You are staring down a stalled compactor in an active landfill cell, and this 694-page Bomag BC 772 RS-2, BC 772 RB-2, BC 672 RS-2, BC 772 EB-2 Service Manual PDF (OEM 008 923 63) is what it takes to clear the breakdown. Detailed wiring diagrams trace out the ESX control and engine electrics so you can hunt down EMR3 flashing codes. The document also maps out the A4VG85 travel pump circuit through complete hydraulic schematics, backing up mechanical procedures for repairing the oscillating articulated joint and replacing the wheel caps. Lock down your repairs with factory data, torquing the M14x1.5 fine-thread wheel nuts to exactly 150 Nm and verifying the main battery reads 12.6 V on an open circuit. Standing alone on the fill with no one to ask is a rough spot, but this bookmarked, text-searchable reference gets the machine rolling across the lift before the shift ends.
What's Inside This Bomag BC 772 RS-2, BC 772 RB-2, BC 672 RS-2, BC 772 EB-2 Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 7-32 | Introduction, Safety Regulations, General Repair Instructions |
| Earth Compactor - Refuse Compactor | 33-44 | Bomag Refuse Compactor, Bomag Soil Compactor |
| Technical Data | 45-56 | Weights, Dimensions, Travel Characteristics, Engine, Compactor Wheels, Steering |
| Maintenance | 57-68 | Fuels and Lubricants, Table of Fuels and Lubricants, Running-In Instructions, Maintenance Table |
| Electrics | 69-100 | Battery Service, Checking the Main Battery Switch, Starting the Engine with Jump Leads, Main Battery Switch, Main Fuse, Hydraulic Oil Temperature, Pressure Switch |
| Electronic Control | 101-190 | Esx Control |
| Engine Electrics | 191-302 | Engine Control Unit, Pin Assignment, System Faults per Flashing Code, Flashing Code, Diagnose with Serdia, Diagnose with CAN-bus, Diagnostics Interface, EMR3 List of Fault Codes |
| Engine | 303-354 | Diesel Engine, Engine Description Tcd 2015 V 6 Cylinder, Lubrication Oil Circuit Tcd 2015, Coolant Circuit Tcd 2015, Fuel Circuit Tcd 2015, Injection System Tcd 2015 |
| Automatic Belt Tensioner | 355-368 | Removing the Belt Tensioner, Preassembly of a Belt Tensioner, Installing the Belt Tensioner |
| Hydraulics | 369-446 | Hydraulic Circuit, Travel Pumps, A4VG85 Da, Travel Pump, A4VG85 Ht, Steering and Working Pump, Axial Piston Swash Plate Principle., Troubleshooting Axial Piston Pumps |
| Automatic Air Conditioning | 447-500 | Overview, Physical Basics, Refrigerant R134a, Compressor Oil / Refrigeration Oil, Working Principle of the Air Conditioning System, Monitoring Devices, Components |
| Central Lubrication System | 501-520 | System Layout, Technical Description, Control, Lubrication Process, Progressive Distributor, Lubrication Oil Pump, Check the Central Lubrication System, Top Up |
| Oscillating Articulated Joint | 521-534 | Removing and Installing Live Ring, Repairing the Oscillating Articulated Joint, Removing and Installing the Steering Cylinders, Checking the Condition of the Articulated Joint |
| Compactor Wheels and Dozer Blade | 535-540 | Replacing the Wheel Caps, Welding on New Wheel Caps, Adjust Scrapers and Edge Cutter, Checking the Cutting Plates, Replacing the Cutting Plates If Necessary |
| Suppliers Documentation | 541-628 | Steering/Working Pump, Wheel Drive |
| Circuit Diagrams | 629-694 | Hydraulic Diagram Eb/Rb, Hydraulic Diagram Rs, Wiring Diagram |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Tightening torques for wheel nuts (fine thread) M12x1.5 | 100 Nm | p. 29 |
| Tightening torques for wheel nuts (fine thread) M14x1.5 | 150 Nm | p. 29 |
| V-belt retightening interval | 15 minutes | p. 65 |
| Battery open-circuit voltage (fully charged) | 12.6 V | p. 70 |
| Battery open-circuit voltage (50% discharged) | 12.3 V | p. 70 |
| Hydraulic oil temperature sensor (291 OHM) | 40 °C | p. 73 |
| Hydraulic oil temperature sensor (36 OHM) | 120 °C | p. 73 |
| Socket head cap screws tightening torque | 50 Nm | p. 410 |
| Tightening torque for hexagon screws (console) | 463 Nm | p. 525 |
| Tightening torque for socket head cap screws (live ring) | 463 Nm | p. 527 |
| Engine Oil Capacity | 36L | p. 63 |
| Hydraulic Oil Capacity | 350L | p. 63 |
Bomag BC 772 RS-2, BC 772 RB-2, BC 672 RS-2, BC 772 EB-2 Common Problems This Manual Covers
Bomag BC 772 RS-2 engine starts then quickly stops and severe fault lamp flashes on the console.
Check the main battery switch and test the battery open-circuit voltage. Verify it reads at least 12.6 V for a fully charged state as shown on page 70. Interrogate the ESX control for the specific EMR3 fault code before attempting another crank.
Manual Section: Engine Electrics p. 70Oscillating articulated joint feels loose during compaction passes or knocks when steering at full lock.
Inspect the live ring and steering cylinders for excessive play. Torque the socket head cap screws on the live ring to exactly 463 Nm. Review the repair procedure on page 527 before removing the 45 kg steering cylinder from the frame.
Manual Section: Oscillating Articulated Joint p. 527Travel pump emits unusual noises and machine loses drive performance while pushing heavy refuse.
Drain the tank and inspect the charge circuit fine filter for metal debris. Replace the 12 µm filter element documented on page 404. Run the engine at low idle for 3 minutes to bleed the hydraulic system as specified on page 442.
Manual Section: Hydraulics p. 404Engine overheats rapidly under load and coolant boils over the reservoir cap during continuous operation.
Pull the thermostat and test it in a heated water bath after draining the cooling system. Verify it begins opening at exactly 83°C per the specification on page 326. Measure the stroke length to confirm it reaches a full 8 mm.
Manual Section: Engine p. 326Frequently Asked Questions
What is the wheel nut torque on the Bomag BC 772 RS-2 and BC 672 RS-2?
The tightening torque for wheel nuts (fine thread) on the BC 772 models is 500 - 600 Nm for M22x1.5 thread diameter. p. 29
How do I clear ESX control unit fault codes on the Bomag BC 772 RS-2?
To delete all stored faults, ensure the engine is not running, enter code number 710, and then switch the ignition off and on again. p. 116
What is the engine oil change interval on the Bomag BC 772 RS-2 (Deutz TCD 2015)?
The engine oil change interval for DQC III and DQC IV quality oils is 500 operating hours. p. 60
What is the TCD 2015 valve clearance on the Bomag BC 772 RS-2, BC 772 RB-2, BC 672 RS-2, BC 772 EB-2?
The intake valve clearance is 0.25 mm and the exhaust valve clearance is 0.30 mm. p. 67
What is the cylinder head cover torque on the Bomag BC 772 RS-2 (Deutz TCD 2015)?
The tightening torque for the cylinder head covers is 22 Nm (16 ft. lbs). p. 318
How is this Bomag BC 772 RS-2 Service Manual delivered?
A 694-page Service Manual in searchable PDF format, available the moment you complete checkout. View on computer, tablet, or phone, with no shipping wait.
Can I print a copy of this Bomag BC 772 RS-2 Service Manual for the shop?
You can. The PDF is unlocked and carries no copy protection, so print the sections you want and keep the file as your backup.
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