Bomag 851

Service Training
Multi Purpose Compactor

BMP 851
Part-No. 008 097 35 01/2006

Service Training
Table of contents
Foreword A1
Documentation A2
General A3
Technical data and adjustment values B1

Maintenance B2
Maintenance table B3
Diesel engine C1
Checking and adjusting the valve clearance C3
Checking and adjusting the clearance C5
Plug-type injection pump C 14
Travel system D1
Travel pump D5
Travel motor D6
Control valve block D8
Vibration E1
Vibration pump E5
Vibration control E6
Vibration motor E7
Electrical system up to year of construction 2002, S/N 101 720 03 ... F1

Power supply F1
Throttle control F2
Starting F3
Monitoring F5
Brakes F5
Vibration F6
Speed range selection F8
BMP 851
Service Training
Electrical system from year of construction 2003, S/N 101 720 04 ... G1
Power supply G1
Throttle control G2
Starting G3
Monitoring G5
Brakes G5
Vibration G6
Speed range selection G7
Documentation on BLM-control (from year 2003)

see separate table of contents
Electric circuit diagram
Hydraulic diagram
BMP 851
Service Training
Foreword
Since its first market launch the large quantities of the trench compactor of product range BW 85 T were
sold all over the world.
Despite this continuing sales success BOMAG decided to revise and redesign this machine range in
order to adapt it to the technical standard of today.
Since this type of equipment is intended for a wide range of applications we have chosen the name BMP
851. The designation BMP represents "BOMAG Multi-Purpose" (multi-purpose compactor). This
designation clearly distinguishes this machine from its predecessors.
For the customer service department the revision and redesign of this machine family was reason
enough to revise also the training documents for this machine and to update these to the latest
circumstances.
The contents of this training shall enable the service engineer to perform adjustments and trouble
shooting as well as all necessary repair work in a professional manner. The owner of the machine
should recognize that the service engineer is fully familiar with the machine. He should realize that the
service engineer applies the correct measures to detect a possible fault on the machine and that all
repair measures are performed with skill and knowledge.
Persons participating on this training course should be confident when having to work on this machine.
In this case the training has achieved its goal.
BMP 851 -A1-

Service Training
Documentation
For the BOMAG machines described in this training manual the following documentation is additionally
available:
Attention!
The currently valid part numbers for the documents can be taken from the Doclist or the
Customer Service page in the BOMAG (BOMAG Secured Area) in accordance with the serial
number of the machine.
1. Operating and maintenance instructions

2. Spare parts catalogue
3. Wiring diagram *
4. Hydraulic diagram *
5. Repair instructions
6. Service Information
* The document versions valid at the date of printing are part of this training manual.
BMP 851 -A2-

Service Training
General
The toughest application for multi-purpose compactors is the operation in trenches for sewage lines,
pipeline construction, drainage systems, etc. Due to their compact design, their freedom of lateral
overhang and their excellent manoeuvrability these rollers are particularly suitable for this type of work.
All drive components of the machine are perfectly protected against damage caused by contact with
trench walls and by dropping stones etc.
Fig. 1 BMP 851
Since the hydraulic oil flows through deep drilled bore holes in the central frame down to the flanged on
travel motors, there was no necessity to route any hoses in this particularly endangered area between
the drums.
The entire installation space for engine and drive components is well protected against the entering of
dirt.
A strong single-point lifting hook is located above the hydraulic oil tank. With this lifting hook the machine
can be easily lowered into and lifted out of the trench.
The machine is equipped with four drums. Each of these drums is driven by its own travel motor.
BMP 851 -A3-

Service Training
The two travel motor per machine side are connected in series, whereby slippage between front and
rear drums is avoided.
Both machine sides are hydraulically controlled, independently from each other. This enables perfect
steering of the machine by simply operating the two machine sides with different travel speeds. The
machine can even be turned on the spot by simply operating the two machine sides in opposite
directions.
In contrast to its predecessor BW 85 T this machine is now equipped with
• two gear pumps for the travel system and
• two 4/3-way solenoid valves for selection of travel direction
as standard.
For enhanced traction the drums are provided with padfeet.
The vibration works with a central exciter between the drums. This exciter is hydraulically driven by
means of a gear pump and a gear motor.
When driving without vibration this oil flow is also available for the travel system.
The machine is operated by means of two travel levers, a rotary switch for mode of vibration (manual /
automatic), a rotary switch for high and low travel speed range and a selector lever for sense of rotation
of exciter shaft.
In dangerous areas the control unit can be removed from the machine, but remains connected with a
machine by a cable. The operator can thus operate the machine from without the danger zone.
Apart from this the machine can also be operated with a radio remote control. This type of control is
described in the chapter "Electrics".
The sense of rotation of the exciter shaft can be reversed by actuation of a 4/3-way solenoid valve. This
solenoid valve is electrically coupled with the travel system, so that the sense of rotation of the exciter
shaft changes with the travel direction of the machine. In "Manual"-mode this valve can be used to
choose the sense of rotation of the exciter shaft, independently from the travel direction of the machine.
For reasons of safety the machine is fitted with a back-up protection. This feature switches the travel
drive off if the operator is trapped between the machine and an obstruction. By shifting the travel levers
forward the machine can then be moved away from the operator.
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Service Training
Technical data and adjustment values
The following pages contain technical data valid at the date of printing (see front page of this manual).
Attention!
The currently valid technical data and adjustment values can be taken from the BOMAG Intranet
or Extranet (BOMAG Secured Area) in accordance with the serial number of the machine.
BMP 851 -B1-

BOMAG Central Service Seite 1 von 2
BOMAG Central Service - Technical data and adjustment values
Status: 2003-04-09
Product type: BMP 851

Type No.: 720 03
Serial numbers from: 101 720 03 0101
Engine:
Manufacturer: Hatz
Type: 2G40
Combustion principle: 4-stroke-Diesel
Cooling: Air
Number of cylinders: 2
Power acc. to ISO 9249: 14 kW
Power data at nominal speed of: 2800 1/min
Low idle speed: 1800+/-50 1/min
High idle speed: 2800+/-100 1/min
Spec. fuel consumption: 238 g/kWh
Valve clearance, inlet: 0,1 mm
Valve clearance, outlet: 0,1 mm
Opening pressure, injection valves: 250 +8 bar
Starter voltage: 12 V
Starter power: 1,5 kW
Travel pump:
Manufacturer: Ultra
Type: 7702 L
Number: 2
System: Tandem-Zahnradpumpe
Max. displacement: 3 cm3/U
Max. flow ratio: 8,4 l/min
High pressure limitation: 250 +50 / -150 bar
Travel motors:
Manufacturer: Danfoss
Type: OMT 630
Number: 4
System: Gerotor-motor
Displacement stage 1: 630 cm3/U
Vibration pump:
Manufacturer: Ultra
Type: 7702 L
System: Gear pump
Starting pressure: 200 +/-20 bar
Operating pressure, soil dependent: 80-150 bar
Vibration motor:
Manufacturer: Ultra
Type: 1 MR 11
.../search_components_result.asp?Type=Prod&Text=851&OrderBy=Maschinentyp%5D%2C09.04.03
BOMAG Central Service - Technical data and adjustment values
Status: 2003-04-09
Product type: BMP 851

Type No.: 720 04
Serial numbers from: 101 720 04 1001
Engine:
Manufacturer: Hatz
Type: 2G40
Combustion principle: 4-stroke-Diesel
Cooling: Air
Number of cylinders: 2
Power acc. to ISO 9249: 14 kW
Power data at nominal speed of: 2800 1/min
Low idle speed: 1800+/-50 1/min
High idle speed: 2800+/-100 1/min
Spec. fuel consumption: 238 g/kWh
Valve clearance, inlet: 0,1 mm
Valve clearance, outlet: 0,1 mm
Opening pressure, injection valves: 250 +8 bar
Starter voltage: 12 V
Starter power: 1,5 kW
Travel pump:
Manufacturer: Ultra
Type: 7702 L
Number: 2
System: Tandem-Zahnradpumpe
Max. flow ratio: 8,4 l/min
High pressure limitation: 250 +50 / -150 bar
Travel motors:
Manufacturer: Danfoss
Type: OMT 630
Number: 4
System: Gerotor-motor
Displacement stage 1: 630 cm3/U
Vibration pump:
Manufacturer: Ultra
Type: 7702 L
System: Gear pump
Starting pressure: 200 +/-20 bar
Operating pressure, soil dependent: 80-150 bar
Vibration motor:
Manufacturer: Ultra
Type: 1 MR 11
.../search_components_result.asp?Type=Prod&Text=851&OrderBy=Maschinentyp%5D%2C09.04.03
Number: 1
System: Gear motor
Displacement: 11 cm3/U
Frequency: 32 Hz
Amplitude: 2,1 mm
Filling capacities:
Engine oil: 2,5 l (SAE 15W-40, API SJ/CF)
Hydraulic oil: 38 l (HVLP 46 VI 150)
Vibration bearing housing: 1,3 l (SAE 15W-40, API SJ/CF)
.../search_components_result.asp?Type=Prod&Text=851&OrderBy=Maschinentyp%5D%2 09.04.03
Number: 1
System: Gear motor
Displacement: 11 cm3/U
Frequency: 32 Hz
Amplitude: 2,1 mm
Filling capacities:
Engine oil: 2,5 l (SAE 15W-40, API SJ/CF)
Hydraulic oil: 38 l (HVLP 46 VI 150)
Vibration bearing housing: 1,3 l (SAE 15W-40, API SJ/CF)
.../search_components_result.asp?Type=Prod&Text=851&OrderBy=Maschinentyp%5D%2 09.04.03
Service Training
Maintenance
The multi-purpose compactor BMP 851 is a heavy-duty machine for both general compaction work as
well as difficult applications in trenches. To be able to meet these demands the machine must always
be ready to be loaded up to its limits. Apart from this all safety installations must always be fully
functional.
Thorough maintenance of the machine is therefore mandatory. It not only guarantees a remarkably
higher functional safety, but also prolongs the lifetime of the machine and of important components.
The time required for thorough maintenance is only minor when being compared with the malfunctions
and faults that may occur if these instructions are not observed.
The maintenance intervals are given in operating hours. It is quite obvious that with each maintenance
interval all the work for shorter preceding intervals must also be performed. During the 2000 hour
interval you must also perform the maintenance work for the 250, 500 and 1000 hour intervals.
It should also be clear, that with the 2500 hours interval only the work for the 10, 250 and 500 hour
intervals must be performed.
During maintenance work you must only use the fuels and lubricants mentioned in the table of fuels and
lubricants (oils, fuels, grease etc.).
These training documents include an operation and maintenance manual. Please refer to these
instructions for the individual maintenance intervals and the description of the individual maintenance
tasks.
BMP 851 -B2-

Service Training
Maintenance table
every 1000 oper. hours

Running-ininspect.
(25 op. hours)
Maintenance work Remark
as required
Change the engine oil filter X
Change the engine oil X
Check, adjust the valve clearance I/E 0.1mm X
Check the engine for leaks X
Check fastening of air filter and other X
attachment parts
Retighten fastening screws of engine X
mounts
Change the oil for the exciter shaft X
bearings
Check the engine oil level up to 200 oper. X
hours
2x per day
Check bolted connections on machine, after 200 oper. X
tighten if necessary hours
Check intensively for leaks up to 200 oper. X
hours
Check the engine oil level Dipstick mark X X X X X
Empty the water separator X X X X X
Check the fuel level approx. 19 l X X X X X
Check the hydraulic oil level Inspection glass X X X X X
Check the air intake hose X X X X
Clean cooling fins / cooling fan X X X X
Change engine oil and oil filter min. 1 x per year X X X X
Check, adjust the valve clearance I/E 0,1 mm X X X X
BMP 851 -B3-

Service Training
Check oil level for exciter shaft bearings Inspection bore X X X X
Check, clean the air filter, replace if X X X
necessary

Running-ininspect.
(25 op. hours)
Maintenance work Remark
as required
Battery maintenance Grease the poles X X X
Drain the fuel tank sludge X X X
Change the fuel filter X X
Change the oil in the exciter shaft bearing min. 1 x year X X
housing
Change hydraulic oil and breather filter min. every 2 years X X
Change the hydraulic oil filter min. every 2 years X X
and after repairs in
the hydraulic
system
Adjust the scrapers X
Bleed the fuel system only after the tank X
has run dry
Tighten all bolted connections Observe the X
tightening torques!
Engine conservation Before longer X
periods of standstill
BMP 851 -B4-

Service Training
Diesel engine
The multi-purpose compactor BMP 851 is powered by an air cooled Hatz diesel engine of product range
2 G 40. This engine is a two-cylinder engine with direct fuel injection.
The cast iron cylinders are arranged in upright position. The crankcase is made of aluminium die
casting. The cylinder heads are manufactured of light metal.
Crankshaft and conrods run in friction bearings. Timing of the valves is accomplished by the camshaft
via pushrods and rocker arms.
The engine is equipped with a pressure circulation lubrication. With this system the engine oil is pumped
by an internal gear pump to the lubrication points. The engine oil is permanently filtered by a filter
arranged in the main oil flow.
The cooling fan integrated in the flywheel supplies the engine with cooling air. The generator for the
voltage supply of the machine's electric system is also mounted in the flywheel.
The most important features of this engine are:
• excellent access to all operating and service points,
• low fuel consumption,
• robust design, long lifetime,
• reliability, because no V-belt is required for cooling fan and generator,
• safe and easy starting with electric starter,
• service friendly due to automatic bleeding of injection pump
• environmentally friendly due to low fuel and oil consumption as well as excellent exhaust emission
values.
BMP 851 -C1-

Service Training
Fig. 1 Hatz diesel engine
1 Fuel line (fuel pump - injection pump 2 Air cowling

3 Oil dipstick 4 Fuel return line
5 Injection valve 6 Eye bolt (transport hook)
7 Starter 8 Air duct
9 Air intake pipe 10 Identification plate
11 Glow plug * 12 Oil bath air filter *
13 Oil pressure switch 14 Rain cap *
15 Oil filler plug 16 Fuel pressure pipes
17 Cylinder head cover 18 Lubrication oil line
19 Exhaust manifold 20 Injection pump
21 Stop lever 22 Throttle lever
23 Fuel pump 24 Lubrication oil filter
25 Start button * 26 Oil drain plug
27 Protection grid 28 Air duct housing
29 Plug connection 30 Voltage regulator
31 Engine mount 32 Crankshaft - power take off
33 Fuel line (fuel filter - fuel pump) 34 Fuel filter
* not available on every engine version
BMP 851 -C2-

Service Training
Adjusting the valve clearance
The valve clearance must be checked in compliance with the maintenance instructions and adjusted, if
necessary.
The valve clearance must only be checked and adjusted when the engine is cold.
Intake and exhaust valves = 0.1 mm
The following must be observed when performing tests and adjustment work:
Cylinder 1 = flywheel side - clockwise rotation
Cylinder 2 = power take-off side - anti-clockwise rotation.
Strictly observe the sense of rotation!
Fig. 2 Cylinder head
BMP 851 -C3-

Service Training
• Unscrew screws (1) from both valve covers (3) and take off washers (2), covers (3) and gaskets (4).
• Turn crankshaft in direction of engine rotation, until the valves on cylinder 2 are overlapping (i.e.
intake valve not yet closed, exhaust valve starts to open).
• Turn the crankshaft for another 180° in direction of engine rotation.
• Check the valve clearance on cylinder 1 with a feeler gauge.
The feeler gauge must fit through the gap between rocker arm and valve stem with only minor
resistance.
• Turn the crankshaft further for another 180° and check the valve clearance on cylinder 2.
If the valve clearance is not correct, the corresponding valve needs to be adjusted accordingly.
Fig. 3 Valve clearance
• Slacken hexagon nut (1) with an open end spanner and turn stud (2) with a screwdriver, so that feeler
gauge (3) fits with only minor resistance through the gap between rocker arm and valve stem after
tightening nut (1).
• Adjust all valves.
Once all valves have been adjusted reassemble the valve covers with new gaskets.
Perform a test run and check the engine for leaks.
BMP 851 -C4-

Service Training
Checking and adjusting the head clearance
After replacing piston, cylinder, conrod, crankshaft and/or crankcase the correct head clearance must
be adjusted.
With too small head clearance there is a risk of damage to piston, cylinder head and valves.
If the head clearance is too big the engine lacks in power and is difficult to start.
For the adjustment of the head clearance gaskets "b" of different thickness (see illustration) are
available.
Fig. 4 Head clearance
BMP 851 -C5-

Service Training
Measuring process
• Slightly clamp down the cylinder with a gasket of any desired, but defined thickness, using clamping
bow (7).
• Attach depth gauge (8) and hold it.
Make sure to measure against the piston bottom and not into any cavity that may be present!
•Turn the crankshaft until the piston has reached and passed top dead centre "TDC".
• Compare value "c" indicated by the depth gauge with the nominal value (0.6 - 0.65 mm) and use a
gasket which is thinner or thicker by the required difference (install this instead of the one initially
used).
• Repeat the measuring procedure with the new gasket, to be on the safe side.
Use only one gasket. Never combine two or more gaskets to one pack.
•Reassemble the engine and check for leaks
BMP 851 -C6-

Service Training
Travel system
The multi-purpose compactor BMP 851 works with a hydrostatic travel system. The travel circuits are
open hydraulic circuits and consist mainly of
• travel pump,
• travel motors,
• control valve block
and the connecting pressure hoses. Each of the four drums is driven by its own hydraulic motor. In this
design always two travel motors of one machine side are connected in series.
This series connection avoids slipping of only one drum under severe soil conditions.
Each pair of travel motors is supplied by its own travel pump. These travel pumps are joined together
with the vibration pump to a triple pump unit.
This pump combination is directly driven by the engine with full engine speed.
The travel pumps draw the hydraulic oil through a suction filter in the hydraulic oil tank and deliver it to
the control valve block. When the travel levers are not actuated, the oil flows through brake valve (13)
under low pressure back to the tank.
• If the travel direction valves (14 and 15) in the control valve block are energized, the oil flow
capacities from both travel pumps are directed to the travel motor pairs on both machine sides, in
dependence on the respective valve position. When shifting both travel levers backwards the
machine will drive in reverse.
• If one of the travel levers is actuated and the second lever remains in neutral position, the machine
will drive a curve, whereby only the drums on the operated machine side will rotate.
• When shifting the travel levers to opposite directions, both drum pairs will also rotate in opposite
directions, causing the machine to turn on the spot.
With this design feature the travel system has the additional function of a steering system.
• When shifting both travel levers forward the machine will drive forward.
BMP 851 -D1-

Service Training
19 19 13
12
14
A5.1 B5.1 A5.2 B5.2 A8 B8
5.1 5.2 08
18
04
11
6.1
10
6.2 09
03 250 bar
01 07
250 bar 02 200 bar

T P3 P2 P1
15
M 16
17
Fig. 1 Hydraulic diagram
01 Pressure relief valve 02 Shuttle valve

03 Pressure relief valve 04 Brake valve
5.1 4/3-way valve, left 5.2 4/3-way valve, right
6.1 Check valve - cartridge 6.2 Check valve - cartridge
07 Pressure relief valve 08 4/3-way valve
09 4/2-way valve block 10 Flow divider
11 Control block 12 Travel system, left
13 Travel system, right 14 Vibration
15 Gear pump, triple 16 Diesel engine
17 Suction filter 18 Parking brake
19 Centre frame
BMP 851 -D2-

Service Training
Fig. 2 Control of machine up to year 2002, S/N 101 720 03 ....
1 Hydraulic oil tank 2 Central lifting feature

3 Socket for receiver of radio remote control
4 Rotary switch, cable/radio remote control 5 Operating hour meter
6 Charge control lamp 7 Engine oil pressure control lamp
8 Backup protection bow 9 Control box for cable remote control
10 Locking clamp for service flap 11 Socket for cable remote control
12 Fuse box 13 Fuel tank
14 Engine hood lock 15 Vibration control lever
16 Travel lever for left hand drums 17 Travel lever for right hand drums
18 Rotary speed range selector switch 19 Rotary switch for vibration
BMP 851 -D3-

Service Training
Fig. 3 Control of machine from year 2003 S/N 101 720 04 ....
1 Engine hood lock 2 Central lifting feature

3 Receiver (behind sheet) 4 CAN-Bus display module
5 Fuses 6 Selector switch for cable/radio remote
control
7 Main battery switch 8 Charge control lamp
9 Engine oil pressure control lamp 10 Control unit
11 Dummy socket for spiral cable plug 12 Locking clamp for service flap
13 Travel lever for left hand drums 14 Switch for vibration manual/automatic
15 Travel speed switch 16 Engine speed switch
17 Travel lever for right hand drums 18 Switch for vibration forward/reverse
19 Emergency stop switch 20 Battery check for control unit (radio)
BMP 851 -D4-

Service Training
21 Horn button 22 Ignition key
When working without vibration the oil flow delivered by the vibration pump is also directed to the travel
circuits through the two-fold flow divider. This increases the travel speed of the machine. This "2nd travel
speed range" is normally used for quick transportation of the machine between different locations of
use on a construction site.
Vibration can only be switched on in 1st speed range. The oil flow to the two-fold flow divider is then
interrupted by the 4/2-way solenoid valve (11) and guided to the vibration motor through 4/3-way
solenoid valve (16).
The brake valve (13) is opened against the adjustment spring by application of the actual travel pressure
through shuttle valve (8) and the pilot line.
If, for instance, the machine shows a tendency to roll down when driving downhill, the travel pressure
will drop so that the brake valve is no longer actuated. Now the return flow from the travel motors must
flow back against the resistance of the brake valve, thereby braking the travel motors.
Pressure relief valves limit the pressure in the travel circuits to 250 bar.
Travel pump
The travel pumps are directly driven gear pumps. Both pumps are joined together with the vibration
pump to a triple pump unit.
Fig. 4 Travel pump
1 Screw 2 Spring ring

3 End cover 4 O-ring
5 Backing seal 6 Sleeve seal
7 Bushing 8 Bushing
9 Housing 10 Driven pinion
BMP 851 -D5-

Service Training
11 Drive shaft with oinion 15 Flange
16 Sealing washer 17 Circlip
The drive gear is connected with the upstream gear pump by means of a coupling (i.e. indirectly with
the diesel engine). Drive gear and driven gear are positioned by a bearing plate in such a way, that the
gears mesh with minimum clearance when rotating.
The displacement chambers are created between the tooth flanks, the inside wall of the housing and
the faces of the bearing plates.
During operation of the pump the hydraulic oil is transported in these chambers from the suction side to
the pressure side. This causes a vacuum in the suction line by which the hydraulic oil is drawn out of
the tank. These tooth chambers convey the fluid to the pump outlet from where it is pressed to the
consumer.
To ensure a safe function of the pump the tooth chambers must be so tightly sealed that the hydraulic
fluid can be transported from the suction side to the pressure side without any losses.
Outer gear pumps are fitted with gap seals. In dependence on the operating pressure there will be
losses from the pressure side to the suction side. An axial pressure field presses the bearing plate on
the cover side against the front face of the gears, making sure that only a very little quantity of oil will
leak from the pressure side to the suction side when the pressure increases.
The pressure field is always under the actual system pressure.
The travel pumps deliver the hydraulic oil from the tank through the control valve block to the travel
motors and back to the tank.
Travel motor
The drums of the BMP 851 are driven by Danfoss travel motors of product range OMT 630. The two
motors per machine side are joined in series, which helps to avoid slippage of only one drum under
severe soil conditions.
BMP 851 -D6-

Service Training
The motor is bolted with its accurately machined front face oil tight to the centre frame of the machine
and is supplied with pressure oil through deep drilled bore holes in the frame. The drum is bolted to the
flange face of the output shaft.
Fig. 5 Travel motor
The positive displacement part of the motor consists of a housing integrated internally geared outer ring
with seven "teeth" and an externally geared rotor with six teeth. The shape of the teeth ensures proper
sealing between outer ring and rotor. One half of the tooth chamber formed between outer ring and rotor
is always connected with the pressure side, while the other half is connected with the discharge side.
The motor is controlled by a rotating plate valve. The following illustration described the function of the
motor.
BMP 851 -D7-

Service Training
Fig. 6 Cutaway drawing of travel motor
The intermediate shaft (4) drives valve plate (1), which thereby rotates synchronously with the rotor and
is pressed by balance plate (2) and the pressure oil against channel plate (3). The channel plate has
nine bores leading to the tooth gaps of the outer ring with the rollers. By rotation of the plate valve over
these bores the pressure oil is guided into the enlarging tooth chambers and, at the same time,
displaced out of the decreasing chambers. This orbital principle causes rotation of the rotor, which rolls
on the rollers in the tooth gaps.
The splined shaft (5) transfers the rotation of the rotor to the hollow shaft (6). The hollow shaft carries
the drive flange for the drum on its outer end. The shaft runs in two taper roller bearings.
Control valve block
The control valve block contains all control and safety elements needed in the both travel circuits and
in the vibration circuit.
These are
• 2 pressure relief valves (250 bar) for both travel circuits,
BMP 851 -D8-

Service Training
• 1 pressure relief valve (200 bar) for the vibration circuit,
• 1 shuttle valve for actuation of the brake valve
• 1 3/2-way solenoid valve for speed range selection,
• 1 two-fold flow divider,
• 1 return flow brake valve
• 2 4/3-way solenoid valve to control the travel circuits,
• 1 4/3-way solenoid valve to control the vibration.
When starting the engine with all control valves set to initial position, hydraulic oil will flow from the travel
pumps to the travel direction valves and from there back to the tank.
Fig. 7 Control valve block
When switching the travel speed range selector valve to high travel speed, the pump flow from the
vibration pump is also fed into both travel circuits through the two-fold flow divider. However, in this case
the machine cannot be operated with vibration. The flow divider outlet ports are fitted with two check
valves. These prevent oil from running out of the travel circuits into the vibration circuit.
The two control valves (14 and 15) can be operated independently from each other. This enables
operation of both machine sides with different travel speeds or even to opposite directions.
Due to this "skid steering" the machine is extremely manoeuvrable and can also be excellently
controlled under very confined spatial conditions.
The shuttle valve between both pressure lines always feeds the highest pressure (max. 250 bar) to the
reversing brake valve. This valve shuts off the return flow from the travel system to the tank when the
BMP 851 -D9-

Service Training
system is without pressure, thus preventing a pumping function of the travel motors and thereby a rolling
of the machine when the engine is stopped.
The ports on the control valve block are numbered and can thereby easily assigned to the respective
consumer ports.
P1 = Inlet vibration pump (first segment of triple pump unit)

P2 = Inlet first travel pump (second segment of triple pump unit)
P3 = Inlet second travel pump (third segment of triple pump unit)
A5.1 = Outlet to left hand travel motors (port 7 on centre frame)
B5.1 = Outlet to left hand travel motors (port 1 on centre frame)
A5.2 = Outlet to right hand travel motors (port 4 on centre frame)
B5.2 = Outlet to right hand travel motors (port 10 on centre frame)
A8 = Outlet to vibration motor
B8 = Outlet to vibration motor
Note:
Assignment of valves (Y..) see wiring diagram, sheet 202
BMP 851 - D 10 -
Service Training
Vibration
The vibration system of the machine is also hydraulically driven. The vibration system consists of
• the vibration pump,
• the speed range selector valve (in the control valve block),
• the vibration control valve (in the control valve block),
• the vibration motor and
the central exciter.The vibrator shaft in the central exciter is mounted in a tube between the front and
rear drums and is directly driven by the vibration motor.
The vibration system is designed in such a way, that it can be perfectly adapted to any operational con-
ditions.
BMP 851 -E1-

Service Training
19 19 13
12
14
A5.1 B5.1 A5.2 B5.2 A8 B8
5.1 5.2 08
18
04
11
6.1
10
6.2 09
03 250 bar
01 07
250 bar 02 200 bar

T P3 P2 P1
15
M 16
17
Fig. 1 Hydraulic diagram
01 Pressure relief valve 02 Fixed shuttle valve

03 Pressure relief valve 04 Lowering brake valve
5.1 4/3 way valve, left 5.2 4/3 way valve, right
6.1 Non-return valve - cartridge 6.2 Non-return valve - cartridge
07 Pressure relief valve 08 4/3 way valve
09 4/3 way valve 10 Flow divider
11 Control block 12 Travel system, left
13 travel system, right 14 Vibration
15 gear pump, tripple 16 Diesel engine
17 Suction filter 18 Parking brake
19 Central crossmember
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Fig. 2 Control of machine up to year 2002, S/N 101 720 03 ....
The following vibration modes are possible:
• Automatic vibration. The travel speed range selector valve (11) is set to low speed range and the
flow to the vibration control valve (16) is open. If the direction of vibration is selected with switch 15
(vibration forward or reverse) and "automatic" mode is chosen, the actuation of the travel control val-
ves (14 and 15) will effect the 4/3-way solenoid valve (16) electrically in such a way, that the sense
of rotation of the vibrator shaft corresponds with the travel direction of the machine and that it chan-
ges when reversing thetravel direction.This improves the traction of the machine. When reversing the
travel levers, the vibration will be shut down with a slight delay (0.7 seconds).
• Manual vibration control. In this control mode the operator can select the sense of rotation of the
vibrator shaft as it is required for the respective situation. He can also switch the vibration completely
off.
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Fig. 3 Control of machine from year 2003 S/N 101 720 04 ....
The chapter "electrics" contains a more detailed description of the electrical control of the valves.
The vibration circuit is protected by a pressure relief valve (200 bar) against overloads.
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Vibration pump
The vibration pump is a directly driven gear pump. The travel pumps and the vibration pump are joined
together to a triple pump unit. The vibration pump segment is the first pump section, viewed from the
drive side.
The drive pinion is connected to the diesel engine via a coupling. Drive gear and driven gear are posi-
tioned to each other by a bearing plate, so that the gears mesh with only minimal play.
Fig. 4 Vibration pump
1 Screw 2 Spring washer

3 End cover 4 O-ring
5 Backing seal 6 Bush seal
7 Bush 8 Bush
9 Housing 10 Driven pinion
11 Drive shaft with pinion 15 Flange
16 Sealing washer 17 Circlip
The pumping chambers are formed between the teeth, the housing wall and the front faces of the bea-
ring plates.
While the engine is running these chambers transport the hydraulic oil from the suction side to the pres-
sure side. This causes a vacuum in the suction line, which draws the hydraulic oil out of the hydraulic
oil tank. The chambers between the teeth transport the hydraulic oil to the pump outlet and press it out
to the consumer.
To ensure proper function of the pump, the chambers between the teeth must be so tightly sealed, that
the hydraulic oil is transported from the suction side to the pressure side almost without any loses.
External gear pumps are designed with gap seals. This results in losses from the pressure side to the
suction side, which depend on the operating pressure. To make sure that only a little quantity of oil flows
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from the pressure side to the suction side, the bearing plate on the pump cover side is pressed against
the faces of the pinions by a axial pressure field.
The pressure in the pressure field is always identical with the system pressure.
The travel pumps deliver the oil from the tank via the control valve block to the travel motors and from
there back to the tank.
Vibration control
The control elements for the vibration are integrated in the same control valve block as the control ele-
ments for the travel system. The vibration control is even linked to the travel system control as follows:
• If the machine is operated in high travel speed range, the 2/4-way solenoid valve will cut the oil flow
to the vibration motor off and send it through the flow divider and feeds it into the two travel circuits.
• When operating the vibration in automatic mode, there is an electrical connection between the travel
direction valves and the control valve for the sense of rotation of the vibrator shaft. The sense of ro-
tation of the vibrator shaft is now always identical with the travel direction of the machine, i.e. it sup-
ports tze traction of the machine. When changing the travel direction, the sense of rotation of the
vibrator shaft will also change.
In "manual" mode the vibration can be switched on and off as desired, however also only in low speed
range. In this control mode it is possible to adapt the vibrator shaft individually to the respective opera-
ting conditions.
When the vibration is switched on, the oil flow from the vibration must first of all accelerate the vibrator
shaft. The pressure caused bis this high starting resistance (starting pressure) is limited to max. 200 bar
by a pressure relief valve in the control valve block.
Once the final speed of the vibrator shaft is reached, the resistance of the vibrator shaft will decrease
and the pressure will drop to a value (operating pressure), that is determined by external influences (de-
gree of compaction of soil, condition of soil etc.).
Vibration motor
The vibration motor is a gear motor. The motor is connected to the vibrator shaft in the central exciter
housing between the front and rear drums via a Bowex coupling and drives the shaft with output speed.
The design of the vibration motor is identical with the design of the vibration pump. A more detailed de-
scription is therefore not necessary.
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Electric system up to year of construction 2002, S/N 101
720 03 ....)
Table of potentials
Potentials Meaning
30 Battery - plus,
31 Vehicle ground, battery - minus
15 is energized when the ignition is ON via relay (K11), fused with 30 A
via fuse F01
C Regulator output C
G identical with potential "15", fused with 20 A via F53
L free of potential when engine is running - ground potential when engi-
ne is stopped
K15 identical with potential "15"
Power supply (sheet 002)
Battery
The minus pole of the battery (G01) is permanently connected to the vehicle ground (potential 31).
The plus pole of the battery (G01) is connected to potential 30.
The potentials 30, 31 and B+ are always directly connected to the battery. The current flow can
only be interrupted if the battery is empty or deconnected.
Generator
The generator produces alternating current.
The generator is connected to the regulator (N01) via the two terminal clamps (G). The regulator rectifies
the alternating voltage of the generator and controls the vehicle system voltage and the charging current
for the battery.
When the engine is running the current flows through the regulator (N01), potential B+ to potential 30.
The ground potential 31 is directly connected with the regulator (-).
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When the diesel engine is running terminal „L“ of the regulator (N01) id free of potential, when the engine
is stopped it is applied to ground potential.
When the diesel engine is at standstill or the generator is defective, terminal "L" is negative (-) (ground
potential), the charge control light (H08) (Sheet 004) will light up.
Terminal "C" on the regulator (N01) provides voltage for potential "C". Potential "C" controls the opera-
ting hour meter (P00) (Sheet 004) and the engine oil pressure warning light.
Engine speed control (from S/N 101 720 03 1164)
The throttle control switch S127 enables switching between low and high idle speed. In low idle speed
the rotary switch S127 is open.
Solenoid for engine speed control Y46 (Fig. 1)
The engine solenoid is equipped with a pick-up coil and a retaining coil. These coils are switched in se-
ries mode. The retaining coil has a considerably higher resistance than the pick-up coil. The „aux“-con-
nection is arranged between both coils. The solenoid contains a switch, which is directly mechanically
connected with thegovernor rod of the diesel engine. This switch bridges the retaining coil, until the end
position o0f the governor rod is reached (high speed)
K114
1
aux +
2
5 3
3
4
-
Fig. 1 Logic sketch engine speed solenoid Y46
1 Governor rod (diesel engine 2 Switch
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3 Retaining coil 4 Pick-up coil
5 Engine solenoid
This bridging has the effect, that the same potential is applied to the „aux“-terminal as on the „+“-termi-
nal. When this bridge is opened the potential applied to the „aux“-terminal is almost identical with the
potential applied to the „-“-terminal, because of the lower resistance of the pick-up coil and the higher
resistance of the retaining coil.
High speed
When closing S127 (switching to high speed), current flows to control input 15 as well as to the signal
input 30 of relay K113.
Timer relay K13 switches the input signal (30) from output contact 87a to output contact 87 one second
after control voltage has been applied to input 15.
That means that the timer relay enables current to flow for 1 se4cond via output 87a to the coil of relay
K97, after switching over to high speed.
In this time the contact of relay K97 closes and the „+“-contact of the engine solenoid Y46 is energized.
At the same time +12V is applied to terminal 86 of relay K114.
The engine solenoid responds via the pick-up coil and moves the governor rod of the diesel engine to-
wards high speed. The voltage of +12V is still applied to contact 85 of relay K114. Under this condition
+12V is applied to K114 from both sides and the relay does therefore not react.
Only when the end position of the engine solenoid is reached (full speed) the governor rod will open the
switch inside the solenoid. Current flows now in series through the retaining coil and then to the pick-up
coil. Due to the low resistance of the pick-up coil a potential almost similar to ground is applied to termi-
nal „aux“ and to terminal 85 of relay K114. Relay K114 responds and the contact of the relay closes.
The coil of relay K97 is thereby directly and independently energized by the timer relay K113 (self-
latching function).
If the end position is not reached within aone second after switching on S127 because of an incorrect
adjustment of the governor rod, the internal switch of Y46 will not6 open and 12V remain applied to con-
tact 85 of relay K114. In this case relay K114 will not switch. K97 will then only be supplied via the timer
relay K113. However, since relay K113 switches over to contact 87 after one second, relay K97 drops
off, the engine solenoid is no longer energized and the engine speed drops back to low idle speed. This
circuitry thereby protects the strong pick-up coil against overloads caused by too long current cycles in
case of an incorrect adjustment of the governor rod/engine solenoid.
The Load-Dump-Module switched parallel by the engine soilenoid protects the electrical system of the
machine against voltage peaks, which may occur when switching the engine solenoid on and off.
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Starting (sheet 003)
Ignition switch (S00) in position "0" (ignition off)
The ignition switch (S00) is permanently provided with current via potential 30, fuse (F54) and the switch
(S101) in position „cable remote control“.
The connection to the terminals 15/54 and 50a is interrupted.
Ignition switch (S00) in position "I" (ignition on) with the engine at standstill
Current flows now from terminal 30 on the ignition switch (S00) to the output terminal 15/54.
From here the coil of relay (K11), terminal 30 to 87 is provided with current via the diode (V01). die Spule
von Relais (K11) Klemme 30 auf 87 mit Strom versorgt.
The relay closes and connects potential 30 with potential 15 via the fuse (F01) (Sheet 002).
Potential 15 energizes:
• potential G, reversing protection, via fuse (F53),
• and potential C incl. inclination switch via fuse (F04).
Starting with ignition switch in position "II"
To start the engine:
• the travel levers (S55) and (S75) (Sheet 009) must be „0“-position. Thereby the the vibration module
(A03) (Sheet 007) connects terminal 50a of (S00) and terminal 86 of relay (K39).
• the inclination sensor (B56) (Fig. 3) must not interrupt the current flow to the coil of relay (K68),
• the solenoid valve (Y58) to shut off the fuel supply must be energized via the time relay (K37).
Current flows now from terminal 50a on the ignition switch (S00) to the coil of relay (K11).
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The contact closes and the current will flow:
• from potential 15,
• via fuse (F53),
• the closed contacts of relay (K68) for the inclination sensort
• and the closed contacts of relay (K39)
• to the starter (M01).
The starter will turn and the engine will start.
Ignition switch (S00) in position "0" (ignition off) with the engine running
When turning the ignition switch (S00) to position "0" while the engine is running, potential 15 will drop
off and the solenoid valve (Y58) to shut of the fuel supply closes. The diesel engine will stop.
Monitoring (sheet 004)
When the engine is not running and the igntion is switched on, potential "L" is ground potential.
Current flows:
• from potential 15,
• via fuse (F04),
• and potential C to the coil of relay (K92).
The coil is energized and the contact (K92) opens. The current supply for the operating hour meter (P00)
is interrupted.
Charge control light (H08) and engine oil pressure warning light (H09) are energized and light up.
When the engine is running potential "L" is free of potential. The relay (K92) cannot be energized and
the charge control light (H08) does not light.
The operating hour meter (P00) is energized by potential "C" and counts the operating hours.
The ground supply for the oil pressure warning light (H09) is interrupted when the pressure switch (B06)
opens, the warning light goes out.
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If the machine is working on an inclination of more than 45° (risk of overturning), the coil of relay (K68)
is no longer energized via potential C.
The contact (K68) (Sheet 003) opens and interrupts the current supply to the time relay (K37) (Sheet
003) and thereby to the solenoid valve (Y58) to shut-off the fuel supply. The diesel engine will stop.
If the engine oil pressure drops while the engine is running (lack of oil), the input of relay (K37), terminal
S-, is provided with ground potential. The time relay starts and interrupts the current supply to the fuel
shut-off valve (Y58)after 8 seconds. The diesel engine will stop. At the same time the warning buzzer
(H07) is energized via the time relay (K37), terminal 87, the warning buzzer will sound.
Brake (sheet 006)
If the machine is driving in reverse and the reversing protection is operated, the proximity switch (B41)
will interrupt the current flow to the coils of the relays (K72) and (K88).
The current flow to the solenoid valves (Y17) "forward travel, left" and (Y73) "reverse travel, right" is in-
terrupted and the machine will stop.
Vibration (sheet 007)
Automatic vibration
When switching the switch (S08) to „Automatic“, current will flow:
• from potential K15
• via fuse (F03)
• to the vibration module (A03), input terminal # 9.
Automatic vibration is activated.
To make sure that the vibration will start when shifting the travel lever out of neutral, the vibration switch
(S36) (sense of rotation) must additionally be switched to any desired position.
If the travel levers (S55) and (S75) (Sheet 009) are now shifted to the same direction, the solenoid valve
(Y22) "vibration reverse" or (Y71) "vibration forward" will be energized, depending on the travel direc-
tion.
The vibration will start.
When changing the travel direction, the sense of rotation of the vibrator shaft will also change automa-
tically .
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Driving with vibration is only possible in speed range 1. For this purpose the current supply is interrupted
on output #4 of the vibration module (A03). The solenoid valve (Y03) for the second speed range (Sheet
009) is no longer energized.
When moving both travel levers to opposite directions (skid steering), the vibration module will switch
the vibration off after 0.7 seconds, until the steering motion is finished.
Manual vibration
If the switch (S08) is in position „manual“, the vibration module (A03) does not receive an input signal
at terminal #9.
The vibration and the sense of rotation of the vibrator shaft must now be selected with the switch (S36).
In position vibration "reverse" current flows:
• from switch (S36),
• via fuse (F78),
• input on vibration module (A03) terminal #13,
• output of vibration module terminal #15
• to the solenoid valve (Y22).
The vibrator shaft rotates backwards.
In position vibration "forward" current flows:
• from switch (S36),
• via the fuse (F81),
• input on vibration module (A03) terminal #10,
• output of vibration module terminal #12
The vibrator shaft rotates forward.
Start lock
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If one or both travel levers are actuated, the current flow from terminal 50a on the ignition switch (S00)
(Sheet 003) to coil of relay K39 is interrupted between terminals #16 and #18 on the vibration module
(A03). (K39) cannot close and the engine cannot be started.
Only if all travel levers are set to „0“-position, the connection between terminals #16 and #18 on (A03)
is reestablished.
(K39) can now be closed via the ignition switch (S00) and the engine can be started.
Emergency operation
In case of a failure of the vibration module, ther cable from terminal #15 can be plugged to # 14 and the
cable from terminal #12 can be plugged to terminal # 11.
The second travel speed range can also be bridged by changing the cable from terminal #3 to terminal
#4.
The starting lock can also be bridged by plugging the cable from terminal #18 to terminal #17.
Travel speed range selection (sheet 009)
When moving the left hand travel lever (S55) to travel direction forward, current will flow:
• from potential K15,
• switch (S55),
• fuse (F55),
• diode (V05),
The left hand travel drive will be activated in forward.
In addition a signal LF flows to the vibration module (A03) (sheet 007) for the vibration control.
When moving the left hand travel lever (S55) in reverse direction, current will flow:
• switch (S55),
• fuse (F56),
• diode (V06),
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Service Training
• relay (K88) (if the reversing protection is not actuated),
The left hand travel system is activated in reverse.
In addition a signal LF flows to the vibration module (A03) (sheet 007) for the vibration control.
The travel control for the right hand travel lever is accomplished by the switch (S75) to the solenoid val-
ves (Y72) "forward travel, right" and (Y73) "reverse travel, right".
When the switch (S42) is closed, current will flow:
• fuse (F26),
• relay K45 (if the dashboard flap is folded in)
• vibration module (A03) input #2 (sheet 007),
• vibration module (A03) output #4 (sheet 5),
• diode (V04),
The machine drives in the 2. speed range.
If the dashboard flap is folded down (see illustration), the potential between potential K15 and coil of
relay K45 is interrupted by the proximity switch (B86). (K45) drops off and the valve for speed range 2
(Y03) changes to speed range 1.
When switching the vibration off or when moving the travel control levers to opposite directions
(skid steering), the vibration module (A03) will switch the 2. speed range off.
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Electric system from year of construction 2003, S/N 101
720 04 ....)
Table of potentials
Potentials Meaning
30 charging Battery plus - charge voltage for charging of remote control via spiral
cable
30 K Battery plus - supply of remote control via F54, protected with 5A
30 S Battery plus - supply for diagnostic plug
31 Vehicle ground battery minus
15 is supplied via relay (K11) when ignition is ON, protected with 10 A by
F103
C Regulator - output C
L Potential free when engine is running - ground potential when engine
is stopped
W Rotation signal from diesel engine
Power supply
Battery
The minus pole of battery (G01) is permanently connected to vehicle ground (potential 31).
The plus pole of battery (G01) is connected to potential 30.
Potentials 30S, 31, B+, 30charging and 30K are always directly connected with the battery. The
current is only be interrupted if the battery is empty or disconnected.
Generator
The generator produces alternating current.
It is connected to regulator (N01) through both terminals (G). The regulator rectifies the alternating
current produced by the generator and regulates both the mains voltage and the charge current for the
battery.
When the engine is running current flows through regulator (N01), potential B+ to potentials 30charging,
30K and 30S.
Ground potential 31 is connected with regulator (-) through battery ground strap, engine ground strap
and engine block.
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When the engine is running, terminal "L" on regulator (N01) potential free, when the engine is stopped
it has ground potential.
With the engine stopped or a defective generator terminal L becomes negative (-) (ground potential),
charge control light (H08) (sheet 002) can light.
Terminal „C“ of regulator (N01) informs the regulator about the actual voltage on potential 15.
Throttle control
The throttle control switch S127 enables switching between low and high idle speed. At low idle speed
the rotary switch S127 is open.
Throttle control solenoid Y46 (Fig. 1)
The throttle control solenoid has a pickup winding and a holding winding connected in series. The
holding winding has a far higher resistance than the pickup winding. The "aux"-terminal is connected
between both windings. The solenoid has an integrated switch, which is directly mechanically connected
with the engine governor rod. This switch bridges the holding winding, until the end position of the
governor rod (high speed) is reached.
K97
X3:9 +
A 70 -
Modul 1
X3:4
aux +
2
5 3
4
-
Fig. 1 Circuit sketch for throttle control solenoid Y46
1 Engine governor rod 2 Switch

3 Holding winding 4 Pickup winding
5 Engine solenoid
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The bridging has the effect that the same potential is applied to the "aux"-terminal as to the "+" terminal.
If the bridging is opened almost the same potential is applied to the "aux"-terminal as to the "-" terminal,
because of the low resistance of the pickup winding and the high resistance of the holding winding.
High engine speed
When S127 is closed (switched to high engine speed), current flows through terminal X2:3 to the
corresponding input on the cable remote control: Now the cable control integrated CAN bus (A69) sends
a signal to module A70 through lines CAN+ and CAN-. As a result, A70 applies 12V to K97, terminal 86,
through output X3:9.
The engine solenoid picks up the pickup winding and moves the governor rod of the engine towards
high engine speed. At that time +12V is still applied to the "aux"-terminal of the engine solenoid.
Only when the end position of the engine solenoid is reached (full speed), the governor rod will open the
switch in the engine solenoid. Current now flows successively through the holding winding and then
through the pickup winding. Due to the low resistance of the pickup winding the potential applied to
terminal "aux" and terminal X3:4 is almost identical with ground potential.
If the end position is not achieved when switching on S127 because of a wrong adjustment of the
governor rod, the internal switch of Y46 will not open and 12V is still applied to terminal X3:4. Power
module A70 switches output X3:9 to ground with a one minute delay, K97 drops off, the engine solenoid
is no longer energized and the engine returns to low idle speed. This circuitry thereby protects the strong
pickup winding against overloads caused by excessive energizing periods in case of incorrectly
adjusted governor rod/engine solenoid.
Starting
Ignition switch (S00) in position "0" (ignition off)
The ignition switch (S00) is permanently supplied with electric power by potential 30K, via fuse (F54)
and switch (S101) in position "cable remote control".
The connection to terminals "Engine start" and "Ignition on" are interrupted.
Ignition switch (S00) in position "I" (ignition on) with the engine at rest
Current flows through terminal X2:3 into input "Ignition on" of the cable remote control. Now the cable
control integrated CAN bus (A69) sends a signal to module A70 through lines CAN+ and CAN-. Module
A70 then applies 12V to K11, terminal 86, through output X3:7 and also 12V to terminal 1 of the fuel
valve Y58 through output X3:10.
The relay closes and connects potential 30S with potential 15 through fuse (F01) (sheet 002).
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Service Training
Potential 15 now supplies:
• the protection of the transmitter holder
• the inclination switch B56
• potential C of the regulator
• the display module P18
• and the control lights H08 and H09.
Ignition switch in position "II" starting
To start the engine:
• the travel levers (S55) and (S75) must be in position "0".
• the inclination sensor (B56) must not have interrupted the current flow to terminalX3:23 on module
A70
Current flows through terminal X2:3 into input "Engine start" of the cable remote control. Now the cable
control integrated CAN bus (A69) sends a signal to module A70 through lines CAN+ and CAN-. As a
result, A70 applies 12V to K39, terminal 86, through output X3:6.
The contact closes and current flows:
• from the potential of battery terminal +,
• via fuse (F119),
• to the starter (M01, terminal 50).
The starter rotates and starts the engine.
Ignition switch (S00) in position "0" (ignition off) with the engine running
When turning the ignition switch (S00) to position "0" while the engine is running, the current flow to the
input "Ignition on" on the cable remote control is interrupted. Now the cable control integrated CAN bus
(A69) sends a signal to module A70 through lines CAN+ and CAN-. Module A70 then applies 0V to K11,
terminal 86, through output X3:7 and also 0V to terminal 1 of the fuel valve Y58 through output X3:10.
The fuel shut-off solenoid valve (Y58) closes. The engine stops.
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Service Training
Monitoring
With the engine stopped and ignition switched on potential L is ground potential.
Charge control lamp (H08) and engine oil pressure warning lamp (H09) are supplied with current and
light up.
At the same time ground potential is applied to module A70 through terminal X3:2. The module
integrated operating hour meters is interrupted by an internal logic.
With the engine running potential L is potential free. Charge control lamp (H08) does not lights.
Module A70 detects the voltage on potential L through terminal X3:2. The module integrated operating
hour meter is started by an internal logic.
The ground supply for oil pressure warning lamp (H09) is interrupted by opening of the pressure switch
(B06), the warning lamp goes out.
If the machine is subjected to inclinations beyond 45° (machine has turned over), the inclination sensor
B56 will interrupt the current flow to terminal X3:23 on module A70 . Through an internal logic the
module then applies 0V to K11, terminal 86, through output X3:7 and also 0V to terminal 1 of the fuel
valve Y58 through output X3:10. The engine stops.
If the engine oil pressure drops while the engine is running (lack of oil), module A70 will apply 0V to
terminal K11, terminal 86, and 0V to terminal valve of the fuel valve Y58 after a period of 8 seconds
through an internal logic. The engine will stop and the warning horn is supplied with 12V through X3:8
and X3:36 and sounds.
Brake
When the machine drives in reverse and the back-up protection bow is actuated the initiator (B41) will
interrupt the current flow to terminal X3:27 on module A70.
An internal logic in the module applies 0V to terminal 1 on solenoid valves Y17 and Y73 for reverse travel
left and right through output X3:21 and X3:24. The machine stops.
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Service Training
Vibration
Automatic vibration
When switching the switch (S08) to position "Automatic, module A70 switches the valves for vibration
in forward and reverse according to the following logic:
If travel levers (S55) and (S75) are operated to the same travel direction, one of the solenoid valves
(Y22) for vibration in reverse or (Y71) vibration in forward is triggered, depending on the chosen travel
direction.
The vibration starts running.
When changing the travel direction the sense of rotation of the exciter shaft will change accordingly.
Driving with vibration is only possible in first speed range. The solenoid valve (Y03) for second speed
range (sheet 009) is no longer excited.
When moving the two travel levers to opposite directions (skid steering), the vibration module will shut
down vibration after 0.7, until skid steering is finished.
For the vibration to start when actuating the travel levers the vibration switch (S36) (sense of rotation)
must additionally be switched to any direction.
Manual vibration
When the switch (S08) is in position „Manual“ the vibration must be switched on and the sense of exciter
shaft rotation selected with switch (S36).
Valves Y22 and Y71 (vibration forward/reverse) are triggered by the logic of module A70 according to
the manually selected sense of rotation.
The solenoid valve Y03 for second speed range is no longer energized once switch S36 is out of "0"
position. Driving with vibration is only possible in first speed range.
Start interlock
If one or both travel levers are actuated the internal logic of module A70 interrupts the current flow to
terminal 86, relay K39. The engine cannot be started.
The engine can only be started after the travel levers have been returned to "0"-position.
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Travel speed range selector
By actuation of the travel levers S55 and S75 the cable control integrated CAN bus (A69) sends
corresponding signals to module A70 through lines CAN+ and CAN-. The internal logic of the module
energizes the solenoid valves 0V or 12 V, so that the machine drive forward or backward accordingly.
When closing switch S42, the internal logic in module A70 will switch 12 V to solenoid valve Y03 through
terminal X3:11. The machine drives in second speed range.
With the dashboard flap folded down (see illustration) the connection to terminal X3:25 on module A70
is interrupted. The internal logic of module A70 switches the output X3:11 to 0V. The valve for 2nd speed
range (Y03) drops back to 1st speed range.
When switching on vibration or when moving the two travel levers to opposite directions (skid
steering) module (A70) switches the 2nd speed range off.
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Fig. 2 Arrangement of central electrics; Assignment of components see wiring diagram, sheet 201/
202
BMP 851 -G8-

Service Training
Fig. 3 Arrangement of central electrics; Assignment of components see wiring diagram, sheet 201
left
BMP 851 -G9-

Department TES
Description of function/logic of the Multi

Purpose Compactor BMP 851
- New design remote control -
Status March 2003
This description requires the wiring diagram: BMP 851 with CAN Bus
1. General:
All information is permanently communicated via a CAN - Bus, i.e. any depressed/not depressed
button is immediately reported to the receiver. This means, the machine is permanently aware of all
transmitter switch positions.
During the transfer of data the LED on the transmitter flashes green or lights permanently green (cable
operation). However, this does not mean that data are received from the machine. With this system no
data are transmitted from the machine to the transmitter.
The transfer of signals from the remote control transmitter to the machine is terminated :
- when exceeding the maximum transmitting range of max. 50 m for radio or 20 m for infrared
remote control
- if the radio or infrared control connection is interrupted by a fault or an obstruction for longer than
2 seconds
- in case of a power failure on transmitting or receiving unit
- in case of faults in the remote control electronics
- in case of interruption of the cable connection during cable operation
Standards:
EN 500 part 4 status May 1997

BGR 149 (previously ZH1/295)
2. Ignition on ( S00 )
To switch on the ignition it is necessary that
1. the main battery switch (S 30) is switched on,

2. the remote control selector switch (S 101) is in position cable or wireless operation
Then turn ignition switch (S00) to position 1. The transmitter is switched on. The starting sequence of
the internal electronics is executed and, with infrared or radio remote control, the transmitting range is
built up. The transmitter is not able to check the quality or the existence of the transmitting path! After
this the warning buzzer inside the transmitter will sound 2 times, if the transmitter electronics is free of
faults. If the emergency stop button (S01) has not been activated, the activation contact of the remote
control will be switched at the same time.
On the radio/infrared remote control it may take up to 10 seconds to switch on the activation contact
when the radio receiver is in sleep mode. Once the activation contact on the remote control has been
switched on, the actual control of the machine (BLM module) is started. During the making operation
relay K11 and BMFSD (BOMAG Fault Status Display) as well as the control lamps for oil pressure and
charge control are switched on. After successful completion of the making operation the warning horn
will sound once for a short time.
Ch.Fondel, Abt. TES LogikFunktionBMP_gb.doc 1 von 5

09.04.03
Department TES
The machine can now be started. Fuel valve (Y58) is now switched. After short actuation of the horn
button all hydraulic valves can now be controlled from the remote control. Apart from this it is also
possible to make entries in the BMFSD.

09.04.03
Department TES
3. Starting ( S00 )
To start the engine turn the ignition switch (S00) clockwise to the stop (position 2) and hold it in this
position until the engine has started.
Further starting attempts are only possible after switching the ignition off (position 0). When the
ignition switch is turned to position 0, the transmitter transmits the command "engine off" and switches
off automatically. If the transmitter is switched off by the ignition switch, it takes 2 seconds until the
engine receives the final command to shut down. The ignition can only be switched on again and the
engine restarted after the engine has stopped. During the starting process the engine solenoid Y26 is
energized, independently from the position of the switch for engine speed (S127).
During the starting process the switch for vibration (S 36) and the travel levers must not be actuated,
because otherwise the electronics would prevent starting of the engine for safety reasons.
4. Engine speed switch (S127)

This push button has 2 positions, high and low engine speed
In position "high engine speed" the engine solenoid Y 46 is energized.
In position "low engine speed" the engine solenoid Y 46 is not energized.
5. Travel lever (S55, S75)

These travel levers (buttons) are used to control the travel movements of the machine.
In "automatic vibration mode" the travel signals are evaluated to switch on and control the direction of
vibration.
Depending on the position, the 2nd speed range will be shut down.
6. Speed range selector switch (S42)

This switch has 2 positions, for 1st and 2nd speed range.
In position "2nd speed range" solenoid Y03 is energized.
Shut off conditions for 2nd speed range (in remote control operation) :
Switch S36 is not in neutral position or
left and right hand travel levers are actuated to opposite directions
Shut off conditions for 2nd speed range (in all cases) :
With the remote control flap folded open the 2nd speed range is disabled.
If the shut-off conditions do not exist the 2nd speed range should only be reactivated with a delay of
approx. 0.6 to 0.7 seconds.
Reasons for the temporal delay:

If switch S36 is quickly switched from vibr. forward to vib. reverse“,
the 2nd speed range would for a short moment be activated when shifting through 0-position.
When changing quickly from counter-rotating steering (S55, S75) to the left to counter rotating steering
to the right the 2nd speed range would be activated for a short moment when shifting through 0-
position.
7. Switch for vibration man./auto (S08)

This switch has 2 positions, manual and automatic vibration.
The functions of this switch are closely related with switch S36.

09.04.03
Department TES
8. Schalter for vibration manR/0/manF (S36)

The functions of this switch depend on switch S08.
- Switch S08 in position „man“ and switch S36:
in position 0: vibration is off
in position R: vibration in reverse switched on (Y22) and the 2nd travel speed switched off.
in position F: vibration in forward switched on (Y71) and the 2nd travel speed switched off.
- Switch S08 in position „auto“ and switch S36:
in position 0: vibration is off
in position R or in position V: 2nd speed range is switched off.
Depending on operation of the travel levers the logic module decides on the direction of
vibration.
Both travel lever forward:
Vibration switched on in forward (Y71)
Conditions for maintaining this control :
At least one of the travel levers must be position "forward", the second travel lever
may be in "0"-position at the same time.
Conditions for shut down of vibration:
Both travel levers have been returned to "0"-position or the travel levers are actuated
to opposite directions (e.g. left forward and right reverse)
To switch on the vibration both travel levers must be actuated to the same direction.
Both travel levers in reverse:
Vibration switched on in reverse (Y22)
Conditions for maintaining this control :
At least one of the travel levers must be position "reverse", the second travel lever
may be in "0"-position at the same time.
Conditions for shut down of vibration:
Both travel levers have been returned to "0"-position or the travel levers are actuated
to opposite directions (e.g. left forward and right reverse).
To switch on the vibration both travel levers must be actuated to the same direction.
Shut down of vibration by operating the travel levers to opposite directions with a delay of 0.6 to 0.7
seconds.
If both travel levers are returned to "0"-position the vibration will be switched off immediately.
09.04.03
Department TES
9. Safety bow with switch (B41)

If the safety bow is not operated the machine will travel in reverse as soon as the travel levers (S55
and S75) are actuated. If the machine reverses and the bow is actuated, the reverse motion will stop
immediately (Y17 and Y73 are disabled). When returning the bow to initial position after being
actuated, travvelling of the machine can only be resumed after returning the travel levers to neutral
position.
10. Inclination switch (B56)

If the inclination switch does not emit a signal to the BML module for more than 1 second, the engine
will be shut down for safety reasons.
11. BMFSD - display module

During the making process the module shows the code 7101 for a period of 2 seconds, this is the so-
called machine type code, which documents the correct software setting. After this the display
permanently shows the expired operating hours. This value is saved in the machine control and
cannot be changed. If this display shows a flashing code, this is a fault code or a warning. The
meaning of these codes is listed in the table at the end.
12. Horn
The warning horn on the machine can be operated by pressing the corresponding horn button on the
transmitter (S 03).
The horn also sounds :
• when the machine is ready for starting

• in case of a severe fault (e.g. lack of oil when the engine is running)
• partly also in case of warnings (see fault code table at the end)
13. Charging the transmitter, cable operation of a radio remote

control
Under optimal conditions the powerpack in the radio transmitter has a capacity of max. 100h. After this
time the powerpack needs to be recharged. Recharging can be performed in an external battery
charger or inside the transmitter.
If the transmitter switches off during operation because of a too low battery capacity, the transmitter
may still be used for normal cable remote control operation. For this purpose connect the transmitter
with the spiral cable on the machine and set the operating mode switch (S101) to cable operation.
After this the machine must be restarted. During cable operation the power pack is recharged. If the
power pack is to be recharged without the engine running (e.g. over night) it is enough to connect the
spiral cable with the transmitter. The main battery switch (S 30) must be switched on, the operating
mode switch (S101) is of no significance for the recharging process. The recharging function is
automatically switched off by the micro controller inside the transmitter when the recharging process is
finished. This avoids further discharging of the machine battery.

09.04.03
Documentation
BMP 851
with
CAN - Bus Remote Control and
BLM Module
Autor: Ch. Fondel, TES

Stand: 09.10.2002
Version: 1.00
Table of contents
Table of contents
TABLE OF CONTENTS ............................................................................................. 2
1 CONFIRMATION OF CHANGES ......................................................................... 4
2 FUNCTIONS OF THE BLM CONTROL ............................................................... 5

2.1 Description of the display module ............................................................................................ 5
2.2 Input of code numbers ............................................................................................................... 5
2.3 Showing stored faults ................................................................................................................ 6
2.4 Deletes all stored faults.............................................................................................................. 6
2.5 Adjusting the machine type ....................................................................................................... 7
2.6 Adjusting the type of remote control ........................................................................................ 8
3 DESCRIPTION OF THE SIGNALS ON THE BML CONTROL............................. 9
4 FAULT CODES AND WARNING MESSAGES OF THE BLM CONTROL ........ 11

4.1 Overview .................................................................................................................................... 11
4.2 Fault codes of travel functions................................................................................................ 12
4.3 Fault codes of work functions ................................................................................................. 15
4.4 Fault codes of remote control ................................................................................................. 16
4.5 General fault codes diesel engine, machine .......................................................................... 17
4.6 Faults in parameterization ....................................................................................................... 20
5 INPUT CODES FOR BLM CONTROL ............................................................... 21

5.1 Outputs for travel functions..................................................................................................... 21
5.2 Outputs for work functions...................................................................................................... 23
5.3 Inputs logic and power module ............................................................................................... 24
5.4 Diesel engine, machine electrics............................................................................................. 25
5.5 Checking the function of the remote controls ....................................................................... 27
5.6 System information................................................................................................................... 28
5.7 Setting the remote control type............................................................................................... 28
Ch.Fondel, Dept. TES DokuBMP851_gb.doc Page 2 of 29

Version 1.00 dated 17.02.03
Table of contents
5.8 Fault log ..................................................................................................................................... 28
5.9 Reading out the operating hour meter.................................................................................... 28
5.10 Setting the machine type...................................................................................................... 29
Ch.Fondel, Abt. TES DokuBMP851_gb.doc

Version 1.00 vom 17.02.03
Confirmation of changes
1 Confirmation of changes
No. Date Description of changes resp.
1 19.06.2002 Creation of version 1.00 Ch. Fondel
2 09.10.2002 Revision of version 1.00 Ch. Fondel

Functions of the BLM control
2 Functions of the BLM control

During normal and trouble-free operation the so-called BMFSA display module informs about the
operating hours the machine has performed with the engine running. During the first 2 seconds after
starting the machine the so-called machine type code (7101 for BMP 851)is displayed. Then the
display automatically changes to the operating hours. The operating hours are registered in the central
control and cannot be deleted or manipulated.
2.1 Description of the display module

The display module consists of a 4-digit display and two keys, F1 and F2.
The display module is used for the output of fault codes and display values as well as for the input of
code numbers.
An occurring fault is indicated by flashing. If several faults are detected, the displayed fault codes will
change in a 3 second cycle.
Display values such as machine type code and operating hours are permanently displayed.
Values ranging from 0 0 0 0 ...9
9 9 9 9 can be displayed. Higher values will trigger the display „9999
9999“.
9999
Negative values are indicated by flashing of the „Minus LED“. The display module can only show
values when the potential 15 (relay K11) in the machine is switched. If the ignition is switched
on, the warning horn sounds in intervals and the module remains dark, potential 15 is not
applied. See also fault 5060 ff.
The following description describes the input of code numbers.
Vorzeichen
057 667 72
15/54
2.2 Input of code numbers

For the display of operating states and for the diagnose of control inputs and outputs various code
numbers must be entered on the display module of the control. The input of a code number is
performed as follows:
1. Press both keys (F1 and F2) on the display module for 2 seconds.
. The value 0 0 0 0 will be displayed, whereby the 1st digit is flashing.
2. The value of the flashing digit can be increased by pressing the left hand key (F1). When the figure
9 is displayed and the left hand key (F1) is pressed again, the display will return to the value 0 .
3. When pressing the right hand key (F2) the flashing digit will move one digit to the right. When the
4th digit is flashing, the right hand key (F2) is pressed once again to confirm the input. The desired
function is then executed or the desired value is displayed respectively.
In order to terminate a display function you must either enter code number 0 0 0 0 or switch the ignition
off.

2.3 Showing stored faults
The ten latest faults are stored in the central control.

Switch on function „Show stored faults“:
• Enter code number 0 7 0 0 . This code number enables the function „Show stored faults“.
Switch off function „Show stored faults“:

• Enter code number 0 7 0 I . This code number disables the function „Show stored faults“.
Note: Apart from the stored faults the current faults are also displayed.
2.4 Deletes all stored faults
Execute the function „Delete all stored faults“:

• The engine must not be running!
• Enter code number 0 7 1 0 . This code number deletes all stored faults.
Note: The stored faults can only be deleted when the engine is not running.

2.5 Adjusting the machine type
Since this control is used on two machines with CAN - Bus remote control it is necessary to adjust the
central control to the corresponding machine type or remote control when switching it on for the first
time. On new machine this adjustment is made during production. This adjustment is only required
when replacing a central control unit in the field.
The machine type can be checked by entering the code 7010. 7010 If no machine type is adjusted the fault
code 7011 will be displayed when switching on the first time.
The following machine types can be adjusted:
Machine type Machine type code

BMP 851 7101
BPH 80/65 S 7102
Note: Parameter adjustments can only be performed when the engine is not running.
• Enter code number 7 0 1 0 . This code number activates the function "Adjusting machine type“.
The display module now permanently shows the code 7 0 1 0 .
• select and enter the machine from the table above.
The display module now permanently shows the entered code. (e.g. 7 1 0 1 )
• Enter code number 7 0 1 1 . This code number confirms the entered machine type.
After confirming the machine type the control switches off and back on again. The machine type is
thereby displayed for 3 seconds (e.g. 7 1 0 1 ). Hereafter the machine type is always displayed for 3
seconds when switching on the ignition.
Attention: A machine must not be operated with a wrong type adjustment, because in such a
case the correct function of the control cannot be assured!
On new controls the machine type is not adjusted. The warning 7010 appears in the
display.

2.6 Adjusting the type of remote control
Since this machine may be equipped with two different types of wireless remote controls the machine
control needs to be informed about the control type presently used
The remote control type can be checked by entering the code 0665.
0665
The following machine types can be adjusted:
Remote control type Type code

Radio remote control 0662
Infrared remote control 0663
Note: Parameter adjustments can only be performed when the engine is not running.
• Enter code number 0660.

0660 This code number activates the function "Adjusting remote control type“.
The display module now permanently shows the code 0 6 6 0 .
• select and enter the remote control type from the table above.
The display module now permanently shows the entered code. (e.g. 0662)
0662
• Enter code number 0 6 6 1 . This code number confirms the entered remote control type.
After confirming the remote control type the control switches off. The control automatically switches on
again is now ready for starting.
Attention: A machine must not be operated with a wrong type adjustment, because in such a
case the correct function of the control cannot be assured!
On new controls the remote control type 0662 (radio remote control) is set as default.

Description of the signals on the BML control
3 Description of the signals on the BML control

Notes:
Wherever the value of 12 V is mentioned in the following text it refers to the current battery
voltage under due consideration of voltage drops in the lines.
BML terminal Signal description Nominal values (voltage / current)

X3:01 Supply, ground
X3:02 Input signal L from generator regulator, active low Regulator switches to potential free when machine is running,
otherwise to ground
X3:03 Input oil pressure switch, active low, B 06 The ground signal is applied as long as no oil pressure is present
X3:04 Input signal Aux from solenoid for rotary speed regulation The Aux signal (ground) is applied when the pin is fully retracted.
X3:05 Input not occupied
X3:06 Output relay K39, starter Relay on . 12 V
Relay off . 0 V, no consumer connected 2.9 V
X3:07 Output relay K11, changeover potential 30 to 15 Relay on . 12 V
X3:08 Output 1 horn, see also X3:36, H 07 Horn on . 12 V
Horn off . 0 V, no consumer connected 2.9 V
X3:09 Output relay K97, solenoid for rotary speed regulation Relay on . 12 V
X3:10 Output fuel valve, Y 58 Valve on . 12 V
Valve off . 0 V, no consumer connected 2.9 V
X3:11 Output hydraulic valve 2nd gear, Y 03 Valve on . 12 V
X3:12 Output hydraulic valve vibration forward Y 71 Valve on . 12 V
X3:13 Output hydraulic valve vibration reverse, Y 22 Valve on . 12 V
X3:14 Input voltage supply 12 V to ground
X3:16 Serial interface RS 232 RxD Measurement not possible!!
X3:17 Serial interface RS 232 TxD Measurement not possible!!
X3:18 not used
X3:19 Output hydraulic valve driving left forward, Y 16 Valve on . 12 V
Ch.Fondel, Abt. TES DokuBMP851_gb.doc 9 von 29

Description of the signals on the BML control
BML terminal Signal description Nominal values (voltage / current)

X3:20 Input 5, not used
X3:21 Output hydraulic valve driving left reverse, Y 17 Valve on . 12 V
X3:22 Output hydraulic valve driving right forward, Y 72 Valve on . 12 V
X3:23 Input inclination sensor, active high, B 56 Positive signal (+12V) , is applied when machine is not inclined.
X3:24 Output hydraulic valve driving right reverse, Y 73 Valve on . 12 V
X3:25 Input proximity switch, flap on remote control, B 09 Switch sends positive signal, when flap is folded down.
X3:26 Output 13, not used
X3:27 Input proximity switch for safety bow, B 41 Switch sends positive signal, as long as the bow is not operated.
X3:30 CAN - Bus, CAN - Measurement not possible!
X3:31 CAN - Bus, CAN + Measurement not possible!
X3:32 Serial interface RS 232 BSL Measurement not possible!
X3:36 Output 2 horn, see also X3:08, H 07 Horn on . 12 V
Horn off . 0 V, no consumer connected 2.9 V
X3:37 Activation input, cable remote control, S 101 Set selector switch for remote control type to cable, switch on remote
control, switch on ignition, emergency stop not operated . 12 V
X3:39 Activation input, IR- or radio remote control, S 101 Set selector switch for remote control type to wireless, switch on
remote control, switch on ignition, emergency stop not operated
. 12 V

Fault codes and warning messages of the BLM control
4 Fault codes and warning messages of the BLM control

4.1 Overview
Fault code : Function Group : Remark:

1000 – 1999 Travel system only 4-digit
2500 – 2999 Remote controls only 4-digit
5000 – 5499 Diesel engine only 4-digit
7000 – 7499 Input codes for machine parameterization only 4-digit
7500 - 7999 Operating hour meter, load spectrum (input codes) only 4-digit
8000 – 8999 severe software fault only 4-digit
9000 - 9998 External IO nodes, joysticks, data collectors (CAN communication and hardware defects ) only 4-digit
9999 Unknown fault, display value higher than +- 10000, is automatically displayed by the BMFSA only 4-digit

4.2 Fault codes of travel functions
Code Fault reaction Fault description Possible cause Terminal Input

on BLM code for
diagnose
10I0 Output is switched off, function no Output valve driving left forward, Y 16 . Excessive current flow in current path, X3:19 -
longer possible The current flow from this output is too high probably because of a defective coil or
. output was switched off! a short circuit to ground
1011 Output is switched off, function no Output valve driving left forward, Y 16 . Short circuit to ground in the current X3:19 -
longer possible Short circuit current flowing from this output path
. output was switched off! . Lines rubbed through
. Valve defective
1012 Output is switched off, function no Output valve driving left forward, Y 16 . Wire breakage in current path X3:19 1010
longer possible No or too low current flow out of this output . Current path connected to +12V 1011
1012
1013 Engine is shut down Output valve driving left forward, Y 16 . Current path connected to +12V X3:19 1010
Although the output is switched off, voltage 1011
is present 1012
1020 Output is switched off, function no Output valve driving left reverse, . Excessive current flow in current path, X3:21 -
longer possible Y 17 probably because of a defective coil or
The current flow from this output is too high a short circuit to ground
. output was switched off!
1021 Output is switched off, function no Output valve driving left reverse, . Short circuit to ground in the current X3:21 -
longer possible Y 17 path
Short circuit current flowing from this output . Lines rubbed through
. output was switched off! . Valve defective
1022 Output is switched off, function no Output valve driving left reverse, . Wire breakage in current path X3:21 1020
longer possible Y 17 . Current path connected to +12V 1021
No or too low current flow out of this output 1022
1023 Engine is shut down Output valve driving left reverse, . Current path connected to +12V X3:21 1020
Y 17 1021
is present


on BLM code for
diagnose
1030 Output is switched off, function no Output valve driving right forward, Y 72 . Excessive current flow in current path, X3:22 -
1031 Output is switched off, function no Output valve driving right forward, Y 72 . Short circuit to ground in the current X3:22 -
. Valve defective
1032 Output is switched off, function no Output valve driving right forward, Y 72 . Wire breakage in current path X3:22 1030
1032
1033 Engine is shut down Output valve driving right forward, Y 72 . Current path connected to +12V X3:22 1030
is present 1032
1040 Output is switched off, function no Output valve driving right reverse, Y 73 . Excessive current flow in current path, X3:24 -
1041 Output is switched off, function no Output valve driving right reverse, Y 73 . Short circuit to ground in the current X3:24 -
. Valve defective
1042 Output is switched off, function no Output valve driving right reverse, Y 73 . Wire breakage in current path X3:24 1040
1042
1043 Engine is shut down Output valve driving right reverse, Y 73 . Current path connected to +12V X3:24 1040
is present 1042


on BLM code for
diagnose
1050 Output is switched off, function no Output valve 2nd gear, Y 03 . Excessive current flow in current path, X3:11 -
1051 Output is switched off, function no Output valve 2nd gear, Y 03 . Short circuit to ground in the current X3:11 -
. Valve defective
1052 Output is switched off, function no Output valve 2nd gear, Y 03 . Wire breakage in current path X3:11 1050
1052
1053 Output is switched off, engine runs only Output valve 2nd gear, Y 03 . Current path connected to +12V X3:11 1050
with idle speed Although the output is switched off, voltage 1051
is present 1052

4.3 Fault codes of work functions

on BLM code for
diagnose
1305 Output is switched off, function no Output valve vibration forward, Y 71 . Excessive current flow in current path, X3:12 -
1306 Output is switched off, function no Output valve vibration forward, Y 71 . Short circuit to ground in the current X3:12 -
. Valve defective
1307 Output is switched off, function no Output valve vibration forward, Y 71 . Wire breakage in current path X3:12 1305
1307
1308 Output is switched off, engine runs only Output valve vibration forward, Y 71 . Current path connected to +12V X3:12 1305
with idle speed, 2nd gear is locked Although the output is switched off, voltage 1306
is present 1307
1310 Output is switched off, function no Output valve vibration reverse, Y 22 . Excessive current flow in current path, X3:13 -
1311 Output is switched off, function no Output valve vibration reverse, Y 22 . Short circuit to ground in the current X3:13 -
. Valve defective
1312 Output is switched off, function no Output valve vibration reverse, Y 22 . Wire breakage in current path X3:13 1310
1312
1313 Output is switched off, engine runs only Output valve vibration reverse, Y 22 . Current path connected to +12V X3:13 1310
with idle speed, 2nd gear is locked Although the output is switched off, voltage 1311
is present 1312

4.4 Fault codes of remote control

on BLM code for
diagnose
2500 Engine is stopped, all functions are Operation of two remote control system . A remote control with cable and a
locked, horn sounds at the same time wireless remote control are operated at
the same time.
2600 Engine stopped, emergency stop relay Remote control emergency stop . Emergency stop on remote control
in the control is switched off, all outputs operated
on control are switched off
2601 Engine stopped, emergency stop relay Fault in data transfer between remote . Battery empty
in the control is switched off, all outputs control sender and receiver . Radio or infrared transmission
on control are switched off disturbed
. Distance between sender an machine
too big
2611 Engine is shut down. CANopen – fault in bus communication CANopen Slave cable control has not
sent a node guarding answer
2612 Engine is shut down CANopen – fault in bus communication CANopen Slave radio remote control has
not sent a node guarding answer
2613 Engine is shut down CANopen – fault in bus communication CANopen Slave infrared remote control
has not sent a node guarding answer

4.5 General fault codes diesel engine, machine

on BLM code for
diagnose
5015 Only warning, horn sounds, display Potential 15 missing . Fuse F 103 defective X3:20 not
module is dark Control has switched relay K11, no voltage . Relay K11 defective possible
. Cable breakage in wiring loom
5016 Only warning Battery voltage too low . Battery acid level too low 0561
Battery voltage already below 11 Volt when . Battery defective
switching on . Battery discharged
5020 Only warning, horn sounds Input engine oil pressure, B 06 . The oil pressure switch has measured X3:03 5020
Oil pressure switch delivers the signal „no a too low oil pressure. The engine may
engine oil pressure“ be shut down.
Should this message be displayed

even though the engine is not running,
the following faults should be
examined:
. Current path has short circuit to ground
. Engine oil level not correct
. Engine oil pump defective
. Pressure relief valve after engine oil
filter soiled
. Oil pressure switch defective
5021 Engine shut down by too low oil Input engine oil pressure, B 06 . see fault code 5 0 2 0 X3:03 5020
pressure Fault 5 0 2 0 present longer than 8 seconds
. Engine is shut down
5022 Only warning, horn sounds Input engine oil pressure, B 06 . Engine oil pressure switch defective X3:03 5020
Machine can be started Oil pressure switch delivers the signal . Cable breakage to oil pressure switch
„engine oil pressure present“ even though
the engine is not running
Faults or warning 5020 and 5021 are only evaluated and displayed when the engine is running. However, evaluation of fault 5022 only occurs after switching the
ignition on and as long as the engine is not started.


on BLM code for
diagnose
5031 Machine standing Engine stopped or stalled . Lack of fuel
.
5040 Output is switched off, engine stops Output fuel valve, Y 58 . Excessive current flow in current path, X3:10 -
The current flow from this output is too high probably because of a defective coil or
5041 Output is switched off, engine stops Output fuel valve, Y 58 . Short circuit to ground in the current X3:10 -
Short circuit current flowing from this output path
. Valve defective
5042 Output is switched off, engine stops Output fuel valve, Y 58 . Wire breakage in current path X3:10 5040
No or too low current flow out of this output . Current path connected to +12V 5041
5042
5043 Output is switched off, engine stops Output fuel valve, Y 58 . Current path connected to +12V X3:10 5040
is present 5042
5050 Output is switched off, engine runs only Output relay K 97, . Excessive current flow in current path, X3:09 -
with idle speed Engine speed solenoid probably because of a defective coil or
The current flow from this output is too high a short circuit to ground
5051 Output is switched off, engine runs only Output relay K 97, . Short circuit to ground in the current X3:09 -
with idle speed Engine speed solenoid path
Short circuit current flowing from this output . Lines rubbed through
5052 Output is switched off, engine runs only Output relay K 97, . Wire breakage in current path X3:09 5050
with idle speed Engine speed solenoid . Current path connected to +12V 5051
No or too low current flow out of this output 5052
5053 Output is switched off, engine runs only Output relay K 97, . Current path connected to +12V X3:09 5050
with idle speed Engine speed solenoid 51051
is present


on BLM code for
diagnose
5060 Output switched off, no potential 15 on Output relay K 11, changeover of . Excessive current flow in current path, X3:07 -
machine, control is working, engine is potential 15 probably because of a defective coil or
stopped or cannot be started The current flow from this output is too high a short circuit to ground
5061 Output switched off, no potential 15 on Output relay K 11, changeover of . Short circuit to ground in the current X3:07 -
machine, control is working, engine is potential 15 path
stopped or cannot be started Short circuit current flowing from this output . Lines rubbed through
5062 Output switched off, no potential 15 on Output relay K 11, changeover of . Wire breakage in current path X3:07 5060
machine, control is working, engine is potential 15 . Current path connected to +12V 5061
stopped or cannot be started No or too low current flow out of this output 5062
5063 Output switched off, no potential 15 on Output relay K 11, changeover of . Current path connected to +12V X3:07 5060
machine, control is working, engine is potential 15 5061
stopped or cannot be started Although the output is switched off, voltage 5062
is present
5070 Output switched off, engine cannot be Output relay K 39, starter . Excessive current flow in current path, X3:06 -
started The current flow from this output is too high probably because of a defective coil or
5071 Output switched off, engine cannot be Output relay K 39, starter . Wire breakage in current path X3:06 -
started Short circuit current flowing from this output . Current path connected to +12V
5072 Output switched off, engine cannot be Output relay K 39, starter . Wire breakage in current path X3:06 5070
started No or too low current flow out of this output . Current path connected to +12V 5071
5072
5073 All outputs switched off, engine Output relay K 39, starter . Current path connected to +12V X3:06 5070
stopped, safety relay switched off Although the output is switched off, voltage 5071
is present 5072
No display for fault codes 5060 to 5063, because the display module is not supplied with voltage. The horn sounds if these faults occur. These faults are only
stored and serve only for internal processing in the control.


on BLM code for
diagnose
5080 Output switched off, horn cannot sound Output horn, H 07 . Excessive current flow in current path, X3:08 -
5085 The current flow from this output is too high probably because of a defective coil or X3:36
5081 Output switched off, horn cannot sound Output horn, H 07 . Short circuit to ground in the current X3:08 -
5086 Short circuit current flowing from this output path X3:36
. Horn defective
5082 Output switched off, horn cannot sound Output horn, H 07 . Wire breakage in current path X3:08 5080
5087 No or too low current flow out of this output . Current path connected to +12V X3:36 5081
5082
5083 Horn may sound continuously Output horn, H 07 . Current path connected to +12V X3:08 5085
5088 Although the output is switched off, voltage X3:36 5086
is present 5087
Due to the higher operating current two outputs are switched parallel for operation of the horn.
4.6 Faults in parameterization

on BLM code for
diagnose
7010 Machine cannot be started, module is not No machine type set Module is new, parameters were deleted 0725
completely initialized

Input codes for BLM control
5 Input codes for BLM control

5.1 Outputs for travel functions
Input code Description of display function Display values

1010 Output valve driving left forward, Y 16 Display value = output voltage in Volt
Voltage at output
1011 Output valve driving left forward, Y 16 Display value = output current in Amperè
Current at output
1012 Output valve driving left forward, Y 16 0000 = Output not triggered
Logic level of control 0001 = Output triggered
1015 Valve control, left 0100 = Driving, left forward
0010 = Drum stopped
0011 = Driving, left reverse
1020 Output valve driving left reverse, Y 17 Display value = output voltage in Volt
Voltage at output
1021 Output valve driving left reverse, Y 17 Display value = output current in Amperè
Current at output
1022 Output valve driving left reverse, Y 17 0000 = Output not triggered
1030 Output valve driving right forward, Y 72 Display value = output voltage in Volt
Voltage at output
1031 Output valve driving right forward, Y 72 Display value = output current in Amperè
Current at output
1032 Output valve driving right forward, Y 72 0000 = Output not triggered
1035 Valve control, right 0100 = Driving, right forward
0010 = Drum stopped
0011 = Driving, right reverse
1040 Output valve driving right reverse, Y 73 Display value = output voltage in Volt
Voltage at output
1041 Output valve driving right reverse, Y 73 Display value = output current in Amperè
Current at output
1042 Output valve driving right reverse, Y 73 0000 = Output not triggered


1050 Output valve 2nd gear, Y 03 Display value = output voltage in Volt
Voltage at output
1051 Output valve 2nd gear, Y 03 Display value = output current in Amperè
Current at output
1052 Output valve 2nd gear, Y 03 0000 = Output not triggered

5.2 Outputs for work functions

1305 Output valve vibration forward, Y 71 Display value = output voltage in Volt
Voltage at output
1306 Output valve vibration forward, Y 71 Display value = output current in Amperè
Current at output
1307 Output valve vibration forward, Y 71 0000 = Output not triggered
1309 Vibration valve control 0100 = Vibration forward
0010 = No vibration
0011 = Vibration reverse
1310 Output valve vibration reverse, Y 22 Display value = output voltage in Volt
Voltage at output
1311 Output valve vibration reverse, Y 22 Display value = output current in Amperè
Current at output
1312 Output valve vibration reverse, Y 22 0000 = Output not triggered

5.3 Inputs logic and power module

1400 Input signal L from generator regulator 12 V > Generator stopped
Ground, 0 V > Generator running
1401 Input oil pressure switch, B 06 12 V > No oil pressure
Ground, 0 V > Oil pressure
1402 Input limit switch engine speed solenoid, Aux 12 V > Solenoid retracted
0V Ground > Solenoid not in end position
1405 Input inclination sensor, B 56 12 V > Inclination less than 45°
0V Ground > Inclination higher than 45°
1406 Input limit switch, flap on remote control, B 09 12 V > Flap folded down
Ground , 0V > Flap folded open
1407 Input limit switch for safety bow, B 41 12 V > Bow not operated
Ground , 0V > Bow operated
1409 Activation input, cable remote control, S 101 12 V > Operating mode cable remote control
1410 Activation input radio or infrared remote control, S 101 12 V > Operating mode wireless

5.4 Diesel engine, machine electrics

5010 Engine speed Display value = revolutions per minute (rpm)
5020 Engine oil pressure, B 06 0000 = No engine oil pressure
Shows status of input engine oil pressure 0001 = Engine oil pressure OK
5030 Inclination sensor, B 56 0000 = No signal, machine inclined more than 45°, or switch defective
Shows the switching state of the inclination switch 0001 = OK, inclination of machine less than 45°
5040 Output fuel valve, Y 58 Display value = output voltage in Volt
Voltage at output
5041 Output fuel valve, Y 58 Display value = output current in Amperè
Current at output
5042 Output fuel valve, Y 58 0000 = Output not triggered
5050 Output relay K 97, engine speed solenoid Display value = output voltage in Volt
Voltage at output
5051 Output relay K 97, engine speed solenoid Display value = output current in Amperè
Current at output
5052 Output relay K 97, engine speed solenoid 0000 = Output not triggered
5053 Status diesel engine 0000 = Engine OFF
Shows the status of the diesel engine. The state is determined on 0001 = Engine ON
basis of signal L from generator, oil pressure and engine speed
signal
5060 Output relay K 11, potential changeover Display value = output voltage in Volt
Voltage at output
5061 Output relay K 11, potential changeover Display value = output current in Amperè
Current at output
5062 Output relay K 11, potential changeover 0000 = Output not triggered
5070 Output relay K 39, starter Display value = output voltage in Volt
Voltage at output
5071 Output relay K 39, starter Display value = output current in Amperè
Current at output
5072 Output relay K 39, starter 0000 = Output not triggered


5080 Output horn, H 07 Display value = output voltage in Volt
Voltage at output
5081 Output horn, H 07 Display value = output current in Amperè
Current at output
5082 Output horn, H 07 0000 = Output not triggered
5085 Output 2 horn, H 07 Display value = output voltage in Volt
Voltage at output
5086 Output 2 horn, H 07 Display value = output current in Amperè
Current at output
5087 Output 2 horn, H 07 0000 = Output not triggered
Due to the higher operating current two outputs are switched parallel for operation of the horn.

5.5 Checking the function of the remote controls

2500 Actuation of right hand travel lever on remote control, S 75 0100 = Travel lever shifted forward
0010 = Travel lever not moved
0100 = Travel lever shifted backward
2501 Actuation of left hand travel lever on remote control, S 55 0100 = Travel lever shifted forward
0010 = Travel lever not moved
0100 = Travel lever shifted backward
2502 Position of switch for vibration direction, S 36 0100 = Switch operated to forward, vibration forward
0010 = Switch not operated
0100 = Switch operated to backward, vibration backward
2503 Position of switch for type of vibration, S 36 0100 = Switch operated to forward, automatic vibration
0010 = Switch not operated, manual operation
2504 Position of switch for fast speed, S 42 0100 = Switch operated to forward, fast speed selected
0010 = Switch not operated, fast speed disabled
2505 Position of switch for engine speed, S 127 0100 = Switch operated to forward, high speed
0010 = Switch not operated, idle speed
2506 Position of button for horn, S 03 0000 = Button not operated
0001 = Button operated
With the input codes listed above it is possible to check the transfer of the individual switching signals from the remote controls to the central control unit.
For testing the spiral cable switch the operating mode switch to cable operation, connect the spiral cable to the sender and start the machine. If the engine starts,
the spiral cable is OK.

5.6 System information

0555 Software Version 3-digit version number
Shows the software version number.
056I Supply voltage Display value = voltage in V
Shows the voltage value
5.7 Setting the remote control type

0660 Switches on function „Set remote control type“ see adjustment instructions (page 7)!
0661 confirms the entered remote control type see adjustment instructions (page 7)!
0662 Preselect radio remote control, default setting see adjustment instructions (page 7)!
0663 Preselect infrared remote control see adjustment instructions (page 7)!
5.8 Fault log

0700 Switches on function „Show stored faults“ see adjustment instructions (page 6)
0701 Switches off function „Show stored faults“ see adjustment instructions (page 6)
0710 Deletes all stored faults see adjustment instructions (page 6)
5.9 Reading out the operating hour meter

7500 Display of hours, operating hour meter The full hours are displayed
7501 Display of minutes, operating hour meter The minute digits of the operating hour meter are displayed

5.10 Setting the machine type

7101 Preselect machine type BMP 851 see adjustment instructions (page 7)!
7102 Preselect machine type BPH 80/65s see adjustment instructions (page 7)!
7010 Switches on function „Set machine type“ see adjustment instructions (page 7)!
7011 Confirms entered machine type see adjustment instructions (page 7)!

Kob, 28.07.2004
LOGIC Hetronic control with BLM modul (A 70) for BMP 851
For (see below) The following is necessary (see below)

1
2 Ignition on (K11) Power supply X3:14, X3:28, X3:42
3 Ground on X3:1, X3:15
4 Aktivation signal X3:39 or X3:37 (12 V from transmitter)
5
6 Display on Ground on monitoring module (P18 -)
7 Voltage on monitoring module (P18 + )
8 Communication between A 70 and P18 through Can - and Can + o.k. [digital>>no constant voltage]
9
10 Display shows CTO Ground on monitoring module (P18 -)
11 Voltage on monitoring module (P18 + )
12 No communication between A 70 and P18 through Can - and Can + [digital>>no constant voltage]
13
14 Engine start Power supply X3:14, X3:28, X3:42
17 Initializing program finished ( 2sec after Aktivation signal X3:39 or X3:37 (constantly 12 V)) >> Horn
18 Travel levers in neutral
19 Vibration switch in neutral
20 Slope sensor signal 12 V (X3:23)
21 First starting after ignition on (start repeat lock)
Engine not turning >> at least two of the following signals must have the mentioned status >> X3:2
22 [L] on ground, X3:41 [W] lower than 100 Hz, X3:3 [p] on ground
23 Key switch start signal through Can - and Can + [digital>>no constant voltage]
24
Fuel valve open
25 before starting Power supply X3:14, X3:28, X3:42
28 Initializing program finished ( 2sec after Aktivation signal X3:39 or X3:37 (constantly 12 V)) >> Horn
Kob, 28.07.2004

29
30
Fuel valve open after
31 starting Power supply X3:14, X3:28, X3:42
34 Engine oil pressure signal is not disapearing (ground) longer than 8 sec.
35 Slope sensor signal 12 V (X3:23) is not disapearing longer than 1 sec
Engine turning >> at least two of the following signals must have the mentioned status >> X3:2 [L]
36 potential free, X3:41 [W] higher than 100 Hz, X3:3 [p] potential free.
37
38 Travel forward Power supply X3:14, X3:28, X3:42
Starter switch must have been turned to start position or horn button pushed at least once after
41 ignition on and initializing phase.
Travel lever S 55 and/or S 75 in forward position (signal through Can - and Can + [digital>>no
42 constant voltage])
43
44 Travel revers Power supply X3:14, X3:28, X3:42
48 Proximity switch revers protection bow 12 V (X3:27)
Travel lever S 55 and/or S 75 in revers position (signal through Can - and Can + [digital>>no
49 constant voltage])
50
51
52
Kob, 28.07.2004

53
54
55
56
57 Engine rpm Power supply X3:14, X3:28, X3:42
61 Switch S 127 on (signal through Can - and Can + [digital>>no constant voltage])
During starting of the engine the engine rpm solenoid is generally activated (K97) as long as the
62 NOTE >>> starter is activated.
63
64 2nd speed travel Power supply X3:14, X3:28, X3:42
68 Proximity switch on flap for transmitter 12 V (X3:25)
69 Switch S 42 on (signal through Can - and Can + [digital>>no constant voltage])
70
71 Note >>>> 2 sec delay
72
73
74
75
76
77
78
79
80
TROUBLE SHOOTING Remote control Hetronic for BMP 851 with cable control
SYMPTOMS POSSIBLE CAUSES COUNTERMEASURE

Check engine oil level. Check pressure switch. Red
1 1. Engine shuts off for no reason Engine oil pressure or switch control light on when engine running?
Check if + and - terminal have good connection. Check

2 Battery main battery switch for loose contact.Change battery.
Switch open? Move the switch up and down. If display
3 Emergency switch on , the switch is closed. Loose contact ?
4 F 54, F 67, F 103 Replace fuses. (Possibly internal crack by vibration)
5 Toggle switch for cable / remote S 101 Check terminal connections. Bridge switch.
6 K 11 Replace relais. Check socket (loose contact?)
Check continuity . Any short cirquit between cables or to
7 Umbilical cord housing of plug? Replace cord.
Check all connectors for loose contact (move cables on
each plug while engine is running to find loose
contacts). Check also connectors at regulator and big
8 All wire harnesses ground cable from engine to frame.
9 Transmitter Replace transmitter
Check sensor signal when engine shuts down (input
10 Slope sensor code 1405). Bridge X8 terminal 1+2. Replace sensor.
Disconnect black 4 pole connector on top of regulator. If
11 Regulator o.k. replace regulator.
12 A 70 modul (BLM) Replace module
13 Main wire harness Replace harness
14 Engine wire harness Replace harness
Check AC voltage between two yellow wires coming

from generator while regulator and generator
unplugged. About 26 V AC in high idle. Check continuity
between the two yellow wires coming from generator.
15 Generator Check if short cirquit from each wire to ground.
16

17
18
19 2. Ignition on, display on, but no starting Toggle switch vibration S 36 Switch in neutral? Check switch with input code 2502.
Move travel levers to neutral. Check lever positions with
20 Travel levers (not in neutral) input code 2500 and 2501.
If starter turns, but engine shuts off, disconnect black 4
pole connector on top of regulator. If not better, clean or
21 Fuel valve sticking or not working replace fuel valve
Charge signal and oil pressure both not on ground If charge and oil control light both are off you can´t start.
22 (s.control lights) See also regulator problem line 11
23 F 119 Replace fuses. (Possibly internal crack by vibration)
If clicking noise every second from A 70 module ,
24 Battery battery is bad. Replace battery.
Check sensor signal (input code 1405). Bridge X8
25 Slope sensor terminal 1+2 if not o.k.. Replace sensor.
Check relais output signal with input code 5070 (starter
repeat lock!!). Replace relais. Check socket (loose
26 K 39 contact?)
On the key switch the two wires at the top are
27 Key switch connected for starting. Ev. replace key switch.
28 Transmitter replace transmitter
If voltage at terminal 50 of the starter o.k. replace
29 Starter Motor starter.
30 A 70 modul (BLM) Replace module
Check all connectors for loose contact (move cables on
each plug while trying to start to find loose contacts).
Check also connectors at regulator and big ground
31 All wire harnesses cable from engine to frame.
32 Main wire harness replace harness
33 Engine wire harness replace harness

34
Push horn button. Or start only after warning horn came
35 3. After starting no functions Not waited for horn before starting up.
If the switch was open for a short time only, the engine
may still run, but no other functions. Move the switch up
and down. If display on, the switch is closed. Loose
Emergency switch contact on switch ?
36 Transmitter Replace Transmitter
37 Umbilical cord housing of plug? Loose contact ?Replace cord.
38 A 70 modul (BLM) replace module
40
41
If the switch was open for a short time only, the engine
4. During operation suddenly no travel may still run, but no other functions. Move the switch up
functions, engine keeps on running in low and down. If display on, the switch is closed. Loose
42 speed. Emergency switch contact on switch ?
43 Umbilical cord housing of plug? Loose contact? Replace cord.
44 Transmitter Replace Transmitter
47
48
5. Display shows code CTO, when ignition Check continuity . Any short cirquit between cables or to
49 on Umbilical corde (short cirquit can+ can-) housing of plug? Loose contact? Replace cord.
Check X3:30 or X3:31 loose.Or short cirquit X24:6 + 7
50 Main wire harness or short cirquit X23:11 + 12. Replace cable
52

53
Check toggle switch with input code 2505. Ev. Replace
54 6. Everything is o.k., exept high rpm Toggle switch S 127 switch.
55 F 14 Replace fuse.(Possibly internal crack by vibration)
56 Solenoid Y46 (adjustment) If fuse blowing again, adjust solenoid.
Check relais output signal with input code 5050.
57 K 97 Replace relais. Check socket (loose contact?)
60 Engine wire harness replace harness
61
62
63
64 7. Engine stops directly after starting Fuel valve sticking or not working not better, clean or replace fuel valve
o.k. replace regulator.Check also connectors at
65 Voltage regulator regulator and big ground cable from engine to frame.
Check AC voltage between two yellow wires coming

from generator while regulator and generator
unplugged. About 26 V AC in high idle. Check continuity
between the two yellow wires coming from generator.
66 Generator Check if short cirquit from each wire to ground.
68
69
TROUBLE SHOOTING Radio Remote control Hetronic for BMP 851 (used without cable in radio mode),
provided the control works well with cable. (NOTE: METAL DEVICES LIKE STEEL ROPES ETC , ATTACHED TO
THE MACHINE, CAN INTERFER WITH THE RADIO CONTROL)
change antenna (watch frequency range on antenna).
Bad or wrong antenna
1 1.No reaction from the machine Check plug connector from antenna to receiver.
2 receiver not connected to electric system Check plug connector from machine to receiver
receiver and transmitter have different serial

put together only sender and transmitter with same
numbers
3 serial number
4 battery of transmitter empty or bad recharge or replace accumulator
5 Distance more than 30 m go closer to machine
7 Bad transmitter or receiver replace both, transmitter and receiver
8
9 2. Ignition on, display on, but no starting Switch for vibration is not in neutral Switch in neutral? Check switch with input code 2502.
10 Battery of transmitter is empty or bad recharge or replace accumulator
12
13 3. Engine shuts off for no reason Battery of transmitter is empty or bad recharge or replace accumulator
check if there are other systems working (aeroplanes
14 Interference with other remote systems cranes etc.)
change antenna (watch frequency range on antenna).
Bad or wrong antenna
15 Check plug connector from antenna to receiver.
16 Distance more than 30 m go closer to machine

Switch open? Move the switch up and down. If display
18 Emergency switch on , the switch is closed. Loose contact ?
20 Main wire harness Replace harness
21 Bad antenna or antenna cable Replace antenna
TROUBLE SHOOTING Radio Remote control Hetronic for BMP 851 (used without cable in radio mode),
provided the control works well with cable. (NOTE: METAL DEVICES LIKE STEEL ROPES ETC , ATTACHED TO
THE MACHINE, CAN INTERFER WITH THE RADIO CONTROL)
22
23
Check list for trouble shooting BMP 851 / Hetronic
Customer:
Location: Serial no.:
Date: Operating hours:
BASIC FUNCTIONS CABLE CONTROL
please carry out please cross or make a
step by step: note below:
1 Is the main battery switch S30 on? yes no

2 Open the rear cover Is the switch S101 (cable / wireless) in cable mode? cable wireless
3 Is the emergency push button S01 pulled out? out in
4 Is the umbilical cord connected to the control box yes no
5 Is the toggle switch (S36) for vibration in neutral? yes no
6 Are the travel levers in neutral? yes no
7 Are any toggle switches bent? no yes
8
8 Turn the ignition on Is the warning horn coming on? yes no
9 (do not start yet) Is the display on? yes no
10 At first the display is showing the code no. 7101 7102
11 Than the display is showing a constant code no.>>>>>>
12
13
14 Then the display is showing flashing code no.>>>>>>>
15
16
17 The code numbers are flashing every second yes no
18 Charge light (yellow) is on yes no
19 Oil pressure light (red) is on yes no
20
20 Read the failure
21 codes in the store
22 of the display Then the display is showing flashing code no.>>>>>>>
23 (Input code 0700)
24
25
25 Any reaction from the starter? yes no
26 Turn the key to the The starter is only clicking, but does not turn yes no
27 starting position The starter is turning yes no
28 The engine starts yes no
29 Engine starts, but after a few seconds the engine stalls yes no
30
31
32 Then the display is showing flashing code no.>>>>>>>
33
34
35
Actuate the toggle
switch S 127 for
35 engine rpm Engine rpm changes when toggle switch S 127 is actuated yes no
36 Actuate the travel The machine is traveling forward and revers yes no
37 levers The machine is traveling only forward yes no
38 The machine does not travel yes no
Inhaltsverzeichnis: BMP 851
table of contents: BMP 851 ab Serial−Nr./from serial−no. : 101 72004 1001
Blatt Nr.: Zeichnungsnummer

Funktionsgruppe function unit
sheet no.: drawing − no.
001 724 001 54 Stromlaufplan Circuit Diagram
002 724 001 54 Stromlaufplan circuit diagram
101 724 001 54 Bauteilliste component listing
201 724 001 54 Zentralelektrik E−Box
15.01.2003
Nallin Stromlaufplan 724 001 54
15.01.2003 circuit diagram
Kneip 1201 001
30S
3:14
15
3:2
B E X6:A
F X7:A X21:1 X20:1
Regler X9:4 10A F103 F.. F67 Neigungssensor X8:1
Reserve
governor 25A 6 slope sensor
2 5 br
Sicherheitsbügel
Security bow
H08 H09
W
2:11 X1:1 B56
30 45_G
X1:6 K11
BR/BN
BR/BN
X21:2 X20:2
Signal Pot 15
2:8 Klappe
B+ W C
87 87a flap t=1s
IR/Funk Aktivierung
X9:2
2:3
Kabel Aktivierung
N01 sw bl 2:4 L
gr/ge
X1:4
2:2
Motor steht: Masse geschaltet
SW/BK
SW/BK
B41 Ladekontrolle
3:14
3:14
3:14
RS 232 Rx
RS 232 Tx
Motor läuft: potentialfrei BL/BU B86
3:2
3:2
G G L BL/BU charge control B06
aux
3:7
3:2
X1:2 X9:1 L
X8:3
X8:2
X8:4
− 2:19 X6:C X6:B X7:C X7:B P
Can −
Can +
BSL
X9:5
engine off: gnd−potential
engine running: no potential
X9:6
Motoröldruck
X3:2 X3:32 30 31 39 37 4 X3:20 16 17 41 X3:14 28 42 X3:27 X3:25 X3:23 X3:3 engine oil
pressure
B06:geschlossen, bei zu
G02 B41: geschlossen, wenn Sicher− B86: geschlossen, wenn Klappe mit
geringem Motoröldruck
heitsbügel nicht betätigt ist Senderhalterung eingeklappt ist
Generator B06: closed, if oil
B41: closed, if sec. bow B86: closed, if bracket
generator is not actuated is flapped in
pressure is to low
30Laden A70 Modul Logik/Leistung

3:2
30 K 3:7
F54 4
5A
D
X3:29 X3:1 15 X3:6 X3:9 X3:7 X3:10 X3:13 X3:12 X3:11 X3:19 X3:21 X3:22 X3:24 X3:26 X3:33 X3:8 X3:36
A C
Nicht belegt Nicht belegt
F119 F14 not used not used
RS 232 gnd
20A 1 3 30A X9:3
30 30
+ K39 K97 X1:5 X10:7 X10:2 X10:1 X10:6 X10:3 X10:5 X10:4
2:6 2:7
G01 −
3:14
87 87a 87 87a X9:7

V01
X12:2 X12:1 1 1 1 1 1 1 1 1
3 X1:3
2:8
Y58 2 Y22 2 Y71 2 Y03 2 Y16 2 Y17 2 Y72 2 Y73 2 H07

30 50 86 86 86
aux
S30
4 AW/HW + K39 K97 K11
M01 X10:8 X9:8
Y46 85 85 85
− −
X12:3 31 3:1
Batterie Motordrehzahl 2:2 2:3 2:4 Kraftstoffsbstellung Vibration vorwärts Fahren vorwärts, li Fahren vorwärts, re Signalhorn
battery engine rpm fuel switch off vibration, forward traveling forw. lh traveling forw. rh signal horn
Starter Motorstart Umschaltung Pot 30/15 Vibration rückwärts 2. Gang Fahren rückwärts, li Fahren rückwärts, re
starter engine start switch pot.30/15 vibration, backward 2nd speed range traveling backw. lh traveling backw. rh
Motordrehzahl
engine rpm
15.01.2003
15.01.2003
Kneip circuit diagram 002
2:19 15
Can +
2:7
Can −
2:6
Vorverstärker Infrarot BSL

preamplifier infrared 2:6
2:10 RS 232 Rx
W04
RS 232 Tx
nur ZA/NS Infrarot

only option infrared
2:10
30 K
2:2 RS 232 gnd
2:4
X25:1−4
2 2:19 30S
S101 Antenne
W05 antenna
X25:1
X25:3
X25:4
Umschalter Kabel/Drahtlos
X25:2
switch, cable / wireless 1 3
nur ZA/NS Funk

only option radio
Can− Can+−
IR/Funk Aktivierung
2:8 Kabel Aktivierung 2:7
IR/radio activation
30Laden
2:2
X23:11
X23:12
X23:10
X22:6
X22:4
X22:2
X22:1
X22:3
X22:5
X23:4
X23:8
X23:6
X23:9
X23:3
X23:5
X26:1
X24:2
X24:3
X24:4
X24:5
X24:8
X24:6
X24:7
X24:1
F1 F2
− +
Kabelsteuerung W02 Empfänger Funk W03 Empfänger Infrarot Diagnose P18
cable control receiver Radio receiver infrared diagnostics
oder / or Anzeigemodul
ZA / option monitoring module
X22:1−6
Spiralkabel
4:2
Spiral cable
2:20 31
14.01.2003
15.01.2003
Vibration man/auto
Vibration man/auto
Motordrehzahl Vibr. manR/0/manV Signal Horn ZA/NS Funkfernsteuerung
engine rpm Vibr. auto/0/auto signal horn
Schlüsselschalter option radio remote control
Fahrhebel links 2. Gang NOT−STOP Fahrhebel rechts Key switch
ZA/NS IR−Fernsteuerung
travel lever lh 2nd speed range emergency off travel lever rh option IR remote conrol
W07
Fernsteuerung , Kabel/Funk
Gelbes Gehäuse
R0V Remote Control, Cable/Radio
R0V R0V Yellow Body
a0a 012
0 0 01
W08
S55 S08 S42 S127 S01 S36 S75 S03 S00 Fernsteuerung , Kabel/Infrarot
Rotes Gehäuse
Zündung ein (K11)

Remote Control, Cable/Infrared
ignition on (K11)
Red Body
Engine start
Motorstart
W06
Fernsteuerung , Kabel
grün/green: Datentransfer ok / Data transfer ok
Blaues Gehäuse H77
Remote Control, Cable LED gn + rd bei drahtlosem Betrieb / with wireless operation
Blue Body rot/red: Akku Warnung / battery warning
Funk Infrarot
H78 Warnsummer radio infra red
warning buzzer A69 Elektronik CAN−Bus
A69 elektronic CAN−bus G05
− +
Can −
Can −
Can +
Can +
supply
Versorgung
gnd
Aktivierung
activation
battery charging
Akku laden
X2:4
X2:2
X2:1
X2:5
X2:3
X2:6
Achtung: Laden des Akkus ist nur möglich

bei angestecktem Spiralkabel und
eingeschaltetem Batteriehaupschalter
X2:1−6
Attention: charging of the battery is only possible
Spiralkabel
3:5 with connected spiral cable and
battery disconnect switch in position "on"
Spiral cable
14.01.2003
15.01.2003
Name Bl. Pf. Benennung title TYP
A69 004 13 Elektronik CAN−Bus Electronic CAN−Bus
A70 002 11 Modul Logik/Leistung Modul Logic/power
B06 002 20 Druckschalter Motoroel Pressure switch, engine oil max 3W

B41 002 14 Naeherungsinitiator Sicherheitsbuegel Proximity switch, security bow
B56 002 17 Neigungsschalter Slope sensor
B86 002 16 Naeherungsschalter 2.Gang Proximity switch, 2nd speed range
F.. 002 5 Reserve

F14 002 3 Sicherung Hubmagnet Motor Fuse, shut off solenoid, engine 30A
F54 002 2 Sicherung Kabelsteuerung Fuse, cable control 5A
F67 002 12 Sicherung Steuerung (Potential 30) Fuse, controller (pot.30) 25A
F103 002 4 Sicherung Potential 15 fuse, potential 15 10A
F119 002 2 Sicherung Motor Fuse, motor 20A
Kneip
15.01.03
Nallin
15. 1. 3
G01 002 1 Batterie Battery 12V/55Ah

G02 002 2 Generator Generator
G05 004 18 Akku Recharchable Battery Ni−MH3,6V/1,2Ah
H07 002 19 Warnsummer Betriebsstoerung Warning buzzer, breakdown 4A

H08 002 19 Meldeleuchte Ladekontrolle Indicator light, charge control LED ge/ye
H09 002 19 Meldeleuchte Oeldruck Motor Indicator light, engine oil pressure LED rt/rd
H77 004 6 Meldeleuchte Datentransfer/Akku leer Indicator light data transfer/battery low LED gn/rd
H78 004 6 Warnsummer Sender Warning buzzer transmitter
K11 002 8 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHW

K39 002 6 Relais Anlasser Relay, starter BOSCHW
K97 002 7 Lastrelais load relay BOSCHW
M01 002 1 Starter Starter Aw45A/HW10A
N01 002 1 Regler Regulator
P18 003 18 Fehleranzeige Elektronik Fault indication, electrinic
S00 004 14 Startschalter Starter switch

S01 004 7 Schalter NOT AUS Switch, emergency off
S03 004 12 Taster Signalhorn Push button, warning horn
S08 004 4 Vibrationsschalter man./autom. Switch, vibration, man./autom.
S30 002 1 Batterietrennschalter Switch, battery disconnect
S36 004 8 Vibrationsschalter Switch, vibration
S42 004 5 Stufenumschalter schnell−langsam Speed range selector, fast−slow
S55 004 2 Schalter Fahrhebel Switch, travel control lever
component listing
S75 004 11 Schalter Fahrhebel Switch, travel control lever

S101 003 7 Schalter Kabel−/Fernsteuerung Switch cable−/remote control
Bauteilliste
S127 004 5 Schalter Motordrehzahl Switch, engine rpm
V01 002 8 Diode Diode FE5B
W02 003 8 Empfaenger Funk Receiver Radio

W03 003 11 Empfaenger Infrarot Receiver Infrared
W04 003 11 Vorverstaerker Infrarot Preamlifier Infrared
W05 003 13 Antenne Antenna
W06 004 2 Fernsteuerung, Kabel Remote control, Cable
W07 004 17 Fernsteuerung, Kabel/Funk Remote Control, Cable/Radio
W08 004 17 Fernsteuerung, Kabel/Infrarot Fernsteuerung, Cable/Infrared
X1:1 002 3 Motorstecker Engine connector

X2:1 004 3 Spiralkabel Spiral cable
X2:1−6 004 3 Spiralkabel Spiral cable
X3:1 002 5 Modul A70 Modul A70
1

2

724 001 54

101

Name Bl. Pf. Benennung title TYP
X6:A 002 14 B41 B41
X6:B 002 14 B41 B41
X6:C 002 13 B41 B41
X7:A 002 16 B09 B09
X7:B 002 16 B09 B09
X7:C 002 15 B09 B09
X8:1 002 17 B56 B56
Kneip
15.01.03
Nallin
15. 1. 3
X8:2 002 17 B56 B56

X8:3 002 17 B56 B56
X8:4 002 16 B56 B56
X9:1 002 4 Motorsignale engine signals
X10:1 002 12 Magnetventile solenoid valve
X12:1 002 3 Starten starting unit
X20:1 002 19 LED H09 rot LED H09 red
X20:2 002 19 LED H09 rot LED H09 red
X21:1 002 19 LED H08 gelb LED H08 yellow
X21:2 002 19 LED H08 gelb LED H08 yellow
X22:1−6 003 4 Spiralkabel Spiral cable
component listing

Bauteilliste

X23:3 003 11 Empfänger Receiver
X24:1 003 17 Diagnose diagnostics
X25:1 003 10 Vorverstärker Preamplifier
X25:1−4 003 11 Vorverstärker Preamplifier
X26:1 003 13 Antenne Antenna
Y03 002 12 Magnetventil Fahrstufenumschaltung Solenoid valve, speed range selector 2,9A
Y16 002 13 Magnetventil Fahrtrichtung vorwaerts Solenoid valve, travel direction forw. 2,9A
Y17 002 14 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw. 2,9A
Y22 002 10 Magnetventil Vibration Solenoid valve, vibration 2,6A
Y46 002 3 Magnetventil Regelstange Motor Solenoid valve, governor rod, engine m.60A 1s, 0.8A
Y58 002 9 Magnetventil Kraftstoffabschaltung Solenoid valve, fuel switch off 14W
Y71 002 11 Magnetventil Vibration Solenoid valve, vibration 2,6A
Y72 002 15 Magnetventil Fahrtrichtung vorwaerts Solenoid valve, travel direction forw. 2,9A
Y73 002 16 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw. 2,9A
22
724 001 54
102
X7
X21 X20 X6
A F119 1
321 B F103 2
C F14 3 P18
X9 X10 X24 S101
D F54 4
E 5 A70 gelb
yellow H08
F F67 6
rot
red H09
S30
Massepunkt
Ground X3
X12
B56
X25 X22 X8
K11
K39
K97
ZA/NS, option
X26
Rückseite Armaturenblech
W02 oder/or reverse, instrument panel sheet
W03
X23
16.01.2003
Nallin Zentralelektrik 724 001 54
16.01.2003
Kneip E−Box 201
14.01.2003
Nallin Magnetventile 724 001 54
15.01.2003
Kneip solenoid valves 202

Bomag 851

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Service Training

Multi Purpose Compactor

Part-No. 008 097 35 01/2006

Technical data and adjustment values B1

Electrical system up to year of construction 2002, S/N 101 720 03 ... F1

Documentation on BLM-control (from year 2003)

Electric circuit diagram

BMP 851 -A1-

1. Operating and maintenance instructions

BMP 851 -A2-

Fig. 1 BMP 851

BMP 851 -A3-

In contrast to its predecessor BW 85 T this machine is now equipped with

• two gear pumps for the travel system and

• two 4/3-way solenoid valves for selection of travel direction

For enhanced traction the drums are provided with padfeet.

BMP 851 -A4-

BMP 851 -B1-

BOMAG Central Service - Technical data and adjustment values

Product type: BMP 851

BOMAG Central Service - Technical data and adjustment values

Product type: BMP 851

BMP 851 -B2-

every 1000 oper. hours

BMP 851 -B3-

every 1000 oper. hours

BMP 851 -B4-

The most important features of this engine are:

• excellent access to all operating and service points,

• low fuel consumption,

• robust design, long lifetime,

• reliability, because no V-belt is required for cooling fan and generator,

• safe and easy starting with electric starter,

• service friendly due to automatic bleeding of injection pump

BMP 851 -C1-

Fig. 1 Hatz diesel engine

1 Fuel line (fuel pump - injection pump 2 Air cowling

BMP 851 -C2-

Cylinder 1 = flywheel side - clockwise rotation

Cylinder 2 = power take-off side - anti-clockwise rotation.

Strictly observe the sense of rotation!

Fig. 2 Cylinder head

BMP 851 -C3-

• Turn the crankshaft for another 180° in direction of engine rotation.

• Check the valve clearance on cylinder 1 with a feeler gauge.

Fig. 3 Valve clearance

• Adjust all valves.

Perform a test run and check the engine for leaks.

BMP 851 -C4-

Checking and adjusting the head clearance

Fig. 4 Head clearance

BMP 851 -C5-

• Attach depth gauge (8) and hold it.

•Reassemble the engine and check for leaks

BMP 851 -C6-

• control valve block

BMP 851 -D1-

A5.1 B5.1 A5.2 B5.2 A8 B8

250 bar 02 200 bar

Fig. 1 Hydraulic diagram

01 Pressure relief valve 02 Shuttle valve

BMP 851 -D2-

Fig. 2 Control of machine up to year 2002, S/N 101 720 03 ....

1 Hydraulic oil tank 2 Central lifting feature