When the paving train stops and you have an hour to clear a hopper fault before the mat cools, this 470-page Bomag BMF 2500 S service manual PDF provides factory procedures for your material transfer vehicle under OEM publication 008 401 48 EN. The document lays out extensive electrical and hydraulic schematics, routing the closed hydraulic circuit's conveyor belt pump and MCR conveyor belt motor lines directly to the control valve block. Detailed troubleshooting charts let you trace fault logs from the steering angle sensor or CAN display straight to the root cause. Factory specifications confirm chain lubrication system operating intervals at 3 minutes of operation per 11 minutes of break, while defining the tightening torque for high pressure cartridges at 22 Nm. Being alone on a night shift with a dead machine and no one to ask is a tough spot. Download this bookmarked, text-searchable file and keep the answers on your laptop right where the machine sits.
What's Inside This Bomag BMF 2500 S Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 7-62 | Introduction |
| Overview of Machine | 63-78 | Component Overview - Electrics, Component Overview - Hydraulics, Lubrication Points |
| Electric Systems | 79-222 | Wiring Looms, CAN - Overview, Overview, Display (Changing the Diesel Engine Speed, Typical Engine Data), Component Description (Steering Angle Sensor), Bomag Telematic |
| Diesel Engine | 223-318 | Description (Cooling System, Engine Oil System, Air Intake System, Fuel System, Exhaust System, Engine Electrics) |
| Hydraulic System | 319-370 | Open and Closed Hydraulic Circuit, Hydraulic Units (Control Valve Block, Hydraulic Oil Tank, Conveyor Belt Pump H1, Mcr Conveyor Belt Motor), Fan Circuit, Working Circuit |
| Assembly Groups | 371-396 | Hopper (Description), Conveyor Belt (Description, Repair), Conveyor Belt, Slewable - B01 (Description, Cooling System (Description) |
| Troubleshooting | 397-402 | Preliminary Remarks, Emergency Procedures (Actuating the Emergency Stop Switch, Disconnecting the Battery, Towing the Machine) |
| Special Tools | 403-410 | Electrics, List of Special Tools |
| Appendix | 419-470 | Circuit Diagrams |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Chain lubrication system operating intervals | 3 minute operation, 11 minutes break | p. 377 |
| Tightening torque for high pressure cartridges | 22 Nm | p. 22 |
| Engine displacement | 6700 cm³ | p. 224 |
| Engine power | 170 kW | p. 224 |
| Tightening torque for M5 screws | 4 Nm | p. 270 |
| Tightening torque for M10 screws | 21 Nm | p. 270 |
| Tightening torque for injector feed pipe union nut | 55 Nm | p. 274 |
| Tightening torque for injector bracket screws | 8 Nm | p. 274 |
| Tightening torque for injector supply line nuts | 50 Nm | p. 279 |
| Tightening torque for valve cover screws | 24 Nm | p. 290 |
| Weight of the slewing belt | 4.5 t | p. 389 |
| Flushing pressure relief valve setting | 14 bar | p. 339 |
Bomag BMF 2500 S Common Problems This Manual Covers
Bomag BMF 2500 S engine turns over but refuses to fire due to intermittent electrical interlock faults
Check the engine failure codes in the fault log. Inspect the starter connections and verify M5 screw torque is exactly 4 Nm as shown on page 270. Test the seat and park position switches for continuity before tracing the main harness.
Manual Section: Diesel Engine - Engine ElectricsMaterial transfer conveyor chain runs dry during continuous asphalt feeding operations and chatters violently
Verify the chain lubrication system operating intervals on page 377. Program the timer for a 3 minute operation followed by an 11 minutes break. Inspect the pump reservoir level and clear any blockages in the distribution lines to restore proper oil flow to the pins.
Manual Section: Assembly Groups p. 377Conveyor belt hydraulic motor overheats during extended shifts and stalls out under heavy material load
Review the hydraulic schematic to locate the closed-loop circuit components. Test the flushing pressure relief valve setting and adjust it to exactly 14 bar as specified on page 339. Drain the hydraulic oil tank if fluid shows signs of thermal degradation.
Manual Section: Hydraulic System Troubleshooting p. 339Diesel engine runs rough under load with visible fuel weeping around the upper cylinder head
Inspect the fuel delivery components using the service procedures. Torque the injector feed pipe union nut to 55 Nm and secure the injector bracket screws to 8 Nm as detailed on page 274. Replace any cracked lines to prevent pressure loss.
Manual Section: Injector Feed Pipe Repair p. 274Top end engine oil leak develops down the block after reaching full operating temperature
Remove the top covers and clean the sealing surfaces thoroughly. Install a new gasket and tighten the valve cover screws evenly to 24 Nm as shown on page 290. Run the 6700 cm³ displacement engine, noted on page 224, up to temperature to verify the seal.
Manual Section: Valve Cover Repair p. 290Frequently Asked Questions
How do I clear or reset a fault code on the BMF 2500 S?
Many fault codes on the BMF 2500 S clear automatically once the error condition is no longer present and the joystick is back in neutral. For faults that do not clear on their own, the Electric Systems troubleshooting chapter on page 103 covers the reset procedure for specific system checks. p. 103
What is the tightening torque for the high pressure cartridges when towing the Bomag BMF 2500 S?
When preparing the machine for towing, you must tighten the counter nut on the high pressure cartridges to a torque of 22 Nm. p. 22
What is the tightening torque for M10 screws with strength class 8.8 on the Bomag BMF 2500 S?
For screws with a metric unified thread and a strength class of 8.8, the tightening torque for an M10 dimension is 50 Nm, assuming a coefficient of friction of 0.14. p. 49
What is the required tightening torque for the valve cover screws on the Bomag BMF 2500 S?
When mounting the valve cover, the screws must be tightened starting from the middle towards the outside to a torque of 24 Nm. p. 290
What is the nominal injector sealing ring thickness on the Bomag BMF 2500 S diesel engine?
The nominal thickness for the injector sealing ring is 1.5 mm. If the measured thickness of a removed sealing ring is not up to this nominal value, it must be replaced. p. 272
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