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Fayat Group BOMAG BM 500/15, Service Manual

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Fayat Group BOMAG BM 500/15 Service Manual Download Page 6

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

7

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................................................................................................................. 387

7.3  Functional conditions

...............................................................................................................

388

7.3.1  Functional conditions - introduction.......................................................................................... 388
7.3.2  Functional conditions - left side plate....................................................................................... 389
7.3.3  Functional conditions - right side plate..................................................................................... 394
7.3.4  Functional conditions - hold-down............................................................................................ 399
7.3.5  Functional conditions - scraper................................................................................................ 403
7.3.6  Functional conditions - support wheel, rear left........................................................................ 408
7.3.7  Functional conditions - support wheel, rear right...................................................................... 411
7.3.8  Functional conditions - conveyor belt....................................................................................... 419
7.3.9  Functional conditions - milling.................................................................................................. 422
7.3.10  Functional conditions - brake................................................................................................. 425

7.4  Troubleshooting, electrical systems

.......................................................................................

428

7.4.1  Measuring method................................................................................................................... 428
7.4.2  Diagnostics concept................................................................................................................. 432
7.4.3  Understanding electric circuit diagrams................................................................................... 435
7.4.4  ESX, checking the electric power supply................................................................................. 447
7.4.5  Codes - General Information.................................................................................................... 455
7.4.6  Error codes............................................................................................................................... 456
7.4.7  BOMAG DTC fault code list..................................................................................................... 490
7.4.8  Query codes............................................................................................................................. 522

7.5  Trouble shooting, hydraulics

...................................................................................................

534

7.5.1  Troubleshooting table for hydraulic components..................................................................... 534
7.5.2  Troubleshooting axial piston motors........................................................................................ 542
7.5.3  Troubleshooting axial piston pumps......................................................................................... 544
7.5.4  Insufficient hydraulic power...................................................................................................... 546

7.6  Trouble shooting, diesel engine

..............................................................................................

549

7.6.1  Starting the engine with jump leads......................................................................................... 549
7.6.2  Bleed the fuel system............................................................................................................... 549
7.6.3  Engine malfunctions................................................................................................................. 551
7.6.4  Deutz DTC fault code list, EMR4............................................................................................. 554

8

Special tools

......................................................................................................................................

615

8.1  Available special tools

..............................................................................................................

616

8.1.1  Special tools, electrics.............................................................................................................. 616
8.1.2  Special tools, hydraulic system................................................................................................ 617

Table of contents

 

BM 500/15

 

6

Find manuals at https://best-manuals.com

Summary of Contents for BOMAG BM 500/15

Page 1: ...BM 500 15 Cold planer Service Manual S N 101 882 02 1001 S N 101 882 04 1001 03 2018 008 400 24 EN...

Page 2: ...2 Find manuals at https best manuals com...

Page 3: ...s 43 1 3 2 Notes on repair 44 1 3 3 Parking the machine in secured condition 60 2 Technical data 63 2 1 Fuels and lubricants 70 2 1 1 Engine oil 70 2 1 2 Fuel 71 2 1 3 Coolant 72 2 1 4 Hydraulic oil 7...

Page 4: ...er 134 4 7 5 Water tank functions 134 4 7 6 Activation of relay in automatic mode 135 4 7 7 Conveyor belt ON via double and single buttons 136 4 7 8 Driving against the closed brake 137 4 7 9 Speed dr...

Page 5: ...Checking and adjusting the scraper pressure 232 5 6 8 Checking and adjusting the conveyor belt pressure 234 5 6 9 Checking and adjusting the hydraulic breaker pressure 236 5 6 10 Checking and adjusti...

Page 6: ...422 7 3 10 Functional conditions brake 425 7 4 Troubleshooting electrical systems 428 7 4 1 Measuring method 428 7 4 2 Diagnostics concept 432 7 4 3 Understanding electric circuit diagrams 435 7 4 4...

Page 7: ...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 Table of contents BM 500 1...

Page 8: ...Table of contents BM 500 15 8 Find manuals at https best manuals com...

Page 9: ...1 General General BM 500 15 9 Find manuals at https best manuals com...

Page 10: ...uction This manual n addresses the BOMAG Customer Service and professionally trained personnel n provides support for repair work or maintenance procedures on the machine This manual described the dei...

Page 11: ...AG parts These have been specially adapted to the corresponding machine In this way you will prevent any problems arising and unnecessary downtimes of your machine This manual is not subject of an upd...

Page 12: ...t prevention instructions n generally accepted safety and road traffic regulations n country specific safety regulations It is the duty of the operator to be acquainted with the safety regu lations an...

Page 13: ...practices for safe and environment friendly disposal of fuels and lubricants as well as replacement parts 1 2 1 3 Personal protective equipment Depending on the work to be carried out personal protect...

Page 14: ...cified oper ating maintenance and repair measures 1 2 1 5 Improper use Dangers may arise from the machine when it is used for purposes other than the one it is intended for Any danger caused by improp...

Page 15: ...toxic atmosphere or limiting soil conditions Such conditions require special additional measures to remove or reduce the hazard The operating company must make sure that all users read and understand...

Page 16: ...achine Both the machine as well as all other system components comply with the currently valid safety regulations Nevertheless remaining risks cannot be ruled out completely even when using the machin...

Page 17: ...nts 1 2 4 1 Preliminary remarks The operating company must ensure that all professional users have read and follow the corresponding safety data sheets for the individual fuels and lubricants Safety d...

Page 18: ...ith diesel fuel Wear your personal protective equipment pro tective gloves protective clothing Do not inhale any fuel fumes Avoid contact CAUTION Danger of slipping on spilled diesel fuel Immediately...

Page 19: ...h hazard caused by contact with oil Wear your personal protective equipment pro tective gloves protective clothing Do not inhale any oil vapours Avoid contact CAUTION Danger of slipping on spilled oil...

Page 20: ...ome into contact with hot components Smoking and open fire is prohibited Wear your personal protective equipment pro tective gloves protective clothing CAUTION Health hazard caused by contact with hyd...

Page 21: ...s Wear your personal protective equipment pro tective gloves protective clothing Do not inhale any fumes Avoid contact CAUTION Danger of slipping on spilled coolant Immediately bind spilled coolant wi...

Page 22: ...ately call for medical advice in case of cau terization WARNING Danger of injury caused by exploding gas mix ture Remove the plugs before starting to recharge the battery Ensure adequate ventilation S...

Page 23: ...ons 1 2 5 Loading transporting the machine Transport the machine only with the wheel folded out danger of tipping over Use only stable loading ramps of sufficient load bearing capacity The ramp inclin...

Page 24: ...your personal protective equipment hard hat safety boots if necessary also goggles and ear protection Make sure that the machine is equipped with the required lighting according to the requirements o...

Page 25: ...with jump leads Connect positive with positive and negative with negative ground cable always connect the ground strap last and disconnect it first A wrong connection will cause severe damage in the e...

Page 26: ...ty is poor Do not climb onto or off the machine while the machine is driving Change the travel direction only at standstill Do not use the machine to transport persons In case of unusual noises and de...

Page 27: ...nst normal clothes Do not store working clothes and respiratory equipment together with normal clothes Wash dust covered working clothes at regular intervals Special caution is required when lowering...

Page 28: ...eaving the machine n shift all control levers to Neutral position Off or 0 n apply the parking brake n shut down the engine pull off the ignition key n pull off the main battery switch n secure the ma...

Page 29: ...ust gases Ensure an adequate supply of fresh air Keep a safe distance to combustible or explosive materials When performing regeneration at standstill park the machine out doors at a safe distance fro...

Page 30: ...d maintenance instructions including the information concerning the replacement of parts Maintenance work must only be performed by qualified and author ized persons Keep unauthorized persons away fro...

Page 31: ...t the correct hose type pressure range is used at the right location 1 2 11 3 Working on the engine Do not work on the fuel system while the engine is running danger to life due to high pressures Wait...

Page 32: ...on engine and exhaust system Never use gasoline or other easily inflammable substances for cleaning When cleaning with a high pressure cleaner do not subject elec trical parts and insulation material...

Page 33: ...Replace damaged and illegible stickers or signage immediately Fig 8 General Concerning your safety BM 500 15 33...

Page 34: ...Fig 9 Warning sticker Danger of being pulled in by belt drive and cooling fan and hot surface Fig 10 General Concerning your safety BM 500 15 34...

Page 35: ...shing hazard for hands and feet Warning sticker Danger of tipping over Warning sticker Keep a distance Warning sticker Watch out for manhole covers Fig 11 Fig 12 Fig 13 Fig 14 General Concerning your...

Page 36: ...high voltage power lines Warning sticker Follow operating instructions Warning sticker Danger of crushing Warning sticker Danger of being pulled in by wheel Fig 15 Fig 16 Fig 17 Fig 18 General Concer...

Page 37: ...the machine during travel Warning sticker Danger of injury when operating the roof Prohibition sticker High pressure cleaning Prohibition sticker No drinking water Fig 19 Fig 20 Fig 21 Fig 22 General...

Page 38: ...ion sticker Push button assignment on travel lever Information sticker Scraper pressure and conveyor belt speed Information sticker Ball valve position on conveyor belt or hydraulic breaker Fig 23 Fig...

Page 39: ...ion sticker Hydraulic breaker connection Information sticker Lashing point Information sticker Lifting point Information sticker Diesel Fig 27 Fig 28 Fig 29 Fig 30 General Concerning your safety BM 50...

Page 40: ...ation sticker Water Information sticker Hydraulic oil Information sticker Hydraulic oil level Information sticker Main battery switch Fig 31 Fig 32 Fig 33 Fig 34 General Concerning your safety BM 500...

Page 41: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com...

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