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Summary of Contents for Fayat Group BOMAG BF 800 C
- Page 1 Service - Manual BF 800 C S/N 821 837 17 1001 ..S/N 821 837 71 1001 ..S/N 821 837 19 1001 ..S/N 821 837 66 1001 ..S/N 861 893 50 1001 ..S/N 861 893 60 1001 ..Road Finisher Catalogue number.
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- Page 3 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 E-Plan wiring diagrams 4.1 Understanding E-Plan circuit diagrams...
- Page 4 Table of Contents 6.1 EMR3 system components 6.2 Deutz EMR 3 - engine connections 6.3 Pin assignment of engine control EDC16 / EMR3 6.4 Rotary speed sensor for camshaft 6.5 Crankshaft speed sensor 6.6 Rail pressure sensor 6.7 Fuel pressure sensor 6.8 Fuel control unit 6.9 Injector 6.10 Oil pressure sensor...
- Page 5 Table of Contents 7.24 Block diagram Emergency Stop functions 7.25 Electronic control units 7.26 Checking the voltage supply for the control unit 7.27 Diagnostics concept Error codes -- general information 8.1 Error codes - BF800 -- general information Input codes 9.1 Input codes -- Display: Function and operation 9.2 Input codes -- automatic calibration of currents in the travel system 9.3 Input codes -- manual calibration of currents in the travel system...
- Page 6 Table of Contents Electric screed heating, repair 15.1 Electric screed heating 15.2 Electric screed heating - commissioning 15.3 Faults in the electric heating Travel drive, description 16.1 Travel system Hydraulics 17.1 Hydraulic circuit 17.2 Component overview -- hydraulics 17.3 Description of travel pump 17.4 View of the machine 17.5 Pumps for: Scraper belt, augers, vibration &...
- Page 7 Table of Contents Circuit diagrams 23.1 Hydraulic diagram 23.2 Electric circuit diagrams 008 917 73 BOMAG Find manuals at https://best-manuals.com...
- Page 8 Table of Contents BOMAG 008 917 73 Find manuals at https://best-manuals.com...
- Page 9 1 General 008 917 73 BOMAG Find manuals at https://best-manuals.com...
- Page 10 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 11 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 12 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 13 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 14 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 15 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 16 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 17 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 18 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 19 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 20 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 21 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 22 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 23 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 24 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 25 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 26 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 27 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 28 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 29 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 30 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 31 2 Technical data 008 917 73 BOMAG...
- Page 32 Technical data Technical data Fig. 13 Dimensions in 3360 2550/3000 3865 3055 6800 2500 BF 800 C with S600 screed BF 800 C -S 500 BF 800 C -S 600 Weights Operating weight (CECE) 20700 21000 Weight of basic screed 3900 4200 Screed...
- Page 33 Technical data BF 800 C -S 500 BF 800 C -S 600 Fuel Diesel Diesel Permissible ambient tempera- °C -20 ... +50 -20 ... +50 ture Track Crawler tracks (WxL) 300x3360 300x3360 Hopper Capacity Auger Diameter Rated speed Electric system Voltage Batteries (2) 2x100...
- 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 A1 & A2 Travel pumps Manufacturer Bosch-Rexroth Type...
- Page 35 Technical data I Service pump Manufacturer Bosch-Rexroth Type A10VO System Gear pump Quantity Displacement /rev Maximum pressure Nominal pressure Standby pressure Working pressure: Maximum speed 3100 J Charge pump for travel system Manufacturer Bosch-Rexroth Type AZPF System Gear pump Quantity Displacement /rev...
- Page 36 Technical data Nominal pressure Maximum speed 3600 O Pump asphalt vapour extraction system drive Manufacturer Bosch-Rexroth Type AZPF System Gear pump Quantity Displacement /rev Maximum pressure Maximum speed 3000 HYDRAULIC MOTORS Travel motors Manufacturer Bosch-Rexroth Type A6VE Quantity System Axial piston/bent axle Nominal pressure Top pressure...
- Page 37 Technical data Motor speed (on drive pinion) 114-117 Speed (on shaft of scraper belt) 61-64 Quantity Fan motor Manufacturer Haldex Type WM09 System Gear motor Max. displacement. /rev Maximum pressure Nominal pressure Rated speed 1280-1320 GEARBOX Travel gear Manufacturer Bonfiglioli Type 710C3B System...
- 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 3 Maintenance 008 917 73 BOMAG...
- Page 40 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.
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