Fayat Group BOMAG BM 500/15 User manual

Service - Manual
Catalogue number.
008 916 85 10/2012
BM 500/15
BM 600/15
S/N 101 882 00 1001 ....
S/N 101 882 01 1001 ....
S/N 101 882 10 1001 ....
S/N 101 882 11 1001 ....
Compact milling machine

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Table of Contents
BOMAG 3008 916 85
General 9
1.1 Introduction 10
1.2 Safety regulations 11
1.3 General repair instructions 15
1.4 Tightening torques 25
Technical data 29
2.1 Technical data 30
Maintenance 35
3.1 General notes on maintenance 36
3.2 Fuels and lubricants 37
3.3 Table of fuels and lubricants 40
3.4 Running-in instructions 41
3.5 Maintenance table 42
Electrics 45
4.1 Battery service 46
4.2 Starting with jump wires 47
4.3 Main battery switch 47
4.4 Main fuse 48
4.5 Fuses 48
4.6 Component overview 50
4.7 Overview of wiring looms 52
4.8 Control elements 57
4.9 Overview 58
4.10 Multi-function display 60
4.11 Data collector 62
4.12 Functional block diagram overview of functions, complete 65
4.13 Functional block diagram components connected to CAN1 and CAN2 66
4.14 Functional block diagram CAN1 and CAN2 with control elements 67
4.15 Block diagram of travel circuit 68
4.16 Functional block diagram for conveyor belt drive 69
4.17 Functional block diagram milling drive 70
4.18 Functional block diagram functions without control 71
4.19 Functional block diagram height adjustment with levelling 72
4.20 Functional block diagram height adjustment without levelling 73
4.21 Functional block diagram switches in display and on travel lever 74
4.22 Functional block diagram Telematic 75
4.23 Functional block diagram monitoring functions 76
4.24 Functional block diagram water sprinkling system 77
4.25 Functional block diagram Emergency Stop function 78
4.26 Air filter vacuum switch 79
4.27 Float switch, coolant tank 79
4.28 Water tank filling level. 80
4.29 Charge control light, operating hour meter 80
4.30 Functional conditions left side plate 82
4.31 Functional conditions right side plate 88
4.32 Functional conditions for hold-down 94
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Table of Contents
BOMAG4008 916 85
4.33 Functional conditions for scraper 100
4.34 Functional conditions support wheel rear left 107
4.35 Functional condition support wheel rear right 111
4.36 Operating conditions for conveyor belt 122
4.37 Conditions for milling 126
4.38 Functional conditions for brake 132
4.39 Electronic control units 136
4.40 Checking the voltage supply for the control unit 138
4.41 Diagnostics concept 146
Codes -- general information 149
5.1 Error codes - general information 150
5.2 Query codes - general information 152
5.3 Input codes - general information 153
Error codes 155
6.1 Error code lists 157
Query codes 189
7.1 Query code lists 191
Input codes 201
8.1 Input codes -- Display Function and operation 202
8.2 Input codes -- restoring factory settings 204
8.3 Input codes calibration of surge currents for height adjustment 205
8.4 Input codes -- showing logged errors 207
8.5 Input codes -- showing logged errors with operating hours 208
8.6 Input codes -- deleting the error log 209
Replacement of components 211
9.1 How to proceed when replacing components? 212
Engine 213
10.1 Diesel engine 214
10.2 Engine description TCD 2012 215
10.3 Lubrication oil circuit TCD 2012 / 2013 217
10.4 Coolant circuit TCD 2012 / 2013 218
10.5 Fuel system TCD 2012 / 2013 219
10.6 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 222
10.7 Exhaust gas recirculation TCD 2012 / 2013 227
10.8 Checking the engine oil level 228
10.9 Change engine oil and oil filter cartridge 228
10.10 Checking, cleaning the water separator 229
10.11 Replacing the fuel pre-filter cartridge, bleed the fuel system 230
10.12 Replace the fuel filter cartridges 232
10.13 Air filter maintenance 233
10.14 Checking the coolant level 235
10.15 Check the anti-freeze agent concentration 235
10.16 Changing the coolant 236
10.17 Clean the cooling fins on engine and hydraulic oil cooler 237
10.18 Checking / replacing the ribbed V-belt 237
10.19 Check the engine mounts 238
10.20 Adjust the valve clearance 239
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Table of Contents
BOMAG 5008 916 85
10.21 Adjusting the control piston play 240
10.22 Engine problems 241
10.23 Special tools, Deutz engine (TCD 2012 2V) 244
Engine electrics 259
11.1 EMR3 system components 260
11.2 Pin assignment of engine control EDC16 / EMR3 265
11.3 Rotary speed sensor for camshaft 270
11.4 Rotary speed sensor for crankshaft 271
11.5 Rail pressure sensor 272
11.6 Fuel pressure sensor 274
11.7 Fuel control unit 275
11.8 Injector 276
11.9 Oil pressure sensor 277
11.10 Sensor for charge air temperature and charge air pressure 278
11.11 EMR coolant temperature sensor 280
11.12 Glow plugs 282
11.13 Sensor, water in fuel 283
11.14 Diagnose with SERDIA 285
11.15 EMR3 List of fault codes 288
11.16 Diagnose with CAN-bus 359
11.17 Diagnostics interface 360
Milling drive, description 365
12.1 Milling drive 366
Milling drive, repair 373
13.1 Overview clutch repair 374
13.2 Repair overview V-belt unit 375
13.3 Gearbox repair overview 378
13.4 Remove the clutch 380
13.5 Install the clutch 382
13.6 Checking, tightening, replacing the V-belt for the milling drum drive 384
13.7 Remove the gearbox 386
13.8 Install the gearbox 390
13.9 Milling drum spur wheel gear, oil change 393
13.10 Checking milling cutters and scraper bar, replacing if required 395
13.11 Checking the friction liner wear 399
Milling drum, description 401
14.1 Milling drum 402
Milling drum, repair 405
15.1 Repair overview milling drum 406
15.2 Replacing tool holders 407
15.3 Replacing the milling drum 408
Milling drum housing, description 411
16.1 Milling housing 412
Milling drum housing, repair 419
17.1 Repair overview hold-down 420
17.2 Repair overview right hand side plate 421
17.3 Repair overview left hand side plate 422
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Table of Contents
BOMAG6008 916 85
17.4 Repair overview scraper 423
17.5 Repair overview scraper, split 427
17.6 Remove the hold-down 429
17.7 Install the hold-down 431
17.8 Remove the left side plate 433
17.9 Install the left side plate 435
17.10 Remove the right side plate 437
17.11 Install the right side plate 439
17.12 Remove the scraper 441
17.13 Install the scraper 442
Conveyor belt, description 443
18.1 Conveyor belt 444
Conveyor belt, long - repair 449
19.1 Repair overview conveyor belt 450
19.2 Check, tighten the conveyor belts 465
19.3 Lubricating the conveyor belt 466
19.4 Checking safety rope and chain 467
Conveyor belt, short - repair 469
20.1 Repair overview conveyor belt, short 470
Travel drive, description 479
21.1 Travel system 480
Travel drive, repair 487
22.1 Repair overview support wheel rear left 489
22.2 Repair overview support wheel rear right 491
22.3 Repair overview front axle 3-wheeler 501
22.4 Repair overview front axle 4-wheeler 503
22.5 Repair overview steering 505
22.6 Remove the rear left support wheel 509
22.7 Install the rear left support wheel 512
22.8 Remove the rear right support wheel 516
22.9 Install the rear right support wheel 520
22.10 Lubricating the steering (3-wheeler) 524
22.11 Lubricating the steering (4-wheeler) 525
Hydraulics - general 527
23.1 Hydraulic circuit 528
23.2 Hydraulics - component overview 530
23.3 Description of travel pump 533
23.4 Troubleshooting axial piston pumps 540
23.5 View of the machine 543
23.6 Description of working pump 544
23.7 View of the machine 546
23.8 Description of tandem pump 547
23.9 View of the machine 549
23.10 Description of POCLAIN travel motor 550
23.11 View of the machine 553
23.12 Desxcription of travel motor BOSCH REXROTH 554
23.13 View of the machine 556
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Table of Contents
BOMAG 7008 916 85
23.14 Checking the hydraulic oil level 557
23.15 Checking hydraulic hoses and electric cables 558
23.16 Changing the hydraulic oil 558
23.17 Change the hydraulic oil filter 560
Hydraulics - travel circuit 561
24.1 Description of driving 563
24.2 Description of crawler system 565
Hydraulics - milling operation 569
25.1 Description of clutch 570
25.2 View of the machine 571
25.3 Milling box hydraulics 572
25.4 View of the machine 574
Hydraulics - further functions 579
26.1 Conveyor belt hydraulics 580
26.2 Protective roof hydraulics 581
Tests and adjustments 583
27.1 Special tools, tests and adjustments 584
27.2 Checking and adjusting the levelling 588
27.3 Checking/adjusting the roof adjustment 591
27.4 Checking and adjusting the clutch operating pressure 592
27.5 Checking/adjusting the brake releasing pressure 594
27.6 Checking and adjusting the steering pressure 596
27.7 Checking and adjusting working hydraulics "MP" 597
27.8 Checking and adjusting working hydraulics "MP1" 598
27.9 Checking/adjusting the scraper pressure 599
27.10 Conveyor belt: Checking and adjusting the pressure 600
27.11 Hydraulic breaker: Checking and adjusting the pressure 602
27.12 Checking / adjusting the maximum pressure of the travel pump 604
Suppliers documentation 607
28.1 Travel pump 609
28.2 Travel motor 667
28.3 Steering valve 721
28.4 Travel motor 737
28.5 Conveyor belt motor 839
Circuit diagrams 853
29.1 Hydraulic diagram 161 855
29.2 Wiring diagram 72 875
29.3 Wiring diagram 77 933
29.4 Wiring diagram 84 993
29.5 Wiring diagram 98 1053
29.6 Wiring diagram 108 1115
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Table of Contents
BOMAG8008 916 85
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BOMAG 9008 916 85
1 General
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1.1 Introduction
BOMAG10 008 916 85
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
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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