Fayat Group BOMAG BM 500/15 Service Manual
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Fayat Group BOMAG BM 500/15 Service Manual

Compact milling machine
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Service - Manual
Compact milling machine
Catalogue number.
008 916 85
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 ....
10/2012

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Summary of Contents for Fayat Group BOMAG BM 500/15

  • Page 1 Service - Manual 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 Catalogue number. 10/2012 008 916 85...
  • Page 2 Find manuals at https://best-manuals.com...

  • 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 Electrics 4.1 Battery service...
  • Page 4 Table of Contents 4.33 Functional conditions for scraper 4.34 Functional conditions support wheel rear left 4.35 Functional condition support wheel rear right 4.36 Operating conditions for conveyor belt 4.37 Conditions for milling 4.38 Functional conditions for brake 4.39 Electronic control units 4.40 Checking the voltage supply for the control unit 4.41 Diagnostics concept Codes -- general information...
  • Page 5 Table of Contents 10.21 Adjusting the control piston play 10.22 Engine problems 10.23 Special tools, Deutz engine (TCD 2012 2V) Engine electrics 11.1 EMR3 system components 11.2 Pin assignment of engine control EDC16 / EMR3 11.3 Rotary speed sensor for camshaft 11.4 Rotary speed sensor for crankshaft 11.5 Rail pressure sensor 11.6 Fuel pressure sensor...
  • Page 6 Table of Contents 17.4 Repair overview scraper 17.5 Repair overview scraper, split 17.6 Remove the hold-down 17.7 Install the hold-down 17.8 Remove the left side plate 17.9 Install the left side plate 17.10 Remove the right side plate 17.11 Install the right side plate 17.12 Remove the scraper 17.13 Install the scraper Conveyor belt, description...
  • Page 7 Table of Contents 23.14 Checking the hydraulic oil level 23.15 Checking hydraulic hoses and electric cables 23.16 Changing the hydraulic oil 23.17 Change the hydraulic oil filter Hydraulics - travel circuit 24.1 Description of driving 24.2 Description of crawler system Hydraulics - milling operation 25.1 Description of clutch 25.2 View of the machine...
  • Page 8 Table of Contents BOMAG 008 916 85 Find manuals at https://best-manuals.com...

  • Page 9: General

    1 General 008 916 85 BOMAG Find manuals at https://best-manuals.com...

  • Page 10: 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 11: 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 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 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 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. 2)) 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. 11 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 008 916 85 BOMAG...

  • Page 30: Technical Data

    Technical data Technical data Fig. 12 BM 500/15 Weights Operating weight (CECE) with conveyor belt 7600 Max. operating weight 8400 Basic weight (3-wheel, without conveyor belt) 6700 Additional weight of options 4-wheel version Weather roof Scraper split Conveyor belt long Conveyor belt, short Milling drum Milling depth...
  • Page 31 Technical data BM 500/15 Drive Engine manufacturer Deutz Type TCD 2012 L04 2V Cooling Water Number of cylinders Rated power ISO 3046 kW/PS 92/125 Rated speed 2100 Fuel Diesel Wheels Type of wheels Solid rubber Wheel size rear (Ø x B) 560 x 254 Wheel size front 3-wheel (Ø...
  • Page 32 Technical data Additional engine data Manufacturer Deutz AG Combustion principle 4-stroke diesel Low idle speed 825 - 875 High idle speed 2125 - 2175 Specific fuel consumption g/kWh Valve clearance intake Valve clearance exhaust Travel pump Manufacturer Bosch-Rexroth Type A10VG System Axial piston/swash plate Max.
  • Page 33 Technical data Steering valve Manufacturer Eaton Type XCEL 45 System Hydraulic steering unit Maximum system pressure 165 - 185 Clutch Manufacturer Stromag Type Hydraulic clutch Static torque 2000 Dynamic torque 1700 Spring pressure "Decoupling" 17 - 25 Maximum speed 2200 Minimum speed Milling drum drive gear Manufacturer...
  • Page 34 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 35: Maintenance

    3 Maintenance 008 916 85 BOMAG...

  • Page 36: 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 37: Fuels And Lubricants

    Fuels and lubricants 3.2 Fuels and lubricants www.deutz.com Engine oil SERVICE \ Betriebsstoffe und Additive \ Deutz Quality Class \ DQC-Freigabeliste General SERVICE \ Operating Liquids and Addi- Modern diesel engines put high demands on the lubri- tives \ Deutz Quality Class \ DQC Release cation oil used.
  • Page 38 Fuels and lubricants Oil change intervals boundaries of the following analysis values should generally be used. The longest permissible time a lubrication oil should remain in an engine is 1 year. If the following oil change intervals are not reached over a period of 1 Analysis values ASTM year, the oil change should be performed at least once...
  • Page 39 Fuels and lubricants We therefore highly recommend our BOMAG cooling Note system protection agent. When working at temperature below -41 °C(-42 °F) If our cooling system protection agent is not available you should consult our local service representative. for any important reasons, you may, in exceptional cases, use products that have been approved by the Environment engine manufacturer.

  • Page 40: 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, E7-04, E4-07, E6-04 approx. 8 litres API: CG-4, CH-4, CI-4, CI-4 Plus, CJ-4 SAE 10W-40 (-20 °C to +40 °C) (BOMAG 009 920 06;...

  • Page 41: 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 42: Maintenance Table

    Maintenance table 3.5 Maintenance table Maintenance work Comment Checking the engine oil level Dipstick mark Check the fuel level Instrument cluster Check the hydraulic oil level Inspection glass Check the coolant level Inspection glass 5.10 Check water level, spray nozzles 5.11 Check milling cutters and scraper bar, several times a day replace if required...
  • Page 43 Maintenance table Maintenance work Comment 5.28 Oil change in milling drum angular min. 1x per year gear see foot note 5.29 Oil change in milling drum spur wheel min. 1x per year gear see foot note 5.30 Replace the fuel filter cartridge 5.31 Replacing the fuel pre-filter cartridge, bleed the fuel system 5.32 Check the engine mounts...
  • Page 44 Maintenance table Maintenance work Comment 5.47 Engine conservation oil change after 250 and 500 operating hours, then every 500 operating hours ** Also in case of repair in the hydraulic system. BOMAG 008 916 85...

  • Page 45: Electrics

    4 Electrics 008 916 85 BOMAG...

  • Page 46: Battery Service

    Battery service 4.1 Battery service Danger Danger of cauterisation ! Danger of explosion! When working on the battery do not use open fire, do not smoke! The battery contains acid. Do not let acid come in contact with skin or clothes! Wear protective clothing! Do not lay any tools on the battery! Fig.

  • Page 47: Starting With Jump Wires

    Starting with jump wires 4.2 Starting with jump wires 4.3 Main battery switch Caution When using external starting aid two external bat- teries (24 V system) are required, one for each on- board battery. A wrong connection will cause severe damage in the electric system.

  • Page 48: Main Fuse

    Main fuse 4.4 Main fuse 4.5 Fuses Fig. 17 No. 2 = Main fuses for battery F159, 125A = Preheating system, engine F125, 80A = Pre-fuse F00, 40A = Main fuse F01, 30A = Main fuse Note The main fuses are located in the battery compart- ment Fig.
  • Page 49 Fuses X1:13, 10A = (F09) Parking and tail light, left X1:14, 10A = (F10) Parking and tail light, right Fig. 19 X1:20, 25A = (F37) Water pump X1:21, 10A = (F231) Socket junction box X1:22, 10A = (F05) Socket rear X1:23, 10A = (F245) Socket driver's stand X1:24, 10A...

  • Page 50: Component Overview

    Component overview 4.6 Component overview Fig. 20 Fig. 21 BOMAG 008 916 85...
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