Bomag BMF 2500 M Service Manual 00840156

Description

• Model List:
  • BMF 2500 M

• 1. Table of contents
• 2. General
• 2.1. Introduction
• 2.2. Concerning your safety
• 2.2.1. Basic prerequisites
• 2.2.1.1. General
• 2.2.1.2. Explanation of signal words used
• 2.2.1.3. Personal protective equipment
• 2.2.1.4. Intended use
• 2.2.1.5. Improper use
• 2.2.2. Definition of responsible persons
• 2.2.2.1. Operating company
• 2.2.2.2. Expert / qualified person
• 2.2.2.3. Driver / operator
• 2.2.3. Basic safety regulations for safe operation
• 2.2.3.1. Remaining dangers, remaining risks
• 2.2.3.2. Regular safety inspections
• 2.2.3.3. Modifications and alterations to the machine
• 2.2.3.4. Damage, defects, misuse of safety devices
• 2.2.4. Handling fuels and lubricants
• 2.2.4.1. Preliminary remarks
• 2.2.4.2. Safety regulations and environmental protection regulations for handling diesel fuel
• 2.2.4.3. Safety regulations and environmental protection regulations for handling AdBlue/DEF
• 2.2.4.4. Safety regulations and environmental protection regulations for handling oil
• 2.2.4.5. Safety regulations and environmental protection regulations for handling hydraulic oil
• 2.2.4.6. Safety regulations and environmental protection regulations for handling coolants
• 2.2.4.7. Safety regulations and environmental protection regulations for handling battery acid
• 2.2.5. Emergency procedures
• 2.2.5.1. Actuating the emergency stop switch
• 2.2.5.2. Disconnecting the battery
• 2.2.5.3. Towing the machine
• 2.2.6. Maintenance and repair
• 2.2.6.1. Preliminary remarks and safety notes
• 2.2.6.2. Working on hydraulic lines
• 2.2.6.3. Working on the engine
• 2.2.6.4. Maintenance work on electric components and battery
• 2.2.6.5. Cleaning work
• 2.2.7. Operating the machine, working operation
• 2.2.7.1. Persons in the danger zone
• 2.2.7.2. Driving the machine
• 2.2.7.3. Driving on inclinations and slopes
• 2.2.7.4. Cross slope
• 2.2.7.5. Parking the machine
• 2.2.8. Safety features
• 2.3. Fuels and lubricants
• 2.3.1. Engine oil
• 2.3.1.1. Oil viscosity
• 2.3.1.2. Oil change intervals
• 2.3.2. Fuel
• 2.3.2.1. Fuel quality
• 2.3.2.2. Winter fuel
• 2.3.2.3. Storage
• 2.3.3. AdBlue/DEF
• 2.3.3.1. AdBlue/DEF quality
• 2.3.3.2. Low outside temperatures
• 2.3.3.3. Storage
• 2.3.3.4. Cleanliness
• 2.3.4. Coolant
• 2.3.4.1. General
• 2.3.4.2. Water quality
• 2.3.5. Hydraulic oil
• 2.3.5.1. Mineral oil based hydraulic oil
• 2.3.5.2. Biodegradable hydraulic oil
• 2.3.6. Gear oil SAE 75W90
• 2.3.7. Gear oil SAE 80W140
• 2.4. Notes on repair
• 2.4.1. General repair instructions
• 2.4.1.1. Repair notes for electrics
• 2.4.1.2. Repair notes for hydraulics
• 2.4.1.3. Repair notes for Common Rail engines
• 2.4.1.4. Repair notes for gaskets and mating surfaces
• 2.4.1.5. Repair notes for ball and roller bearings
• 2.4.1.6. Feather keys and keyways
• 2.4.1.7. Repair notes for cotter pins
• 2.4.1.8. Repair notes for screws and nuts
• 2.4.1.9. Strength classes, metric screws and nuts
• 2.4.1.10. Identification of UNFthreads
• 2.4.2. Tightening torques
• 2.5. Description
• 2.5.1. Description of use
• 2.5.2. Assembly groups and description of function
• 2.5.3. Machine description
• 3. Overview of machine
• 3.1. Component overview Electrics
• 3.2. Component overview hydraulics
• 3.3. Lubrication points
• 4. Electric systems
• 4.1. Wiring looms
• 4.2. CAN overview
• 4.3. Overview
• 4.4. Display
• 4.4.1. Changing the diesel engine speed
• 4.4.2. Display of typical engine data
• 4.5. Component description
• 4.5.1. Steering angle sensor
• 4.6. BOMAG Telematic
• 4.7. Trouble shooting
• 4.7.1. Calling up the fault log
• 4.7.2. Fault code lists
• 4.8. Starting the engine with jump leads
• 4.9. Deutsch plug, series DT and DTM
• 5. Diesel engine
• 5.1. Description
• 5.1.1. General information
• 5.1.2. Cooling system
• 5.1.2.1. Description of thermostat
• 5.1.3. Engine oil system
• 5.1.4. Air intake system
• 5.1.5. Fuel system
• 5.1.6. Exhaust system
• 5.1.7. Engine electrics
• 5.1.7.1. Intake air pressure and temperature sensor
• 5.1.7.2. Coolant temperature sensor
• 5.1.7.3. Rotary speed sensors
• 5.1.7.4. Injectors
• 5.1.7.5. Sensor, water in fuel
• 5.1.7.6. Rail pressure sensor
• 5.1.7.7. Sensor DEFfilling level and temperature
• 5.1.7.8. Coolant control valve DEFtank
• 5.1.7.9. Sensor DEFquality
• 5.1.7.10. NOxsensor before exhaust gas aftertreatment system
• 5.1.7.11. NOxsensor after exhaust gas aftertreatment system
• 5.1.7.12. SCR temperature sensor
• 5.1.7.13. Heating 1 DEFline
• 5.1.7.14. DEFdosing valve
• 5.2. Repairs
• 5.2.1. Thermostat removal/installation
• 5.2.2. Check the thermostat
• 5.2.3. Check starter
• 5.2.4. Starter removal/installation
• 5.2.5. Injector removal/installation
• 5.2.6. Checking the injector
• 5.2.7. Injector supply line removal/installation
• 5.2.8. Checking the injector supply line
• 5.2.9. Injector feed pipe removal/installation
• 5.2.10. Checking the injector feed pipe
• 5.2.11. Valve cover gasket removal/installation
• 5.2.12. Valve cover seal
• 5.2.13. Valve cover removal/installation
• 5.2.14. Checking the valve cover
• 5.3. Trouble shooting, diesel engine
• 5.3.1. Fuel consumption too high
• 5.3.2. Oil consumption too high
• 5.3.3. Engine oil pressure too high
• 5.3.4. Engine oil pressure too low
• 5.3.5. Engine oil loss
• 5.3.6. Engine oil contaminated
• 5.3.7. Fuel in engine oil
• 5.3.8. Coolant temperature too high (gradually)
• 5.3.9. Coolant temperature too high (suddenly)
• 5.3.10. Coolant temperature too low
• 5.3.11. Frequent blockage of the air filter
• 5.3.12. The diesel engine turns poorly or not at all (starter)
• 5.3.13. The diesel engine turns poorly or not at all
• 5.3.14. The diesel engine starts poorly or not at all (no smoke)
• 5.3.15. The diesel engine does not reach its nominal speed
• 5.3.16. The diesel engine stops again after starting
• 5.3.17. Insufficient engine power
• 5.3.18. Poor acceleration or response of the engine
• 5.3.19. Irregular engine operation in idling speed
• 5.3.20. Irregular engine operation or misfiring
• 5.3.21. Engine speed fluctuates in lower and upper idle speed
• 5.3.22. The rotary speed fluctuates under load
• 5.3.23. The diesel engine stops unexpectedly
• 5.3.24. The diesel engine emits secondary noises
• 5.3.25. The diesel engine emits secondary noises (during combustion)
• 5.3.26. Excessive engine vibrations
• 5.3.27. Increased DEF consumption
• 5.3.28. Generator does not run or only poorly
• 6. Hydraulic system
• 6.1. Open and closed hydraulic circuit
• 6.2. Hydraulic units
• 6.2.1. Control valve block
• 6.2.2. Hydraulic oil tank
• 6.2.3. Conveyor belt pump H1
• 6.2.4. MCR conveyor belt motor
• 6.3. Fan circuit
• 6.4. Working circuit
• 6.5. Conveyor belt circuit
• 6.6. Travel circuit
• 6.7. Trouble shooting, hydraulics
• 6.7.1. Insufficient hydraulic power
• 6.7.2. Trouble shooting axial piston pumps
• 6.7.3. Trouble shooting axial piston motors
• 6.7.4. Fault table hydraulic components
• 7. Assembly groups
• 7.1. Hopper
• 7.1.1. Description
• 7.2. Conveyor belt
• 7.2.1. Description
• 7.2.2. Repair
• 7.2.2.1. Changing the conveyor belt
• 7.3. Cooling system
• 7.3.1. Description
• 8. Troubleshooting
• 8.1. Preliminary remarks
• 8.2. Emergency procedures
• 8.2.1. Actuating the emergency stop switch
• 8.2.2. Disconnecting the battery
• 8.2.3. Towing the machine
• 9. Special tools
• 9.1. Special tools, electrics
• 9.2. Special tools, hydraulic system
• 9.2.1. Special tools, tests and adjustments
• 9.2.2. Special tools for flushing
• 9.3. List of special tools
• 10. Index
• 11. Appendix
• 11.1. A Circuit diagrams
• 11.1.1. Wiring diagram 94013137