Fayat Group BOMAG BF 800-P Series Service Manual
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Fayat Group BOMAG BF 800-P Series Service Manual

Road finisher
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Service - Manual
Catalogue number.
008 921 54
BF 800_P
S/N 821 837 65 1001 ....
S/N 821 837 70 1001 ....
S/N 821 837 67 1001 ....
S/N 821 837 74 1001 ....
Road Finisher
03/2013

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Summary of Contents for Fayat Group BOMAG BF 800-P Series

  • Page 1 Service - Manual BF 800_P S/N 821 837 65 1001 ..S/N 821 837 70 1001 ..S/N 821 837 67 1001 ..S/N 821 837 74 1001 ..Road Finisher Catalogue number. 03/2013 008 921 54...
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  • Page 3: Table Of Contents

    Table of Contents General 1.1 Introduction 1.2 Safety regulations 1.3 General repair instructions 1.4 Tightening torques Technical data 2.1 Technical data Maintenance 3.1 General notes on maintenance 3.2 Fuels and lubricants 3.3 Table of fuels and lubricants 3.4 Running-in instructions 3.5 Maintenance table Engine 4.1 Diesel engine...
  • Page 4 Table of Contents 5.7 Fuel pressure sensor 5.8 Fuel control unit 5.9 Injector 5.10 Oil pressure sensor 5.11 Sensor for charge air temperature and charge air pressure 5.12 EMR coolant temperature sensor 5.13 Glow plugs 5.14 Sensor, water in fuel 5.15 Air filter vacuum switch 5.16 Float switch, coolant tank 5.17 Charge control light, engine RPM-meter...
  • Page 5 Table of Contents the front wheel drive 8.3 Input codes -- travel signal by push button for max. screed relief 8.4 Input codes -- Changing the type of speed potentiometer 8.5 Input codes -- blocking/releasing screed extensions 8.6 Input codes -- Activating/deactivating the screed heat in low idle speed 8.7 Input codes -- activate/deactivate the cleaning function 8.8 Input codes -- Saving/loading TCU settings 8.9 Input codes -- Teaching L.C.S.
  • Page 6 Table of Contents 15.5 Pumps for: Scraper belt, augers, vibration & tampers 15.6 View of the machine 15.7 Description of fan pump 15.8 View of the machine 15.9 Description of charge pumps 15.10 Check the hydraulic oil level 15.11 Change hydraulic oil and hydraulic oil filter Hydraulics - travel circuit 16.1 Description of driving 16.2 Description of brake circuit...

  • Page 7: General

    1 General 008 921 54 BOMAG Find manuals at https://best-manuals.com...

  • Page 8: Introduction

    Introduction 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.

  • Page 9: Safety Regulations

    Safety regulations Important notes Block the articulated joint with the articulation lock. Safety regulations Use protective clothes like hard hat, safety boots These safety regulations must be read and ap- and gloves. plied by every person involved in the repair /main- tenance of this machine.
  • Page 10 Safety regulations Start the extraction fan before starting work and Operation of high-voltage systems guide with the progressing work as required. Always isolate the burner when laying it down (re- Note move possible electrode residues). The rules and statutory regulations valid in the corre- Protect cables from being damaged, use cables sponding do apply in addition to the notes given here.
  • Page 11 Safety regulations Fire extinguishers charged with FOAM, CO Environment or POWDER must be available wherever fuel is It is strictly prohibited to drain off oil into the soil, stored, filled in, drained off, or where work on fuel the sewer system or into natural waters. Old oil systems is performed.
  • Page 12 Safety regulations Engine The installation and use of non-genuine spare parts or non-genuine accessories may therefore have an adverse effect on the specific characteristics of the Danger machine and thereby impair the active and/or pas- Do not work on the fuel system while the engine is sive driving safety.

  • Page 13: General Repair Instructions

    General repair instructions General Electrics General repair instructions Before removing or disassembling parts, assem- General blies, components or hoses mark these parts for Due to the fast technical development electric and easier assembly. electronic vehicle systems become more intelligent Before assembling and installing parts, assemblies and more comprehensive day by day, and can hardly or components oil or grease all movable parts or be dispensed with in hydraulic and mechanical vehicle...
  • Page 14 General repair instructions Battery Plug-in connectors on control units are only dust and water tight if the mating connector is plugged Rules for the handling of batteries on! Control units must be protected against spray water, until the mating connector is finally plugged When removing a battery always disconnect the mi- nus pole before the plus pole.
  • Page 15 General repair instructions Generator Starter motor Before removing the generator you must disconnect So-called jump starting (using an additional external the ground cable from the minus pole of the battery battery) without the battery connected is dangerous. while the ignition is switched off. Do not disconnect When disconnecting the cables from the poles high in- the generator while the engine is running, because ductivities (arcs, voltage peaks) may occur and de-...
  • Page 16 General repair instructions Hydraulic system Perform measurements at operating temperature of the hydraulic oil (approx. 40 ¯C). After changing a component perform a high and Caution charge pressure test, if necessary check the speed Repair work on hydraulic elements shall only per- of the exciter shaft.
  • Page 17 General repair instructions Notes on cleanliness for Common Rail Blow drying with compressed air is only permitted while the fuel system is still closed. engines When using steam cleaning equipment cover con- Special requirements with respect to cleanliness in trol unit, cable plugs, all other electrical connections the fuel system do apply for commissioning, mainte- and the generator beforehand and do not expose nance and repair work, particularly for engines with...
  • Page 18 General repair instructions Do not use any previously used cleaning or testing Remove loose parts (e.g. paint scales that may fluids for cleaning. have come off during assembly work) with an indus- trial vacuum cleaner or any means of extraction. Compressed air should never be used for cleaning when the fuel system is open.
  • Page 19 General repair instructions Fuel hoses Gaskets and mating surfaces Leaking sealing faces can mostly be traced back to in- correct assembly of seals and gaskets. Before assembling a new seal or gasket make sure that the sealing surface is free of pitting, flutes, cor- rosion or other damage.
  • Page 20 General repair instructions Feather keys and keyways able, you should use a plastic tube or adhesive tape to prevent the sealing lip from being damaged. Lubricate the outer rim (arrow 3 (Fig. 3)) of the seal Caution and press it flat on the housing seat. Feather keys may only be reused if they are free of damage.
  • Page 21 General repair instructions Ball and roller bearings Check shaft and bearing housing for discolouration or other signs of movement between ball or roller bearing and seats. Caution Make sure that shaft and housing are free of burrs Ball and roller bearings may only be reused if they before assembling the ball or roller bearing.
  • Page 22 General repair instructions Screws and nuts Strength classes, metric screws The strength classes (from 3.6 to 12.9) are specified Tightening torque for all strength classes from a nominal diameter of 5mm. The corresponding identification can be found where allowed for by the shape of the screw. Caution Tighten nuts or screws with the tightening tor- ques specified in the following tables of tighten-...
  • Page 23 General repair instructions Strength classes of metric nuts Identification in clock system Nuts are differentiated by three load groups. Each load group has a special designation system for the strength class assigned, so that the load group can be clearly identified. Nuts for screw joints with full load capability (4, 5, 6, 8, 10, 12) Fig.
  • Page 24 General repair instructions Identification of UNF-threads Cotter pins Fig. 12 In places where cotter pins are used, these must be reassembled. Cotter pins must generally be renewed after disassembly. Cotter pins must be assembled as shown in the illus- tration, unless specified differently. Fig.

  • Page 25: Tightening Torques

    Tightening torques The values specified in the table apply for screws: Tightening torques black oiled with surface protection A4C with surface protection DACROMET Note DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC- ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with metallic-silver appearance.
  • Page 26 Tightening torques Tightening torques for screws treated with anti-seizure paste OKS 240 (copper paste) Tightening torques Nm Screw dimension 10.9 12.9 M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 2 1036 1184 1520 M27 X 2 1263 1536 1136...
  • Page 27 Tightening torques The values specified in the table apply for screws: black oiled with surface protection A4C with surface protection DACROMET Note The difference between Withworth and UNF/UNC threads is the fact that UNF and UNC threads have 60° flanks, as the metric ISO-thread, whereas Withworth has a flank of only 55°.
  • Page 28 Tightening torques Tightening torques for screws with UNF thread, UNF Unified National Fine Thread Series, American Unified Fine Thread Tightening torques Nm Screw dimension 10.9 12.9 1“ - 12 1300 1600 1 1/8“ - 12 1350 1900 2300 1 1/4“ - 12 1900 2700 3200...

  • Page 29: Technical Data

    2 Technical data 008 921 54 BOMAG...
  • Page 30 Technical data Technical data Fig. 13 BF 800 P S 500 Dimensions in mm 3125 2550 3865 3055 6800 2550 Weights Operating weight (CECE) 20000 Weight of basic screed 3900 Travel characteristics Working speed (1/2) m/min 0 - 20 / 0 - 40 Transport speed (1/2) km/h 0 - 7 / 0 - 15...
  • Page 31 Technical data Conveyor auger Quantity Auger diameter Rated speed Reversing operation Standard Screed Basic width retracted 2500 Basic width extended 5000 Max. working width 9000 Min. paving width with reducing skids 1800 Mat height Smoothing plate depth Smooting plate thickness Heating electric Straight crossfalls...
  • Page 32 Technical data Weights Operating weight (CECE) 20300 Weight of basic screed 4200 Travel characteristics Working speed (1/2) m/min 0 - 20 / 0 - 40 Transport speed (1/2) km/h 0 - 7 / 0 - 15 Max perm. inclination (ramp) °...
  • Page 33 Technical data Smoothing plate depth Smooting plate thickness Heating electric Straight crossfalls -2.5 ... +4.5 Tamper frequency 0 ... 29 Vibration frequency 20 ... 58 Filling capacities Fuel (diesel) approx. 315 Engine oil approx. 20 Coolant approx. 20 Hydraulic oil approx.
  • Page 34 Technical data Additional engine data Combustion principle 4-stroke diesel Low idle speed 950 - 1050 High idle speed 1900 - 2100 Angle de- Valve clearance intake 75-85 gree Angle de- Valve clearance exhaust 120-130 gree HYDRAULIC PUMPS A → Travel pump rear wheel drive Manufacturer Bosch-Rexroth Type...
  • Page 35 Technical data H → Pump tamper drive Manufacturer Bosch-Rexroth Type A10VG System Axial piston variable displacement pump Quantity Displacement /rev Maximum pressure 250 - 270 Maximum speed 3900 I → Service pump Manufacturer Bosch-Rexroth Type A10VO System Axial piston variable displacement pump Quantity Displacement /rev...
  • Page 36 Technical data Maximum pressure Maximum speed 3000 N → Pump fan drive Manufacturer Bosch-Rexroth Type A10VO System Axial piston variable displacement pump Quantity Displacement /rev Maximum pressure Nominal pressure Maximum speed 3600 O → Pump extractor drive for asphalt va- pours Manufacturer Bosch-Rexroth...
  • Page 37 Technical data System Orbital motor Max. displacement. /rev Rated speed 100 - 108 Quantity Scraper belt motors Manufacturer Poclain Type MS 05 System Orbital motor Max. displacement. /rev Motor speed (on drive pinion) 114-117 Speed (on shaft of scraper belt) 61-64 Quantity Fan motor...
  • Page 38 Technical data The following noise and vibration data acc. to - EC Machine Regulation edition 2006/42/EC - the noise regulation 2000/14/EG, noise protection guideline 2003/10/EC - Vibration Protection Regulation 2002/44/EC were determined during conditions typical for this type of equipment and by application of harmonized standards.

  • Page 39: Maintenance

    3 Maintenance 008 921 54 BOMAG...

  • Page 40: General Notes On Maintenance

    General notes on maintenance 3.1 General notes on maintenance Notes on the performance of the engine On diesel engines both combustion air and fuel injec- When performing maintenance work always comply tion quantities are thoroughly adapted to each other with the appropriate safety regulations. and determine power, temperature level and exhaust Thorough maintenance of the machine guarantees far gas quality of the engine.

  • Page 41: Fuels And Lubricants

    Fuels and lubricants 3.2 Fuels and lubricants Engine oil Quality For use in DEUTZ engines the lubrication oils are classified in DEUTZ Lubrication Oil Quality Classes (DQC). Approved engine oils Deutz ACEA DQC II-05 E3-96, CG-4, DHD-1 E5-02, CH-4, E7-04, CI-4, E4-07, CI-4 Plus,...
  • Page 42 Fuels and lubricants sulphur content has a negative effect on the oil Fresh water analysis values change intervals. The fuel level should always be topped up in due time Conversion to other units: so that the fuel tank is never run dry, as otherwise filter - German degree (°dH)] max.
  • Page 43 Fuels and lubricants Mineral oil based hydraulic oil The hydraulic system is operated with hydraulic oil HV www.deutz.com 46 (ISO) with a kinematic viscosity of 46 mm /s at 40 °C and 8 mm /s at 100 °C. For topping up or for oil >>SERVICE >>...

  • Page 44: Table Of Fuels And Lubricants

    Table of fuels and lubricants 3.3 Table of fuels and lubricants Assembly Fuel or lubricant Quantity Summer Winter Attention Observe the level marks Motor - Engine oil ACEA: E3-96, E5-02, E7-08, E4-07, E6-08, E9-08 approx. 20 litres API: CG-4, CH-4, CI-4, CI-4 Plus, CJ-4 SAE 10W-40 (-15 °C to +40 °C) (BOMAG 009 920 06;...

  • Page 45: Running-In Instructions

    Running-in instructions 3.4 Running-in instructions The following maintenance work must be per- formed when running in new machines or over- hauled engines: Caution Up to approx. 250 operating hours check the en- gine oil level twice every day. Depending on the load the engine is subjected to, the oil consumption will drop to the normal level after approx.

  • Page 46: Maintenance Table

    Maintenance table 3.5 Maintenance table Maintenance work Comment Check the engine oil level Dipstick mark Check the fuel level Check the hydraulic oil level Inspection glass Check the coolant level Inspection glass 5.10 Lubricate the machine 5.11 Service the scraper belt 5.12 Service the scraper belt drive chain 5.13 Service the auger 5.14 Grease the screed extension sliding sur-...

  • Page 47: Change The Coolant

    Maintenance table Maintenance work Comment 5.29 Replace the fuel pre-filter cartridge, bleed the fuel system 5.30 Changing hydraulic oil and hydraulic oil fil- at least every 2 years 5.31 Oil change in transfer case min. 1x per year 5.32 Oil change in rear hubs min.
  • Page 48 Maintenance table BOMAG 008 921 54...
  • Page 49 4 Engine 008 921 54 BOMAG...
  • Page 50 Diesel engine 4.1 Diesel engine compact design low noise level The engine of series TCD 2012/2013 are 4 or 6 cylin- almost vibration free operation der inline engines with water cooling and EMR3 elec- low fuel consumption tronics. low exhaust emission EPA/COM IIl The engines are mainly designed in two-valve tech- nology with turbo charging and intercooler.
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