Fayat Group BOMAG BF 800 C User manual

Service - Manual
Catalogue number.
008 917 73 02/2013
BF 800 C
Road Finisher
S/N 821 837 17 1001 ....
S/N 821 837 71 1001 ....
S/N 821 837 19 1001 ....
S/N 821 837 66 1001 ....
S/N 861 893 50 1001 ....
S/N 861 893 60 1001 ....

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Table of Contents
BOMAG 3008 917 73
General 9
1.1 Introduction 10
1.2 Safety regulations 11
1.3 General repair instructions 15
1.4 Tightening torques 27
Technical data 31
2.1 Technical data 32
Maintenance 39
3.1 General notes on maintenance 40
3.2 Fuels and lubricants 41
3.3 Table of fuels and lubricants 44
3.4 Running-in instructions 45
3.5 Maintenance table 46
E-Plan wiring diagrams 49
4.1 Understanding E-Plan circuit diagrams 50
4.2 Circuit symbols in E-Plan 59
4.3 Identification of switch blocks in the wiring diagram 62
4.4 Designation of components in the wiring diagram 63
4.5 Terminal designations in wiring diagram 64
Engine 67
5.1 Diesel engine 68
5.2 Engine description TCD 2012 69
5.3 Lubrication oil circuit TCD 2012 / 2013 71
5.4 Coolant circuit TCD 2012 / 2013 72
5.5 Fuel system TCD 2012 / 2013 73
5.6 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 75
5.7 Exhaust gas recirculation TCD 2012 / 2013 79
5.8 Wastegate - charge pressure controller on TCD-engines 80
5.9 Engine problems 82
5.10 Checking the engine oil level 85
5.11 Changing engine oil and oil filter cartridge 85
5.12 Replacing the fuel pre-filter cartridge, bleed the fuel system 86
5.13 Replace the fuel filter 88
5.14 Check, clean the water separator 89
5.15 Check the coolant level 90
5.16 Replace the coolant 90
5.17 Checking the thermostat in disassembled state 91
5.18 Air filter maintenance 92
5.19 Clean the cooling fins on engine and hydraulic oil cooler 94
5.20 Intercooler, drain off oil and condensation water 95
5.21 Adjust the valve clearance 95
5.22 Checking the ribbed V-belt, replacing if necessary 96
5.23 Replace the crank case ventilation valve 97
5.24 Engine conservation 98
5.25 Special tools, Deutz engine (TCD 2012 2V) 99
Engine electrics 115
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Table of Contents
BOMAG4008 917 73
6.1 EMR3 system components 116
6.2 Deutz EMR 3 - engine connections 121
6.3 Pin assignment of engine control EDC16 / EMR3 122
6.4 Rotary speed sensor for camshaft 127
6.5 Crankshaft speed sensor 128
6.6 Rail pressure sensor 129
6.7 Fuel pressure sensor 130
6.8 Fuel control unit 132
6.9 Injector 133
6.10 Oil pressure sensor 134
6.11 Sensor for charge air temperature and charge air pressure 136
6.12 EMR coolant temperature sensor 138
6.13 Glow plugs 140
6.14 Sensor, water in fuel 140
6.15 Air filter vacuum switch 141
6.16 Float switch, coolant tank 142
6.17 Charge control light, engine RPM-meter 143
6.18 Diagnose with SERDIA 144
6.19 Diagnose with CAN-bus 147
6.20 Diagnostics interface 148
6.21 EMR3 List of fault codes 150
6.22 Generator 221
6.23 Replacing the voltage regulator 230
6.24 Electric starter 232
Electrics 239
7.1 Service the battery, check the main battery switch 240
7.2 Starting the engine with jump leads 241
7.3 Starting with jump wires 241
7.4 Fuses 242
7.5 Fuse assignment 243
7.6 Component overview - Electrics 246
7.7 Overview of wiring looms 254
7.8 Control elements 267
7.9 View of control panel 268
7.10 Instrument cluster 270
7.11 Data collector 272
7.12 View of external operator stations 276
7.13 View of external operator stations 277
7.14 View of screed control panel 278
7.15 View of electric heating control panel 279
7.16 Functional block diagram overview of functions, complete 280
7.17 Block diagram components on CAN 281
7.18 Block diagram CAN with control elements 282
7.19 Block diagram of travel circuit 283
7.20 Block diagram material feed 284
7.21 Block diagram screed 285
7.22 Block diagram screed heating 286
7.23 Functional block diagram monitoring functions 287
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Table of Contents
BOMAG 5008 917 73
7.24 Block diagram Emergency Stop functions 288
7.25 Electronic control units 289
7.26 Checking the voltage supply for the control unit 291
7.27 Diagnostics concept 299
Error codes -- general information 303
8.1 Error codes - BF800 -- general information 304
Input codes 307
9.1 Input codes -- Display: Function and operation 308
9.2 Input codes -- automatic calibration of currents in the travel system 309
9.3 Input codes -- manual calibration of currents in the travel system 312
9.4 Input codes -- travel signal by push button for max. screed relief 315
9.5 Input codes -- Changing the type of speed potentiometer 317
9.6 Input codes -- Activating/deactivating the screed heat in low idle speed 318
9.7 Input codes -- activate/deactivate the cleaning function 319
9.8 Input codes -- Saving/loading TCU settings 320
9.9 Input codes -- Teaching L.C.S. Function 321
9.10 Input codes -- changing the tamper start and stop ramps 323
9.11 Input codes -- Changing the currents for the tamper pump 326
9.12 Input codes -- changing the tamper start and stop ramps 329
9.13 Input codes -- Changing the currents for the vibration pump 332
9.14 Input codes -- Saving/loading SCU settings 335
9.15 Input codes -- Restoring factory settings of the SCU 336
9.16 Input codes -- Activate/deactivate hydraulic front gate 337
9.17 Input codes -- Changing the currents in the auger pumps 338
9.18 Input codes -- Change the auger start / stop ramps 341
9.19 Input codes -- Changing the currents in the scraper belt pumps 344
9.20 Input codes -- Enable/disable lifting the auger block together with the screed
347
9.21 Input codes -- Saving/loading MCU settings 348
9.22 Input codes -- Restoring factory settings of the MCU 349
9.23 Input codes -- driving against the closed brake 350
9.24 Input codes -- showing logged errors 351
9.25 Input codes -- showing logged errors with operating hours 352
9.26 Input codes -- deleting the error log 353
Replacement of components 355
10.1 How to proceed when replacing components? 356
Material hopper, description 357
11.1 Material hopper and transport 358
Vibrating screed, description 365
12.1 Screed 366
Basic settings on the screed 371
13.1 Notes on the screed adjustment (type S500 & S600) 372
13.2 Bringing the straight crossfalls to zero position 373
13.3 Aligning basic screed and mobile sections 374
Assembling the screed extensions 377
14.1 Notes on assembling screed extensions 378
14.2 Assembling the screed extensions 381
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Table of Contents
BOMAG6008 917 73
Electric screed heating, repair 393
15.1 Electric screed heating 394
15.2 Electric screed heating - commissioning 399
15.3 Faults in the electric heating 401
Travel drive, description 403
16.1 Travel system 404
Hydraulics 409
17.1 Hydraulic circuit 410
17.2 Component overview -- hydraulics 412
17.3 Description of travel pump 417
17.4 View of the machine 423
17.5 Pumps for: Scraper belt, augers, vibration & tampers 424
17.6 View of the machine 431
17.7 Description of fan pump 433
17.8 View of the machine 437
17.9 Description of charge pumps 438
17.10 Check the hydraulic oil level 440
17.11 Change hydraulic oil and hydraulic oil filter 441
Hydraulics - travel circuit 445
18.1 Description of driving 446
18.2 Description of brake circuit 448
Hydraulics - material transport 451
19.1 Description of scraper belts 452
19.2 Description of augers 453
19.3 Description tamping 454
19.4 Description vibration 455
Hydraulics - Service 457
20.1 Description of fan circuit 458
20.2 Description of Service (a) 459
20.3 Description of Service (b) 460
20.4 Description of Load Control System (LCS) 461
Tests and adjustments 463
21.1 Special tools, tests and adjustments 464
21.2 Checking and adjusting the vibration 468
21.3 Checking/adjusting tamping 475
21.4 Checking/adjusting the scraper belts 486
21.5 Checking/adjusting the augers 493
21.6 Checking & adjusting the service pump/cylinder functions 499
21.7 Checking & adjusting the time for screed levelling 503
21.8 Checking/adjusting the hopper wings 505
21.9 Checking/adjusting the mobile screed 507
Suppliers documentation 509
22.1 Travel pump 511
22.2 Travel motor 549
22.3 Service pump and fan pump 603
22.4 Pump scraper chains, augers, tamper, vibration 633
22.5 Travel gear 691
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Table of Contents
BOMAG 7008 917 73
Circuit diagrams 761
23.1 Hydraulic diagram 763
23.2 Electric circuit diagrams 783
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Table of Contents
BOMAG8008 917 73
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BOMAG 9008 917 73
1 General
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1.1 Introduction
BOMAG10 008 917 73
1.1 Introduction
This manual addresses the professionally qualified
personnel or the after sales service of BOMAG, and
should be of help and assistance in correct and effi-
cient repair and maintenance work.
This manual describes the disassembly, dismantling,
assembly, installation and repair of components and
assemblies. The repair of components and assem-
blies is only described as this makes sense under due
consideration of working means and spare parts sup-
ply.
Documentation
For the BOMAG machines described in this manual
the following documentation is additionally available:
1 Operating and maintenance instructions
2 Spare parts catalogue
3 Service information
4 Fundamental electrics
Use only genuine BOMAG spare parts.
Spare parts needed for repairs can be taken from the
spare parts catalogue for the machine.
This manual is not subject of an updating service; for
this reason we would like to draw your attention to our
additional "Technical Service Bulletins".
In case of a new release all necessary changes will be
included.
In the course of technical development we reserve the
right for technical modifications without prior notifica-
tion.
Information and illustrations in this manual must not
be reproduced and distributed, nor must they be used
for the purpose of competition. All rights according to
the copyright law remain expressly reserved.
!Danger
These safety regulations must be read and ap-
plied by every person involved in the repair /main-
tenance of this machine. The applicable accident
prevention instructions and the safety regulations
in the operating and maintenance instructions
must be additionally observed.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG
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