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Fayat Group BOMAG BC 463 RB-3 Service Manual

Refuse compactor
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Service Manual
BC 463 RB-3 / BC 473 RB/RS/EB-3
S/N 101 930 12 1001> / S/N 101 930 13 1001> / S/N 101 930 14 1001> / S/N 101 930 15 1001>
Refuse compactor
Fast moving soil compactor
008 402 12 EN
© 06/2018

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Summary of Contents for Fayat Group BOMAG BC 463 RB-3

  • Page 1 Service Manual BC 463 RB-3 / BC 473 RB/RS/EB-3 S/N 101 930 12 1001> / S/N 101 930 13 1001> / S/N 101 930 14 1001> / S/N 101 930 15 1001> Refuse compactor Fast moving soil compactor 008 402 12 EN ©...
  • Page 2 Find manuals at https://best-manuals.com...

  • Page 3: Table Of Contents

    Table of contents Table of contents General..............................9 1.1 Introduction..........................10 1.2 Concerning your safety......................12 1.2.1 Basic prerequisites........................12 1.2.2 Definition of responsible persons....................15 1.2.3 Fundamentals for safe operation....................16 1.2.4 Handling fuels and lubricants..................... 18 1.2.5 Loading / transporting the machine.................... 24 1.2.6 Start up procedure........................
  • Page 4 Table of contents 3.4.1 Diesel engine........................... 109 3.4.2 Air conditioning......................... 111 3.4.3 Central lubrication system......................112 3.4.4 Overview of maintenance flaps and doors................115 Electric systems..........................117 4.1 Basic principles......................... 119 4.1.1 Measuring method........................119 4.1.2 Understanding circuit diagrams....................124 4.1.3 Telemecanique switch......................
  • Page 5 Table of contents 5.4.1 Charge circuit, engine hood, brake and travel speed range selection........287 5.4.2 Travel system........................... 295 5.4.3 Cooling system......................... 299 5.4.4 Working hydraulics........................305 5.5 Inspection and maintenance work..................313 5.5.1 Maintenance Table........................313 5.5.2 Checks prior to start up......................313 5.5.3 Every 500 operating hours.......................
  • Page 6 Table of contents 6.6.2 Fuse assignment........................492 6.6.3 Control panel..........................492 6.6.4 Inspection and maintenance work.................... 494 Troubleshooting..........................497 7.1 Preliminary remarks........................499 7.2 Emergency procedures......................500 7.2.1 Actuating the emergency stop switch..................500 7.2.2 Emergency exit........................500 7.2.3 Disconnect the battery......................500 7.2.4 Towing the machine.........................
  • Page 7 Table of contents 7.8.7 Check the fuel supply....................... 652 7.8.8 Circuit diagram, AIRTRONIC D2/D4..................654 Special tools............................659 8.1 Special tools, electrics......................660 8.2 List of special tools........................661 Measures prior to extended shutdown period................663 9.1 Measures before shutting down....................664 9.2 Battery service during prolonged machine downtimes............
  • Page 8 Table of contents BC 463 RB-3 / BC 473 RB/RS/EB-3 Find manuals at https://best-manuals.com...

  • Page 9: General

    General General BC 463 RB-3 / BC 473 RB/RS/EB-3 Find manuals at https://best-manuals.com...

  • Page 10: Introduction

    General – Introduction 1.1 Introduction............... 10 1.2 Concerning your safety..........12 1.2.1 Basic prerequisites..........12 1.2.2 Definition of responsible persons......15 1.2.3 Fundamentals for safe operation......16 1.2.4 Handling fuels and lubricants........18 1.2.5 Loading / transporting the machine......24 1.2.6 Start up procedure...........
  • Page 11 General – Introduction Documentation For the BOMAG machines described in this manual the following documentation is additionally available: Operating and maintenance instructions Spare parts catalogue Service information (if necessary) Maintenance/parts service Specialist teams are available for you in Germany, Europe and overseas.

  • Page 12: Concerning Your Safety

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

  • Page 15: Definition Of Responsible Persons

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

  • Page 16: Fundamentals For Safe Operation

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

  • Page 18: Handling Fuels And Lubricants

    General – Concerning your safety 1.2.4 Handling fuels and lubricants 1.2.4.1 Preliminary remarks The operating company must ensure that all professional users have read and follow the corresponding safety data sheets for the individual fuels and lubricants. Safety data sheets provide valuable information about the following characteristics: name of substance possible dangers...
  • Page 19 General – Concerning your safety 1.2.4.2 Safety regulations and environmental protection regulations for handling diesel fuel WARNING! Danger of burning by ignited diesel fuel! – Do not allow diesel fuel to come into contact with hot components. – Smoking and open fire is prohibited! –...
  • Page 20 General – Concerning your safety 1.2.4.3 Safety regulations and environmental protection regulations for handling oil WARNING! Danger of burning by ignited oil! – Do not allow oil to come into contact with hot components. – Smoking and open fire is prohibited! –...
  • Page 21 General – Concerning your safety 1.2.4.4 Safety regulations and environmental protection regulations for handling hydraulic oil WARNING! Danger of injury caused by escaping pressure fluid! – Always depressurize the hydraulic system before starting work in the hydraulic system. – Wear your personal protective equipment (pro- tective gloves, protective clothing, goggles).
  • Page 22 General – Concerning your safety 1.2.4.5 Safety regulations and environmental protection regulations for handling coolants WARNING! Danger of scalding by hot fluid! – Open the compensation tank only when the engine is cold. – Wear your personal protective equipment (pro- tective gloves, protective clothing, goggles).
  • Page 23 General – Concerning your safety 1.2.4.6 Safety regulations and environmental protection regulations for handling battery acid WARNING! Danger of cauterization with acid! – Wear your personal protective equipment (pro- tective gloves, protective clothing, goggles). – Do not allow clothes, skin or eyes to come into contact with acid.

  • Page 24: Loading / Transporting The Machine

    General – Concerning your safety Safety regulations and environmental protection regulations when handling lubrication 1.2.4.7 grease CAUTION! Health hazard caused by contact with lubrica- tion grease! – Wear your personal protective equipment (pro- tective gloves, safety goggles, protective clothing). – Avoid contact.

  • Page 25: Start Up Procedure

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

  • Page 26: Driving The Machine; Working Operation

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

  • Page 28: Refuelling

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

  • Page 29: Maintenance Work

    General – Concerning your safety 1.2.9.3 Towing the machine Tow the machine only in case of emergency or to avoid an acci- dent. Before releasing the parking brake apply suitable measures to secure the machine against unintended rolling. Use a tractor vehicle with sufficient traction and braking power for the unbraked towed load.
  • Page 30 General – Concerning your safety Any hydraulic oil must be caught and disposed of in an environ- mentally friendly manner. Always catch and dispose of hydraulic oils separately. Do not start the engine after draining the hydraulic oil. Once all work is completed (with the system still depressurized!) check all connections and fittings for leaks.

  • Page 31: Repair

    General – Concerning your safety 1.2.10.5 Working on the air conditioning Faults on the air conditioning should only be remedied by author- ized service personnel. Do not perform welding work in the vicinity of the air conditioning. Danger of explosion! Do not release refrigerant into the atmosphere, but dispose of it in line with environmental regulations.
  • Page 32 General – Concerning your safety 90° B-930-0172 Fig. 7 BC 463 RB-3 / BC 473 RB/RS/EB-3...
  • Page 33 General – Concerning your safety Engine Coolant Hydraulic Oil Spec.: • MB 325.5 • Deutz DQC CC-14 Part No.: 009 940 03 (20 l) 20 °C 68 °F 90° STOP 50mm . 1.97in STOP 50mm . 1.97in Diesel B-930-0173 Fig. 8 BC 463 RB-3 / BC 473 RB/RS/EB-3...
  • Page 34 General – Concerning your safety 90° B-930-0171 Fig. 9 BC 463 RB-3 / BC 473 RB/RS/EB-3...
  • Page 35 General – Concerning your safety Hydraulic Oil Engine Coolant Spec.: • MB 325.5 • Deutz DQC CC-14 Part No.: 009 940 03 (20 l) 20 °C 68 °F 90° STOP 50mm . 1.97in STOP 50mm . 1.97in Diesel B-930-0170 Fig. 10 BC 463 RB-3 / BC 473 RB/RS/EB-3...
  • Page 36 General – Concerning your safety 90° B-930-0174 Fig. 11 BC 463 RB-3 / BC 473 RB/RS/EB-3...
  • Page 37 General – Concerning your safety Engine Coolant Hydraulic Oil Spec.: • MB 325.5 • Deutz DQC CC-14 Part No.: 009 940 03 (20 l) 20 °C 68 °F 90° STOP 50mm . 1.97in STOP 50mm . 1.97in Diesel B-930-0175 Fig. 12 BC 463 RB-3 / BC 473 RB/RS/EB-3...
  • Page 38 General – Concerning your safety Warning sticker - Danger zone Fig. 13 Warning sticker - Danger of being pulled in: Shut down the engine Fig. 14 Warning sticker - Danger of cutting and getting caught by radiator Fig. 15 Warning sticker - Danger of crushing Fig.
  • Page 39 General – Concerning your safety Warning sticker - Follow operating instructions Fig. 17 Instruction sticker - Always wear your seat belt Fig. 18 Information sticker - Emergency exit Fig. 19 Information sticker - Disconnecting the battery B-DEC-0219 Fig. 20 BC 463 RB-3 / BC 473 RB/RS/EB-3...

  • Page 40: Hydraulic Oil

    General – Concerning your safety Information sticker - Lashing point Fig. 21 Information sticker - Clean cooling module 50mm . 1.97in B-DEC-0059 Fig. 22 Information sticker - Filler opening for hydraulic oil Hydraulic Oil B-DEC-0214 Fig. 23 Information sticker - Hydraulic oil level Fig.
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