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Fayat Group BOMAG BM 500/15 Service Manual

Cold planer
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Service Manual
BM 500/15
S/N 101 882 02 1001> / S/N 101 882 04 1001>
Cold planer
008 400 24 EN
© 03/2018

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Summary of Contents for Fayat Group BOMAG BM 500/15

  • Page 1 Service Manual BM 500/15 S/N 101 882 02 1001> / S/N 101 882 04 1001> Cold planer 008 400 24 EN © 03/2018...
  • 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 Basic safety regulations for safe operation................16 1.2.4 Handling fuels and lubricants..................... 17 1.2.5 Loading/transporting the machine....................
  • Page 4 Table of contents Electric systems..........................93 4.1 Basic principles........................... 95 4.1.1 Deutsch plug, series DT and DTM..................... 95 4.1.2 Clip-on technology........................99 4.1.3 Magnetic coil plug........................102 4.1.4 Telemecanique switch......................104 4.2 Operating consoles........................107 4.3 Central electrics........................110 4.4 Wiring............................111 4.5 Description of electrical components..................
  • Page 5 Table of contents 5.1.2 Swash plate principle, motor....................173 5.1.3 Swash plate principle, pump....................174 5.2 Hydraulic components position....................176 5.3 Position of hydraulic pumps....................181 5.4 Description of hydraulic components..................182 5.4.1 Gear pump AZPF........................202 5.4.2 Travel pump, A10VG18-63 EP....................203 5.4.3 Steering valve..........................
  • Page 6 Table of contents 6.5.2 Inspection and maintenance work.................... 368 6.6 Water system..........................373 6.6.1 Description..........................373 6.6.2 Inspection and maintenance work.................... 378 Troubleshooting..........................385 7.1 Preliminary remarks........................386 7.2 Emergency procedures......................387 7.2.1 Actuating the emergency stop switch..................387 7.2.2 Disconnecting the battery......................387 7.2.3 Towing the machine.........................
  • Page 7 Table of contents 8.2 List of special tools........................620 Index..............................623 Appendix............................631 A Circuit diagram 230..................635 B Circuit diagram 269..................699 C Wiring diagram 296..................763 D Hydraulic diagram 264................. 821 E Hydraulic diagram 277.................. 841 F Hydraulic diagram 343.................. 861 BM 500/15 Find manuals at https://best-manuals.com...
  • Page 8 Table of contents BM 500/15 Find manuals at https://best-manuals.com...

  • Page 9: General

    General General BM 500/15 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 Basic safety regulations for safe operation....16 1.2.4 Handling fuels and lubricants........17 1.2.5 Loading/transporting the machine......23 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 BOMAG machine has been built in compliance with the latest technical standard and complies with the applicable regulations and technical 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 height regulation by pulling on the rope sensor, driving on public roads without a permit. climbing onto or off the machine while driving is prohibited. transporting persons, except the machine driver, is prohibited. starting and operation of the machine in explosive environments and in underground mining is prohibited.

  • Page 16: Basic Safety Regulations For Safe Operation

    General – Concerning your safety Observe your local laws and regulations. Rights, obligations and rules of conduct for driver or operator: The driver or operator must: be instructed about his rights and obligations, wear protective equipment as appropriate for the application, have read and understood the operating instructions, have made himself familiar with the operation of the machine, be physically and psychologically able to drive and operate the...

  • Page 17: Handling Fuels And Lubricants

    General – Concerning your safety We wish to make explicitly clear that we have not tested or approved any parts or accessories not supplied by us. The installation and/or use of such products may have an adverse effect on the active and/or passive safety. 1.2.3.4 Damage, defects, misuse of safety devices Machines which are not safe to operate or in traffic must be imme-...
  • Page 18 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 19 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 20 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 21 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 22 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 23: 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 24: Start Up Procedure

    General – Concerning your safety Lifting tackle must not be damaged by machine components. Secure the machine on the transport vehicle against rolling, slip- ping and turning over. Loads must only be attached and hoisted by an expert / capable person.

  • Page 25: Driving The Machine, Working Operation

    General – Concerning your safety 1.2.6.2 Starting the engine The machine must only be started and operated from the driver’s stand. Before starting and moving the machine make sure that no person under the machine, in the swinging range of the conveyor belt, or in the vicinity of the track wheels.
  • Page 26 General – Concerning your safety Always keep the machine horizontal when driving into or out of the milling track. Make sure that no overhangs protrude into the public traffic. Ensure a sufficient distance to the ceiling when driving into a building.
  • Page 27 General – Concerning your safety 1.2.7.4 Cross slope Steer and drive especially carefully with the support wheel folded in. Danger of turning over! Always unfold the support wheel for transport. The tipping angle was measured on level, hard ground with the machine stopped and not steering.

  • Page 28: Refuelling

    General – Concerning your safety Never reach into the running conveyor system (e.g. for the purpose of cleaning). Never swing the loading conveyor belt over persons or the truck cabin. Milling application with levelling During milling applications with levelling system components and system assemblies of the machine are moved manually or automatically.

  • Page 29: Regeneration Of Exhaust Gas Aftertreatment System

    General – Concerning your safety You should therefore always make sure that the filling system is properly grounded and that there is equipotential bonding to the machine. If necessary use a connecting cable between filling system and vehicle ground. Monitor the entire refuelling process. Do not spill any fuel.

  • Page 30: Maintenance Work

    General – Concerning your safety 1.2.10.3 Towing the machine Tow the machine only in a 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 31: Engine

    General – Concerning your safety 1.2.11.2 Work 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 machine when performing adjustment work in the hydraulic system.

  • Page 32: Repair

    General – Concerning your safety 1.2.11.4 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.
  • Page 33 General – Concerning your safety Replace damaged and illegible stickers or signage immediately. Fig. 8 BM 500/15...
  • Page 34 General – Concerning your safety Fig. 9 Warning sticker - Danger of being pulled in by belt drive and cooling fan and hot surface Fig. 10 BM 500/15...
  • Page 35 General – Concerning your safety Warning sticker - Crushing hazard for hands and feet Fig. 11 Warning sticker - Danger of tipping over Fig. 12 Warning sticker - Keep a distance Fig. 13 Warning sticker - Watch out for manhole covers Fig.
  • Page 36 General – Concerning your safety Warning sticker - Watch out for high voltage power lines Fig. 15 Warning sticker - Follow operating instructions Fig. 16 Warning sticker - Danger of crushing Fig. 17 Warning sticker - Danger of being pulled in by wheel Fig.
  • Page 37 General – Concerning your safety Warning sticker - Do not enter and exit the machine during travel Fig. 19 Warning sticker - Danger of injury when operating the roof Fig. 20 Prohibition sticker - High pressure cleaning Fig. 21 Prohibition sticker - No drinking water Fig.
  • Page 38 General – Concerning your safety Prohibition sticker - Access forbidden, keep a distance Fig. 23 Information sticker - Push button assignment on travel lever Fig. 24 Information sticker - Scraper pressure and conveyor belt speed Fig. 25 Information sticker - Ball valve position on conveyor belt or hydraulic breaker Fig.
  • Page 39 General – Concerning your safety Information sticker - Hydraulic breaker connection Fig. 27 Information sticker - Lashing point Fig. 28 Information sticker - Lifting point Fig. 29 Information sticker - Diesel Fig. 30 BM 500/15...
  • Page 40 General – Concerning your safety Information sticker - Water Fig. 31 Information sticker - Hydraulic oil Fig. 32 Information sticker - Hydraulic oil level Fig. 33 Information sticker - Main battery switch Fig. 34 BM 500/15...
  • Page 41 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

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