Bomag BM 500-15 Cold Planer Service Manual 00891685

Description

• Model List:
  • BM 500-15 Cold Planer

• 1. Table of contents
• 2. General
• 2.1. Introduction
• 2.2. Concerning your safety
• 2.2.1. Basic prerequisites
• 2.2.2. Definition of responsible persons
• 2.2.3. Basic safety regulations for safe operation
• 2.2.4. Handling fuels and lubricants
• 2.2.5. Loading/transporting the machine
• 2.2.6. Startup procedure
• 2.2.7. Driving the machine, working operation
• 2.2.8. Refuelling
• 2.2.9. Emergency procedures
• 2.2.10. Maintenance work
• 2.2.11. Repair
• 2.2.12. Signage
• 2.3. Fuels and lubricants
• 2.3.1. Engine oil
• 2.3.2. Fuel
• 2.3.3. Coolant
• 2.3.4. Hydraulic oil
• 2.3.5. Gear oil ISO VG 220
• 2.3.6. Lubrication grease
• 2.3.7. Hightemperature lubrication grease
• 2.4. List of fuels and lubricants
• 2.5. Parking the machine in secured condition
• 3. Technical data
• 3.1. Noise and vibration data
• 3.1.1. Noise data
• 3.1.2. Vibration data
• 4. Overview of machine
• 4.1. Overview of electric system
• 4.2. Wiring
• 4.3. Overview of hydraulics
• 4.4. Overview of maintenance flaps and doors
• 5. Troubleshooting
• 5.1. Functional conditions
• 5.1.1. Functional conditions introduction
• 5.1.2. Functional conditions left side plate
• 5.1.3. Functional conditions right side plate
• 5.1.4. Functional conditions holddown
• 5.1.5. Functional conditions scraper
• 5.1.6. Functional conditions support wheel, rear left
• 5.1.7. Functional conditions support wheel, rear right
• 5.1.8. Functional conditions conveyor belt
• 5.1.9. Functional conditions milling
• 5.1.10. Functional conditions brake
• 5.2. Trouble shooting axial piston pumps
• 6. Electrics
• 6.1. Codes General Information
• 6.2. Error codes
• 6.2.1. Error code lists
• 6.3. Query codes
• 6.3.1. Query code lists
• 6.4. Input Codes
• 6.4.1. Display, layout and operation
• 6.4.2. Resetting to factory settings
• 6.4.3. Calibration of surge currents for height adjustment
• 6.4.4. Switching the unit system over
• 6.4.5. Water tank functions
• 6.4.6. Activation of relay in automatic mode
• 6.4.7. Conveyor belt ON via double and single buttons
• 6.4.8. Driving against the closed brake
• 6.4.9. Speed droop monitoring / display
• 6.4.10. Viscous fan
• 6.4.11. Software version
• 6.4.12. Milling clutch switching processes
• 6.4.13. Reversing with the milling drum switched ON
• 6.4.14. Showing the hydraulic oil temperature
• 6.4.15. 3way milling stage selector switch
• 6.4.16. Showing stored faults
• 6.4.17. Showing saved faults with operating hours
• 6.4.18. Deleting the error log
• 6.5. Replacement of components
• 6.6. Block diagrams
• 7. Diesel engine
• 7.1. Diesel engine description
• 7.1.1. Lubrication oil circuit
• 7.1.2. Cooling circuit
• 7.1.3. Fuel system
• 7.1.4. Common Rail
• 7.1.5. Exhaust gas recirculation
• 7.1.6. Wastegate charge pressure controller
• 7.1.7. Engine faults
• 7.2. Engine electrics
• 7.2.1. EMR3 system components
• 7.2.2. Pin assignment of engine control
• 7.2.3. Rotary speed sensor for camshaft, B114
• 7.2.4. Crankshaft speed sensor, B130
• 7.2.5. Rail pressure sensor, B93
• 7.2.6. Fuel pressure sensor, B145
• 7.2.7. Fuel Control Unit Y137
• 7.2.8. Injectors, Y147, Y149, Y169 and Y170
• 7.2.9. Oil pressure sensor, B88
• 7.2.10. Charge air temperature/charge pressure sensor, B133
• 7.2.11. EMRcoolant temperature sensor, B113
• 7.2.12. Glow plugs, R81R84
• 7.2.13. Sensor for water in fuel, B124
• 7.2.14. Air filter vacuum switch, B03
• 7.2.15. Float switch, coolant tank, B55
• 7.2.16. Diagnostics interface
• 7.2.17. Diagnose with Serdia
• 7.2.18. Diagnostics with CANbus
• 7.2.19. Deutz DTC error code list, EMR3
• 7.2.20. Removing and installing the electric starter
• 7.3. Inspection and maintenance work
• 7.3.1. Maintenance Table
• 7.3.2. Checks prior to start up
• 7.3.3. Every 250 operating hours
• 7.3.4. Every 500 operating hours
• 7.3.5. Every 1000 operating hours
• 7.3.6. Every 2000 operating hours
• 7.3.7. Every 3000 operating hours
• 7.3.8. Every 6000 operating hours
• 7.3.9. As required
• 8. Hydraulic system
• 8.1. Component overview hydraulics
• 8.2. Description of components
• 8.3. Repairs
• 8.3.1. Changing gear pumps on auxiliary drive of diesel engine
• 8.4. Inspection and maintenance work
• 8.4.1. Maintenance Table
• 8.4.2. Checks prior to start up
• 8.4.3. Every 250 operating hours
• 8.4.4. Every 500 operating hours
• 8.4.5. Every 1000 operating hours
• 8.4.6. Every 2000 operating hours
• 9. Assembly groups
• 9.1. Drive unit
• 9.1.1. Description
• 9.1.2. Repair
• 9.2. Milling drum
• 9.2.1. Description
• 9.2.2. Repair
• 9.3. Milling housing
• 10. Tests and adjustments
• 10.1. Special tools, hydraulic system
• 10.1.1. Special tools, tests and adjustments
• 10.1.2. Special tools for flushing
• 10.2. Checking and adjusting the levelling
• 10.3. Checking and adjusting the roof adjustment
• 10.4. Checking and adjusting the clutch operating pressure
• 10.5. Checking and adjusting the brake releasing pressure
• 10.6. Checking and adjusting the steering pressure
• 10.7. Working hydraulics Checking and adjusting the pressure MP
• 10.8. Checking and adjusting the scraper pressure
• 10.9. Checking and adjusting the conveyor belt pressure
• 10.10. Checking and adjusting the hydraulic breaker pressure
• 10.11. Checking and adjusting the maximum pressure of the travel pump
• 11. Special tools
• 11.1. Special tools, electrics
• 11.2. Special tools, hydraulic system
• 11.2.1. Special tools, tests and adjustments
• 11.2.2. Special tools for flushing
• 11.3. List of special tools
• 12. Index
• 13. Appendix
• 13.1. Appendices
• 13.2. A Circuit diagram 72
• 13.3. B Circuit diagram 77
• 13.4. C Circuit diagram 84
• 13.5. D Circuit diagram 98
• 13.6. E Circuit diagram 108
• 13.7. F Circuit diagram 163
• 13.8. G Wiring diagram 268
• 13.9. H Circuit diagram 295
• 13.10. I Hydraulic diagram 343