Fayat Group BOMAG BM 1000/35 User manual

BM 1000/35
Cold planer
Service Manual
S/N 101 883 03 1001>
© 11/2017008 400 32 EN

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Table of contents
1 General................................................................................................................................................... 7
1.1 Introduction Service Manual........................................................................................................ 8
1.2 Concerning your safety................................................................................................................ 9
1.2.1 Handling fuels and lubricants....................................................................................................... 9
1.2.2 Working on hydraulic lines......................................................................................................... 14
1.2.3 Working on the engine............................................................................................................... 15
1.2.4 Maintenance work on electric components and battery............................................................. 15
1.2.5 Working on heating elements..................................................................................................... 16
1.2.6 Cleaning work............................................................................................................................ 16
1.2.7 Parking the machine in secured condition................................................................................. 17
1.3 Fuels and lubricants................................................................................................................... 18
1.3.1 Engine oil................................................................................................................................... 18
1.3.2 Fuel............................................................................................................................................ 18
1.3.3 Coolant....................................................................................................................................... 19
1.3.4 Hydraulic oil................................................................................................................................ 20
1.3.5 Gear oil....................................................................................................................................... 21
1.3.6 Lubrication grease...................................................................................................................... 21
1.3.7 High-temperature lubrication grease.......................................................................................... 22
1.4 List of fuels and lubricants........................................................................................................ 23
1.5 Repair notes for hydraulics........................................................................................................ 24
2 Technical data...................................................................................................................................... 27
3 Total overview of machine.................................................................................................................. 35
3.1 Component overview - Electrics................................................................................................ 36
3.2 Component overview -- hydraulics........................................................................................... 39
4 Trouble shooting................................................................................................................................. 51
4.1 Overviews.................................................................................................................................... 52
4.1.1 Overview - Travel System.......................................................................................................... 52
4.1.2 Overview - Milling drive.............................................................................................................. 55
4.1.3 Overview - Height adjustment.................................................................................................... 58
4.1.4 Overview - Steering.................................................................................................................... 62
4.1.5 Overview - Conveyor belt functions........................................................................................... 65
4.1.6 Overview - Swivelling the slewable chassis............................................................................... 71
4.2 Functional conditions................................................................................................................. 74
4.2.1 Functional conditions - introduction............................................................................................ 74
4.2.2 Functional conditions - Starting the diesel engine...................................................................... 75
4.2.3 Functional conditions - Shutting down the diesel engine........................................................... 76
4.2.4 Functional conditions - Release of travel lever.......................................................................... 77
4.2.5 Functional conditions - Activating transport speed..................................................................... 78
4.2.6 Functional conditions - Activating working speed...................................................................... 79
4.2.7 Functional conditions - Swivelling the track chain drive............................................................. 80
4.2.8 Functional condition - Switch on the milling drum...................................................................... 81
4.2.9 Functional condition - Switch off the milling drum...................................................................... 82
4.2.10 Functional conditions - Switch on conveyor belt...................................................................... 83
4.2.11 Functional conditions - Switch off conveyor belt...................................................................... 85
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4.2.12 Functional condition - Moving the conveyor belt...................................................................... 86
4.2.13 Functional condition - Unfolding and folding the conveyor belt................................................ 87
4.2.14 Functional conditions - Activate/deactivate the differential lock............................................... 89
4.2.15 Functional conditions - Scraper (all functions)......................................................................... 90
4.2.16 Functional conditions - Hold-down (all functions)..................................................................... 92
4.2.17 Functional conditions - Side doors (left & right) (all functions)................................................. 94
4.2.18 Functional conditions - Lifting the machine.............................................................................. 97
4.2.19 Functional conditions - lowering the rear of the machine....................................................... 100
4.2.20 Functional conditions - Switching the water spraying system on/off...................................... 101
4.2.21 Functional conditions - Switching the high pressure cleaner on/off....................................... 103
4.2.22 Functional conditions - Switching the filling pump on/off........................................................ 104
4.2.23 Functional conditions - sunroof up/down................................................................................ 105
4.2.24 Functional conditions - Opening/closing engine hood............................................................ 107
4.2.25 Functional conditions - Tool change....................................................................................... 108
4.3 Fault codes................................................................................................................................ 110
5 Electric systems................................................................................................................................ 197
5.1 Control units.............................................................................................................................. 198
5.2 Display....................................................................................................................................... 205
5.2.1 Display - General..................................................................................................................... 205
5.2.2 Operating the extraction system............................................................................................... 211
5.2.3 Operating the camera.............................................................................................................. 212
5.2.4 Display „Menu“ ........................................................................................................................ 213
5.3 Reserve wiring........................................................................................................................... 222
6 Motor.................................................................................................................................................. 225
6.1 General description.................................................................................................................. 226
6.2 Engine electrics......................................................................................................................... 229
6.2.1 Engine management MTU....................................................................................................... 229
6.2.2 Sensors MTU 6R 1000............................................................................................................. 232
6.3 Lubrication oil circuit................................................................................................................ 233
6.4 Cooling circuit........................................................................................................................... 238
6.5 Fuel system............................................................................................................................... 240
7 Hydraulic system.............................................................................................................................. 245
7.1 Component description............................................................................................................ 246
7.2 Travel pump............................................................................................................................... 276
7.3 Conveyor belt pump................................................................................................................. 278
7.4 Fan pump................................................................................................................................... 279
7.5 Working pump........................................................................................................................... 281
7.6 Towing the machine.................................................................................................................. 282
7.7 Trouble shooting axial piston pumps..................................................................................... 283
8 Assembly groups.............................................................................................................................. 287
8.1 drive unit.................................................................................................................................... 288
8.1.1 Description............................................................................................................................... 288
8.2 Milling unit................................................................................................................................. 297
8.2.1 Description............................................................................................................................... 297
8.3 Milling drum............................................................................................................................... 300
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8.3.1 Description............................................................................................................................... 300
8.3.2 Repair....................................................................................................................................... 309
8.4 Conveyor unit............................................................................................................................ 319
8.4.1 Description............................................................................................................................... 319
8.4.2 Repair....................................................................................................................................... 323
8.5 Undercarriage............................................................................................................................ 331
8.5.1 Description............................................................................................................................... 331
8.5.2 Repair....................................................................................................................................... 341
8.6 Water system............................................................................................................................. 342
8.6.1 Description............................................................................................................................... 342
8.6.2 Operation................................................................................................................................. 345
8.7 Dust extraction.......................................................................................................................... 349
8.7.1 Description............................................................................................................................... 349
9 Index................................................................................................................................................... 351
Appendix............................................................................................................................................ 355
A Circuit diagrams............................................................................................ 357
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Table of contents
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1 General
General
BM 1000/35
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1.1 Introduction Service Manual
This manual:
naddresses the BOMAG Customer Service and professionally
trained personnel.
nprovides support for repair work or maintenance procedures on
the machine.
This manual described the deinstallation, dismantling , assembly,
installation as well as the repair of components and assembly
groups as far as this makes sense with respect to tools and spare
parts supply.
For the BOMAG machines described in this manual the following
documentation is additionally available:
nOperating and maintenance instructions
nSpare parts catalogue
nService information (if necessary)
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 the additionally published
service informations.
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 notification.
Information and illustrations in this manual must not be reproduced
and distributed, nor must they be used for the purpose of competi-
tion without the consent of BOMAG. All rights according to the
copyright law remain expressly reserved.
DANGER!
Danger to life when disregarding the safety reg-
ulations!
– Strictly follow the safety regulations in this
instruction manual.
General
Documentation
Genuine BOMAG spare parts
Updating service
Copyright
General – Introduction Service Manual
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1.2 Concerning your safety
1.2.1 Handling fuels and lubricants
1.2.1.1 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:
nname of substance
npossible dangers
ncomposition / information on constituents
nfirst-aid measures
nfire fighting measures
nmeasures in case of accidental release
nhandling and storage
nlimitation and monitoring of exposure / personal protective
equipment
nphysical and chemical properties
nstability and reactivity
ntoxicological data
nenvironmental data
nnotes on waste disposal
ninformation on transport
nlegislation
nother data
General – Concerning your safety
BM 1000/35
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1.2.1.2 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!
–Wear your personal protective equipment (pro-
tective gloves, protective clothing).
CAUTION!
Health hazard caused by contact with diesel
fuel!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
– Do not inhale any fuel fumes.
– Avoid contact.
CAUTION!
Danger of slipping on spilled diesel fuel!
– Immediately bind spilled diesel fuel with an oil-
binding agent.
ENVIRONMENT!
Diesel fuel is an environmentally hazardous
substance!
– Always keep diesel fuel in proper containers.
–Immediately bind spilled diesel fuel with an oil-
binding agent and dispose of properly.
– Dispose of diesel fuel and fuel filters according
to regulations.
Fig. 1
General – Concerning your safety
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1.2.1.3 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!
–Wear your personal protective equipment (pro-
tective gloves, protective clothing).
CAUTION!
Health hazard caused by contact with oil!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
– Do not inhale any oil vapours.
– Avoid contact.
CAUTION!
Danger of slipping on spilled oil!
– Immediately bind spilled oil with an oil-binding
agent.
ENVIRONMENT!
Oil is an environmentally hazardous substance!
– Always keep oil in proper containers.
–Immediately bind spilled oil with an oil-binding
agent.
–Dispose of oil and oil filter according to regula-
tions.
Fig. 2
General – Concerning your safety
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1.2.1.4 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).
Should pressure fluid penetrate the skin, imme-
diate medical help is required.
WARNING!
Danger of burning by ignited hydraulic oil!
– Do not allow hydraulic oil to come into contact
with hot components.
– Smoking and open fire is prohibited!
–Wear your personal protective equipment (pro-
tective gloves, protective clothing).
CAUTION!
Health hazard caused by contact with hydraulic
oil!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
– Do not inhale any oil vapours.
–Avoid contact.
CAUTION!
Danger of slipping on spilled oil!
– Immediately bind spilled oil with an oil-binding
agent.
ENVIRONMENT!
Oil is an environmentally hazardous substance!
– Always keep oil in proper containers.
– Immediately bind spilled oil with an oil-binding
agent.
–Dispose of oil and oil filter according to regula-
tions.
Fig. 3
General – Concerning your safety
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1.2.1.5 Safety regulations and environmental protection regulations for handling coolants
WARNING!
Danger of scalding by hot fluid!
– Open the coolant compensation tank only after
the engine has cooled down.
– Wear your personal protective equipment (pro-
tective gloves, protective clothing, goggles).
CAUTION!
Health hazard caused by contact with coolant
and coolant additives!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
– Do not inhale any fumes.
– Avoid contact.
CAUTION!
Danger of slipping on spilled coolant!
– Immediately bind spilled coolant with an oil-
binding agent.
ENVIRONMENT!
Coolant is an environmentally hazardous sub-
stance!
– Always keep coolant and coolant additives in
proper containers.
–Immediately bind spilled coolant with an oil-
binding agent and dispose of it according to
regulations.
–Dispose of coolant according to regulations.
Fig. 4
General – Concerning your safety
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1.2.1.6 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.
–Rinse off spilled battery acid immediately with
lots of water.
Rinse acid off clothes, skin or eyes immediately
with lots of clean water.
Immediately call for medical advice in case of cau-
terization.
WARNING!
Danger of injury caused by exploding gas mix-
ture!
– Remove the plugs before starting to recharge
the battery.
–Ensure adequate ventilation.
– Smoking and open fire is prohibited!
– Do not lay any tools or other metal objects on
the battery.
– Do not wear jewellery (watch, bracelets, etc.)
when working on the battery.
– Wear your personal protective equipment (pro-
tective gloves, protective clothing, goggles).
ENVIRONMENT!
Battery acid is an environmentally hazardous
substance!
– Dispose of battery and battery acid according
to regulations.
1.2.2 Working on hydraulic lines
Relieve hydraulic pressures before working on hydraulic lines.
Hydraulic oil escaping under pressure can penetrate the skin and
cause severe injury. Immediately call for medical advice when
injured by hydraulic oil.
Do not step in front of or behind the wheels/track chains when per-
forming adjustment work in the hydraulic system.
Do not change the setting of pressure relief valves.
Fig. 5
General – Concerning your safety
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Drain the hydraulic oil at operating temperature – danger of
scalding!
Any hydraulic oil must be collected and disposed of in an environ-
mentally friendly way.
Always collect and dispose of hydraulic oils separately.
Do not start the engine after draining off the hydraulic oil. Once all
work is completed (with the system still depressurized!) check all
connections and fittings for leaks.
Hydraulic hoses must be visually inspected at regular intervals.
Do not mix up hoses by mistake.
Only genuine BOMAG replacement hydraulic hoses ensure that
the correct hose type (pressure range) is used at the right location.
1.2.3 Working on the engine
Do not work on the fuel system while the engine is running -
danger to life due to high pressures!
Wait until the engine has stopped, then wait another approx. 15
minutes.
Keep out of the danger zone during the initial test run.
In case of leaks return to the workshop immediately.
Make sure that the engine cannot be accidently started during
service and repair work.
Drain the engine oil at operating temperature – danger of scalding!
Wipe off spilled oil, collect leaking oil and dispose of it in an envi-
ronmentally friendly way.
Store used filters and other oil contaminated materials in a sepa-
rate, specially marked container and dispose of them in an environ-
mentally friendly way.
Do not leave any tools or other objects, that could cause damage,
in the engine compartment.
The settings for idle speed and highest speed must not be
changed, since this would affect the exhaust gas values and cause
damage to engine and power train.
Engine and exhaust system work with high temperatures. Keep
combustible materials away and do not touch any hot surfaces.
Check and change coolant only when the engine is cold. Collect
coolant and dispose of it in an environmentally friendly way.
1.2.4 Maintenance work on electric components and battery
Before starting to work on electric parts of the machine disconnect
the battery and cover it with insulating material.
Do not use fuses with higher ampere ratings and do not bridge
fuses - fire hazard!
General – Concerning your safety
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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.
Metal objects (e.g. tools, rings, watch straps) must not come in
contact with the battery poles – danger of short circuit and burning!
When recharging non-serviceable batteries remove all plugs, to
avoid the accumulation of explosive gases.
When recharging switch off the charging current before removing
the charging clamps.
Ensure sufficient ventilation, especially if the battery is to be
charged in a closed room.
Dispose of old batteries according to regulations.
1.2.5 Working on heating elements
Danger to life! High voltage 230/400 Volt!
Work on the electric heating system must only be carried out by
persons who have been trained for these activities.
Heating elements must only be changed with the engine shut down
and the main battery switch pulled out.
The heating elements become very hot during operation. Allow to
cool down to an appropriate level before disassembling the heating
elements.
After replacing a heating element you should generally perform an
insulation and PE-conductor measurement!
1.2.6 Cleaning work
Be extremely cautious when performing cleaning work with the
engine running.
Allow the engine to cool down before starting cleaning work on
engine and exhaust system.
Never use gasoline or other easily inflammable substances for
cleaning.
When cleaning with steam cleaning equipment do not subject elec-
trical parts and insulation material to the direct jet of water, or cover
it beforehand.
Do not guide the water jet into the exhaust pipe and into the air
filter.
General – Concerning your safety
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1.2.7 Parking the machine in secured condition
1. Drive the machine onto level and firm ground.
2. Shift the travel lever to “Middle” position.
3. Press the parking brake switch.
4. Completely lower the screed with the toggle switch/button for
lifting/lowering the screed (b).
NOTICE!
Danger of engine damage!
– Do not shut down the engine all of a sudden
from full load speed, but let it idle for about two
minutes.
5. Turn the ignition key to position “0” and pull it out.
6. Turn the main battery switch counter-clockwise and pull it
out.
Fig. 6
Fig. 7
Fig. 8
Fig. 9
General – Concerning your safety
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1.3 Fuels and lubricants
1.3.1 Engine oil
1.3.1.1 Oil quality
The following engine oil specifications are permitted:
nEngine oils acc. to Mercedes-Benz operating instructions sheet
no. 228.5 or 228.51
The list of approved engine oils is also available on the Internet
under the following address:
http://bevo.mercedes-benz.com/
Avoid mixing engine oils.
1.3.1.2 Oil viscosity
Since engine oil changes its viscosity with the temperature, the
ambient temperature at the operating location of the engine is of
utmost importance when choosing the viscosity class (SAE-class).
Only use multi-purpose oils.
The temperature data of the SAE-class always refer to fresh oils.
The engine oil ages during travel operation because of soot and
fuel residues. This adversely affects the properties of the engine
oil, especially at low ambient temperatures.
Optimal operating conditions can be achieved by using the oil vis-
cosity chart as reference.
1.3.1.3 Oil change intervals
If the oil change intervals are not reached over a period of 2 years,
the oil change should be performed at least every 2 years, irre-
spective of the operating hours reached.
1.3.2 Fuel
1.3.2.1 Fuel quality
You should preferably use commercial diesel fuel with a sulphur
content of less than 0.5 %.
When using a diesel fuel with a high sulphur content of 0.5 % to
1.0 % the oil change intervals must be halved.
Fuels with a sulphur content of more than 1.0 % are not permitted.
In order to fulfil national emission regulations one must strictly use
the legally required fuels (e.g. sulphur content).
Fig. 10: Oil viscosity diagram
General – Fuels and lubricants
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The following fuel specifications are recommended:
nEN 590
nASTM D975 Grade-No. 1-D and 2-D
nJIS K 2204 Grade Fuel 1 and Grade Fuel 2 with lubrication
properties acc. to EN 590
1.3.2.2 Winter fuel
For winter operation use only winter diesel fuel, to avoid clogging
because of paraffin separation.
At very low temperatures disturbing paraffin separation can also be
expected when using winter diesel fuel.
Diesel fuels suitable for temperatures down to -44 °C (-47 °F) are
available for Arctic climates.
NOTICE!
Danger of engine damage!
– The admixture of petroleum and the addition of
“flow enhancing additives” (fuel additives) is
not permitted.
1.3.2.3 Storage
Even traces of zinc, lead and copper can cause deposits in the
injection nozzles, especially in modern Common-Rail injection sys-
tems.
Zinc and lead coatings in refuelling systems and fuel lines are not
permitted.
Copper containing materials (copper lines, brass items) should be
avoided, because they can cause catalytic reactions in the fuel with
subsequent depositing in the injection system.
1.3.3 Coolant
1.3.3.1 General
The coolant is a mixture of water and anti-corrosion/anti-freeze
agent.
The anti-corrosion/anti-freeze agent in the coolant has the fol-
lowing properties:
nHeat transfer
nCorrosion protection
nCavitation protection
nFrost protection
nIncrease of boiling temperature
General – Fuels and lubricants
BM 1000/35
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Leave the coolant in the system all year around. This applies also
for countries with high ambient temperatures.
Check the anti-corrosion/anti-freeze concentration in the coolant
every six months.
Use only approved anti-corrosion/anti-freeze agents.
1.3.3.2 Topping up coolant
NOTICE!
Danger of engine damage!
Use only prepared coolant with 50 % by volume
anti-corrosion/anti-freeze as per sheet 325.5 or
326.5 to replenish the system.
Information on operating fluids tested by Mer-
cedes-Benz and approved for your engine can be
found on the internet under:
http://bevo.mercedes-benz.com/
Only fill in anti-corrosion/anti-freeze agent of the
same quality range.
In case of coolant loss, do not fill only with water, but add also the
appropriate proportion of approved anti-corrosion/anti-freeze
agent.
1.3.3.3 Replacing coolant
nevery 3 years
When renewing the coolant you must make sure that the coolant
contains 50 Vol.-% by weight of anti-corrosion/anti-freeze agent.
This corresponds with a frost protection down to -37 °C (-35 °F).
Do not exceed a proportion of 55 Vol.-% (frost protection down to
approx. -45 °C (-49 °F)). Otherwise heat discharge and anti-freeze
properties will be adversely affected.
The water in the coolant must meet certain requirements, which
are most frequently met by drinking water. If the water quality is not
sufficient, you should have water specially prepared. Follow the
operating fluids instructions according to sheet 310.1 issued by
Mercedes-Benz.
1.3.4 Hydraulic oil
1.3.4.1 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 (104 °F) and
8 mm2/s at 100 °C (212 °F).
General – Fuels and lubricants
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