ignition, ex-
cept in cases of emergency.
With engine-independent air heating systems*
allow the heating to run for another 2 minutes.
Fig. 191
● Turn the main battery switch (Fig. 193) to po-
sition "II" and check by voltage measurement
(ignition key test) whether the batteries are
disconnected from the electric system of the
machine.

Fig. 192

● Open the access cover in the floor in front of

the cabin door (Fig. 192).
● Clean battery poles and pole clamps and
grease them with pole grease (Vaseline).
● Retighten the pole clamps.
● Check the fastening of the battery.
● On serviceable batteries check the acid level,
if necessary top up to the filling mark with dis-
tilled water.

* Optional equipment

BC 572 RB-2
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5.18 Check the engine mounts 5.19 Servicing the air condition-
ing

The air conditioning unit is attached to the

ROPS and can be access from outside for
service work.

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

’ Danger
Danger of accident!
Fig. 194

● Check all fastening screws on the engine Do not clean with a hot water jet. Heat will
mounts (Fig. 194) for tight fit, tighten if neces- cause extreme overpressure, which could
sary. cause damage or explosion of the system.

● Check condition of engine mounts, replace if

necessary.
Clean the condenser

Fig. 195

● Fold the air intake grid (Fig. 195) back.

6II  BC 572 RB-2

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Fig. 196 Fig. 198

● Clean the condenser fins on front and back ● Start operation of the air conditioning (Fig.
with compressed air or cold water (Fig. 196). 198).

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

Checking the refrigerant level

● Start the engine.

Fig. 199

● Open the air outlet nozzles (Fig. 199).

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

i Note
The adjusted temperature must be below the actu-
Fig. 197 al temperature inside the cabin, so that the com-
pressor will be switched on.
● Switching on the control unit (Fig. 197).

BC 572 RB-2
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Fig. 200
● Check whether the white float (Fig. 200) inside
the inspection glass of the drier/collector unit
floats right at the top.
i Note
The refrigerant level is correct.
Fig. 201
● If the white float (Fig. 201) inside the inspec-
tion glass of the drier/collector unit floats at the
bottom, inform the service department.
i Note
The refrigerant level is not correct.
● Refrigerant must be filled up, if necessary
check the air conditioning system for leaks.
6I@
Checking the moisture level of the dry-
ing agent
Fig. 202
● Check the moisture indication pearl (Fig. 202)
inside the inspection glass of the drier/collec-
tor unit.
orange = Drying agent o.k.
colour-
less = moisture level of drying agent too
high.
● Inform the service department. Replace drier/
collector unit, check air conditioning system.
‘Caution
Have the drier/collector unit replaced by the
service department every year before the oper-
ating season.
Checking the condition of the drier/col-
lector unit
‘Caution
According to the regulation for pressure reser-
voirs all pressure reservoirs must be repeated-
ly inspected by a specialist. In this sense
repeated inspections are external examina-
tions, normally on pressure reservoirs in oper-
ation. In connection with this inspection the
drier/collector unit must be visually examined
twice every year. During these inspections
special attention must be paid to corrosion
and mechanical damage. If the reservoir is not
in proper condition it must be replaced for
safety reasons, as a precaution to protect op-
erators and third parties against any danger
 BC 572 RB-2
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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 re-
placed, to avoid bursting and further damage.
5.20 Checking condition of radi-
ator, intercooler and hy-
draulic oil cooler, clean,
cleaning the engine
i Note
Dirty operating conditions, particularly lubrication
oil and fuel deposits on the cooling fins reduce the
cooling effect. You should therefore immediately
seal any oil or fuel leaks near cooling fan, cylinder
or oil cooler and subsequently clean the cooling
fins.

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

Fig. 203

● Check the drier/collector unit (Fig. 203) for me-

chanical damage or rust.

Fig. 204

● Remove the service covers on left (Fig. 204)

and

BC 572 RB-2
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Fig. 205
● right hand side (Fig. 205) of the air duct hous-
ing.
‘Caution
During cleaning take care not to damage the
fins on hydraulic oil cooler, intercooler and ra-
diator. Keep a safe distance with the spray
nozzle.
i Note
Clean the coolers in the correct sequence.
● Clean hydraulic oil cooler, intercooler and radi-
ator from the air duct side first.
Fig. 206
● Remove the service door (Fig. 206).
● Clean all coolers from the air intake side.
● Remove dried on dirt with a suitable brush.
● Blow the cooling air channels out with com-
pressed air.
6I
● 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.
● Blow the engine dry with compressed air.
Flush off loosened dirt with a water jet.
● 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.
● After wet cleaning run the engine warm to
evaporate all water residues and to avoid cor-
rosion.
● Reinstall the service covers.
 BC 572 RB-2
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At the closest point (2) (Fig. 208) there must be

5.21 Check the fastening of the metal to metal contact between the edge cutters
scrapers and the shell surfaces of the compactor wheels.

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

Fig. 207

● Check fastening screws 2 (Fig. 207) and 3

(Fig. 208) on scrapers 1 (Fig. 207)

Fig. 209

● Check the inner sides of the compactor

wheels, remove wires, cables, ropes, etc. (Fig.
209).
● Check the scraper bars 1 (Fig. 209), replace if
worn.

Fig. 208

● and on the lateral edge cutters 1 (Fig. 208) for

tight fit, retighten if necessary.

i Note
The tightening torques apply for screws covered
with OKS 240 (copper paste).
● Check the gap between scrapers 2 (Fig. 208)
and compactor wheels, it must be approx.
5 mm (0,2“).

i Note
Only this adjustment ensures effective cutting of
wires.

BC 572 RB-2
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5.22 Check the oil level in the 5.23 Checking, filling the central
travel gear lubrication system

The following lubrication points are provided

i Note economically and reliably with grease by the
Check the oil level in all four travel gears. central lubrication system.

For quality and quantity of oil refer to the "table ● 2 x at the lower bearing block for the dozer
of fuels and lubricants". blade,
● 1 x eye of the dozer blade cylinder,
● 4 x steering cylinder eyes,
● 2 x on the articulated joint,
● 4 x on the slewing ring in the articulated joint
It is differentiated between the two cycles pause
and work.
Pause: Over a time period of 60 minutes there will
be no lubrication.
Work: Adjusted in the factory.

Checking:
Fig. 210

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

210) is at the deepest point.
● Clean the area around the level inspection
plug and unscrew the plug.
● Check the oil level. The oil level must reach the
bottom edge of the bore.
● If necessary fill in oil, for this purpose clean the
area around the filler plug and unscrew the
plug.
● Fill in oil through the filler bore, until it starts to
run out through the level inspection bore.
Fig. 211
● Clean the oil filler and inspection plug and
screw it back in tightly. ● Switch the ignition on.
● Actuate the push button (Fig. 211) for 2 sec-
onds.

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Filling with a manual grease gun

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

Fig. 212

● The stirring device in the transparent container

1 (Fig. 212) moves and presses the grease to
the lubrication points.

i Note
The push button must only be used to check the
system.
Fig. 213
Failure of a lubrication point ● Remove both covers from the cartridge 1 (Fig.
(e.g. lubrication point blocked) 213).
● Grease emerging from the opening 3 (Fig. ● Unscrew the connecting fitting from the manu-
212) indicates that one of the lubrication points al grease gun (2).
is blocked. ● Pull the rod completely out.
● Eliminate the cause. ● Push the cartridge with the triangular mark for-
ward into the grease gun.
Filling via the grease nipple. ● Check, whether the sealing ring is correctly in-

‘Caution ●
serted in the connecting fitting.
Screw the connecting fitting on to the manual
Ensure strict cleanliness, as otherwise the dis- grease gun.
tributor will be blocked.
Do not fill the grease container via the cover.
Fill the grease container when the grease level
has dropped down to 1/4 of the filling capacity.
● 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.
● Switch the ignition on, press the push button
(Fig. 211) for 2 seconds, the system starts to
work.

BC 572 RB-2
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5.24 Replacing the fresh air and

circulation air filters

Fig. 214

● Clean the area around the covering cap of the

central lubrication system.
● Unscrew the covering cap from the central lu-
brication system and unscrew the plug from Fig. 215
the manual grease gun (Fig. 214).
● Unscrew the cover.
● Screw the manual grease gun on the socket of
● Take the old fresh air filter out and insert the
the central lubrication system.
new fresh air filter (Fig. 215).
● Operate the rod to press the grease into the
● Fasten the cover with screws.
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. 216

● remove the slotted cover from the console be-

hind the driver’s seat.
● Remove both circulation air filters and insert
the new circulation air filters (Fig. 216).
● Fasten the slotted cover to the console.

6IY  BC 572 RB-2

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Every 1000 operating hours

5.25 Checking, adjusting the

valve clearance

‘ Caution
We recommend to have this work carried out
by trained personnel or our after sales service.
Before checking the valve clearance let the en-
gine cool down for at least 30 minutes. The en-
gine oil temperature must be less than 80 °C.

Fig. 218

● Check the valve clearance between rocker

arm and valve (Fig. 218) with a feeler gauge.
Intake valve = 0.35 ± 0.05 mm, angle degree
75
Exhaust valve = 0.45 ± 0.05 mm, angle degree
105

Fig. 217
● Loosen the crankcase ventilation valve (2)
(Fig. 217) and swing it to the side.
● Remove the valve cover (1).
i Note
The feeler gauge must fit through the gap with little
resistance. If the gap is too narrow or too wide for
the feeler gauge, the valve must be adjusted.
● Check the valve clearance on all cylinders.
Adjust the valve clearance

Valves Cylinder
overlapping 1 5 3 6 2 4
adjustment 6 2 4 1 5 3

● Use a cranking device to crank the engine to

overlapping position.

Fig. 219

● Loosen the counter nut (1) (Fig. 219).

BC 572 RB-2
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5.26 Replacing the fuel filter car-

tridges

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

“
Danger
Health hazard!
Do not inhale any fuel fumes.

‘Caution
Ensure strict cleanliness! Thoroughly clean
Fig. 220 the area around the fuel filters.
● Attach the rotation angle disc (3) (Fig. 220) After work on the fuel system bleed the sys-
and the spanner socket (4) to the valve clear- tem, perform a test run and check for leaks.
ance adjustment screw (2).
Additional bleeding of the fuel system by a 5
● Fix the magnet (5) of the rotation angle disc. minute test run in idle speed or low load is
● Turn the rotation angle disc clockwise against mandatory.
the stop (rocker arm no clearance) and set the
scale to zero. Environment
● Turn the rotation angle disc clockwise, until the Catch running out fuel and dispose of environ-
specified angle is reached. mentally.
● Turn the rotation angle disc clockwise, until the ● Open the left hand engine compartment doors.
specified angle is reached.
● Hold the rotation angle disc tight, so that it
does not turn, and tighten counter nut (1) (Fig.
219) with 20 Nm.
● Repeat this adjustment procedure an all other
cylinders, after cranking the crankshaft ac-
cordingly.
● Check the gasket of the valve cover, replace it
if necessary.
● Reassemble the cylinder head cover (tighten-
ing torque: 9 Nm).
● Reassemble the crankcase ventilation valve.

66I  BC 572 RB-2

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5.27 Replacing the fuel pre-filter

cartridge, bleeding the fuel
system

“
Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke and do not spill any fu-
el.
Fig. 221
“
Danger
● Loosen both fuel filters (Fig. 221) using a suit-
able filter wrench and screw it off. Health hazard!
● Clean the sealing face on the filter carriers Do not inhale any fuel fumes.
from any dirt.
‘
‘
Caution
Caution
Ensure strict cleanliness! Thoroughly clean
The filter cartridge must never be filled before- the area around the fuel filters.
hand. After work on the fuel system bleed the sys-
tem, perform a test run and check for leaks.
Additional bleeding of the fuel system by a 5
minute test run in idle speed or low load is
mandatory.

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

Change the fuel pre-filter cartridge

Fig. 222

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

tridge (Fig. 222).
● Turn the new filter cartridge on by hand, until
the seal contacts.
● Then tighten hand-tight.
● Always bleed the fuel system after changing
the fuel pre-filter cartridge (see next chapter).
● Check for leaks after a short test run.

Fig. 223

● (1) Shut down the engine (Fig. 223).

BC 572 RB-2
 666
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● (2) Pull the cable off the water separator. ● Slacken the bleeding screws on the fuel pre-fil-
Loosen the bleeding screw and drain off fuel ters for 2 to 3 turns.
from the bleeding screw.
● Operate the fuel hand pump (2) manually, until
● (3) Loosen and unscrew the fuel pre-filter car- fuel flows out of the loosened bleeding screws
tridge using an appropriate filter wrench. without air bubbles.
● (4) Unscrew the water separator from the filter ● Then tighten the bleeding screws while pump-
cartridge. ing.
● (5) Apply a thin coat of oil to the rubber seal of ● Start the engine and run it 5 minutes with idle
the water separator. speed.
● (6) Turn the water separator on by hand, until
the seal contacts, then tighten hand-tight.
● (7) Apply a thin coat of oil to the rubber seal of
the filter element.
● (8) Turn the filter cartridge on by hand, until the
seal contacts, then tighten hand-tight. Plug the
cable of the water sensor back on.

Bleed the fuel system

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

Fig. 224

● Slacken the bleeding screw (1) (Fig. 224) on

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

66@  BC 572 RB-2

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5.28 Checking the fastening of 5.29 Checking the crankcase

engine / turbocharger / com- ventilation valve
bustion air hoses

Fig. 226

Fig. 225 ● Check condition and tight fit of crankcase ven-

tilation valve (Fig. 226).
● Check exhaust pipe and lubrication oil line to
and from the exhaust turbo charger (Fig. 225)
for tight fit and leaks.
● Check connecting sockets for tight fit.
● Retighten the fastening screws for oil sump
and engine mounts.

BC 572 RB-2
 66
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5.30 Oil change in travel gear

“ Danger
Danger of scalding!
When draining off hot oil.

‘ Caution
Drain oil only at operating temperature.
Perform the oil change on all four drive gears.
Fig. 228
For quality and quantity of oil refer to the "table
of fuels and lubricants". ● Fill in oil through the filler bore (Fig. 228), until
it starts to run out through the level inspection
bore.
Environment
Catch running out oil and dispose of environ- ● Clean the level control and filler plug and
mentally. screw it back in with a new seal ring.

Fig. 227

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

227) is at the deepest point.
● Clean the surrounding area. Clean and un-
screw filler, level control and drain plugs.
● 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.

66  BC 572 RB-2

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5.31 Changing the fuel filter for 5.32 Checking, cleaning the oil
the cabin heater (diesel) bath air filter for the cabin
heater (diesel)
“ Danger
Fire hazard! i Note
When working on the fuel system do not use Check, clean every day during the heating period.
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.

Fig. 230

● Loosen the quick locks and take the oil bowl

(Fig. 230) 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 fu-

Fig. 229
● Open the flap on the front frame.
● Pull the hoses from both sides off the fuel filter
(Fig. 229).
● Take the fuel filter out of the bracket.
● Insert a new fuel filter with the point of the ar-
row facing towards the pump and push both
hoses on.
● Remove the cover.
els, lubricants and filling capacities.
i 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 ap-
prox. -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.

BC 572 RB-2
 66
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5.33 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 dis-
pose 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.
i Note
The filter elements must be changed with every
hydraulic oil change or after major repairs in the
hydraulic system.
Fig. 232
‘
Caution
Catch oil running out.
● Do not use the oil in the filter bowl.
● Take the old filter element 3 (Fig. 232) 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. 231

● Remove the locking wire, if present.

● Unscrew the spigot nut 1 (Fig. 231).
● Take the filter bowl (2) with the filter element
off.

66S  BC 572 RB-2

 ‹Œz ŽŽŽ „twsr{ q|}

5.34 Oil change in splitter gear

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

‘ Caution
Drain oil only at operating temperature.
For quality and quantity of oil refer to the "table Fig. 234
of fuels and lubricants".
● Unscrew the plug (Fig. 234)from the oil drain
socket.
Environment ● Drain off and catch transmission oil.
Catch running out oil and dispose of environ-
● Screw the plug back in once the oil has run
mentally.
out.
“
Danger
Danger of injury!
Lower the rear bottom cover to the ground af-
ter unscrewing it, do not let it drop down.
● Remove the rear bottom cover.

Fig. 235

● Fill in new oil (Fig. 235).

● Tighten the breather filter.

Fig. 233

● Clean the area around the breather filter (Fig.

233) and unscrew the breather filter.
● Cleaning the breather filter.

BC 572 RB-2
 66U
 ‹Œz ŽŽŽ „twsr{ q|}

Fig. 236

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

236).
● Start the engine and run it for a short while.
● Check the oil level again, if necessary top up
oil.
● Check for leaks.

66Y  BC 572 RB-2

 ‹Œz ”ŽŽŽ „twsr{ q|}

Every 2000 operating hours

5.35 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 sys-
tem. Fig. 237
● Use only lint-free cleaning cloths. ● Unscrew the breather filter (Fig. 237) from the
compensation tank.
‘
Caution
Replace the hydraulic oil filter element with
‘Caution
every hydraulic oil change. Do not remove the filter element from the cover
of the compensation tank.
i 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 hy-
draulic oil.
When changing from mineral oil based hydrau- Fig. 238
lic oil to an ester based biologically degradable
oil, you should consult the lubrication oil serv-
ice of the oil manufacturer for details.
“
Danger
Danger of scalding!
Environment Danger of scalding when draining off hot hy-
Catch old oil and dispose of environmentally. draulic oil!

● Remove the rear cover.
● Unscrew plug 1 (Fig. 238) 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 appropri-
ate size.

BC 572 RB-2
 66Z
 ‹Œz ”ŽŽŽ „twsr{ q|}

● Open drain cock (2) and let the old oil run out. For quality and quantity of oil refer to the table
of fuels and lubricants.
● 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

i 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. 240

‘ Caution
● Check the oil level in the inspection glass (Fig.
240) (arrows).
Do not use any detergents. This will contami-
nate the hydraulic oil!
● Insert a new seal and reinstall the cover.
i Note
At a temperature of approx. 20 °C the oil level
should be at 1/3 of the inspection glass.
Fill in hydraulic oil.
With hot hydraulic oil and a too high oil level hy-
draulic oil can flow through the overflow into the
engine compartment.
● 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.
Fig. 239
Environment
i Note Catch running out oil and dispose of environ-
We recommend to use the filling and filtering unit mentally.
(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 hy-
draulic oil filter and protects the hydraulic system.
● Fill in new hydraulic oil through the screen
(Fig. 239).

6@I  BC 572 RB-2

 ‹Œz ”ŽŽŽ „twsr{ q|}

5.36 Check/change the coolant

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

‘ Caution
Do not start the engine after draining off the
coolant.
Fig. 242
In case of lubrication oil entering into the cool- ● Unscrew the cap (Fig. 242).
ing system or a suspicious turbidity caused by
corrosion residues or other suspended matter,
the coolant must be drained off and the com-
plete cooling system needs to be cleaned. Lu-
brication oil can damage the sealing materials
used in the engine.
When changing the coolant without any signs
of contamination, cleaning of the cooling sys-
tem is not necessary.

‘
Caution
Do not mix different coolants and additives of
any other kind.
Fig. 243
Environment ● Connect the drain hose to the drain cock (Fig.
Catch coolant and dispose of environmentally. 243).
● Guide the drain hose into a vessel of appropri-
ate size.
● Open the drain cock and let the coolant run
out.
● Check the condition of the coolant.
● Thoroughly flush the engine if the coolant is
contaminated by corrosion residues or other
suspended matter.
● Fill in clean water.
● Start the engine and flush the cooling system
out for a short while.

Fig. 241 ● Drain all water off.

● Open the safety flap (Fig. 241). ● After the coolant has run out close the drain
cock, remove the drain hose.

BC 572 RB-2
 6@ 6
 ‹Œz ”ŽŽŽ „twsr{ q|}

‘
Caution
5.37 Checking the condition of
The anti-freeze concentration (additive) must
be at least 35 Vol% and maximum 45 Vol%. the articulated joint

“
Danger
Health hazard!
The mixing of nitrite based anti-freeze agents
with amine based agents results in the forma-
tion of health affecting nitrosamines.

Fig. 245

● Check all fastening screws (Fig. 245) for tight

fit, tighten if necessary.
● Check the condition of the lubrication lines 1
(Fig. 245) to the bearings for the steering cyl-
inder rods.
Fig. 244

● Fill coolant in through the opening in the com-

pensation tank (Fig. 244).

For quality and quantity of coolant refer to the

"table of fuels and lubricants".
● Close the compensation tank.
● For bleeding start the engine and run it warm.
● Check the coolant level, top up if necessary.

6@@  BC 572 RB-2

 ‹Œz •ŽŽŽ „twsr{ q|}

Every 3000 operating hours

5.38 Replacing the ribbed V-belt

and the idler pulley

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

‘
Caution
Replace the ribbed V-belt and the idler pulley
at the latest after two years.
Fig. 246
● Press the idler pulley for the ribbed compres-
sor V-belt* in direction "A" (Fig. 246).
● Take off the ribbed V-belt.
● Replace the idler pulley.
Fig. 247
● Press the idler pulley (1) (Fig. 247) in direction
of arrow using a socket wrench (3), until the
locking pin (4) engages in the assembly bore.
● Take the ribbed V-belt (2) first off the smallest
pulley.
● Unscrew fastening screws (5) and take off
idler pulley.
● Assemble a new idler pulley and tighten the
fastening screw with 80 Nm
● Install the new ribbed V-belt.
● Counter the idler pulley with a ratchet and re-
move the locking pin.
● Check whether the ribbed V-belt is correctly
seated in the guides.

Fig. 248
● Press the idler pulley for the ribbed compres-
sor V-belt in direction "A" (Fig. 248).
● Install the new ribbed V-belt.
● Swing the idler pulley back in direction "B".
● Check whether the ribbed compressor V-belt
* Optional equipment is correctly seated in the guides.

BC 572 RB-2
 6@
‹Œz •ŽŽŽ „twsr{ q|}

5.39 Checking exhaust gas recir-

culation, control lever and
valve

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

6@  BC 572 RB-2

 ‹Œz –ŽŽŽ „twsr{ q|}

Every 6000 operating hours

5.40 Replace the crankcase ven- 5.41 Electronic injector test EMR
tilation valve
i Note
This work must only be performed by authorized
service personnel.

Fig. 249

● Replace the crankcase ventilation valve (Fig.

249).

BC 572 RB-2
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5.42 Replacing the glow plugs 5.43 Changing the injection

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

6@S  BC 572 RB-2

 —} ˜|s

As r equired

5.44 Cleaning, changing the dry

air filter cartridge

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

Fig. 251

● Unscrew wing nut (1) (Fig. 251) and remove

cover (2).

Fig. 250
Maintenance of the dry air filter is due when air fil-
ter control light (g) (Fig. 250) in the left instrument
cluster lights permanently, but at the latest after
one year.
Fig. 252
i Note ● Unscrew hexagon nut (1) (Fig. 252) and pull
Once the air filter warning light lights up, work may safety cartridge (4) out.
be continued until the end of the day.
● The safety cartridge remains in the housing.

‘ Caution Cleaning the main filter element

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

BC 572 RB-2
 6@U
—} ˜|s

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

Fig. 255

● Remove the insert (Fig. 255) from the filter

housing and clean it.
● Wipe the filter housing out with a cloth. Do not
clean with compressed air.
● Reinsert the element.
Fig. 253

● Blow the filter cartridge out from inside to out-
side with dry compressed air (max. 5 bar) (Fig.
253), until all dust has been removed.
Fig. 254
● Examine the filter cartridge with a torch for
cracks and holes in the paper bellows (Fig.
254).
Changing the safety filter element
‘
Caution
The safety filter element must not be cleaned
and should not be used again after it has been
removed.
Break the seal only to replace the safety filter
element.
The safety filter element must be replaced:
● if the main filter element is defective,
● after five times cleaning of the main filter ele-
ment,
● at the latest after 2 years,
● if the air filter warning light in the instrument
cluster comes on again after the main filter el-
ement has been serviced.

‘
Caution
Do not continue to run the machine with a
damaged main filter element. If in doubt use a
new main filter element.

6@Y  BC 572 RB-2

 —} ˜|s

5.45 Clean the condenser

‘
Caution
A soiled condenser results in a considerable
reduction of air conditioning power.
Under tough operating conditions (extremely
dusty conditions) it may be necessary to clean
the condenser several times per day.
If, during operation of the air conditioning sys-
tem, the warning buzzer sounds switch the air
Fig. 256 conditioning off and clean the condenser.
● Unscrew hexagon nut 1 (Fig. 256) and pull
safety cartridge (2) out. ™
Danger
● Insert a new safety cartridge and fasten it with Danger of accident!
a new fastening nut. Do not clean with a hot water jet. Heat will
● Insert the element into the filter housing. cause extreme overpressure, which could
cause damage or explosion of the system.
● Insert a new main filter cartridge and fasten it
with a new fastening nut.
● Screw the cover on.

Fig. 257

● Fold the air intake grid (Fig. 257) back.

™ Danger
Danger of accident!
Use a ladder (BOMAG-retrofit kit no. 007 610
06) to clean the cooling fins.
Ensure safe standing of the ladder.
● Unhook the holding ropes.

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

BC 572 RB-2
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5.46 Adjust scrapers and edge

cutter

Scrapers

Fig. 258

● Clean the condenser fins on front and back

with compressed air or cold water (Fig. 258).

Fig. 259

● Check the condition of all scrapers 1 (Fig. 259)

on the compactor wheels, replace damaged or
worn scrapers.
● Check the gap between scrapers and compac-
tor 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. 259)
and adjust the scrapers to a gap of approx. 0
or 5 mm.
● Retighten the slackened screws.
● Tightening torque 502 Nm.

i Note
The tightening torques apply only for screws cov-
ered with OKS 240 (copper paste).

6I  BC 572 RB-2

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

Fig. 260

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

260) on the compactor wheels, replace dam-
aged or worn edge cutters.
Fig. 261
● Check the gap (2) between edge cutters and
compactor wheels. ● Check the condition of the cutting plates 1
(Fig. 261) on the dozer blade/bucket. If the cut-
● At the closest point (2) there must be metal to
ting plate is worn down to the lower edge of the
metal contact between the edge cutters and
dozer blade, turn the cutting plate around or
the shell surfaces of the compactor wheels.
replace it.
● For adjustment slacken the screws (3) and ad-
● Lift the dozer blade/bucket up and support it
just the edge cutters.
safely.

i Note
For manufacturing reasons the shell of the com-
pactor wheels may not be absolutely round.
At the widest points the edge cutters may there-
fore 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.
™ Danger
Danger of accident!
Do not work on the lifted and unsupported doz-
er blade/bucket.
● To change the plate unscrew the hexagon
nuts (2). Take the washer (3) off, cut it of with
a torch, if required.
● Knock the hexagon screws (4) and take the
old cutting plate off.
● Before assembling the new cutting plate check
the contact face on the dozer blade, rework it
if necessary.
● Attach the cutting plate, insert the counter-
sunk screws and observe the locating recess,
install the washer and fasten the assembly.

BC 572 RB-2
 66
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5.48 Fill the provision tank for 5.49 Drain off dirty fluids from
the windscreen washer sys- front and rear frame
tem
Environment
Dispose of dirty fluids environmentally.
● Remove the cover from the front frame.

Fig. 262

● Check the fluid level in both tanks (Fig. 262),

top up if necessary.
● For winter operation fill in the appropriate
amount of ant-freeze agent; refer to the speci-
fications of the manufacturer of the ant-freeze
agent.
Fig. 263
● Unscrew the drain plugs (Fig. 263) from the
front frame, catch running out fluids.
● Seal any leaks, clean the floor and screw the
drain plugs back in.

Fig. 264

● Remove the service door at the tail end of the

machine.
● Unscrew the drain plugs (Fig. 264) from the
rear frame. Catch running out fluids.
● Seal any leaks, clean the floor and screw the
drain plugs back in.

6@  BC 572 RB-2

 —} ˜|s

5.50 Retightening bolted con-

nections

Fig. 265

● Clean the area around the flutter valve (Fig.

265).
● Operate the flutter valve to drain the water off
the ROPS. Fig. 266

Fig. 267

Bolted connections with OKS 240 (copper

paste) (Fig. 266) and normal bolted connec-
tions (Fig. 267).
● 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 qual-
ity designations are stamped on the screw
heads:
8.8 = 8G 10.9 = 10K 12.9 = 12K
The values result in a 90% utilization of the
screw’s yield point at a coefficient of friction µ total
= 0,14.
Compliance with the tightening torques is checked
with torque wrenches.

BC 572 RB-2
 6
—} ˜|s

When using MoS2 lubricants the specified tighten-

ing torques do not apply. 5.51 Conservation
If the engine is to be shut down for a longer period
i Note
of time (e.g. for winter storage), we recommend
Self-locking nuts must always be replaced once the following engine conservation to avoid corro-
they have been unscrewed. sion:
● 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 anti-
corrosion 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, fil-
ter, pump and nozzles are filled with the con-
serving 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 fu-
el. Then reinstall the hoods and the cover.
● Crank the engine several times by hand (with-
out 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. Re-
move this anti-corrosion oil before taking the
machine back into operation.
● Close the air intake opening on the air filter
and the exhaust opening.

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

6  BC 572 RB-2

 —} ˜|s

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

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

BC 572 RB-2
 6
—} ˜|s

6S  BC 572 RB-2

 6 Trouble shooting

BC 572 RB-2
 6U
o|šu }qwsr{

6.1 General notes on trouble

shooting

The following work must only be carried out by

qualified and trained personnel or by the
BOMAG sales service.

Please observe strictly the safety regulations

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

6Y  BC 572 RB-2

 o|šu }qwsr{

6.2 Engine problems

Fault Possible cause Remedy

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

Starter defective Have starter examined by a specialist

Fuel pre-cleaner soiled, control light for clean

water separator lights.

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

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

Specified valve clearance is not correct Adjusting the valve clearance

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

Air in the fuel system Bleed the fuel system

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

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

cialist

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

necessary

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

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

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

BC 572 RB-2
 6Z
o|šu }qwsr{

Fault Possible cause Remedy

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

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

Injection nozzles defective Have examined by a specialist

Dry air filter cartridges soiled (engine air change

filter control light in fault monitoring board
lights)

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

cialist

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

Air in the fuel system Bleed the fuel system

poor fuel quality Observe the fuel quality, if necessary

change the fuel

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

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

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

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

Exhaust turbo charger defective Have examined by a specialist

6I  BC 572 RB-2

 o|šu }qwsr{

Fault Possible cause Remedy

Engine over- Radiator soiled Clean the cooling fins

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

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

Incorrect engine oil level Catch or drain off engine oil

Injection nozzles defective Have examined by a specialist

Injection pump displacement not correctly Have corrected by a specialist

adjusted

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

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

or coolant additives

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

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

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

BC 572 RB-2
 66
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6@  BC 572 RB-2

 o|šu }qwsr{

6.3 General notes on diagnostic

push button and control
light

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

Fig. 269
i Note
After 2 seconds = 2 x short flashes of 0.4 sec-
Depending on the significance of the detected fault
onds of the first digit (recogni-
the engine may keep on running, however, with
tion of the EMR* 2) (Fig. 269).
limitations (limp home), whereby the fault lamp will
continually light, or the engine will be shut down after another 2
and the fault lamp will flash. If the warning lamps seconds = 1 x long flash of 0.8 second of
for engine oil pressure control or coolant level also the second digit for the stored
light up, correct the fault (e.g. top up oil, let the en- fault
gine cool down). after another 2
Once the fault is eliminated the fault lamp will go seconds = 1 x short flash of 0,4 second of
out. the third digit for the stored
fault
The diagnostic button provides the possibility to
read out existing faults in form of flashing codes. ● Write down the fault code and transmit it to the
customer service department.
Example fault code 211
After output of
fault code = 5 seconds pause, the display
by flashing and permanent
light.)
● If necessary repeat as described above to
read out the next fault code.

Fig. 268

● Press the diagnose button (Fig. 268) for ap-

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

* Electronic engine control

BC 572 RB-2
 6
o|šu }qwsr{

6  BC 572 RB-2