Fayat Group BOMAG BM 500/15 Bedienungsanleitung

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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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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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

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