Fayat Group BOMAG BMF 2500 M User manual
BMF 2500 M
Service Manual
S/N 101 940 02 1001> / S/N 101 940 03 1001>
© 11/2017008 401 56 EN
Table of contents
1 General................................................................................................................................................... 7
1.1 Introduction................................................................................................................................... 8
1.2 Concerning your safety................................................................................................................ 9
1.2.1 Basic prerequisites....................................................................................................................... 9
1.2.2 Definition of responsible persons............................................................................................... 12
1.2.3 Basic safety regulations for safe operation................................................................................ 13
1.2.4 Handling fuels and lubricants..................................................................................................... 14
1.2.5 Emergency procedures.............................................................................................................. 20
1.2.6 Maintenance and repair............................................................................................................. 22
1.2.7 Operating the machine, working operation................................................................................ 25
1.2.8 Safety features........................................................................................................................... 28
1.3 Fuels and lubricants................................................................................................................... 31
1.3.1 Engine oil................................................................................................................................... 31
1.3.2 Fuel............................................................................................................................................ 31
1.3.3 AdBlue®/DEF.............................................................................................................................. 32
1.3.4 Coolant....................................................................................................................................... 35
1.3.5 Hydraulic oil................................................................................................................................ 36
1.3.6 Gear oil SAE 75W-90................................................................................................................. 37
1.3.7 Gear oil SAE 80W-140............................................................................................................... 37
1.4 Notes on repair............................................................................................................................ 38
1.4.1 General repair instructions......................................................................................................... 38
1.4.2 Tightening torques..................................................................................................................... 48
1.5 Description.................................................................................................................................. 55
1.5.1 Description of use...................................................................................................................... 55
1.5.2 Assembly groups and description of function............................................................................. 56
1.5.3 Machine - description................................................................................................................. 57
2 Overview of machine.......................................................................................................................... 63
2.1 Component overview - Electrics................................................................................................ 64
2.2 Component overview - hydraulics............................................................................................. 75
2.3 Lubrication points....................................................................................................................... 76
3 Electric systems.................................................................................................................................. 79
3.1 Wiring looms............................................................................................................................... 80
3.2 CAN - overview............................................................................................................................ 87
3.3 Overview...................................................................................................................................... 89
3.4 Display......................................................................................................................................... 95
3.4.1 Changing the diesel engine speed............................................................................................. 95
3.4.2 Display of typical engine data.................................................................................................... 96
3.5 Component description.............................................................................................................. 97
3.5.1 Steering angle sensor................................................................................................................ 97
3.6 BOMAG Telematic....................................................................................................................... 99
3.7 Trouble shooting....................................................................................................................... 100
3.7.1 Calling up the fault log.............................................................................................................. 100
3.7.2 Fault code lists......................................................................................................................... 102
3.8 Starting the engine with jump leads........................................................................................ 217
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3.9 Deutsch plug, series DT and DTM........................................................................................... 218
4 Diesel engine..................................................................................................................................... 223
4.1 Description................................................................................................................................ 224
4.1.1 General information.................................................................................................................. 224
4.1.2 Cooling system......................................................................................................................... 231
4.1.3 Engine oil system..................................................................................................................... 235
4.1.4 Air intake system...................................................................................................................... 240
4.1.5 Fuel system.............................................................................................................................. 241
4.1.6 Exhaust system........................................................................................................................ 242
4.1.7 Engine electrics........................................................................................................................ 245
4.2 Repairs....................................................................................................................................... 262
4.2.1 Thermostat removal/installation............................................................................................... 262
4.2.2 Check the thermostat............................................................................................................... 265
4.2.3 Check starter............................................................................................................................ 267
4.2.4 Starter removal/installation....................................................................................................... 269
4.2.5 Injector removal/installation...................................................................................................... 271
4.2.6 Checking the injector................................................................................................................ 275
4.2.7 Injector supply line removal/installation.................................................................................... 277
4.2.8 Checking the injector supply line.............................................................................................. 280
4.2.9 Injector feed pipe removal/installation...................................................................................... 281
4.2.10 Checking the injector feed pipe.............................................................................................. 283
4.2.11 Valve cover gasket removal/installation................................................................................. 284
4.2.12 Valve cover seal..................................................................................................................... 286
4.2.13 Valve cover removal/installation............................................................................................. 288
4.2.14 Checking the valve cover....................................................................................................... 292
4.3 Trouble shooting, diesel engine.............................................................................................. 293
4.3.1 Fuel consumption too high....................................................................................................... 293
4.3.2 Oil consumption too high.......................................................................................................... 294
4.3.3 Engine oil pressure too high..................................................................................................... 294
4.3.4 Engine oil pressure too low...................................................................................................... 295
4.3.5 Engine oil loss.......................................................................................................................... 296
4.3.6 Engine oil contaminated........................................................................................................... 296
4.3.7 Fuel in engine oil...................................................................................................................... 297
4.3.8 Coolant temperature too high (gradually)................................................................................. 298
4.3.9 Coolant temperature too high (suddenly)................................................................................. 299
4.3.10 Coolant temperature too low.................................................................................................. 300
4.3.11 Frequent blockage of the air filter........................................................................................... 301
4.3.12 The diesel engine turns poorly or not at all (starter)............................................................... 302
4.3.13 The diesel engine turns poorly or not at all............................................................................ 303
4.3.14 The diesel engine starts poorly or not at all (no smoke)........................................................ 304
4.3.15 The diesel engine does not reach its nominal speed............................................................. 304
4.3.16 The diesel engine stops again after starting.......................................................................... 305
4.3.17 Insufficient engine power....................................................................................................... 306
4.3.18 Poor acceleration or response of the engine......................................................................... 307
4.3.19 Irregular engine operation in idling speed.............................................................................. 308
4.3.20 Irregular engine operation or misfiring................................................................................... 309
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4.3.21 Engine speed fluctuates in lower and upper idle speed......................................................... 310
4.3.22 The rotary speed fluctuates under load.................................................................................. 311
4.3.23 The diesel engine stops unexpectedly................................................................................... 313
4.3.24 The diesel engine emits secondary noises............................................................................ 314
4.3.25 The diesel engine emits secondary noises (during combustion)........................................... 315
4.3.26 Excessive engine vibrations................................................................................................... 315
4.3.27 Increased DEF consumption.................................................................................................. 316
4.3.28 Generator does not run or only poorly................................................................................... 317
5 Hydraulic system.............................................................................................................................. 319
5.1 Open and closed hydraulic circuit.......................................................................................... 320
5.2 Hydraulic units.......................................................................................................................... 322
5.2.1 Control valve block................................................................................................................... 322
5.2.2 Hydraulic oil tank...................................................................................................................... 324
5.2.3 Conveyor belt pump H1........................................................................................................... 328
5.2.4 MCR conveyor belt motor........................................................................................................ 334
5.3 Fan circuit.................................................................................................................................. 340
5.4 Working circuit.......................................................................................................................... 341
5.5 Conveyor belt circuit................................................................................................................ 348
5.6 Travel circuit.............................................................................................................................. 351
5.7 Trouble shooting, hydraulics................................................................................................... 354
5.7.1 Insufficient hydraulic power...................................................................................................... 354
5.7.2 Trouble shooting axial piston pumps........................................................................................ 357
5.7.3 Trouble shooting axial piston motors....................................................................................... 359
5.7.4 Fault table hydraulic components............................................................................................ 361
6 Assembly groups.............................................................................................................................. 369
6.1 Hopper........................................................................................................................................ 370
6.1.1 Description............................................................................................................................... 370
6.2 Conveyor belt............................................................................................................................ 372
6.2.1 Description............................................................................................................................... 372
6.2.2 Repair....................................................................................................................................... 381
6.3 Cooling system......................................................................................................................... 385
6.3.1 Description............................................................................................................................... 385
7 Troubleshooting................................................................................................................................ 387
7.1 Preliminary remarks.................................................................................................................. 388
7.2 Emergency procedures............................................................................................................ 389
7.2.1 Actuating the emergency stop switch....................................................................................... 389
7.2.2 Disconnecting the battery......................................................................................................... 389
7.2.3 Towing the machine................................................................................................................. 389
8 Special tools...................................................................................................................................... 393
8.1 Special tools, electrics............................................................................................................. 394
8.2 Special tools, hydraulic system............................................................................................... 395
8.2.1 Special tools, tests and adjustments........................................................................................ 395
8.2.2 Special tools for flushing.......................................................................................................... 397
8.3 List of special tools................................................................................................................... 398
9 Index................................................................................................................................................... 401
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Appendix............................................................................................................................................ 409
A Circuit diagrams............................................................................................ 410
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1.1 Introduction
This manual:
naddresses the BOMAG Customer Service and professionally
trained personnel.
nprovides support for repair work or maintenance procedures on
the machine.
This manual described the deinstallation, dismantling , assembly,
installation as well as the repair of components and assembly
groups as far as this makes sense with respect to tools and spare
parts supply.
For the BOMAG machines described in this manual the following
documentation is additionally available:
nOperating and maintenance instructions
nSpare parts catalogue
nService information (if necessary)
Use only genuine BOMAG spare parts.
Spare parts needed for repairs can be taken from the spare parts
catalogue for the machine.
This manual is not subject of an updating service. For this reason
we would like to draw your attention to the additionally published
service informations.
In case of a new release all necessary changes will be included.
In the course of technical development we reserve the right for
technical modifications without prior notification.
Information and illustrations in this manual must not be reproduced
and distributed, nor must they be used for the purpose of competi-
tion without the consent of BOMAG. All rights according to the
copyright law remain expressly reserved.
General
Documentation
Genuine BOMAG spare parts
Updating service
Copyright
General – Introduction
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1.2 Concerning your safety
1.2.1 Basic prerequisites
1.2.1.1 General
This BOMAG machine has been built in compliance with the latest
technical standard and complies with the applicable regulations
and technical rules.
However, dangers for persons and property may arise from this
machine, if:
nit is used for purposes other than the ones it is intended for,
nit is operated by untrained personnel,
nit is changed or converted in an unprofessional way,
nthe safety instructions are not observed.
Each person involved in the operation, maintenance and repair of
the machine must therefore read and comply with these safety reg-
ulations. If necessary, the operating company must obtain the rele-
vant signatures as confirmation.
Furthermore, the following obviously also applies:
napplicable accident prevention instructions,
ngenerally accepted safety and road traffic regulations,
ncountry specific safety regulations.
It is the duty of the operator to be acquainted with the safety regu-
lations and to apply these accordingly. This also applies for local
regulations and regulations concerning different types of handling
activities. Should the recommendations in these instructions be dif-
ferent from the regulations valid in your country, you must comply
with the safety regulations valid in your country.
1.2.1.2 Explanation of signal words used:
DANGER!
Danger to life if failing to comply!
Sections marked accordingly indicate an extremely
dangerous situation that could lead to fatal or
severe injuries, if this warning is disregarded.
WARNING!
Danger to life or danger of severe injuries if
failing to comply!
Sections marked accordingly indicate a dangerous
situation that could lead to fatal or severe injuries,
if this warning is disregarded.
General – Concerning your safety
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CAUTION!
Danger of injury if failing to comply!
Sections marked accordingly indicate a dangerous
situation that could lead to fatal or severe injuries,
if this warning is disregarded.
NOTICE!
Danger of material damage if failing to comply!
Sections marked accordingly indicate possible
dangers for machines or components.
Sections marked accordingly indicate technical
information or notes on using the machine or its
components.
ENVIRONMENT!
Environmental damage if failing to comply!
Paragraphs marked accordingly indicate 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 protective equipment is required (to be provided
by the operating company):
Working clothes Tight fitting working clothes with low tear resistance, tight
sleeves and without any projecting parts protect against
being caught by moving components.
Safety shoes To protect against heavy falling parts and slipping on
slippery ground.
Protective gloves To protect the hands against excoriation, punctures or
deep injuries, against irritating and caustic substances
as well as against burns.
General – Concerning your safety
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Safety goggles To protect the eyes against airborne particles and
squirting fluids.
Face protection To protect the face against airborne particles and
squirting fluids.
Hard hat To protect the head against falling parts and to protect
against injuries.
Hearing protection To protect hearing against excessive noise.
Respiratory protection To protect respiratory tracts against substances or parti-
cles.
1.2.1.4 Intended use
This machine must only be used for the transport and conveying of
paving material for road pavers.
Suitable paving materials are mixes, rolling or lean concrete, track
ballast and unbonded mineral mixes for block paving subbases.
The machine must only be used inside cordoned off construction
sites.
Intended use also includes compliance with the specified 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 improper use is the sole responsibility of the
operating company or driver/operator, the manufacturer cannot be
made liable.
General – Concerning your safety
BMF 2500 M
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Examples for improper use are:
nkeeping loose objects (e.g. tools) on the operator's platform,
which could cause operating errors,
ntowing, recovering or pushing other vehicles or machines,
nusing the conveyor belt to lift loads,
ndriving on public roads without a permit.
climbing onto or off the machine while driving is prohibited.
transporting persons, except the machine driver, is prohibited.
starting and operation of the machine in explosive environments
and in underground mining is prohibited.
1.2.2 Definition of responsible persons
1.2.2.1 Operating company
The operating company is the natural or juridical person who uses
the machine or in who's name the machine is used.
The operating company must make sure that the machine is only
used for the purpose it is intended for and in strict compliance with
the safety regulations mentioned in these operating and mainte-
nance instructions.
The operating company must determine and assess the danger in
its company. It must then take appropriate action to ensure health
and safety at work for its employees and point out any remaining
dangers.
The operating company must determine whether there are special
operational hazards such as a 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 the information concerning safety.
The operating company is responsible for the planning and profes-
sional execution of regular safety inspections.
1.2.2.2 Expert / qualified person
An expert / qualified person is a person who, based on his/her pro-
fessional education and experience, has profound knowledge in
the field of construction equipment and the machine in question in
particular.
This person is acquainted with the applicable governmental indus-
trial safety regulations, accident prevention instructions, guidelines
and generally acknowledged technical rules and regulations
(standards, directives, technical rules of other member states of
the European Union or other contractual states concerning the
agreement about the European Economic Area) in as far as is nec-
essary to be able to judge the safe condition of this machine.
General – Concerning your safety
BMF 2500 M
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1.2.2.3 Driver / operator
This machine must only be operated by trained, instructed persons
entrusted by the operating company aged 18 or more.
Observe your local laws and regulations.
Rights, obligations and rules of conduct for driver or operator:
The driver or operator must:
nbe instructed about his rights and obligations,
nwear protective equipment as appropriate for the application,
nhave read and understood the operating instructions,
nhave made himself familiar with the operation of the machine,
nbe physically and psychologically able to drive and operate the
machine.
Persons under the influence of alcohol, medication or drugs are not
allowed to operate, service or repair the machine.
Maintenance and repair work requires specific knowledge and
must therefore only be performed by trained specialists.
1.2.3 Basic safety regulations for safe operation
1.2.3.1 Remaining dangers, remaining risks
Despite careful work and compliance with standards and regula-
tions it cannot be ruled out that further dangers may arise when
working with and handling the machine.
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 machine
for the purpose it is intended for and following all information given
in the operating instructions.
A remaining risk can also not be excluded beyond the actual
danger zone of the machine. Persons remaining in this area must
pay particular attention to the machine, so that they can react
immediately in case of a possible malfunction, an incident or failure
etc.
All persons remaining in the area of the machine must be informed
about the dangers that arise from the operation of the machine.
1.2.3.2 Regular safety inspections
Have the machine inspected by an expert / qualified person as
required for the conditions the machine is working under, but at
least once every year.
1.2.3.3 Modifications and alterations to the machine
Unauthorized changes to the machine are prohibited for safety rea-
sons.
General – Concerning your safety
BMF 2500 M
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Original parts and accessories have been specially designed for
this machine.
We wish to make explicitly clear that we have not tested or
approved any parts or accessories not supplied by us.
The installation and/or use of such products may have an adverse
effect on the active and/or passive safety.
1.2.3.4 Damage, defects, misuse of safety devices
Machines which are not safe to operate or in traffic must be imme-
diately taken out of service and shall not be used, until these defi-
ciencies have been properly rectified.
Safety installations and switches must neither be removed nor
must they be made ineffective.
1.2.4 Handling fuels and lubricants
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 data sheets provide valuable information about the following
characteristics:
nname of substance
npossible dangers
ncomposition / information on constituents
nfirst-aid measures
nfire fighting measures
nmeasures in case of accidental release
nhandling and storage
nlimitation and monitoring of exposure / personal protective
equipment
nphysical and chemical properties
nstability and reactivity
ntoxicological data
nenvironmental data
nnotes on waste disposal
ninformation on transport
nlegislation
nother data
General – Concerning your safety
BMF 2500 M
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1.2.4.2 Safety regulations and environmental protection regulations for handling diesel fuel
WARNING!
Danger of burning by ignited diesel fuel!
– Do not allow diesel fuel to come 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 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 bind spilled diesel fuel with an oil-
binding agent.
ENVIRONMENT!
Diesel fuel is an environmentally hazardous
substance!
– Always keep diesel fuel in proper containers.
– Immediately bind spilled diesel fuel with an oil-
binding agent and dispose of properly.
– Dispose of diesel fuel and fuel filters according
to regulations.
Fig. 1
General – Concerning your safety
BMF 2500 M
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1.2.4.3 Safety regulations and environmental protection regulations for handling AdBlue®/DEF
CAUTION!
Health hazard caused by ammonia vapours!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
– Do not inhale ammonia vapours.
– Avoid contact and consumption.
AdBlue®/DEF has not been classified as environ-
mentally harmful.
1.2.4.4 Safety regulations and environmental protection regulations for handling oil
WARNING!
Danger of burning by ignited oil!
– Do not allow oil to come 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 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!
– Immediately bind spilled oil with an oil-binding
agent.
ENVIRONMENT!
Oil is an environmentally hazardous substance!
– Always keep oil in proper containers.
– Immediately bind spilled oil with an oil-binding
agent.
– Dispose of oil and oil filter according to regula-
tions.
Fig. 2
Fig. 3
General – Concerning your safety
BMF 2500 M
16
1.2.4.5 Safety regulations and environmental protection regulations for handling hydraulic oil
WARNING!
Danger of injury caused by escaping pressure
fluid!
– Always depressurize the hydraulic system
before starting work in the hydraulic system.
– Wear your personal protective equipment (pro-
tective gloves, protective clothing, goggles).
Should pressure fluid penetrate the skin, imme-
diate medical help is required.
WARNING!
Danger of burning by ignited hydraulic oil!
– Do not allow hydraulic oil to come 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 hydraulic
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!
– Immediately bind spilled oil with an oil-binding
agent.
ENVIRONMENT!
Oil is an environmentally hazardous substance!
– Always keep oil in proper containers.
– Immediately bind spilled oil with an oil-binding
agent.
– Dispose of oil and oil filter according to regula-
tions.
Fig. 4
General – Concerning your safety
BMF 2500 M
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1.2.4.6 Safety regulations and environmental protection regulations for handling coolants
WARNING!
Danger of scalding by hot fluid!
– Open the compensation tank only when the
engine is cold.
– Wear your personal protective equipment (pro-
tective gloves, protective clothing, goggles).
CAUTION!
Health hazard caused by contact with coolant
and coolant additives!
– 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 with an oil-
binding agent.
ENVIRONMENT!
Coolant is an environmentally hazardous sub-
stance!
– Always keep coolant and coolant additives in
proper containers.
– Immediately bind spilled coolant with an oil-
binding agent and dispose of it according to
regulations.
– Dispose of coolant according to regulations.
Fig. 5
General – Concerning your safety
BMF 2500 M
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1.2.4.7 Safety regulations and environmental protection regulations for handling battery acid
WARNING!
Danger of cauterization with acid!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing, goggles).
– Do not allow clothes, skin or eyes to come into
contact with acid.
– Rinse off spilled battery acid immediately with
lots of water.
Rinse acid off clothes, skin or eyes immediately
with lots of clean water.
Immediately 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.
– Smoking and open fire is prohibited!
– Do not lay any tools or other metal objects on
the battery.
– Do not wear jewellery (watch, bracelets, etc.)
when working on the battery.
– Wear your personal protective equipment (pro-
tective gloves, protective clothing, goggles).
ENVIRONMENT!
Battery acid is an environmentally hazardous
substance!
– Dispose of battery and battery acid according
to regulations.
Fig. 6:
General – Concerning your safety
BMF 2500 M
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1.2.5 Emergency procedures
1.2.5.1 Actuating the emergency stop switch
1. In events of emergency and in case of danger actuate the
emergency stop switch Ä Fig. 7 immediately.
ðThe engine is shut down and the parking brake is closed.
1.2.5.2 Disconnecting the battery
NOTICE!
Danger of damage to the electronic system!
– Pull out the main battery switch at the earliest
40 seconds after switching off the ignition.
1. Turn the main battery switch Ä Fig. 8 anticlockwise and pull
it off to disconnect the battery from the vehicle power supply.
Or remove the battery terminal clamp from the battery.
1.2.5.3 Towing the machine
Tow the machine only in case of emergency or to prevent an acci-
dent.
Always tow only at the shortest distance to the means of transport
or to the nearest parking facility. Towing speed max. 10 m/min
(33 ft/min). In dangerous situations, a towing speed of 15 m/min
(49 ft/min) is permitted for a short time.
Before towing make sure that:
nthe tractor vehicle has sufficient traction and braking power for
the non-braking towed load;
nlifting tackle is of sufficient strength to withstand the load and is
fastened at the points provided for this purpose.
Only use tow bars which have been approved for this purpose.
Fig. 7
S-940-0002
Fig. 8
General – Concerning your safety
BMF 2500 M
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