Service - Manual

BMP 8500
S/N 101 720 11 ....

Multi-purpose compactor

Catalogue number.
008 915 77 12/2010
Simple servicing due to excellent accessibility .....

Bild 1
 Table of Contents

General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 13
1.4 Tightening torques 23
Technical data 27
2.1 Technical data 28
Maintenance 33
3.1 General notes on maintenance 34
3.2 Fuels and lubricants 35
3.3 Table of fuels and lubricants 37
3.4 Running-in instructions 38
3.5 Maintenance table 39
Caddy wiring diagrams 41
4.1 Understanding circuit diagrams 42
4.2 Circuit symbols in the circuit diagram 47
E-Plan wiring diagrams 49
5.1 Understanding wiring diagrams 50
5.2 Circuit symbols in the circuit diagram 59
Electrics 63
6.1 Designation of components in the wiring diagram 64
6.2 Terminal designations in wiring diagram 65
6.3 Battery ground and analog ground 67
6.4 Processor signals 67
6.5 Current and voltage 68
6.6 Resistance 70
6.7 Series / parallel connection 72
6.8 Ohm's law 74
6.9 Electrical energy 74
6.10 Formula diagram 75
6.11 Metrology 76
6.12 Diodes, relays, fuses 80
6.13 Inductive proximity switches 83
6.14 Plug connectors 84
6.15 Deutsch plug, series DT and DTM 85
6.16 Batteries 89
6.17 Battery service 91
6.18 Main battery switch 92
6.19 Main battery fuse 92
6.20 External starting 93
6.21 Generator 93
6.22 Generator repair 100
6.23 Electric starter 104
6.24 Repair of starter 111
6.25 Glow plugs 115
6.26 Engine governor rod positioning solenoid 117

008 915 77 BOMAG 3

Table of Contents

6.27 Engine shut-down solenoid 119

6.28 Oil pressure and low oil pressure circuitry 122
6.29 Coolant temperature and power reduction 125
6.30 Wiring looms 127
6.31 BLM - Power/Logic Module 130
6.32 Checking the voltage supply for the control unit 132
6.33 Controls 140
6.34 Fuses 141
6.35 Entering the machine type code into the display module 142
6.36 Replacing, recharging the radio remote control power pack 143
6.37 BOSS safety system 146
6.38 "Marriage" of transponder and protection field control 148
6.39 BOSS Service Mode 148
6.40 Safety field measurement of the Boss safety system 149
6.41 Fault indicator 149
6.42 Diagnostics concept 150
6.43 Problems with radio remote control Hetronic in radio operation 153
6.44 Problems with remote control Hetronic with spiral cable 155
6.45 Faults in BOSS safety system 158
Electronic control 159
7.1 with safety bow 161
7.2 with safety field control 193
7.3 Logic 227
Service Training 235
8.1 General 237
8.2 Travel system 240
8.3 Travel motor 243
8.4 Multiple gear pump 245
8.5 Vibration 248
8.6 Control valve block 254
8.7 Hose connection centre frame 257
8.8 Hydraulic lines 258
Engine 265
9.1 Checking, adjusting the valve clearance 267
Repair overview for drum 269
10.1 Repair overview for drum 270
Travel system 271
11.1 Special tools 272
11.2 Repairing the travel system 273
Exciter unit 281
12.1 Special tools 282
12.2 Repairing the exciter unit. 283
Suppliers documentation 293
13.1 Travel motor 295
Circuit diagrams 309
14.1 Hydraulic diagram 21 311
14.2 Wiring diagram 724 002 09 319

4 BOMAG 008 915 77

 Table of Contents

14.3 Wiring diagram 724 002 29 335

14.4 Wiring diagram 724 002 30 355

008 915 77 BOMAG 5

Table of Contents

6 BOMAG 008 915 77

 1 General

008 915 77 BOMAG 7

1.1 Introduction

1.1 Introduction
This manual addresses the professionally qualified
personnel or the after sales service of BOMAG, and
should be of help and assistance in correct and effi-
cient repair and maintenance work.
This manual describes the disassembly, dismantling,
assembly, installation and repair of components and
assemblies. The repair of components and assem-
blies is only described as this makes sense under due
consideration of working means and spare parts sup-
ply.

Documentation
For the BOMAG machines described in this manual
the following documentation is additionally available:
1 Operating and maintenance instructions
2 Spare parts catalogue
3 Wiring diagram*
4 Hydraulic diagram*
5 Service Information

Use only genuine BOMAG spare parts.

Spare parts needed for repairs can be taken from the
spare parts catalogue for the machine.
These repair instructions are not subject of an updat-
ing service; for this reason we would like to draw your
attention to our additional "Technical Service Bulle-
tins".
In case of a new release all necessary changes will be
included.
In the course of technical development we reserve the
right for technical modifications without prior notifica-
tion.
Information and illustrations in this manual must not
be reproduced and distributed, nor must they be used
for the purpose of competition. All rights according to
the copyright law remain expressly reserved.

Danger
!

These safety regulations must be read and ap-

plied by every person involved in the repair /main-
tenance of this machine. The applicable accident
prevention instructions and the safety regulations
in the operating and maintenance instructions
must be additionally observed.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG
* The applicable documents valid at the date of print-
ing are part of this manual.

8 BOMAG 008 915 77

Safety regulations
Important notes
1.2 Safety regulations
These safety regulations must be read and ap-
plied by every person involved in the repair /main-
tenance of this machine. The applicable accident
prevention instructions and the safety regulations
in the operating and maintenance instructions
must be additionally observed.
Repair work shall only performed by appropriately
trained personnel or by the after sales service of
BOMAG.
Workshop equipment and facilities as well as the
use and waste disposal of fuels and lubricants,
cleaning agents and solvent as well as gases and
chemicals are subject to legal regulations, which
are intended to provide a minimum on safety. It is
obviously your own responsibility to know and
adhere to these regulations.
This manual contains headers like "Note", "Attention",
"Danger" and "Environment", which must be strictly
complied with in order to inform about and avoid dan-
gers to persons, property and the environment.
i Note
Paragraphs marked like this contain technical infor-
mation for the optimal economical use of the machine.
Caution
! er when working with cranes.
Paragraphs marked like this highlight possible
dangers for machines or parts of the machine.
Danger
!
Paragraphs marked like this highlight possible
dangers for persons.
Environment
Paragraphs marked like this point out practices
for safe and environmental disposal of fuels and
lubricants as well as replacement parts.
Observe the regulations for the protection of the
environment.
General
l
For repair and maintenance work move the ma-
chine on a firm base and shut it down.
l
Always secure the machine against unintended roll-
ing.
l Secure the engine reliably against unintentional
starting.
l Mark a defective machine and a machine under re-
pair by attaching a clearly visible warning label to
the dashboard.
008 915 77 BOMAG
1.2
Block the articulated joint with the articulation lock.
l
l Use protective clothes like hard hat, safety boots
and gloves.
l Keep unauthorized persons away from the machine
during repair work.
l Tools, lifting gear, lifting tackle, supports and other
auxiliary equipment must be fully functional and in
safe condition.
l Use only safe and approved lifting gear of sufficient
load bearing capacity to remove and install parts or
components from and to the machine.
l Do not use easily inflammable or harmful substanc-
es, such as gasoline or paint thinners for cleaning.
l Do not smoke or use open fire and avoid sparks
when cleaning or repairing a tank.
l When performing welding work strictly comply with
the respective welding instructions.
Transport work with cranes and lifting
tackle
i Note
Cranes must only be operated by instructed persons
who had been trained in handling cranes.
l Follow the operating instructions of the manufactur-
l Follow the operating instructions of the operator
when working with cranes.
l Always comply with the applicable accident preven-
tion instructions when working with cranes and lift-
ing tackle.
Precautions and codes of conduct for
welding work
Welding work must only be carried out by properly
trained personnel.
Danger
!
Electric shock!
Sparks, fire hazard, burning of skin!
Infrared or ultraviolet radiation (arc), flashing of
eyes!
Health hazard caused by welding work on highly
alloyed work pieces, metal coatings, paint coat-
ings, plastic coatings, oil containing dirt deposits,
grease or solvent residues, etc.!
l Check welding equipment and cables for damage
before use (also the validity of inspection stickers).
l Ensure good conductivity between ground cable
and workpiece, avoid joints and bearings.
9
1.2
l Start the extraction fan before starting work and
guide with the progressing work as required.
l Always isolate the burner when laying it down (re-
move possible electrode residues).
l Protect cables from being damaged, use cables
with insulated couplings.
l Ensure sufficient fire protection, keep a fire extin-
guisher at hand.
l Welding work in areas where there is a risk of fire or
explosion, must only be carried out with welding
permission.
l Remove any combustible materials from the weld-
ing area or cover such items appropriately.
l Name a fire watch during and after welding work.
l Place welding rod holders and inert gas welding
guns only on properly insulated bases.
l Place the inert gas bottles in a safe place and se-
cure them against falling over.
l
Use a protective screen or hand shield with welding
filter, wear welding gloves and clothes.
l
Switch the welding unit off before connecting weld-
ing cables.
l
Check electrode holders and electric cables at reg-
ular intervals.
Behaviour in case of faults
l
In case of faults on the welding unit switch of the
welding unit immediately and have it repaired by ex-
pert personnel.
l
In case of failure of the extraction system switch the
system off and have it repaired by expert personnel.
Maintenance; waste disposal
l
Replace damaged insulating jaws and welding rod
holders immediately.
l
Replace the welding wire reels only in de-energized
state.
What to do in case of accidents; First Aid
l
Keep calm.
l Call first air helpers.
l
Report the accident.
l
In case of an electric accident: Interrupt the power
supply and remove the injured person from the
electric circuit. If breathing and heart have stopped
apply reactivation measures and call for an emer-
gency doctor.
Old oils
Prolonged and repetitive contact with mineral oils will
remove the natural greases from the skin and causes
dryness, irritation and dermatitis. Moreover, used en-
10 BOMAG
Safety regulations
gine oils contain potentially hazardous contaminants,
which could cause skin cancer. Appropriate skin pro-
tection agents and washing facilities must therefore
be provided.
l Wear protective clothes and safety gloves, if possi-
ble.
l If there is a risk of eye contact you should protect
your eyes appropriately, e.g. chemistry goggles or
full face visor; a facility suitable for rinsing the eyes
should also be available.
l Avoid longer and repetitive contacts with oils. In
case of open incisions and injuries seek medical ad-
vice immediately.
l Apply protective cream before starting work, so that
oil can be easier removed from the skin.
l Wash affected skin areas with water and soap (skin
cleansers and nail brushes will help). Lanolin con-
taining agents will replace natural skin oils that were
lost.
l
Do not use gasoline, kerosene, diesel, thinner or
solvents to wash the skin.
l
Do not put oil soaked cloths into your pockets.
l
Avoid clothes getting soiled by oil.
l
Overalls must be washed at regular intervals. Dis-
pose of non-washable clothes environmentally.
l
If possible degrease components before handling.
Environment
It is strictly prohibited to drain off oil into the soil,
the sewer system or into natural waters. Old oil
must be disposed of according to applicable envi-
ronmental regulations. If in doubt you should con-
sult your local authorities.
Hydraulics
l Always relieve the pressure in the hydraulic system
before disconnecting any lines. Hydraulic oil escap-
ing under pressure can penetrate the skin and
cause severe injury.
l
Always make sure that all screw fittings have been
tightened properly and that hoses and pipes are in
mint condition before pressurizing the system
again.
l Hydraulic oil leaking out of a small opening can
hardly be noticed, therefore please use a piece of
cardboard or wood when checking for leaks. When
injured by hydraulic oil escaping under pressure
consult a physician immediately, as otherwise this
may cause severe infections.
l Do not step in front of or behind the drums, wheels
or crawler tracks when performing adjustment work
in the hydraulic system while the engine is running.
Block drums, wheels or crawler tracks with wedges.
008 915 77
Safety regulations
Reattach all guards and safety installations after
all work has been completed.
Environment
It is strictly prohibited to drain off oil into the soil,
the sewer system or into natural waters. Oil oil
must be disposed of according to applicable envi-
ronmental regulations. If in doubt you should con-
sult your local authorities.
Fuels
!Danger
Repair work shall only performed by appropriately
trained personnel or by the after sales service of
BOMAG.
Follow the valid accident prevention instructions when
handling fuels.
The following notes refer to general safety precau-
tions for danger free handling of fuel.
Fuel vapours not only are easily inflammable, but also
highly explosive inside closed rooms and toxic; dilu-
tion with air creates an easily inflammable mixture.
The vapours are heavier than air and therefore sink
down to the ground. Inside a workshop they may eas-
ily become distributed by draft. Even the smallest por-
tion of spilled fuel is therefore potentially dangerous.
l Fire extinguishers charged with FOAM, CO2 GAS
or POWDER must be available wherever fuel is
stored, filled in, drained off, or where work on fuel
systems is performed.
l
The vehicle battery must always be disconnected,
BEFORE work in the fuel system is started. Do not
disconnect the battery while working on the fuel
system. Sparks could cause explosion of the fuel
fumes.
l Wherever fuel is stored, filled, drained off or where
work on fuel systems is carried out, all potential ig-
nition sources must be extinguished or removed.
Search lights must be fire proof and well protected
against possible contact with running out fuel.
Hot fuels
Please apply the following measures before draining
of fuel to prepare for repair work:
l Allow the fuel to cool down, to prevent any contact
with a hot fluid.
l
Vent the system, by removing the filler cap in a well
ventilated area. Screw the filler cap back on, until
the tank is finally emptied.
008 915 77 BOMAG
1.2
Synthetic rubber
Many O-rings, hoses, etc. are made of synthetic ma-
terial, a so-called fluorocarbon elastomer. Under nor-
mal operating conditions this material is safe and does
not impose any danger to health.
However, if this material becomes damaged by fire or
extreme heat, it may decompose and form highly
caustic hydrofluoric acid, which can cause severe
burns in contact with skin.
l If the material is in such a state it must only be
touched with special protective gloves. The protec-
tive gloves must be disposed of according to appli-
cable environmental regulations immediately after
use.
l If the material has contacted the skin despite these
measures, take off the soiled clothes and seek
medical advice immediately. In the meantime cool
and wash the affected area of skin over a sufficient
time with cold water or lime water.
Poisonous substances
Some of the fluids and substances used are toxic and
must under no circumstances be consumed.
Skin contact, especially with open wounds, must be
avoided.
These fluids and substances are, amongst others,
anti-freeze agents, hydraulic oils, fuels, washing addi-
tives, refrigerants, lubricants and various bonding
agents.
Engine
Danger
!
Do not work on the fuel system while the engine is
running. (Danger to life!)
Once the engine has stopped wait approx. 1 min-
utes for the system to depressurize. The systems
are under high pressure. (Danger to life!)
Keep out of the danger zone during the initial test
rung. Danger caused by high pressure in case of
leaks. (Danger to life!)
When performing work on the fuel system make
sure that the engine cannot be started uninten-
tionally during repair work. (Danger to life!)
l Maintenance and cleaning work on the engine must
only be performed with the engine stopped and
cooled down. Make sure that the electric system is
switched off and sufficiently secured against being
switched on again (e.g. pull off ignition key, attach a
warning label).
l
Observe the accident prevention regulations for
electric systems (e.g. -VDE-0100/-0101/-0104/-
11
1.2 Safety regulations

0105 Electric precautions against dangerous con-
tact voltages).
l Cover all electric components properly before wet
cleaning.
Battery
l Always wear goggles and protective clothing to
service or clean batteries! Battery acid can cause
severe injury by cauterization when coming in con-
tact with skin.
l
Work only well ventilated rooms (formation of oxy-
hydrogen gas).
l Do not lean over the battery while it is under load,
being charged or tested (danger of explosion).
l Keep ignition sources away from the battery. Burn-
ing cigarettes, flames or sparks can cause explo-
sion of the battery
l Use battery chargers etc. only in strict compliance
with the operating instructions.
l
After an accident with acid flush the skin with a suf-
ficient amount of water and seek medical advice.
l
Do not allow children access to batteries.
l
When mixing battery fluid always pour acid into wa-
ter, never vice-versa.
l Always ensure an adequate supply of fresh air
when refuelling in closed rooms.
l Dispose of used filters in accordance with applica-
ble environmental regulations.
l When performing repair and maintenance work col-
lect oils and fuels in suitable containers and dispose
of in compliance with applicable environmental reg-
ulations.
l Do not heat up oils higher than 160 °C because they
may ignite.
l Wipe off spilled or overflown oil using suitable
cleaning means and dispose of in accordance with
applicable environmental regulations.
l Dispose of old batteries according to applicable en-
vironmental regulations.
l There is a danger of scalding when draining off en-
gine or hydraulic oil at operating temperature! Allow
engine and hydraulic system to cool down to a suf-
ficient level.
l
Do not exceed the max. permissible tire pressure.

Special safety regulations

l
Use only genuine BOMAG spare parts for repair
and maintenance work. Genuine spare parts and
original accessories were specially developed, test-
ed and approved for the machine.
l
The installation and use of non-genuine spare parts
or non-genuine accessories may therefore have an
adverse effect on the specific characteristics of the
machine and thereby impair the active and/or pas-
sive driving safety. The manufacturer explicitly ex-
cludes any liability for damage caused by the use of
non-original parts or accessories.
l
Unauthorized changes to the machine are prohibit-
ed for safety reasons.
l Do not perform any cleaning work while the engine
is running.
l
If tests on the articulated joint need to be performed
with the engine running, do not stand in the articu-
lation area of the machine (danger of crushing!).
l
If tests must be performed with the engine running
do not touch rotating parts of the engine (danger of
injury!).
l
Always ensure an adequate supply of fresh air
when starting in closed rooms. Exhaust gases are
highly dangerous!
l Refuel only with the engine shut down. Ensure strict
cleanliness and do not spill any fuel.

12 BOMAG 008 915 77

General repair instructions
General
1.3 General repair instructions
l
Before removing or disassembling parts, assem-
blies, components or hoses mark these parts for
easier assembly.
l Before assembling and installing parts, assemblies
or components oil or grease all movable parts or
surfaces as required and in compliance with the
compatibility of materials.
008 915 77 BOMAG
1.3
Electrics
General
Due to the fast technical development electric and
electronic vehicle systems become more intelligent
and more comprehensive day by day, and can hardly
be dispensed with in hydraulic and mechanical vehicle
systems.
Diagnostics according to plan
Well structured trouble shooting procedures can save
time and money.
Random tests have revealed that purely electronic
components or control units only very rarely are the
actual cause of failures:
l In approx. 10 % of the examined cases the prob-
lems were caused by control units.
l In approx. 15 % sensors and actuators were the
cause of the problems.
By far the highest proportion of all faults could be
traced back to wiring and connections (plugs, etc.).
General:
l
Before changing any expensive components, such
as control units, you should run a systematic trouble
shooting session to eliminate any other possible
fault sources. Knowledge in basic electrics is re-
quired for this purpose. If a fault was diagnosed
without having pulled the plug of the control unit or
inspected the wiring, this should be done before
changing any parts.
l
Check for good cable and ground contacts, there-
fore keep all mechanical transition points between
electric conductors (terminals, plugs) free of oxide
and dirt, as far as this is possible.
l
Always use the machine related wiring diagram for
testing. If one or more faults were detected, these
should be corrected immediately.
l
Do not disconnect or connect battery or generator
while the engine is running.
l
Do not operate the main battery switch under load.
l
Do not use jump leads after the battery has been re-
moved.
l Sensors and electric actuators on control units must
never be connected individually or between exter-
nal power sources for the purpose of testing, but
only in connection with the control unit in question.
l
It is not permitted to pull plugs off while the voltage
supply is switched on (terminal 15 "ON")! Switch the
voltage supply "OFF" first and pull out the plug.
l Even with an existing polarity reversal protection in-
correct polarity must be strictly avoided. Incorrect
polarity can cause damage to control units!
13
1.3 General repair instructions

l Plug-in connectors on control units are only dust Battery

and water tight if the mating connector is plugged
on! Control units must be protected against spray Rules for the handling of batteries
water, until the mating connector is finally plugged When removing a battery always disconnect the mi-
on! nus pole before the plus pole. When installing the bat-
l Unauthorized opening of control electronics (Micro- tery connect the minus pole after the plus pole to avoid
controller MC), modifications or repairs in the wiring short circuits.
can cause severe malfunctions. Fasten the terminal clamps with a little force as possi-
l
Do not use any radio equipment or mobile phones ble.
in the vehicle cab without a proper aerial or in the vi- Always keep battery poles and terminal clams clean to
cinity of the control electronics! avoid high transition resistances when starting and
the related development of heat.
Electrics and welding
Make sure the battery is properly fastened in the vehi-
cle.
!Caution
Before starting welding work you should discon-
nect the negative battery pole or interrupt the
electric circuit with the main battery switch, dis-
connect the generator and pull the plugs off all
control units in order to protect the electrical sys-
tem of the machine.
l Disconnect the minus pole of the battery or interrupt
the electric circuit with the main battery switch.
l Isolate the generator and all control units from the
electric circuit.
l Always fasten the earth clamp of the welding unit in
the immediate vicinity of the welding location.
l When choosing the location for the earth clamp
make sure that the welding current will not pass
through joints or bearings.

14 BOMAG 008 915 77

General repair instructions
Generator
Before removing the generator you must disconnect
the ground cable from the minus pole of the battery
while the ignition is switched off. Do not disconnect
the generator while the engine is running, because
this may cause extremely high voltage peaks in the
vehicle wiring system ("Load Dump"), which could
possibly damage control units, radios or other elec-
tronic equipment.
When disassembling the battery cable, the B+-nut un-
derneath on the generator side may also be loosened.
This nut must in this case be retightened.
When connecting e.g. the battery cable to the terminal
of the generator you must make sure that the polarity
is correct (generator B+ to the + pole of the battery).
Mixing up the polarities by mistake causes short cir-
cuit and damage to the rectifier elements - the gener-
ator will be out of function.
The generator can only be operated with the battery
connected. Under special conditions emergency op-
eration without battery is permitted, the lifetime of the
generator is in such cases especially limited.
Plus and minus cables must be disconnected during
rapid charging of the battery or electric welding on the
vehicle.
When cleaning the generator with a steam or water jet
make sure not to direct the steam or water jet directly
on or into the generator openings or ball bearings. Af-
ter cleaning the generator should be operated for
about 1 - 2 minutes to remove any deposits of water
from the generator.
008 915 77 BOMAG
1.3
Starter motor
So-called jump starting (using an additional external
battery) without the battery connected is dangerous.
When disconnecting the cables from the poles high in-
ductivities (arcs, voltage peaks) may occur and de-
stroy the electrical installation.
For purposes like e.g. purging the fuel systems, start-
ers may be operated for maximum 1 minute without
interruption. Then you should wait for at least 30 min-
utes (cooling down) until trying again. During the 1
minute starting period this process should not be inter-
rupted.
Starter motors must not be cleaned with high pressure
steam cleaning equipment.
The contacts on starter terminals 30, 45, 50 must be
protected against unintended shorting (jump protec-
tion).
When replacing the starter the ring gear on the engine
flywheel must be checked for damage and its number
of teeth - if necessary replace the ring gear.
Always disconnect the battery before starting assem-
bly work in the starter area of the engine or on the
starter itself.
15
1.3
Hydraulic system
!Caution
Repair work on hydraulic elements shall only per-
formed by appropriately trained personnel or by
the after sales service of BOMAG.
Please note
i Note
Cleanliness is of utmost importance. Dirt and other
contaminations must strictly be kept out of the system.
l Connections and screw fittings, filler neck covers
and their immediate surrounding areas must be
cleaned before removal.
l Before loosening hoses, pipe lines etc. relieve all
pressure from the system.
l During repair work keep all openings closed with
clean plastic plugs and caps.
l Never run pumps, motors and engines without oil or
hydraulic oil.
l When cleaning hydraulic components take care not
to damage any fine machine surfaces.
l Chemical and rubber soluble cleansing agents may
only be used to clean metal parts. Do not let such
substances come in contact with rubber parts.
l Rinse of cleaned parts thoroughly, dry them with
compressed air and apply anti-corrosion oil immedi-
ately. Do not install parts that show traces of corro-
sion.
l Avoid the formation of rust on fine machined caused
by hand sweat.
l Use new O-rings or seal rings for reassembly.
l Use only hydraulic oil as sliding agent when reas-
sembling. Do not use any grease!
l Use only the specified pressure gauges. Risk of
damaging the pressure gauges under too high pres-
sure.
l Check the hydraulic oil level before and after the
work.
l Fill in only clean oil as specified in the maintenance
instructions.
l Check the hydraulic system for leaks, if necessary
find and rectify the cause.
l Before taking new hydraulic components into oper-
ation fill these with hydraulic oil as specified in the
operating and maintenance instructions.
l After changing a hydraulic component thoroughly
flush, refill and bleed the complete hydraulic sys-
tem.
16
General repair instructions
l Perform measurements at operating temperature of
the hydraulic oil (approx. 40 ¯C).
l After changing a component perform a high and
charge pressure test, if necessary check the speed
of the exciter shaft.
l The operating pressure of the exciter shaft to a
great extent depends on the base under the vibrat-
ing drum. On hard ground place the drums on a suit-
able base and check the drum pressure. Do not
activate the vibration on a hard, concreted base,
danger of bearing damage.
l After the completion of all tests perform a test run
and then check all connections and fittings for leaks
with the engine still stopped and the hydraulic sys-
tem depressurized.
Before commissioning
l Fill the housings of hydraulic pumps and motors
with hydraulic oil. Use only hydraulic oils according
to the specification in the maintenance instructions.
l
After changing a component flush the hydraulic sys-
tem as described in the flushing instructions.
Taking into operation
l
Bleed the hydraulic circuits.
l
Start up the hydraulic system without load.
l
Check the hydraulic oil level in the tank, if neces-
sary top up with hydraulic oil as specified in the op-
erating and maintenance instructions or drain oil off
into a suitable container.
After taking into operation
l
Check fittings and flanges for leaks.
l
After each repair check all adjustment data, system
pressures, rotational speeds and nominal values in
the hydraulic system, adjust if necessary.
l
Do not adjust pressure relief valves and control
valves to values above their specified values.
BOMAG 008 915 77
General repair instructions
Fuel hoses
Fig. 2
! Caution
All fuel hoses have two layers of material, a rein-
forced rubber coating outside and an internal Vi-
ton hose. If a fuel hose has come loose one must
make absolutely sure that the internal Viton layer
has not been separated from the reinforced outer
layer. In case of a separation the hose needs to be
replaced.
008 915 77 BOMAG
1.3
Gaskets and mating surfaces
Leaking sealing faces can mostly be traced back to in-
correct assembly of seals and gaskets.
l Before assembling a new seal or gasket make sure
that the sealing surface is free of pitting, flutes, cor-
rosion or other damage.
l Inappropriately stored or handled seals (e.g. hang-
ing from hooks or nails) must under no circumstanc-
es be used.
l Assemble seals and gaskets only with sealing com-
pound, grease or oil, if this is specifically specified
in the repair instructions.
l If necessary remove any old sealing compound be-
fore assembling. For this purpose do not use any
tools that could damage the sealing surfaces.
l Sealing compound must be applied thin and evenly
on the corresponding surfaces; take care that the
compound does not enter into oil galleries or blind
threaded bores.
l
Examine the contact faces for scratches and burrs,
remove these with a fine file or an oilstone; take
care that no grinding dust and dirt enters into
tapped bores or enclosed components.
l
Blow out lines, ducts and gaps with compressed air,
replace any O-rings and seals that have been dis-
lodged by the compressed air.
Assembly of radial seals
Fig. 3
l
Lubricate the sealing lips (2) (Fig. 3) with clean
grease; in case of double seals fill the space be-
tween the sealing lips with a generous amount of
grease.
l
Slide the seal over the shaft, with the lip facing to-
wards the fluid to be sealed.
i Note
If possible, use an assembly sleeve (1 (Fig. 3)), to
protect the lip from being damaged by sharp edg-
es, threads or splines. If no assembly sleeve is avail-
17
1.3 General repair instructions

able, you should use a plastic tube or adhesive tape Feather keys and keyways
to prevent the sealing lip from being damaged.
l Lubricate the outer rim (arrow 3 (Fig. 3)) of the seal Caution
!
and press it flat on the housing seat.
Feather keys may only be reused if they are free of
damage.

Fig. 4
l
Press or knock the seal into the housing, until it is
flush with the housing surface.

i Note
Fig. 5
If possible, use a "bell" (1 (Fig. 4)), to make sure that
the seal will not skew. In some cases it may be ad-
l Clean and thoroughly examine the feather key.
visable to assemble the seal into the housing first, be- l Deburr and thoroughly clean the edges of the key-
fore sliding it over the shaft. Under no circumstances way with a fine file before reassembling.
should the full weight of the shaft rest on the seal.
If you have no proper service tools at hand, use a suit-
able drift punch with a diameter which is about 0,4 mm
smaller than the outer diameter of the seal. Use VERY
LIGHT blows with the hammer if no press is available.

18 BOMAG 008 915 77

General repair instructions 1.3
Ball and roller bearings l Check shaft and bearing housing for discolouration
or other signs of movement between ball or roller
bearing and seats.
!Caution
l Make sure that shaft and housing are free of burrs
Ball and roller bearings may only be reused if they
before assembling the ball or roller bearing.
are free of damage and do not show any signs of
wear. l Always mark the individual parts of separable ball or
roller bearings (e.g. taper roller bearings) to enable
correct reassembling. Never assemble the rollers to
an outer race that has already been used, replace
the complete ball or roller bearing instead.

Fig. 7

!Caution
When assembling the ball or roller bearing to the
shaft load must only be applied to the inner race 1
(Fig. 7).
When fitting the bearing into the housing load
must only be applied to the outer race (2).

Fig. 6
l If a ball or roller bearing of a bearing pair shows de-
fects, both ball or roller bearings need to be re-
placed.
l
Remove any lubricant residues from the ball or roll-
er bearing to be examined by washing it with gaso-
line or any other appropriate degreasing agent.
Ensure strict cleanliness.
l
Check balls or rollers, running surfaces, outer faces
of outer races and inner faces of inner races for vis-
ible damage. Replace the ball or roller bearing if
necessary.
l
Check the ball or roller bearing for clearance and re-
sistance between the inner and outer races, replace
if necessary.
l
Lubricate the ball or roller bearing with the recom-
mended type of grease before assembly or reas-
sembly.
l
On greased bearings (e.g. wheel bearings) fill the
space between ball or roller bearing and outer seal
with the recommended type of grease before as-
sembling the seal.

008 915 77 BOMAG 19

1.3 General repair instructions

Screws and nuts Strength classes, metric screws

The strength classes (from 3.6 to 12.9) are specified
Tightening torque
for all strength classes from a nominal diameter of
5mm. The corresponding identification can be found
!Caution where allowed for by the shape of the screw.
Tighten nuts or screws with the tightening tor-
ques specified in the following tables of tighten-
ing torques. Tightening torques deviating from
the ones in the table are specially mentioned in
the repair instructions.
Damaged screws must under no circumstances
be used any longer. Recutting threads with thread
cutters or taps adversely affects the strength and
leak tightness of the screw joint. Damaged or cor-
roded thread pitches can cause incorrect torque
value readings.
Self-locking nuts must generally be replaced after
disassembly.
The use of screws with too high strength can
cause damage!
l Nut of a higher strength can generally be used in-
stead of nuts of a lower strength classification.
l When checking or retightening screw joints to the
specified tightening torque you should first relieve
Fig. 8 Identification of screws
by a quarter turn and then tighten to the correct
torque. Example: A screw is identified with 12.9.
l Before tightening you should lightly oil the thread, in The first number corresponds with 1/100 of the nomi-
order to ensure low friction movement. The same nal tensile strength (minimum tensile strength) in N/
applies for self-locking nuts. mm2.
l Make sure that no oil or grease will enter into blind l
The nominal tensile strength is 12 X 100 N/mm2 =
tapped bores. The hydraulic power generated when
1200 N/mm2.
turning in the screw could cause breakage of the ef-
fected part. The second number specifies 10-times the ration be-
tween lower yield point and nominal tensile strength
(yield point ratio).

i Note
When exceeding the lower yield point, the material will
return to its original shape when being relieved (plas-
tic deformation).
When exceeding the upper yield point the material will
not restore its original shape after being relieved.
l The lower tensile strength is 9/10 X 1200 N/mm2 =
1080 N/mm2.

i Note
However, these values are by no means identical with
the tightening torques, which are to be set on a torque
wrench. The corresponding calculation requires a
higher effort and, in the end, depends on the materials
to be bolted together.

20 BOMAG 008 915 77

General repair instructions 1.3
Strength classes of metric nuts Identification in clock system
Nuts are differentiated by three load groups. Each
load group has a special designation system for the
strength class assigned, so that the load group can be
clearly identified.

Nuts for screw joints with full load capability (4, 5,

6, 8, 10, 12)

Fig. 10 Identification of nuts in clock system

Fig. 9 Identification of nuts
In a connection with a screw, these nuts 1 (Fig. 9)
must be able to bear the full pre-load at the yield point.
Nut height above 0.8 d (d = nominal dimension).
For small nuts (Fig. 10) the clock system can be used
for identification.
l The 12 o'clock position is identified by a dot or the
manufacturer's symbol.
l
The strength class is identified by a dash (b).

Strength class of Strength class of associated

nut screw
4 3.6, 4.6, 4.8
5 3.6, 4.6, 4.8
5.6, 5.8
6 6.8
8 8.8
9 9.8
10 10.8
12 12.8

Nuts for screw joints with limited load factor (04,

05)
The preceding "0" indicates that, due to their low
height, nuts 2 (Fig. 9) in this group are only able to
withstand the force of a screw to a limited extent.
Nut height below 0,8 d (d = nominal dimension).

Nuts for screw joints without specified load factor

(11H, 14H, 17H, 22H)
This standard contains strength classes (hardness
classes) for nuts 3 (Fig. 9), for which no load values
can be specified, e.g. because of their shape and di-
mensions, but which can only be classified by their
hardness.
Nut height below 0,5 d (d = nominal dimension).

008 915 77 BOMAG 21

1.3 General repair instructions

Identification of UNF-threads Cotter pins

Fig. 12
In places where cotter pins are used, these must be
reassembled. Cotter pins must generally be renewed
after disassembly.
Cotter pins must be assembled as shown in the illus-
tration, unless specified differently.
Fig. 11

Screws
The screw head is marked with a stamped in, round
cavity 3 (Fig. 11).

Nuts
An uninterrupted series of stamped in circles parallel
to the axis of the nut on a hexagon area (2).

Studs and brake rods

At the outmost end a short end of the component is re-
duced to its core diameter (1).

22 BOMAG 008 915 77

Tightening torques 1.4
The values specified in the table apply for screws:
1.4 Tightening torques

l black oiled
l with surface protection A4C
l with surface protection DACROMET

i Note
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.

Tightening torques for screws with metric unified thread1

Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M4 3 5 5
M5 6 9 10
M6 10 15 18
M8 25 35 45
M10 50 75 83
M12 88 123 147
M14 137 196 235
M16 211 300 358
M18 290 412 490
M20 412 578 696
M22 560 785 942
M24 711 1000 1200
M27 1050 1480 1774
M30 1420 2010 2400
1 Coefficient of friction μ tot. = 0,14

Tightening torques for screws with metric unified fine thread1

Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M8 x 1 26 37 48
M10 x 1.25 52 76 88
M12 x 1,25 98 137 126
M12 x 1.5 93 127 152
M14 x 1.5 152 216 255
M16 x 1.5 225 318 383
M18 x 1.5 324 466 554
M20 x 1.5 461 628 775
M22 x 1.5 618 863 1058
M24 x 2 780 1098 1294
M27 x2 1147 1578 1920
M30 x 2 1568 2254 2695
1 Coefficient of friction μ tot. = 0,14

008 915 77 BOMAG 23

1.4 Tightening torques

Tightening torques for screws treated with anti-seizure paste OKS 2401 (copper paste)

Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M16 169 240 287
M16 x 1.5 180 255 307
M18 232 330 392
M18 x 1.5 260 373 444
M20 330 463 557
M20 x 1.5 369 502 620
M22 448 628 754
M22 x 1.5 495 691 847
M24 569 800 960
M24 x 2 624 879 1036
M27 840 1184 1520
M27 X 2 918 1263 1536
M30 1136 1608 1920
M30 x 2 1255 1804 2156
3/4“ - 10 UNC 276 388 464
3/4“ - 16 UNC 308 432 520
1 Anti-seizure paste (copper paste) is used for the assembly of screw connections, which are exposed to high temperatures and corrosive
effects. Prevents seizure and corrosion.

Tightening torques for wheel nuts (fine thread) 1 2

Tightening torques Nm
Thread diameter
10.9
M12x1.5 100
M14x1.5 150
M18x1.5 300 - 350
M20x1.5 400 - 500
M22x1.5 500 - 600
1 Coefficient of friction μ tot. = 0,14
2 These values result in a 90% utilization of the yield point

24 BOMAG 008 915 77

Tightening torques 1.4
The values specified in the table apply for screws:
l black oiled
l with surface protection A4C
l with surface protection DACROMET

i Note
The difference between Withworth and UNF/UNC threads is the fact that UNF and UNC threads have 60° flanks,
as the metric ISO-thread, whereas Withworth has a flank of only 55°.
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.

Tightening torques for screws with UNC thread, 1 UNC Unified Coarse Thread Series, American Unified
Coarse Thread

Tightening torques Nm
Screw dimension
8.8 10.9 12.9
1/4“ - 20 11 15 19
5/16“ - 18 23 32 39
3/8“ - 16 39 55 66
7/16“ - 14 62 87 105
1/2“ - 13 96 135 160
9/16“ - 12 140 200 235
5/8“ - 11 195 275 330
3/4“ - 10 345 485 580
7/8“ - 9 560 770 940
1“ - 8 850 1200 1450
1 1/8“ - 7 1200 1700 2000
1 1/4“ - 7 1700 2400 2900
1 3/8“ - 6 2200 3100 3700
1 1/2“ - 6 3000 4200 5100
1 Coefficient of friction μ tot. = 0,14

Tightening torques for screws with UNF thread, 1 UNF Unified National Fine Thread Series, American
Unified Fine Thread

Tightening torques Nm
Screw dimension
8.8 10.9 12.9
1/4“ - 28 13 18 22
5/16“ - 24 25 35 42
3/8“ - 24 45 63 76
7/16“ - 20 70 100 120
1/2“ - 20 110 155 185
9/16“ - 18 155 220 260
5/8“ - 18 220 310 370
3/4“ - 16 385 540 650
7/8“ -14 620 870 1050

008 915 77 BOMAG 25

1.4 Tightening torques

Tightening torques for screws with UNF thread, 1 UNF Unified National Fine Thread Series, American
Unified Fine Thread

Tightening torques Nm
Screw dimension
8.8 10.9 12.9
1“ - 12 930 1300 1600
1 1/8“ - 12 1350 1900 2300
1 1/4“ - 12 1900 2700 3200
1 3/8“ - 12 2600 3700 4400
1 1/2“ - 12 3300 4600 5600
1 Coefficient of friction μ tot. = 0,14

26 BOMAG 008 915 77

 2 Technical data

008 915 77 BOMAG 27

2.1 Technical data

2.1 Technical data

Dimensions in A D H K L S W W1
mm
BMP 8500 1000 520 1275 222 1897 25 850 610)

1 BMP 8500
Weights
Operating weight (CECE) kg 1595
Basic weight kg 1585
Mean axle load (CECE) kg 775

Travel characteristics
Travel speed (1) forward/reverse km/h 0 to 1.3
Travel speed (2) forward/reverse km/h 0 to 2.5
Max. gradability without/with vibration (soil dependent) % 55/45

Drive
Engine manufacturer Kubota
Type D 1005
Cooling Water
Number of cylinders 3
Rated power ISO 9249 kW 14.5
Rated speed rpm 2600
Drive system hydrostatic
Driven drums front + rear

Brake
Service brake hydrostatic
Parking brake mechanical

Steering
Type of steering Articulated joint
Steering operation hydrostatic

Vibration system
Vibrating drum front + rear
Drive system hydrostatic
Frequency Hz 42

28 BOMAG 008 915 77

Technical data 2.1
1
BMP 8500
Amplitude mm 1.12/0.56
Centrifugal force kN 72/36

Filling capacities
Fuel (diesel) l 24
Hydraulic oil l 17
Engine oil l 4.7
Coolant l 4.5
Vibration housing l 2x 1,7

Safety field system

Performance level PL c
Reach of the safety field infront of/behind the machine m > 1.20

Safety field control

Voltage V 8 ... 30
Current consumption @ 12 V A 1.5
Protection class IP 55
Safety field frequency kHz 125
Operating temperature °C -20 ... +80
Storage temperature °C -40 ... +85

Transponder (in remote control)

Voltage (cable operation) V 9 ... 30
Voltage (battery operation) V 3.6
Transmitting frequency range MHz 868/916
Operating temperature °C -20 ... +80
Storage temperature °C -40 ... +85

Safety field antenna

Protection class IP 55
Operating temperature °C -20 ... +85
Storage temperature °C -40 ... +85

Radio remote control

Manufacturer HETRONIC

Transmitter
Frequency band F-band
Transmitting frequency range MHz 868 / 916
Number of channels 1
Reach, depending on environment m approx. 30
Current draw mA approx. 10
Weight kg approx. 1,6

008 915 77 BOMAG 29

2.1 Technical data

1
BMP 8500

Receiver
Receiver frequency range MHz 868 / 916
Current draw mA approx. 10

Transmitter power pack

Voltage V 3.6
Capacity Ah 1.2

Battery charger
Operating voltage V (AC) 110/230
V (DC) 12 - 24
1 The right for technical modifications remains reserved

Additional engine data

Combustion principle 4-stroke diesel
Low idle speed rpm 850 ±50
High idle speed rpm 2750 ±50
Specific fuel consumption g/kWh 255
Valve clearance intake mm 0.145 to 0.185
Valve clearance exhaust mm 0.145 to 0.185
Starter power kW 1.2
Injection pressure 13.73 MPa (140.0 kgf/cm2, 1991 psi)

Travel pump
Type AZPFFB-12-8+5,5+4R
System Triple gear pump
Max. displacement cm3/rev. 5.5
High pressure limitation bar 250

Travel motors
Type 2000 Series
Quantity 2
System Geroller hydraulic motor
Displacement (stage 1) cm3/rev. 306.6

Steering/charge/vibration pump
Type AZPFFB-12-8+5,5+4R
System Triple gear pump
Max. displacement cm3/rev. 8
Starting pressure bar 250
Operating pressure (soil dependent) bar 80 - 150

Vibration motor

30 BOMAG 008 915 77

Technical data 2.1
Type HY/MZFS11/8
Quantity 2
System Gear motor
Displacement cm3/rev. 8

Steering valve
Type 90 SBV
System Control valve

Valve block, working hydraulics

Type 90 SBV
System Control valve

008 915 77 BOMAG 31

2.1 Technical data

The following noise and vibration values according to the EC-directive for machines, edition (91/368/
EEC) were measured at nominal engine speed and with the vibration switched on. The machine was
standing on an elastic base.

During operation these values may vary because of the existing operating conditions.

Noise value
The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is

sound pressure level on the operator’s stand:

LpA = 86 dB(A)

sound capacity level:

LWA =105 dB(A)
These sound values were determined according to ISO 6081 for the sound pressure level (LpA) and ISO 3744,
DIN 45635 for the sound capacity level (LwA).

32 BOMAG 008 915 77

 3 Maintenance

008 915 77 BOMAG 33

3.1
3.1 General notes on maintenance
When performing maintenance work always comply
with the appropriate safety regulations.
Thorough maintenance of the machine guarantees far
longer safe functioning of the machine and prolongs
the lifetime of important components. The effort need-
ed for this work is only little compared with the prob-
lems that may arise when not observing this rule.
The terms right/left correspond with travel direction
forward.
l Always clean machine and engine thoroughly be-
fore starting maintenance work.
l For maintenance work stand the machine on level
ground.
l Always remove the main battery switch for all main-
tenance work.
l Perform maintenance work only with the motor
switched off.
l
Relieve hydraulic pressures before working on hy-
draulic lines.
l
Before working on electric parts of the machine dis-
connect the battery and cover it with insulation ma-
terial.
l
When working in the area of the articulated joint at-
tach the articulation lock (transport lock).
Environment
During maintenance work catch all oils and fuels
and do not let them seep into the ground or into
the sewage system. Dispose of oils and fuels en-
vironmentally.
Keep used filters in a separate waste container
and dispose of environmentally.
Catch biodegradable oils separately.
Notes on the fuel system
The lifetime of the diesel engine depends to a great
extent on the cleanliness of the fuel.
l Keep fuel free of contaminants and water, since this
will damage the injection elements of the engine.
l Drums with inside zinc lining are not suitable to
store fuel.
l When choosing the storage place for fuel make
sure that spilled fuel will not harm the environment.
l Do not let the hose stir up the slurry at the bottom of
the drum.
l
The fuel drum must rest for a longer period of time
before drawing off fuel.
l The rest in the drum is not suitable for the engine
and should only be used for cleaning purposes.
34 BOMAG
General notes on maintenance
Notes on the performance of the engine
On diesel engines both combustion air and fuel injec-
tion quantities are thoroughly adapted to each other
and determine power, temperature level and exhaust
gas quality of the engine.
If your engine has to work permanently in "thin air" (at
higher altitudes) and under full load, you should con-
sult the customer service of BOMAG or the customer
service of the engine manufacturer.
Notes on the cooling system
Prepare and check coolant with highest care, since
otherwise the engine may be damaged by corrosion,
cavitation and freezing.
The coolant is prepared by mixing a cooling system
protection agent (ethylene glycol) into the coolant.
Mixing with cooling system protection agent is neces-
sary in all climatic zones. It prevents corrosion, lowers
the freezing point and raises the boiling point of the
coolant.
Notes on the hydraulic system
During maintenance work on the hydraulic system
cleanliness is of major importance. Make sure that no
dirt or other contaminating substances can enter into
the system. Small particles can produce flutes in
valves, cause pumps to seize, clog nozzles and pilot
bores, thereby making expensive repairs inevitable.
l
If, during the daily inspection of the oil level the hy-
draulic oil level is found to have dropped, check all
lines, hoses and components for leaks.
l
Seal leaks immediately. If necessary inform the re-
sponsible customer service.
l
We recommend to use the BOMAG filling and filter-
ing unit with fine filter to fill the system. This ensures
finest filtration of the hydraulic oil, prolongs the life-
time of the hydraulic oil filter and protects the hy-
draulic system.
l Clean fittings, filler covers and the area around such
parts before disassembly to avoid entering of dirt.
l
Do not leave the tank opening unnecessarily open,
but cover it so that nothing can fall in.
008 915 77
Fuels and lubricants 3.2
3.2 Fuels and lubricants Fuels
Quality
Engine oil Cetan index number: The recommended minimum in-
Quality dex number for the Cetan value is 45. A Cetan index
number higher than 50 should preferably be used, es-
Lubrication oils are classified according to their per-
pecially at ambient temperatures below -20 °C and
formance and quality class. Oils according to other when working at altitudes of 1500 m and more.
comparable specifications may be used.
Diesel fuel specifications: With respect to the percent-
If low sulphur fuel (< 0.05%) is used, you must only
age (ppm) of sulphur the fuel used in the engine must
use engine oils of API1-classification CF, CF-4, CG-4,
comply with all relevant exhaust emission regulations
CH-4 and CI-4.
in the are of use of the engine.
For operation of an engine with high sulphur fuels it is
It is highly recommended to use a fuel with a sulphur
recommended to use an engine oil of classification CF
content of less than 0,10 % (1000 ppm).
or higher with a total base number of at least 10.
When using a diesel fuel with a high sulphur content
of 0.50 % (5000 ppm) to 1.0 % (10.000 ppm), the en-
! Caution gine oil change intervals must behalved.
Engine oils of classification CJ-4 must not be
used!
Caution
!
Oil viscosity Do not use any fuels with a sulphur content of
Since lubrication oil changes its viscosity with the tem- more than 1,0 % (10000 ppm).
perature, the ambient temperature at the operating lo- It is recommended to use diesel fuel that complies
cation of the engine is of utmost importance when with the specifications EN590 or ASTM D975.
choosing the viscosity class (SAE-class) .
Diesel fuel with the designation no. 2-D is a destillate
Optimal operating conditions can be achieved by us- fuel with low volatility, which is especially suitable for
ing the following oil viscosity chart as a reference. industrial engines and heavy-duty commercial vehi-
cles (SAE J313 JUN87).
Ambient temperature Viscosity Since KUBOTA diesel engines with a rated power of
less than 56 kW (75 HP) comply with the exhaust
SAE 30 emission standard of EPA2-stage 4, the use of low or
over 25 °C! SAE10W-30 ultra-low sulphur fuel is mandatory for these engines,
if the engines are operated within the validity area of
SAE 15W-40 the EPA standard. As an alternative to no. 2-D you
SAE 20 may also use diesel fuel no. 2-D S500 or S15; with
ambient temperatures below -10 °C the diesel fuel no.
0°C to 25°C SAE10W-30 1-D S500 or S15 should be used fir no. 1-D.
SAE 15W-40 The fuel level should always be topped up in due time
below 0 °C SAE 10 so that the fuel tank is never run dry, as otherwise filter
and injection lines need to be bled.
SAE10W-30
SAE 15W-40 Winter fuel

Oil change intervals Danger

The longest permissible time a lubrication oil should
remain in an engine is 1 year. If the following oil
change intervals are not reached over a period of 1
year, the oil change should be performed at least once
per year, irrespective of the operating hours reached.
API: CF, CF-4, CG-
4,CH-4 and CI-4= 250 operating hours
!
Fire hazard!
Diesel fuels must never be mixed with gasoline.
For winter operation use only winter diesel fuel, to
avoid clogging because of paraffin separation. At very
low temperatures disturbing paraffin separation can
also be expected when using winter diesel fuel.

Coolant
Always use a mixture of anti-freeze agent and clean,
dehardened water with a mixing ratio of 1:1.

1 American Petroleum Institute 2 United States Environmental Protection Agency

008 915 77 BOMAG 35

3.2 Fuels and lubricants

Under particularly extreme temperature conditions
you should consult the service representation of the
engine manufacturer with respect to the anti-freeze
agent to be used.
There are various types of anti-freeze agents availa-
ble. For this engine you should use ethylene glycol.
Before filling in the coolant mixed with anti-freeze
agent the radiator must be flushed with clean water.
This procedure should be repeated two to three times
to clean the inside of radiator and engine block.
When changing from mineral oil based hydraulic oil to
an ester based biologically degradable oil, you should
consult the lubrication oil service of the oil manufactur-
er for details.
! Caution
Check the filter more frequently after this change.
Perform regular oil analyses for content of water
and mineral oil.

Mixing the anti-freeze agent: Prepare a mixture of Replace the hydraulic oil filter element every 500
50 % anti-freeze agent and 50 % low mineral, clean operating hours.
water. Stirr well before filling it into the radiator. The
method for mixing water and anti-freeze agent de-
pends on the brand of the anti-freeze agent. In this re-
spect see standard SAE J1034 and also the standard
SAE J814c.
Add anti-freeze agent: If the coolant level drops be-
cause of evaporation,only clean water is to be used
for topping up. In case of leakages you must always
fill in anti-freeze agents of the same brand and the
same mixing ratio.

! Caution
Do not mix different coolants and additives of any
other kind.
Do not use any radiator cleaning agent after the anti-
freeze agent has been mixed in. The anti-freeze agent
also contains a corrosion protection agent. If this mix-
es with cleaning agent it may cause the development
of sludge, which could damage the cooling system.

Anti-freeze concentration
50% = -37 °C

Environment
Coolant must be disposed of environmentally.

Mineral oil based hydraulic oil

The hydraulic system is operated with hydraulic oil HV
46 (ISO) with a kinematic viscosity of
46 mm2/s at 40 °C. For topping up or for oil changes
use only high-quality hydraulic oil, type HVLP accord-
ing to DIN 51524, part 3, or hydraulic oils type HV ac-
cording to ISO 6743/3. The viscosity index (VI) should
be at least 150 (observe information of manufacturer).

Bio-degradable hydraulic oil

The hydraulic system can also be operated with a syn-
thetic ester based biodegradable hydraulic oil.
The biologically quickly degradable hydraulic oil Pan-
olin HLP Synth.46 meets all demands of a mineral oil
based hydraulic oil according to DIN 51524.
In hydraulic systems filled with Panolin HLP Synth.46
always use the same oil to top up.

36 BOMAG 008 915 77

Table of fuels and lubricants 3.3
3.3 Table of fuels and lubricants

Assembly Fuel or lubricant Quantity

Summer Winter Attention

Observe the level marks

Engine

- Engine oil Engine oil API: CF, CF-4, CG-4, CH-4 or CI-4 approx. 4.7 litres

SAE 10W/30 (-15 °C to +30 °C)

SAE 15W/40 (-15 °C to + 40 °C)

SAE 30 (+5 °C to +30 °C) SAE 10 (-30 °C to -5 °C)

- Fuel Diesel Winter diesel fuel (down approx. 24 litres

to -12°C)

- Coolant Mixture of water and anti-freeze agent approx. 4.5 litres

Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity approx. 17 litres
46 mm2/s at 40 °C or
ester based biodegradable hydraulic oil

Vibration housing Engine oil SAE 15W/40 2 x 1.7 l

008 915 77 BOMAG 37

3.4 Running-in instructions

3.4 Running-in instructions

i Note
The maintenance plan inside the engine hood of the
machine assists you when servicing the machine!

The following maintenance work must be per-

formed when running in new machines or over-
hauled engines:

Caution
!

Up to approx. 250 operating hours check the en-

gine oil level twice every day.
Depending on the load the engine is subjected to,
the oil consumption will drop to the normal level
after approx. 100 to 250 operating hours.

Maintenance after 50 operating hours

l Change engine oil and filter
l Check the engine for leaks
l Retighten the fastening screws on air filter, exhaust
and other attachments.
l Check screw connections on the machine, retighten
as necessary.
l Retighten fastening screws of engine mounts
l Check the central screw of the drive hub, retighten
if necessary

38 BOMAG 008 915 77

Maintenance table 3.5
3.5 Maintenance table

every 10 operating hours, daily

every 1000 oper. hours

every 2000 oper. hours

every 3000 oper. hours

every 250 oper. hours

every 500 oper. hours

No. Maintenance work Comment

as required
5.6 Check the engine oil level Dipstick mark X
5.7 Check the hydraulic oil level Inspection glass X
5.8 Check the fuel level X
5.9 Fuel filter, draining off water X
5.10 Check the coolant level X
5.11 Check the air intake hose X
5.12 Change engine oil and oil filter1 at least 1x per year X
see foot note
5.13 Check, tension, replace the V-belt X
5.14 Clean radiator cooling fins X
5.15 Change the oil in the vibrator shaft min. 1x per year X
housing
5.16 Check the central screw of the drive see foot note X
hub2
5.17 Drain the fuel tank sludge X
5.18 Change the fuel pre-cleaner, bleed X
the fuel system
5.19 Battery service, checking the main pole grease X
battery switch
5.20 Check the rubber buffers X
5.21 Check, adjust the valve clearance 0.145 ... 0.185 mm X
5.22 Check the safety field in front of/be- X
hind the machine
5.23 Change hydraulic oil and filter3 at least every 2 years X
5.24 Change the coolant X
5.25 Change the fuel lines X
5.26 Check the injection pressure X
5.27 Check the fuel injection pump X
5.28 Check the fuel injection timing X

008 915 77 BOMAG 39

3.5 Maintenance table

every 10 operating hours, daily

every 1000 oper. hours

every 2000 oper. hours

every 3000 oper. hours

every 250 oper. hours

every 500 oper. hours

No. Maintenance work Comment

as required
5.29 Check, clean, change the combustion min. 1x per year X
air filter
5.30 Adjust the scrapers X
5.31 Tightening torques X
5.32 Engine conservation X
1 Running-in instructions: Oil change after 50 and 250 operating hours, then every 250 operating hours When using fuels with a sul-
phur content higher than 0.5% the oil change intervals must be halved.
2 Running-in instructions: check tightening torque after 50 and 250 operating hours, then every 250 operating hours
3 Also in case of repair in the hydraulic system.

40 BOMAG 008 915 77

 4 Caddy wiring diagrams

008 915 77 BOMAG 41

4.1 Understanding circuit diagrams

4.1 Understanding circuit diagrams

Wiring diagrams are graphical representations of circuitry conditions, related to the electrical system. They do
not contain any information about the actual type of wiring, they only serve the purpose of visualizing the circuitry
logics.
The wiring diagram is indispensable for effective and systematic trouble shooting in the vehicle wiring system.
This plan provides the following information:
l Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses,
switches, consumers, relays, ...
l The sequence in which current flows through the individual elements in the electric circuit.
l Connections between the examined, faulty electric circuit and other circuits in the vehicle wiring system.
l Pin assignment of plug-and-socket connections.

Structure
l Table of contents (Fig. 13)
l Function groups (Fig. 14)
l List of components (Fig. 16)

42 BOMAG 008 915 77

Understanding circuit diagrams 4.1
Table of contents (Fig. 13)
The table of contents lists all function groups.

Fig. 13 Table of contents

Example:
Function group "Warning systems“, drawing number XXX XX can be found on page no. 8.

008 915 77 BOMAG 43

4.1 Understanding circuit diagrams

Function groups (Fig. 14)

On the individual pages the electric circuits are combined to function groups.

Arrangement of current paths

The individual current paths must be read as follows:
l From top (plus potential) to bottom (minus potential).
l From left to right.
l From function group to function group.
l Via cross references for potentials and relays.

Fig. 14 Function groups

Potential cross references

Potential cross references serve the purpose of tracking signals, which are transmitted from one function group
to another.

Example:
Potential "15" on page no. 6 is continued to the left on page no. 4 in current path "10" and to the right on page
no. 8 in current path "1“.

Relay cross reference

Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing
contacts.
A mimic diagram with information about the contact types of a relay and their positions in the wiring diagram is
additionally attached to the bottom of each contactor coil.

Example:
The coil of relay (K99) is located on page no. 8 in current path "6".
The mimic diagram under the relay informs that a change-over switch with contact types 30, 87 and 87a is trig-
gered.
The changeover contact can be found on page no. 8 in current path "3".

44 BOMAG 008 915 77

Understanding circuit diagrams 4.1
Current paths
The pages of a circuit diagram are sub-divided into current paths (Fig. 15) (0 ..... 20).

Fig. 15 Current paths

008 915 77 BOMAG 45

4.1 Understanding circuit diagrams

List of components (Fig. 16)

Here you find all components used in alphabetical order, related to the name of the component (A01, A02....).

Fig. 16 List of components

Component cross references

Example:
The warning horn "B 11" is located on page no. 8 in current path 3.

46 BOMAG 008 915 77

Circuit symbols in the circuit diagram 4.2
4.2 Circuit symbols in the circuit diagram
Circuit symbol
l Circuit symbols are standardized representations for electrical appliances. They serve the purpose of a sim-
plified representation of complete systems, from which, however, the function can be clearly identified. This
standardization is in compliance with the globally valid regulations of the IEC (International Electrical Commis-
sion). The standardization serves the purpose of global understanding and fault free connection of appliances,
especially in automobile repairs. Since the wiring diagram is intended to show only the most essential aspects,
the circuit symbol only shows as much of the function, as is needed for easy recognition and for the avoidance
of mistakes.

Fig. 1 Example: Circuit symbol

1 Current source
2 Conductor
3 Switch
4 Ground
5 Filament lamp
6 Filament lamp with two luminous elements
7 Voltmeter
8 Amperemeter
9 Resistance
10 Backup
11 Line connection (fixed)
12 Line connection (separable)

008 915 77 BOMAG 47

4.2 Circuit symbols in the circuit diagram

48 BOMAG 008 915 77

 5 E-Plan wiring diagrams

008 915 77 BOMAG 49

5.1 Understanding wiring diagrams

5.1 Understanding wiring diagrams

Electric circuit diagrams

Electric circuit diagrams are graphic presentations of control logical conditions in the electric system. They do
not contain any information on the type of wiring, their purpose is solely the clarification of control logics.
The wiring diagram is indispensable for effective and systematic trouble shooting in the vehicle wiring system.
This plan provides the following information:
l Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses,
switches, consumers, relays, etc.
l The sequence in which current flows through the individual elements in the electric circuit.
l Connections between the examined electric circuit and other circuits in the vehicle wiring system.
l Pin assignment of plug-and-socket connections.

Structure of a wiring diagram

l Cover sheet, see section "Cover sheet"
l Table of contents, see section "Table of contents"
l Structuring symbol overview, see section "Structuring symbol overview"

i Note
The structuring symbol overview is NOT present in circuit diagrams, which are sorted by systems and local iden-
tification!
l Sheets with illustration of function, see section"Sheets with illustration of function"
l List of fuels and lubricants, see "List of fuels and lubricants"
l Terminal strip overview, see section "Terminal strip overview"
l Plug overview, see section "Plug overview"
l Pin overview, see section "Pin overview"

50 BOMAG 008 915 77

Understanding wiring diagrams 5.1
Cover sheet
The cover sheet, see example (Fig. 2), contains general information.

Fig. 2 Example: Cover sheet

008 915 77 BOMAG 51

5.1 Understanding wiring diagrams

Table of contents
The table of contents, see example (Fig. 3), lists the individual functions and identifies the corresponding sheets
in the wiring diagram.

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Fig. 3 Example: Table of contents

52 BOMAG 008 915 77

Understanding wiring diagrams 5.1
Sheets with representations of functions
l
The main reading direction is sheet by sheet, from top to bottom and from right to left.
l All sheets are successively numbered.
l BOMAG used the resolved type of representation. In this case parts and components with different functions,
which belong to the same components (e.g. relay coil and relay contact), can be represented on different
sheets. Cross-references, which refer to the sheet and current path, serve as linkage between these partial
components (Fig. 4).

Structuring symbols
Relay cross-reference Potential cross-reference

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Mimic diagram of relay Current paths

Fig. 4 Example: Sheet with functions

Current paths (Fig. 4)

l Current paths are successively numbered from 0 to 9.

Potential cross references (Fig. 4)

l Potential cross references serve the purpose of tracking signals, which are transmitted from one representa-
tion of a function to another. Potential cross-references may additionally have structuring symbols assigned
to them.
Example: Potential → 15_54 ∼ +SEAT/16.1 (on sheet 4, current path 8) continues to the right on sheet 16,
current path 1. +SEAT is the structuring symbol.

008 915 77 BOMAG 53

5.1 Understanding wiring diagrams

Relay cross references (Fig. 4)

l Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing
contacts. A mimic diagram with information about the contact types of a relay and their positions in the wiring
diagram is additionally attached to the bottom of each contactor coil.
Example: The relay cross-reference (-K61/4.2) (on sheet 4, current path 4) indicates that the relay coil on sheet
4 is found in current path 2.

54 BOMAG 008 915 77

Understanding wiring diagrams 5.1
List of component
The list of components, see example (Fig. 5), is the first evaluation list that follows the representation of function.
This list contains all components used in the wiring diagram, except terminal strips and plugs.

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Fig. 5 Example: List of components

An electric component is a part, assembly or device in an electrical installation.
l
Components are marked with a combination of letters and numbers. The identification with letters follows the
standard DIN - EN 61346 T1-T2. A component identification (BMK), e.g.: “S04“ always identifies the same
component. In this context the term "component" is always considered a function specific assignment and
does not represent a parts or article number. This ensures that the component with the designation "S04" al-
ways refers to the "Brake Switch", irrespective of whether the abbreviation is used in a wiring diagram for a
single drum roller, a tandem roller, a finisher or a milling machine.
l
The component identifications are alphabetically sorted in the list of components. Each component has the
corresponding cross-references assigned, identifying where it can be found in the wiring diagram, which in-
stallation location it is assigned to and to which part of the system it belongs to. Moreover, the functions (func-
tion text) and the technical characteristics are also described.

i Note
Component identifications are used in both the electrical and the hydraulic documentation and are identical.

008 915 77 BOMAG 55

5.1 Understanding wiring diagrams

Overview of terminal strips

The overview of terminal strips, see axample (Fig. 6), contains all terminal strips used in the circuit diagram.
Each terminal strip starts on a new page and can be localized via the cross-reference in the wiring diagram.

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Fig. 6 Example: Terminal strip overview X1

56 BOMAG 008 915 77

Understanding wiring diagrams 5.1
Overview of plugs
The overview of plugs, see example (Fig. 7), contains all plugs used in the circuit diagram.
The following information is listed for each plug:
l Contact numbering
l Structuring symbols
l Function text
l Use in wiring diagram.

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Fig. 7 Example: Plug overview X0

008 915 77 BOMAG 57

5.1 Understanding wiring diagrams

Overview of pins
The overview of pins, see example (Fig. 8), informs about the type of inputs and outputs of the electronic controls
(E-BOX) used in the machine, as well as their signals and potentials.

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Fig. 8 Example: Overview of pins, control A66

58 BOMAG 008 915 77

Circuit symbols in the circuit diagram 5.2
5.2 Circuit symbols in the circuit diagram

Circuit symbols
Circuit symbols are standardized representations for electrical appliances. They serve the purpose of a simpli-
fied representation of complete systems, from which, however, the function can be clearly identified. This stand-
ardization is in compliance with the globally valid regulations of the IEC (International Electrical Commission).
The standardization serves the purpose of global understanding and fault free connection of appliances, espe-
cially in automobile repairs. Since the wiring diagram is intended to show only the most essential aspects, the
circuit symbol only shows as much of the function, as is needed for easy recognition and for the avoidance of
mistakes.

Fig. 9 Example: Circuit symbol

1 Current source
2 Conductor
3 Switch
4 Ground
5 Filament lamp
6 Filament lamp with two luminous elements
7 Voltmeter
8 Amperemeter
9 Resistance
10Fuse
11Terminal strip
12Plug
Different symbols are used to simplify the differentiation of terminal strips 11 (Fig. 9) and plugs (12) in a wiring
diagram.

i Note
Plugs are mainly used to connect two wiring looms or to connect a wiring loom with a component with cable
connection and mating plug.

008 915 77 BOMAG 59

5.2 Circuit symbols in the circuit diagram

Representation of electric devices

Electronic devices and components are increasingly used in the construction equipment industry. Controls with
software, control elements (e.g. joysticks and man/machine interface (e.g. screens, LC Displays) are frequently
used to represent and control machine functions. The internal construction of such components is in most cases
protected or just too complex to be illustrated in the wiring diagram within the context of the actual machine func-
tion. There are two different ways to simplify the representation of such devices in the diagram.

Black-Box representation(Fig. 10)

The Black-Box representation shows the device as a Box with the connections required for the machine function.
Connections which are not needed do not need to be represented.
The Black-Box representation is mainly used when no differentiated information (e.g. signals on pins) is availa-
ble.

Fig. 10 Example: Central lubrication system

Identification of externally supplied documentation (Fig. 11)

In industrial technology of today it is quite common to integrate externally supplied electric sub-systems into the
projecting of machines. These systems may be composed of various components and wirings. For easier differ-
entiation of BOMAG designation and manufacturer identification the latter appears under the BOMAG designa-
tion with a text frame and a reduced character height.

Fig. 11 Example: Identification of externally supplied documentation

PLC representation(Fig. 12)

The PLC-Box representation of connecting pins uses a table with associated connecting plugs, which are used
in connection with the machine functions. The table symbols can be arranged in a line, if necessary. Connections

60 BOMAG 008 915 77

Circuit symbols in the circuit diagram 5.2
which are not needed do not need to be represented. The PLC-Box representation enables the representation
of further reaching functional descriptions to the individual component connections.

Fig. 12 PLC representation

The PLC-Box representation is mainly used for controls with BOMAG software, or for electronic devices which
were specified accordingly, and where information on the assignment of signals is available.

Identification of similar, adjacent switching symbols

In wiring diagrams you will frequently find the situation that symbols of the same type appear in a line or are
arranged just next to each other. In such cases it is common practice to reduce the identification on the subse-
quent symbol to the criteria, which are different to the previous symbol to the left.

Example: -X0 36 and -X0 37 (Fig. 12)

In the example illustrated here the component identification "-X0" for the left plug symbol is also valid for the right
plug symbol.

008 915 77 BOMAG 61

5.2 Circuit symbols in the circuit diagram

62 BOMAG 008 915 77

 6 Electrics

008 915 77 BOMAG 63

6.1 Designation of components in the wiring diagram

6.1 Designation of components in the wiring diagram

The designation of components in the wiring diagram groups several electrical parts of the machine in one
group. The components can be identified by the following table.

Component designa- Meaning

tion
A Interval switch, indicator relay, modules, electronic component
B Pressure, pressure differential, temperature switches and sensors, transducers
C Capacitor
E Headlights, heater, air conditioning condenser
F Fuses
G Battery, generator
H Control lights, warning buzzer, warning light
K Relays
M Starter, pumps, motors
P Operating hour meter, general gauges
R Transducers, resistors
S Switches, momentary contact switches
V Diode
X Terminal
Y Solenoid valves

64 BOMAG 008 915 77

Terminal designations in wiring diagram 6.2
6.2 Terminal designations in wiring diagram
l For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a
terminal designation. In Germany the designation of the individual connection terminals is determined by the
standard DIN 72552. The following table shows some examples from this DIN standard.

Terminal designation Meaning

15 Switch plus (after battery) : Output of ignition switch

15a Output from dropping resistor to ignition coil and starter

17 Preheating starter switch, preheating

19 Preheating starter switch, starting

30 Battery plus direct

30a Battery changeover relay 12V / 24V, input from battery 2 plus

31 Battery minus direct or ground

31a Battery changeover relay 12V / 24V return line to battery 2 minus
31b Return line to battery minus or ground via switch or relay (switched minus)
31c Battery changeover relay 12V / 24V return line to battery 1 minus

49 Input flasher relay

49a Output flasher relay
49b Flasher relay output 2nd flasher circuit
49c Flasher relay output 3rd flasher circuit

50 Starter, starter control

50a Battery changeover relay, output for starter control

53 Wiper motor input (+)

53a Wiper motor (+) end limit shut down
53b Wiper shunt winding

56 Head light
56a Head light, travel light and travel light control
56b Head lights, dimmed head light
56d Head lights, flash light

57 Parking light for motor cycles (abroad also for cars and trucks)
57a Parking light
57L Parking light left
57R Parking light right

58 Side lights, tail light, number plate light, dashboard light

58b Tail light changeover for single axle trailers
58c Trailer plug for single core wired and trailer fused tail light
58d Adjustable dashboard light, tail light and side light
58L Side light, left
58R Side light, right

61 Generator control

75 Radio, cigarette lighter

76 Loudspeaker

87 Relay contact on breaker and two-way contact, input

008 915 77 BOMAG 65

6.2 Terminal designations in wiring diagram

Terminal designation Meaning

87a Relay contact on breaker and two-way contact, output 1 (breaker side)
87b Relay contact on breaker and two-way contact, output 2
87c Relay contact on breaker and two-way contact, output 3
87z Relay contact on breaker and two-way contact, input 1
87y Relay contact on breaker and two-way contact, input 2
87x Relay contact on breaker and two-way contact, input 3

88 Relay contact for maker

88a Relay contact on maker and two-way contact, (maker side) output 1
88b Relay contact on maker and two-way contact, (maker side) output 2
88c Relay contact on maker and two-way contact, (maker side) output 3
88z Relay contact on maker, input 1
88y Relay contact on maker, input 2
88x Relay contact on maker, input 3

B+ Battery positive
B- Battery minus
D+ Dynamo Plus
D- Dynamo Minus
DF Dynamo field (generator excitation current)
DF1 Dynamo field 1 (generator excitation current)
DF2 Dynamo field 2 (generator excitation current)

66 BOMAG 008 915 77

Battery ground and analog ground
6.3 Battery ground and analog
ground
GND, battery ground
The term "ground" (abbreviated GND) describes a
conductive body which is normally defined with the
potential of "Zero" Volt and represents the reference
potential for operating voltages.
The positive pole of the supply voltage (symbol + ) and
all other electric voltages and electical signals in an
electrical circuitry refer to the ground potential.
On motor vehicles and also on motorbikes and bicy-
cles the ground potential is represented by the chas-
sis or the frame. As a conductive part, which covers
the entire vehicle, it also serves a return conductor for
the vehicle wiring system - the consumers only need
to be wired up.
Terminal designation for GND = terminale 31
AGND, analog ground
Apart from the "normal" battery ground there is also
the analog ground, which is solely reserved for sen-
sors.
008 915 77 BOMAG
6.3
6.4 Processor signals
Signals
Analog signals
Process states are continuous (analog) when they
can be mapped by means of a real number, e.g. tem-
perature = 65.5 °C. The sensor converts a continuous
process status into an analog signal. If the control unit
needs the numerical value of the analog signal, an an-
alog-digital conversion is required.
Analog signals are needed to control, display or mon-
itor limit values. Checking the limit values of physical
quantities leads to the binary information: Limit value
reached/not reached.
Binary signals
Process states are bivalent (binary) if they have only
2 possible states of truth, such as e.g. button pressed/
not pressed, object present/not present. The two
states of truth are mapped by means of defined states
of an information carrier, e.g. not-
pressed'equals0V,'pressed'equals24V.Thesestate-
saredescribedwith{0,1}or{false,true}'
67
6.5 Current and voltage

6.5 Current and voltage The following statements concerning electric volt-
age can be made
l electric voltage is the pressure or force applied to
General
free electrons.
If one wants to describe electric current, this can most l the electric voltage is the cause of electric current
simply be accomplished by means of a comparison:
l electric voltage is a result of the equalization at-
One simply compares electric current with water. tempt of electric charges.
Voltage is measured with a Voltmeter.
Voltage
Unit, Volt

The electric voltage (U) is measured in Volt (V).

Fig. 1
1 (Fig. 1) Charge
2 Voltage
3 Current
The equalization attempt between different electric
charges is referred to as electric voltage.
Voltage sources have two poles of different charge.
On the one side we have the plus pole with a lack of
electrons, on the opposite side the minus pole with a
surplus of electrons. This electric "pressure" is known
as electric voltage.

Fig. 2
If there is a connection between these two poles a dis-
charge will take place, resulting in the flow of an elec-
tric current.
Plus pole= lack of electrons
Minus pole = excess of electrons

68 BOMAG 008 915 77

Current and voltage 6.5
Current Types of current
Electric current generally describes the directed Direct current (D.C.)
movement of charge carriers.
l The charge carriers may either be electrons or ions.
l Electric current can only flow if there is a sufficient
amount of free moving charge carriers.
l The higher the number of electrons flowing through
a conductor per second, the higher the amperage.
Current is measured with an ammeter.

Unit, Ampere Fig. 1 Direct current (D.C.)

The electric amperage (I) is measured in Ampere
(A).
The technical flow direction is specified from
PLUS to MINUS.
i Note
Current actually flows from minus to plus, because the
current flow is made up of negatively charged elec-
trons.
But since this was only discovered after the poles of a
current source had already been designated, the as-
sumption that current flows from plus to minus was
maintained for historic reasons.
Direct current flows with steady voltage and amper-
age from the plus to the minus pole.
Pure D.C.-voltages are only delivered by accumula-
tors or batteries.
The voltage in the vehicle wiring system is no pure
D.C.-voltage. Even without the generator running, but
the consumers switched on, the voltage is not con-
stant, but drops gradually according to the battery
charge condition.
The internal resistance of the battery also causes per-
manent changes in the vehicle voltage, as soon as
consumers are switched on or off.
Alternating current (A.C.)

Circuit

Fig. 2 Alternating current (A.C.)

Fig. 3 Circuit Alternating current not only changes its direction, but
also its amperage.
A simple circuit consists of a current source 1 (Fig. 3),
a consumer (3) and the connecting wiring.
When the circuit is closed, current can flow.
The circuit can be interrupted or closed with a switch
(2).
The system is protected by a fuse (4).

008 915 77 BOMAG 69

6.6 Resistance

6.6 Resistance
Resistance and voltage drop
While current flows through a conductor the current
flow is more or less inhibited by the conductor, this in-
hibitation is referred to as Resistance.
l The cleaner the contacts, the better the current.
l The quality of the ground cable is of the same im-
portance as the supply line.
Unnecessary resistances
Unnecessary resistances are frequently caused by
mechanical connections, even clean ones, but mainly
soiled and oxidizes terminals, too thin cables, material
with poor conductivity or bent open cable lugs.

Bad

Fig. 1 Various size resistors

Fig. 1 Screw-type terminals
Each conductor has its specific resistance, which is
characteristic for the corresponding material. A good Copper wires are squashed and thus become faulty.
conductor has a low resistance, a poor conductor has
Better
a high resistance.

Fig. 2 Spring clamps

Connecting clamps for flexible conductors
BOMAG No. 057 565 72
Ampacity up to 20 Amp.
Cable cross-section 0.08 to 2.5 qmm
Fig. 2 Potentiometer, infinitely adjustable resistor
The resistance can only be measured with a Multime-
ter.

Symbol, R

Unit, Ohm Ω

The electric resistance (R) is measured in Ohm Ω.

Rule of thumb:
l
The thicker the cable cross-section, the lower the
voltage loss.
l
The shorter the cable, the better the current.

70 BOMAG 008 915 77

Resistance 6.6
Sometimes the flanks of flat plugs bend open. If these
are closed again with the help of pliers the flanks will
be excessively strained at the bend and will definitely
break sooner or later. It is better to place a small nail
under the bottom of the cable lug before bending.

Fig. 3
In many cases it is better to replace the contact. Soiled
or oxidized contacts should be cleaned with Ballistol
(Fig. 4) and subsequently wetted with copper paste.
Copper paste is a heat resistant grease, which has
been mixed with copper powder. The paste protects
electric contacts against oxidation. Copper paste
keeps water away.

Fig. 5
Hint for practice:
A tool you cannot buy. The pliers were converted, the
nail is permanently present.

Fig. 4 Balistol oil

008 915 77 BOMAG 71

6.7 Series / parallel connection

6.7 Series / parallel connection
Series connection
In a series circuit the resistors (consumers) are lined
up one after the other and the same current (I) passes
through each of the consumers However, series con-
nection of consumers is not suitable in practice, as
each resistance causes a voltage drop. In the vehicle
wiring system all consumers are designed for the
same vehicle voltage (e.g. 12 Volt).
l In series connection the plus pole of the first battery
must be connected with the minus pole of the sec-
ond battery.
l The sum of all individual voltages is applied to the
free poles.
l The total capacity (Ah) is identical with the capacity
of the individual battery.

Fig. 1 Series connection

Current
In series connection the current is identical at every
point.
Itotal = I1 = I2 = I3

Voltage
The sum of all partial voltages is identical with the total
voltage.
Utotal = U1 + U2 + U3

Resistance
The sum of all partial resistances is identical with the
total resistance.
Rtotal = R1 + R2 + R3

Series connection of batteries

Fig. 2
In order to achieve a vehicle voltage of 24 V two bat-
teries of the same type and capacity must be connect-
ed in series mode.

72 BOMAG 008 915 77

Series / parallel connection
Parallel connection
In parallel connection all resistances (consumers) are
connected between feed and return line.
l All resistances (consumers) are supplied with the
same voltage.
l Each of the resistances (consumers) draws as
much current as required.
6.7
l In parallel connection the plus pole of the first bat-
tery is connected with the plus pole of the second
battery and the minus pole of the first battery with
the minus pole of the second battery.
l Plus and minus poles have the voltage of the single
battery applied.
l The total capacity (Ah) is identical with the sum of
all battery capacities.
The disadvantage of a parallel connection becomes
apparent, by equalizing currents flowing between par-
allel batteries, if the batteries have different states of
charging.

Fig. 3 Parallel connection

Current
The total current is the sum of all currents.
Itotal = I1 + I2 + I3

Voltage
The voltage values are identical at every resistance
(consumer).
Utotal = U1 = U2 = U3

Resistance
The total resistance is less than the lowest individual
resistance.

Parallel connection of batteries

Fig. 4
By connecting 2 batteries of same type and capacity
in parallel mode the capacity can be doubled, be-
cause the individual capacities add up to the total ca-
pacity.

008 915 77 BOMAG 73

6.8 Ohm's law

6.8 Ohm's law 6.9 Electrical energy

In a closed electric circuit voltage, current and resist-
ance must always be considered in close relation.
This relation is represented by Ohm's Law.

Fig. 1
In a closed electric circuit current and voltage gener-
ate energy.
Fig. 1 If a current of 1 Ampere flows at a voltage of 1 Volt,
According to this law a voltage of 1V is required to let energy of 1 Watt is produced.
1A (ampere) flow through a conductor with a resist-
Advice
ance of 1 (Ohm Ω).
By means of this triangle the formula can be easily re-
Advice arranged, the value you are looking form must just be
By means of this triangle the formula can be easily re- blanked off with a finger.
arranged, the value you are looking form must just be
Energy P = I multiplied with U
blanked off with a finger.
Amperage I = P divided by U
Voltage U = I multiplied with R
Voltage U = P divided by I
Resistance R = U divided by I
U = Voltage in Volt
Amperage I = U divided by R
I = Current in Ampere
U = Voltage in Volt
P = Power in Watt
I = Current in Ampere
R = Resistance in OHM Ω

74 BOMAG 008 915 77

Formula diagram 6.10
6.10 Formula diagram
Description:
l Select the desired value from the inner circle.
l Determine the formula variables in the quarter circle
l Calculate

Example:
P = 150 Watt
U = 24 Volt
Sought for = Current in Ampere
I = P : U = 150 W : 24 Volt = 6.25 Ampere

Fig. 1 Formula diagram

Resistance, R Ohm Ω

Voltage, U Volt

Current, I Ampere

Power, P Watt

008 915 77 BOMAG 75

6.11 Metrology

6.11 Metrology Multimeter

This tester is a multimeter and can be used to meas-
Test lamps ure e.g. current, voltage and resistance. Depending
on the design it may also be suitable for transistor and
Test lamp frequency.

Fig. 1 Multimeter
In order to avoid damage:
Fig. 1 Test lamp
l
the range selector switch must be correctly set for
the corresponding measurement.
! Caution l
the test cable must be plugged into the correct
This type of tester must not be used for testing on socket.
electronic components. The high power con- l
the voltage type (AC/DC) must be set.
sumption of the test lamp may destroy electronic l
In case of direct voltage the correct polarity must be
components in the control units.
assured.
Diode test lamp l
the measuring range should be chosen higher at
This instrument is used for simple voltage measure- the beginning of the test.
ments. The test lamp consists of two test points. The l In order to avoid any influence on the circuitry to be
negative measuring cable is connected to ground and measured, the internal resistance of the voltage
the positive measuring cable to the corresponding tester should be as high as possible.
measuring location.

Fig. 2 Diode test lamp

If voltage is present, the corresponding light emitting
diode will light up.

76 BOMAG 008 915 77

Metrology 6.11
Resistance and continuity measurement with mul- Voltage and voltage drop measurement with mul-
timeter timeter

Fig. 2
The continuity tester of the multimeter can be used to
measure whether there is a connection between 2
measuring points.
Fig. 4 Measuring voltage
l Measurement at the voltage source measures the
currently available Voltage.
l The meter is always connected parallel to consum-
er, component or power source.

Fig. 3
The following information should be observed when
measuring resistance and continuity: Fig. 5 Voltage measurement
l The component to be measured must not be con- l
A measurement at the consumer measures the volt-
nected to the power supply during the measure- age drop at this component.
ment.
l At least one side of the component to be measured
must be disconnected from the circuitry, as other-
wise the measuring result may be influenced by
parallel components.
l Polarity is of no significance.

008 915 77 BOMAG 77

6.11 Metrology

Current measurement with the multimeter Clip-on measuring instrument

The clip-on measuring instrument can be used to
measure current, voltage and resistance.

Fig. 6 Measuring current

l The meter is connected in series with the consum-
er. Fig. 1 Clip-on measuring instrument
l During the measurement the current must be able
to flow through the meter, i.e. the electric circuit
must be opened.

Fig. 2
l
For measuring current the individual conductor
must be fully enclosed by the measuring tongs, the
actual measurement takes place without contact.
Fig. 7 Current measurement

Advice
If the electric circuit is difficult to access and the inter-
nal resistance of the consumer is known, the voltage
may also be measured at the consumer.
The current value can then be calculated with the help
of Ohm's law.

78 BOMAG 008 915 77

Metrology 6.11
Magnet tester Power measurement
The electric power of a module within a circuit can be
indirectly determined (calculated) by separate meas-
uring of current and voltage.
However, there are also pure power meters with 4
connections available. The power meter has a electro-
dynamic measuring mechanism. The current circuit
must be opened for measuring. Take care when per-
forming power measurements: Voltage or current path
may already be overloaded during the measurement,
even though the end stop in the meter has not yet
been reached.

Fig. 1 Magnet tester

The magnet tester is used to test solenoid valves and
magnetic coils.
The test lamp responds to the magnetic fields of A.C-
voltage, D.C.-voltage and permanent magnets.
l
The component to be tested does not need to be re-
moved.
l The magnetic coil can also be tested under a pro-
tective cap.

Fig. 2

008 915 77 BOMAG 79

6.12 Diodes, relays, fuses

6.12 Diodes, relays, fuses Diode logics and free-wheeling diode

Diodes

Fig. 1
A diode consists of two different semi-conductors,
which are connected by a separating layer. The max.
conducting state current must not be exceeded.
Plus-voltage on diode:
l At 0.6 – 0.7 Volt (silicium diode) the diode becomes
conductive.
Negative voltage on diode:
l The diode does not allow current to pass through.

Fig. 2 Marking of the cathode

Diodes are used:
l
For rectifying A.C. voltage.
l
For absorbing voltage peaks (free-wheeling diode).
l
For construction of logical circuits.

Fig. 3 Diode circuitry

l The solenoid valve Y48 (Fig. 3) is supplied with
electric current when switch S34 is switched to po-
sition "1" or "2".
l Solenoid valve Y20 is supplied, if the switch is in po-
sition "1".
l Solenoid valve Y21 is supplied, if the switch is in po-
sition "2".
The three diodes V02 serve as free-wheeling diodes
with the function of of eliminating voltage peaks.

80 BOMAG 008 915 77

Diodes, relays, fuses 6.12
Light emitting diodes Relays

Fig. 1 Relays
Relays are commonly used to realize switching proc-
esses.
Fig. 4 LED
A free-wheeling diode prevents induction voltage from
The light emitting diode, also referred to as LED, is a
flowing back from the coil into the vehicle wiring sys-
semi-conductor diode, which generates (emits) light
tem, which would cause interference with electronic
during operation in forward direction. A semi-conduc-
components (control units).
tor crystal thereby emits a light signal, which is con-
verged or scattered by the lenticular shape of the With the possibility of using breaker - maker contacts
head. Light emitting diodes are available in various the effect of an information can be reversed.
colours, sizes and shapes. They are for this reason
used as signal lamps. This component is constructed
of different semi-conductor crystals, depending on its
colour. It works like any other semi-conductor diode.

Fig. 2 Relay circuitry

The windscreen wiper and washer motors can only be
operated via switches S20 and S21, when relay K32
is supplied with electric current (Fig. 2).
86 = Positive supply for coil

008 915 77 BOMAG 81

6.12 Diodes, relays, fuses

85 = Ground supply for coil Fuses

30 = Supply voltage
87 = Normally open contact
87a= Normally closed contact

Fig. 1
Fuses are used to protect lines and equipment against
overloads and short circuit. If the fuse is overloaded
the fusible wire heats up with increasing current, until
it finally melts.

Caution
!

Fuses must not be repaired or bridged.

The melting time at 23 °C is:
l
approx. 1 hour with 1.5 times the rated current
l
approx. 1 minute with 2.5 times the rated current.
A 5 Amp fuse loaded with 1.5 times the rated current
(7.5 Amp) will finally melt after approx. 1.5 hours.
Yellow = 5 A
Brown = 7.5 A
White = 8 A
Red = 16 A
Blue = 25 A

82 BOMAG 008 915 77

Inductive proximity switches 6.13
6.13 Inductive proximity switches NPN circuitry

General
In all automated sequences the use of sensors as a
source of information for the electronic control is indis-
pensable. The sensors deliver the necessary signals
about positions, end positions, filling levels or serve as
pulse transducers for counting tasks or speed detec-
tion. In industrial applications inductive and capacitive Fig. 4 NPN circuitry
proximity switches are today indispensable. Com-
pared with mechanical switches, they offer almost ide- On sensors with NPN-circuitry the output stage con-
al prerequisites: non-contact, wear free operation, tains a NPN-transistor, which switches the load
high switching frequencies and switching accuracies, against the negative operating voltage. The load is
as well as high protection against vibration, dust and connected between the output and the positive oper-
moisture. Inductive sensors detect all metals without ating voltage.
contact, capacitive sensors detect almost all solid and Breaking and making contacts
liquid media, such as metal, glass, wood, plastic, wa-
ter, oil, etc.

Working principle

Fig. 2
The working principle is based on the principle of the
dampened LC-oscillator. The coil of the oscillation cir-
cuit forms a high-frequency magnetic stray field. Fig. 5

This stray field leaks out from the active area of the
proximity switch. If metal or non-ferrous metal enters
into the response range energy is absorbed. The os-
cillator is thus dampened and the resulting change in
current consumption is evaluated.
PNP circuitry
Proximity switches are used as breaking or making
contacts. Depending on the design the switching dis-
tances are 2 or 4 mm. The maximum amperage is 300
mA.
The LED (Fig. 5) lights up, when the initiator has de-
tected metal in its stray field.

Fig. 3 PNP circuitry

On sensors with PNP-circuitry the output stage con-
tains a PNP-transistor, which switches the load
against the positive operating voltage. The load is
connected between the output and the negative oper-
ating voltage. The switch is designed with a normally
open contact, i.e. the contact closes when the initiator
comes in "contact" with metal.

008 915 77 BOMAG 83

6.14 Plug connectors

6.14 Plug connectors

Duties and requirements
Electric plug connectors must provide a reliable con-
nection between different system components and
thus ensure the safe function of the systems under
any operating condition. There design ensures that
they will withstand the applied loads throughout the
lifetime of the machine.
Examples for these loads are:
l Vibration acceleration
l
Temperature fluctuations, high and low tempera-
tures
l Dampness
l Micro movements of the contact with resulting fric-
tion corrosion.
These loads may increase the transition resistances
of the contacts, up to total interruption. Even the insu-
lation resistances may drop and thus cause short cir-
cuits in neighbouring lines. Electric plug connectors
must therefore have the following properties:
l
Low transition resistances of the conductive parts.
l
High insulation strength between conductive parts
Fig. 6 Circuit diagram, making contact
with different voltage potentials.
The circuit diagram (Fig. 6) shows a proximity switch
l
Excellent leak tightness against water and mois-
with normally open contact. ture.
Brown = voltage supply
Blue = ground supply
Black = switching output
The initiator switches the relay (K05)

84 BOMAG 008 915 77

Deutsch plug, series DT and DTM 6.15
6.15 Deutsch plug, series DT and DT Series
DTM

General
Plug connectors DT and DTM have a wedge to hold
the pins and sockets in their position. This wedge can
be removed and replaced, without having to cut any
leads.

Fig. 1 DT plug connection

Fig. 7 Crimp connections

Fig. 2 DT Series
Caution
!

Do not crimp more than one lead per pin or per

socket.
Sockets and pins must not be soldered to leads,
they may only be crimped (see special tools for
electrics).
When connecting sockets and plugs these must
engage with a noticeable click when both halves
interlock.
The plug connection should not be separable
(without loosening the interlock).
Fig. 3 Sectional drawing
Pulling test
This pulling test ensures that the lead is perfectly
crimped and the contact has correctly engaged in the
housing.
l
Perform a pull test on each lead, each of the termi-
nals and connections must withstand a pulling force
of 45 N without any difficulties.

008 915 77 BOMAG 85

6.15 Deutsch plug, series DT and DTM

DT Series
Installing DT contacts

Fig. 4
l Insert the contacts through the rubber grommet until they click into place.
l Insert the orange wedge in direction of arrow.

!Caution
Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force
of 45 N without any difficulties.

i Note
Use the same method when assembling the socket.

Disassembling DT contacts

Fig. 5
l Pull the orange wedge out with long nose pliers.
l Slightly pull the lead and unlock the interlocking hook with a screw driver.
l Pull the contact out of the socket.

i Note
Use the same method when assembling the socket.
In this case the interlock disassembly tool (see special tools for electrics) serves as an aid to remove the wedges.

86 BOMAG 008 915 77

Deutsch plug, series DT and DTM 6.15
DTM Series

Fig. 6 DTM plug connection

Fig. 7 DTM Series

Fig. 8 Sectional drawing

008 915 77 BOMAG 87

6.15 Deutsch plug, series DT and DTM

Installing DTM contacts

Fig. 9
l
Insert the contacts through the rubber grommet until they click into place.
l Insert the orange wedge, until it clicks into place.

!Caution
Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force
of 45 N without any difficulties.

i Note
Use the same method when assembling the socket.

Disassembling DTM contacts

Fig. 10
l Pull the orange wedge (interlock) out with long nose pliers.
l Slightly pull the lead and unlock the interlocking hook with a screw driver.
l Pull the contact out of the socket.

i Note
Use the same method when assembling the socket.
In this case the interlock disassembly tool (see special tools for electrics) serves as an aid to remove the wedges.

88 BOMAG 008 915 77

Batteries 6.16
6.16 Batteries Battery maintenance

Battery – accumulator
Fig. 1
In vehicles batteries are used to start the engine. The
ability to start the engine depends on the charge con-
dition of the batteries.
Lead collectors or accumulators are secondary ele-
ments, i.e they can be recharged after discharging
electric current.
The basic element of a lead accumulator is the cell. It
contains the plate blocks consisting of positive and
negative plates. These plates are separated from
each other by separators.
All positive plates are arranged parallel to the plus
pole, the negative plates parallel to the minus pole of
the cells.
i Note
Maintenance free batteries are gaining more and
more significance, this freedom from maintenance,
however, is only limited to the fact that no water needs
to be added.
If the battery is not charged and discharged over a
longer period of time, the battery will slowly discharge
by itself.
The accumulator may only be discharged down to a fi-
nal discharging voltage of 10.5 Volt, as otherwise
there is a risk of sulphation, i.e. the generated lead
sulphate forms increasingly coarser crystals, which
will finally not react at all or only very sluggishly during
a subsequent charging process.
In the worst case the accumulator can only be dis-
posed of after such an exhaustive discharge.
The following therefore applies for longer downtimes:
l Remove the battery and store it in a cool, dry and
frost protected room.
l Check the open circuit voltage on the battery at reg-
ular intervals (at least once every month).
l Recharge immediately if the open circuit voltage
has dropped to 12.25 Volt (no rapid charging).
i Note
The open circuit voltage of batteries occurs approx. 10
h after the last charging or approx. 1 h after the last
discharge.

Battery test in general

l
Is the battery leaking? Can traces of impact, shock
or compression be found in the leaking area?
l
Check for e.g. incorrect fastening, foreign bodies on
the battery mounting surface and similar.

Fig. 2
All cells are filled with a conductive fluid, the electro-
lyte. For a 12 Volt battery 6 cells are connected in se-
ries.

Capacity
is a synonym for the amount of current taken up and
discharged by a battery over a specified period of
time.

008 915 77 BOMAG 89

6.16 Batteries

Batteries with screw plugs Checking the electrolyte density

Checking the electrolyte level

Fig. 4
Fig. 3 The cells are filled with diluted sulphuric acid as elec-
1 Upper filling level mark trolyte (approx. 25 Vol% sulphuric acid in distilled wa-
ter), also referred to as accumulator acid, which has a
2 Lower filling level mark
density of 1.285 kg/dm3 at a temperature of +27° Cel-
l If the electrolyte level only reaches up to the lower sius. This means that one litre of electrolyte has a
filling level mark (2), fill distilled water into the corre- weight of 1.285 kg. As the cell is being discharged
sponding cells. lead sulphate (PbSO4) will form on both electrodes
and the electrolyte will increasingly change to water.
Since water has a lower specific weight than diluted
sulphuric acid, the density of the electrolyte will also
drop during the discharge and with a fully discharged
cell and a temperature of 27°C it will only be 1.18 kg/
dm3.
With a lead cell the acid density is therefore a meas-
ure for the charge condition. This characteristic is
used to determine the charge condition of a lead bat-
tery. The so-called electrolyte tester (densimeter) is
used for this purpose.

Fig. 5 Checking the electrolyte density:

1) correct
2) poor
3) poor

i Note
(Hold the pipe of the electrolyte tester vertically, with-
out taking it out of the electrolyte.

90 BOMAG 008 915 77

Battery service 6.17
Do not draw too much electrolyte into the pipe. 6.17 Battery service
Make sure that the float is not obstructed in its move-
ment and hold the electrolyte tester at eye level.
! Danger
The electrolyte tester must be read at the highest
Danger of cauterisation !
electrolyte level.
l If the electrolyte temperature deviates from the When working on the battery do not use open fire,
electrolyte tester calibration temperature, the indi- do not smoke!
cated value for the specific electrolyte weight must Do not let acid come in contact with skin or
be corrected acc. to the formula (reference) below. clothes!
Reference Wear protective clothing!
The specific weight varies slightly with temperature. Do not lay any tools on the battery!
To be exact, the specific weight drops by 0.0007 per 1 For recharging remove the plugs (if present) from
°C temperature increase (by 0.0004 per 1 °F) and in- the battery to avoid the accumulation of highly ex-
creases by 0,0007 per 1 °C temperature reduction (by plosive gases.
0,0004 per 1 °F) . If e.g. a temperature of 20 °C (68 °F)
is used as reference, the indicated value of the specif-
ic weight must be corrected acc. to the following for- Environment
mula. Dispose of the old batteries environmentally.
l Specific weight at 20 °C = measuring value + l
Open the maintenance flap and remove the battery
0,0007 × (electrolyte temperature: 20 °C) cover.
l
Specific weight at 68 °F = measuring value + 0,0004
× (electrolyte temperature: 68 °F)

Acid density at 27 °C in kg/dm3

l
1.25 -1.28, open-circuit voltage approx. 12.7 Volt.
Battery is charged.
l
1.20 -1.24, open circuit voltage approx.12.4 to 12.5
Volt, is 50% discharged. Charging is necessary.
l
1.19 and less, open circuit voltage less than 12.3
Volt. Battery is insufficiently charged. The battery
needs to be recharged immediately.
l
If there is a deviation of the specific weight of more
than 0.05 between any of the cells, the battery
needs to be replaced. Fig. 6
l
If the current consumption during charging is not 1/ l
Remove the battery (Fig. 6) and clean the battery
20 of the nominal capacity (example 100 Ah battery:
compartment.
100Ah x 1/20 = 5 A) or full recharging of the battery
results in a final electrolyte density of only 1.24 kg/ l
Clean the outside of the battery.
dm3 or less, the battery shows normal wear by ag- l Clean battery poles and pole clamps and grease
ing. The battery was insufficient charging or ex- them with pole grease or corrosion protection wax
haustive discharge. spray.
l Check the fastening of the battery.

008 915 77 BOMAG 91

6.18 Main battery switch

6.18 Main battery switch 6.19 Main battery fuse

Fig. 7 Fig. 8
No. 1 = Main battery switch No. 2 = Main fuse for battery
Disconnects the ground contact in the electric circuit 80A = (F00)
of the machine.

i Note
If the power pack of the radio remote control is to be
charged, the main battery switch must remain
switched on when the engine is shut down.

92 BOMAG 008 915 77

External starting 6.20
6.20 External starting 6.21 Generator
General
Starting with jump wires
The generator should be of light weight, have a high
rate of efficiency and supply all consumers in the ve-
! Caution hicle with electric current at a steady voltage already
A wrong connection will cause severe damage in at idling speed.
the electric system.
Terminal designations
l Open the rear hood. l B61, L = charge control
l B+, B = battery plus, also with the designation "30"
l
B- = battery minus, also with the designation "31"
l D+ = dynamo plus corresponds with terminal "61"
and "L"
l D- = dynamo minus (this designation is only found
on D.C. generators or A.C. generators with regula-
tor removed)
l DF = dynamo field (this designation is only found on
D.C. generators or A.C. generators with regulator
removed). Note: The designation DF is also found
on older alternators with externally arranged regula-
tor on the connection of the exciting coil to the reg-
Fig. 9
ulator or on the regulator itself
l
Switch on the main battery switch (Fig. 9). l
DF1 = dynamo field 1
l
DF2 = dynamo field 2
Caution
!
l
IG = "15" ignition switch
Only use a 12 volt battery for jump starting.

Fig. 10
l When starting with an external battery connect the
plus poles (Fig. 10) first and the minus poles
(ground cable) after.
l Switch the vibration off
l Start the engine as described above
l After starting disconnect the cable from the minus
poles (ground cable) first and from the plus poles
last.
l Fold the control box back in and close the hood.

008 915 77 BOMAG 93

6.21 Generator

Three-phase generator 6 Brush holder

The AC-generator first of all produces AC-voltage / 7 Rectifier
AC-current. 8 Bearing cover
9 Rotor winding
Why does AC-current need to be rectified?
10Rotor
There are a few components for which can either be
operated with alternating current or direct current, be- 11V-belt pulley
cause they work independently from the current flow
direction.
This includes :
l
Incandescent lamps
l
Fluorescent lamps
l Glow lamps
l Electric heating elements.
There are also a few components that could be oper-
ated either with alternating current, direct current or
three-phase current, if the components were designed
accordingly.
This includes :
l
Electric motors
l
Relays.
Fig. 12 Rotor with claw poles
Finally, a variety of important components solely re-
quire direct current. These will under no circumstanc- In the generator the armature windings are located in-
es work with alternating or three-phase current. side the stationary stator (Fig. 13), whereas the excit-
er winding is arranged on the internally revolving rotor
This includes : (Fig. 12).
l
Accumulators
l
Control units
l
All electronics
l
Communication equipment.

Design and function

Fig. 13 Stator
Fig. 11
The three stator windings (Fig. 13) are electrically off-
1 Fan set to each other by 120°. The excitation of the mag-
2 Holding plate netic field requires direct current, which is fed to the
3 Stator core rotor via two carbon brushes and slip rings.
4 Stator winding
5 Brush

94 BOMAG 008 915 77

Generator 6.21
Charge control light
The charge control light has two duties:
l Indication of the correct generator function
l External excitation of the generator during the start-
ing phase

Fig. 15 plus controlled charging regulator

Fig. 14 3-phase current
(Fig. 15) shows the current flow with the ignition
The wiring diagram (Fig. 14) shows the 3 windings in switched on, engine stopped.
Y-connection and the 6 associated rectifier diodes (D1
to D6).
The diodes D1, D2, D3 are also referred to as minus
diodes, because they have B- as common connection
(minus plate). The other diodes are the plus diodes.
The rectifier diodes have the effect that the negative
half-wave is suppressed and only the positive section
of the wave is allowed to pass, resulting in a pulsating
D.C. voltage.

Fig. 16 plus controlled charging regulator

(Fig. 16) shows the current flow with the ignition
switched on, engine running.
1 Battery
2 Charge controller
3 Ignition switch
4 Charge control light
5 Rectifier
6 Rotor
7 Sliprings / carbon brush
8 Auxiliary rectifier
Normally the charge control light lights with the engine
stopped and the ignition switched on and goes out at
low engine speed, but at the latest after a single,
short-term increase in engine speed from idle speed,
because there is no longer a voltage difference on the
lamp.

008 915 77 BOMAG 95

6.21 Generator

Any other behaviour would indicate a defect on the Charge controller

generator (rectifier, carbon brushes, regulator) or a
The charge controller has the following functions
defect on the lamp, presumed the on-board battery is
not discharged. l To regulate the voltage generated by the generator
A far more important function of the lamp is the transi- l To protect against overloads caused by too high
tion and provision of field current. At standstill there is output current
no magnetic field in the de-energized generator. Since l Protection against reverse current
this is necessary for the generation of electric current,
the rotor must be supplied with current, so that a weak If the output voltage or the output current of the gen-
field can build up. erator exceeds the determined maximum values, the
field current and thus the electric power is reduced.
The current flows from the ignition switch via the
charge control light through the generator winding Electronic charge regulator
against ground (terminal 31) and is limited to approx.
300 mA by the light bulb (4 W) (without the lamp the
current flow would be 2 to 5 A). While the rotor is ro-
tating current is induced into the stator winding,
whereby a small part (2–5 A, depending on speed)
flows through the charge regulator into the field wind-
ing of the rotor and the major part flows to the output
terminals (B+), where it can be tapped as useful cur-
rent. If the charge control light is defective or no bat-
tery is available or the battery is discharged, external
excitation is no longer possible at standstill and no
voltage will be generated, even when the generator is
running.
With used, older generators a weak permanent mag-
netic field may have developed over the lifetime,
which does even exist when no voltage is applied. Fig. 17 Regulator, Kubota engine
This type of machines can even start without charge In AC-generators the electrically generated exciter
control light and produce current during operation. field of the generator rotor is influenced by an at-
However, this is an unintended effect and you should tached electronic charge regulator. Together with the
not presume that a generator without charge control holder for the carbon brushes this regulator forms a
light or external excitation can be started up. unit, which transfers the field current to the sliprings of
the rotor.
The regulator compares the rectified actual current of
the generator with the a stable reference voltage in
the regulator and matches the strength of the exciter
field (field current) by increasing or reducing the cur-
rent flow (PWM, switching controller) in such a way,
that the actual voltage of the generator remains con-
stant, irrespective of load and speed. The generator
voltage is thereby regulated, the generator current,
however, is not measured, but limited by the construc-
tion dependent internal resistance of the stator coils or
thermal monitoring.

96 BOMAG 008 915 77

Generator 6.21
Checking the generator replaced or the following trouble shooting procedure
must be performed.

!Caution
Before removing the generator you must discon-
nect the ground cable from the minus pole of the
battery while the ignition is switched off. Do not
disconnect the generator while the engine is run-
ning, because this may cause extremely high volt-
age peaks in the vehicle wiring system ("Load
Dump"), which could possibly damage control
units, radios or other electronic equipment.
When disassembling the battery cable, the B+-nut
underneath on the generator side may also be
loosened. This nut must in this case be retight-
ened.
When connecting e.g. the battery cable to the ter-
minal of the generator you must make sure that
the polarity is correct (generator B+ to the + pole
of the battery). Mixing up the polarities by mistake
causes short circuit and damage to the rectifier el-
ements - the generator will be out of function.
The generator can only be operated with the bat-
tery connected. Under special conditions emer-
gency operation without battery is permitted, the
lifetime of the generator is in such cases especial-
ly limited.
Plus and minus cables must be disconnected dur-
ing rapid charging of the battery or electric weld-
ing on the vehicle.
When cleaning the generator with a steam or wa-
ter jet make sure not to direct the steam or water
jet directly on or into the generator openings or
ball bearings. After cleaning the generator should
be operated for about 1 - 2 minutes to remove any
deposits of water from the generator.
First one must check whether the generator is actually
defective.
l
This can be easily found out by checking whether
the charge control light in the dashboard lights up. If
the light does not go out, even at higher speeds,
there must be a defect on the generator, the regula-
tor, the wiring or the V-belt.
l
When the engine is at rest, the charge control light
must light up. If not, the lamp may probably be de-
fective. Defects on generator or wiring are obviously
also possible.
The following points allow to contain faults in the volt-
age supply within certain limits.
l Cable connections on the generator OK?
l V-belt OK?
l Generator ground (engine ground) OK?
l Pre-excitation from vehicle electronics OK?
Only if all criteria mentioned above are OK, the fault
must be in the generator itself. In this case it must be

008 915 77 BOMAG 97

6.21 Generator

Measuring the charge current Checking the regulator voltage with the generator
l All plug-and-socket connectors must be free of cor- tester
rosion and intermittent contact. The battery and generator tester comes with an 8-line
l The generator ground connection must be OK. LC display with background illumination and is able to
print out test results via an (optional) thermal printer.
l During the measurement switch on as many con-
sumers as possible.
1 Attach the clip-on ammeter around the B+ line.
2 Gradually increase the engine speed.
3 The generator current must be at least as high as
the total current of all consumers.

Fig. 18
The generator test assesses the regulator voltage and
the ripple factor of the generator voltage.
l
All plug-and-socket connectors must be free of cor-
rosion and intermittent contact.
l
The generator ground connection must be OK.
l
The battery should be in good condition – the idle
speed voltage of the battery should be at least 12.6
Volt.
l
If possible switch off all consumers.
l
Perform the measurement at raised engine speed.

98 BOMAG 008 915 77

Generator 6.21
Checking the regulator voltage with the multime-
ter

Fig. 19
l All plug-and-socket connectors must be free of cor-
rosion and intermittent contact.
l The generator ground connection must be OK.
l
The battery should be in good condition – the idle
speed voltage of the battery should be at least 12.6
Volt.
l
If possible switch off all consumers.
l
Perform the measurement at raised engine speed.
l
The voltage (B+) should adjust itself at 13 to 14 Volt.

008 915 77 BOMAG 99

6.22 Generator repair

Fig. 1

1 V-belt pulley l Disassemble the holding plate (5).

2 Drive bearing plate l Use a press and a suitable device to press the bear-
3 Stator ing (4) out of the drive bearing plate (2).
4 Bearing
l To protect the rotor against damage clamp it lightly
in vice and extract the bearing (7) with a puller.
5 Holding plate
6 Rotor Assembly
7 Bearing
8 Rear bearing plate i Note
9 Rectifier V-belt pulley tightening torque 58.4 to 78.9 Nm.
10 IC-regulator
11 Brush holder
12 Rear covering

Dismantling
l Remove the V-belt pulley (1).
l Remove the rear covering (12).
l Disassemble the brush holder (11).
l
Disassemble the IC-regulator (10).
l
Unscrew the four stator cable fastening screws.
l
Take off the rectifier (9).
l
Take off the rear bearing plate (8).
l Press the rotor (6) out of the drive bearing plate (2).

100 BOMAG 008 915 77

Generator repair 6.22
Bearing Stator

Fig. 2
l Check whether the bearing rotates without obstruc-
tion.
l Replace the bearing if it does not rotate properly.
Fig. 3
l Use the resistance range of the continuity tester to
measure the resistance between the individual lines
of the stator winding.
l If the measuring value does not comply with the fac-
tory specification, replace the stator.
l
Use the resistance range of the continuity tester to
check the continuity between the individual stator
windings and the core.
l
Replace the stator if no infinite value is indicated.

i Note
Factory specification for resistance: Less than 1 OHM.

008 915 77 BOMAG 101

6.22 Generator repair

Rotor Slipring

Fig. 4 Fig. 5
l Measure the resistance between the sliprings. l Check the slipring for score marks.
l If the resistance does not comply with the factory l If score marks are found rework the slipring with
specification, replace the rotor. emery cloth or on a lathe.
l Use the resistance range of the continuity tester to l Measure the outer diameter of the slipring with a
check the continuity between slipring and core. vernier caliper.
l
Replace the rotor if no infinite value is indicated. l
Replace if the measuring value is below the permis-
sible limit.
i Note
Factory specification for resistance: 2.9 OHM. i Note
Outer slipring diameter: 14.4 mm.
Permissible limit: 14.0 mm.

102 BOMAG 008 915 77

Generator repair 6.22
Wear on carbon brushes Rectifier

Fig. 6
l Measure the brush length with a vernier caliper.
l Replace if the measuring value is below the permis-
sible limit.
l Make sure that the brush is light moving.
l A defective carbon brush must be replaced.
Fig. 7
l Use the resistance range of the continuity tester to
check the continuity between the individual rectifier
diodes.
l The rectifier is in good working order when the rec-
tifier diode conducts to one direction and block in
the other direction.

i Note
Brush: 10.0 mm.
Permissible limit: 8.4 mm.

Fig. 8

008 915 77 BOMAG 103

6.23 Electric starter

Regulator 6.23 Electric starter

Fig. 9
l Use the resistance range of the continuity tester to
check the continuity between terminal B (2) and ter-
minal F (1) on the IC-regulator.
l The IC-regulator is in good working order when it
conducts current to one direction, but not in the oth-
er direction.
General
Combustion engines need to be started by means of
a special device, because they are not able to start by
themselves. Considerable resistances caused by
compression and friction must thereby be overcome.
The starter converts the electric energy stored in the
battery into mechanical energy. The starter can only
generate its power when a battery with appropriate
capacity is available.
Duties of the starter:
l to accelerate the combustion engine to start speed
with lowest possible current consumption.
l establish the gear connection between starter and
combustion engine.
l to maintain this connection.
l to switch on the starter current.
After starting the engine:
l
to return the starter pinion to initial position.
l
to switch off the starter current.

104 BOMAG 008 915 77

Electric starter 6.23
2 Ring gear
Starter with spur gear reducer
3 Pinion
The starter is a heat and vibration proof geared motor
4 Freewheeling clutch
with a small, fast running electric motor, the armature
of which drives the pinion with a reduction ration of ap- 5 Holding winding
prox. 1:3 to increase the torque. 6 Pick-up winding
7 Ignition switch
8 Battery
9 Armature

Pinion meshes with the ring gear

Fig. 10 with spur gear reducer

1 Drive gear
2 Armature
3 Exciting winding
4 Brush
Fig. 12
5 Intermediate gear
When the pinion (1) meshes with the flywheel mount-
6 Pinion ed ring gear (4) and the magnetic switch is closed, a
7 Freewheeling clutch strong current flows from the battery (7) directly into
8 Magnetic switch the exciting winding (6) and the armature winding, but
not into the pick-up winding (6). This causes the arma-
9 Armature
ture (3) to rotate with high speed and drives the pinion
Working principle of the starter (1), which in turn drives the ring gear (4) with a speed
of 200 to 300 rpm.
Starter switch in position "START" 1 Pinion
2 Exciting winding
3 Armature
4 Ring gear
5 Holding winding
6 Pick-up winding
7 Battery

Fig. 11
With the starter switch (7) in "START" position current
flows from the battery (8) through the holding winding
(5) and the pick-up winding (6). The armature (9) is
magnetically picked up and presses the pinion (3) out-
wards.
1 Armature

008 915 77 BOMAG 105

6.23 Electric starter

Engine running 4 Holding winding

5 Pick-up winding
6 Ignition switch
7 Battery
8 Armature

Fig. 13
Once the engine is running and drives the pinion (1)
via the ring gear (3), the freewheeling clutch (4) will
open and prevent the armature (2) from being driven
by the engine.
1 Pinion
2 Armature
3 Ring gear
4 Freewheeling clutch

Releasing the starter switch

Fig. 14
When releasing the starter switch (6) it will return from
position "START" to "ON" and interrupt the starter cur-
rent circuit. Current will now flow from the battery (7)
through the contact plate in the pick-up winding (5)
and the holding winding (4).
Since both coils generate opposed magnetic fields,
the magnetic field will collapse and the resetting
spring (3) takes the armature (8) back to its initial po-
sition. This opens the current circuit on the contact
plate and the pinion (1) is pulled back from the ring
gear (2) and stops.
1 Pinion
2 Ring gear
3 Resetting spring

106 BOMAG 008 915 77

Electric starter 6.23
Magnetic switch Freewheeling clutch

Fig. 1 Direct acting electric motor Fig. 1 Freewheeling clutch

The freewheeling clutch is designed in such a way,
that the flow of force is automatically interrupted if the
pinion (5) of the clutch rotates faster than the free-
wheeling ring (1) at higher engine speeds.
This makes sure that the armature will only drive the
ring gear, but can never be driven by the engine.
1 Freewheeling ring
2 Roller
3 Roller spring
4 Splined shaft
5 Pinion
6 Pinion

Fig. 2 Geared motor

Armature (4), contact plate (3) and armature guide (6)
form a closed unit. When the ignition switch is turned
to "START", the armature is picked up and causes the
pinion of the clutch to disengage.
This causes the pinion and the ring gear to mesh,
while the contact plate establishes a connection be-
tween the contacts, which enable the main current to
flow into the armature. Once the ignition switch is
opened, the resetting spring (5) will pull the armature
back to initial position.
1 Holding winding
2 Pick-up winding
3 Contact plate
4 Armature
5 Resetting spring
6 Armature guide

008 915 77 BOMAG 107

6.23 Electric starter

Trouble shooting "Starter" l Ignition switch OK?

!Caution
So-called jump starting (using an additional exter-
nal battery) without the battery connected is dan-
gerous. When disconnecting the cables from the
poles high inductivities (arcs, voltage peaks) may
occur and destroy the electrical installation.
For purposes like e.g. purging the fuel systems,
starters may be operated for maximum 1 minute
without interruption. Then you should wait for at
least 30 minutes (cooling down) until trying again.
During the 1 minute starting period this process
should not be interrupted.
Starter motors must not be cleaned with high
pressure steam cleaning equipment.
The contacts on starter terminals 30, 45, 50 must
be protected against unintended shorting (jump
protection).
When replacing the starter the ring gear on the en-
gine flywheel must be checked for damage and its
number of teeth - if necessary replace the ring
gear.
Always disconnect the battery before starting as-
sembly work in the starter area of the engine or on
the starter itself.
l Travel lever in correct position?
l Emergency stop not actuated?
l Battery sufficiently charged?
l Battery poles OK?
l Main battery fuse OK?
l Main battery switch closed?
l Main starter cable (terminal 30) OK?
l Starter control cable (terminal 50) OK, voltage
drop?
l Ground cable OK?
l Switching of magnetic switches OK?
The sequence of these tests is generally of no signifi-
cance. It mainly depends on:
l the experience of the specialist
l the failure probability of the component to be tested
and the testing effort for the respective part.
Only if all criteria mentioned above are OK, the fault
must be in the starter itself. In this case it can be re-
paired or replaced.

i Note
The most frequent fault is definitely a fully discharged
battery.
If the starter rotates too slowly, either the brushes
are partly worn off, or parts of the exciter or armature
winding is shorted. In some cases oxidized electric
contacts or a soiled ground connection causing ex-
tremely high voltage losses in the overall starter sys-
tem are the cause of problems.
If the starter only emits a clicking sound,- either
the magnetic switch is defect / soiled (dismantle and
clean))- the main contacts on the magnetic switch are
worn off / soiled (scrape off carefully with a file and
clean)- the starter motor is defective / soiled (remove
armature and clean), cover cleaned, moveable parts
with grease.
Frequently a jammed return mechanism is the reason
for a starter failure.
Occasionally worn contacts are found on the magnetic
return switch
Defects on the actual starter motor including pinion
and carbon brushes are very rare.
With a trouble shooting chart the faults in the starter
system can be narrowed down. The starter system
can only work when many conditions are fulfilled at
the same time.
l Immobilizer deactivated?

108 BOMAG 008 915 77

Electric starter 6.23
Testing and measuring the starter Testing and measuring the starter
Function control with the starter removed
i Note
The highest current flows when the starter is blocked!
Caution
!
(Short circuit current in starter). This is the case when
the pinion is engaged and the starter has the duty to Fasten the starter to make sure that it will not
accelerate the flywheel to starting speed. come loose during the test.

Function control with the starter installed

l
Initiate the starting process and measure the volt-
age on the pickup solenoid switch (50a). At least
10.8 Volt should be applied.
l
When operating the starter switch the magnetic
switch must engage in the flywheel ring gear (no-
ticeable clicking sound) and release the starting
current to the starter. On most magnetic switches
the voltage can be measured with the multimeter. If
this does not happen even though voltage is ap-
plied, replace the magnetic switch.

Fig. 2
l
Connect a jumper lead between start terminal (1)
and battery plus (2).
l
Connect a jumper cable instantaneously between
starter housing and battery minus (3).

i Note
If the motor does not start, the starter is defective. Re-
pair or replace the starter.

Checking the magnetic switch

Fig. 3
l
Connect a jumper lead between start terminal (1)
and battery plus (2).
l
Connect a jumper cable instantaneously between
starter housing and battery minus (3).

i Note
If the pinion does not disengage, the magnetic switch
is defective. Repair or replace the starter.

008 915 77 BOMAG 109

6.23 Electric starter

Continuity test for the magnetic switch

Fig. 4
l
Use a continuity tester to check for continuity be-
tween terminal (1) and terminal (29 while holding
the pin depressed.
l Replace the magnetic switch if no continuity is de-
tected.

110 BOMAG 008 915 77

Repair of starter 6.24

Fig. 1

1 Through bolt l Separate the armature (5) from the starter frame
2 Brush (4).
3 Terminal nut C
l Disassemble the housing (13).
4 Starter frame
l Disassemble intermediate gear (7) and freewheel
(6).
5 Armature
l Remove the magnetic switch cover (9).
6 Freewheel
l Disassemble the piston (11).
7 Intermediate gear
8 Housing cover
Caution
!
9 Brush holder
Do not damage carbon bushes or collector.
10 Magnetic switch cover
11 Piston Assembly
12 Terminal nut B l Apply some grease to intermediate gear and free-
13 Housing wheel. Tightening torque for terminal nut (12): 5.88
to 11.8 Nm
Dismantling
l Unscrew the terminal nut (3) and take off the con-
necting cable.
l Disassemble the two through bolts (1).
l
Take off the motor.
l
Disassemble the housing cover (8).
l
Compress the spring and take the carbon brush off
the brush holder.
l
Disassemble the brush holder (9).

008 915 77 BOMAG 111

6.24 Repair of starter

Freewheel Collector and mica capacitor

Fig. 2
l Check the pinion, replace the complete freewheel if Fig. 3
signs of wear or damage are found. l Check the contact surface of the collector for wear
l Make sure that the pinion rotates freely in the free- and rework it with sanding paper if it is slightly worn.
wheeling direction and does not slip in starting di-
rection.
l If the pinion slips or does not rotate to both direc-
tions, replace the freewheel assembly.

i Note
Do not wash the grease in the freewheel out with
chemicals or oils.

Fig. 4
l Measure the outer diameter of the collector at sev-
eral points with an outside micrometer.
l If the smallest outside diameter is below the permis-
sible limit, the rotor must be replaced.

i Note
Factory specification, collector outside diameter:
30.0 mm.
Permissible limit: 29.0 mm.

Fig. 5
l
If the difference between the outer diameter meas-
uring values exceeds the permissible limit have the

112 BOMAG 008 915 77

Repair of starter 6.24
collector reworked to the factory specifications on a Wear on carbon brushes
lathe.

i Note
Factory specification, difference of outer diameter
measurements: Less than 0.02 mm.
Permissible limit: 0.05 mm.

Fig. 7
l If the contact area of the carbon brush is dirty or
dusty, clean it with emery cloth.
l Measure the brush length (A) with a vernier caliper.
l If the length is shorter than the permissible limit, the
brush holder must be replaced.
Fig. 6
1 Segment i Note
2 Counterdraft Factory specification, brush length: 16.0 mm.
3 Collector Permissible limit: 10.5 mm.
a) correct
b) not correct
l
Measure the counterdraft on the collector.
l
If the counterdraft falls short of the lower limit value,
correct it with a saw blade and bevel the segment
edges.

i Note
Factory specification, collector counterdraft: 0.5 to 0.8
mm
Permissible limit: 0.2 mm.

008 915 77 BOMAG 113

6.24 Repair of starter

Brush holder Armature coil

Fig. 8
l Use a continuity tester to check the continuity be-
tween brush holder and holder carrier.
l If continuity is found replace the brush holder.
Fig. 9
l Use the resistance range of the continuity tester to
check the continuity between collector and arma-
ture coil.
l If continuity is found replace the armature.

Fig. 10
l
Use the resistance range of the continuity tester to
check the continuity between the collector seg-
ments.
l
If no continuity is found replace the armature.

114 BOMAG 008 915 77

Glow plugs 6.25
Field coil 6.25 Glow plugs
Measuring the glow plug voltage (R02)
During the starting process the glow plugs are ener-
gized. They are also switched on for 10 seconds when
switching on the ignition.

Fig. 11
1 Replace the
2 Brush
3 Stator
l Use the continuity tester to check the continuity be-
tween line (1) and brush (2).
l If no continuity is found replace the stator frame.
Fig. 1
l Switch on the ignition and check the voltage (within
10 seconds) between cable terminal and engine
block with a line tester.

i Note
If the voltage deviates from the battery voltage you
should measure the voltage on terminal X3:38 (BLM
power module) under the same conditions.
If battery voltage is present on terminal X3:38, either
the wiring loom or the relay K14 is defective.
Fig. 12
If battery voltage is not present on terminal X3:38, the
l
Use the continuity tester to check the continuity be- BLM module must be faulty.
tween brush (2) and stator (3).
l
If continuity is found replace the stator frame. Continuity test

Fig. 2
l Disassemble the glow plug.
l Use a continuity tester to measure the resistance
between glow plug connection and glow plug body.
l If the measured value does not correspond with the
factory specification, the glow plug is defective.

008 915 77 BOMAG 115

6.25 Glow plugs

i Note
Factory specification for resistance approx. 0.9 Ω.

116 BOMAG 008 915 77

Engine governor rod positioning solenoid
Fig. 1
Positioning solenoid
The positioning solenoid for the governor rod (throttle
regulation) has a pickup winding (4) and a holding
Fig. 2
The solenoid is has an integrated limit switch (2),
which is mechanically connected with the governor
rod (1) on the diesel engine. This switch bridges the
holding winding until the end position of the governor
rod is reached (high engine speed)
008 915 77 BOMAG
6.26
winding (3) connected in series. The holding winding
has a far higher resistance than the pickup winding.
The "aux"-connection is connected between the two
windings.
This bridging has the effect, that the "aux"-terminal
has the same potential as the "Plus"-terminal. If the
bridge is open, the "aux"-terminal has almost the
same potential as the "Minus" terminal, because of
the low resistance of the pick-up winding and the high
resistance of the holding winding. The BLM-module
117
6.26 Engine governor rod positioning solenoid

(terminal X3:4) evaluates this signal for monitoring Adjusting the positioning solenoid
purposes.

i Note
If the "aux" signal is not correct despite the switched
on control solenoid, the positioning solenoid will be
de-energized (down to idle speed) by the BML-mod-
ule via relay K97.

Fig. 3
l Switch the ignition on.
l Set the tumbler switch (Fig. 3) to position "MAX".

i Note
When switching on, the solenoid plunger is pulled
against the stop. The limit switch then switches the
pick-up and holding winding in series. The current flow
is reduced from approx. 70 A to approx. 3.5 A.

Fig. 4
l Measure the gap between stop screw (1) and throt-
tle lever (2).

i Note
Adjustments must only be made on the clevis head
(3).

! Caution
The gap should be min. 0.1 mm and max. 0.5 mm.
If the gap is too small, the limit switch in the sole-
noid may not be able to operate and the "aux" sig-
nal will report this condition to the BLM-module
(A70).
In case of a too wide gap the engine will not reach
its maximum speed.

118 BOMAG 008 915 77

Engine shut-down solenoid 6.27

Fig. 1

Fig. 2 (2) back to initial position and the governor rod (3) is
1 Engine shut-down solenoid Y13 blocked in position "No fuel injection".
2 Armature
3 Governor rod
The battery voltage has the effect that the shut-down
solenoid (1) engages the armature (2) to the left, so
that the governor rod can move freely. When switch-
ing off the battery current a spring will pul the armature

008 915 77 BOMAG 119

6.27 Engine shut-down solenoid

Fig. 3
1 Injection pump
2 Engine shut-down solenoid
3 Starter
4 BLM-module
5 Starter battery

Starting the engine

When the starter switch (S131) is operated, current
flows from terminal X3:10 (BLM-module) into the hold-
ing winding (H). At the same time relay K39 is exciter
through terminal X6:3 (BLM-module) and the starter
(terminal 50) is energized.
If the main contact of the starter closes, current will Fig. 4 Terminal C on starter
flow from terminal C on the starter to the pickup wind-
ing (P) and magentize this winding. The magnetic
forces overcome the force of the armature field and
pick up the armature.
If the starter switch is released after the engine has
been started, current will no longer flow from terminal
C on the starter and the pickup winding (P) will no
longer have any magnetic power. The holding winding
(H) still hold the armature in this position.

Shutting down the engine

When the starter switch is switched off, the current
flow from terminal X3:10 (BLM-module) into the hold-
ing winding is interrupted. The spring is now able to
pull back the armature, the governor rod of the injec-
tion pump is pushed back and the fuel supply is inter-
rupted.

120 BOMAG 008 915 77

Engine shut-down solenoid 6.27
Testing the function !Caution
For inspection do not apply current to the pick-up
winding for longer than two seconds.

i Note
P: Terminal for pick-up winding, resistance approx.
0.38Ω
H: Terminal for holding winding, resistance approx.
16Ω
l Disassemble the shut-down solenoid.
l Connect bridging cables between terminal P of the
pick-up winding and switch (4), as well as between
Fig. 5 switch (4) and battery plus.
l Connect bridging cables between terminal H of the
Danger
! holding winding and switch (3), as well as between
Danger of burning! switch (3) and battery plus.
l Connect a bridging cable between the housing of
The shut-down solenoid gets very hot during the the shut-off solenoid and battery minus (ground
stating process. supply).
l
Remove the shut-down solenoid, leave the plug on l Switch the switch (4) on and off.
the solenoid.
l
Connect the housing of the solenoid to engine
ground (ground supply). i Note
l
Start the engine for a moment. When switching the switch (4) on the pin is retracted
and it moves out again when the switch (4) is switched
off.
i Note
l Switch the switch (3) on first and switch (4) after -the
During the starting process the pin is retracted and it pin is retracted into the body of the solenoid and re-
extends again when the ignition is switched off. mains in this position when switch (4) is switched
Testing the shut-off solenoid off.

Fig. 6
1 Plug
2 Battery
3 Switch for holding winding (H)
4 Switch for pick-up winding (P)

008 915 77 BOMAG 121

6.28 Oil pressure and low oil pressure circuitry

Fig. 1
The oil pressure switch is mounted on the cylinder
block and is connected to the lubrication oil channel.
If the oil pressure drops below a specific value for
longer than 8 seconds
l
the warning buzzer will sound
l the engine will be shut down
l a fault code is emitted

122 BOMAG 008 915 77

Oil pressure and low oil pressure circuitry 6.28
With sufficiently high pressures

Fig. 2 The pressure building up after starting the engine will

1 Terminal press the diaphragm (4) up. This lifts the contact rivet
2 Insulator (5) and interrupts the electric circuit between BLM-
module (A70) and engine ground.
3 Spring
4 Diaphragm
5 Contact rivet
6 Contact
7 Oil switch housing
8 BLM-module (A70)
9 Holding winding for engine shut-down solenoid
(Y13)
10 Display module (P18)
11 Warning buzzer (H11)

008 915 77 BOMAG 123

6.28 Oil pressure and low oil pressure circuitry

With insufficient oil pressure, 49 kPa (0.5 kgf/cm2,

7 psi) or lower

Fig. 3
With dropping oil pressure the diaphragm (4) will re-
turn, until the contact rivet (5) contacts again and the
electric circuit is closed.

124 BOMAG 008 915 77

Coolant temperature and power reduction 6.29
6.29 Coolant temperature and power reduction

Fig. 1
The temperature switch is arranged in the coolant circuit of the engine in such a way, that its tip is surrounded
by coolant.
If the temperature rises over a specific value for longer than 8 seconds
l the warning buzzer will sound
l vibration is shut down
l the travel speed is limited. travel range 1
l a fault code is emitted

Parameters
Normally open contact: Closes at 105 °C and opens at 98 °C.

008 915 77 BOMAG 125

6.29 Coolant temperature and power reduction

Fig. 1
H07, Warning buzzer
B53, Coolant temperature switch
Y03, Solenoid valve 2nd speed
Y57, Vibration high amplitude
Y56, Vibration low amplitude

126 BOMAG 008 915 77

Wiring looms 6.30
6.30 Wiring looms

1 Wiring loom, engine

2 Wiring loom, supply central electrics
3 Wiring loom, battery (+) - starter
4 Wiring loom, battery (-) - main battery switch
5 Wiring loom, engine ground - main battery switch

008 915 77 BOMAG 127

6.30 Wiring looms

1 Wiring loom, safety bow

2 Proximity switches

128 BOMAG 008 915 77

Wiring looms 6.30

1 Wiring loom, Hytos solenoid valves

2 Spiral cable

008 915 77 BOMAG 129

6.31 BLM - Power/Logic Module

Control unit
6.31 BLM - Power/Logic Module

Fig. 1
Control units (ECU = electronic control unit or ECM = electronic control module) are electronic modules which
are mainly installed in places where something needs to be controlled or regulated. Control units are used in
almost any electronic sector in the automotive industry, but also to control machines, plants and other technical
processes.
Control units generally work according to the IPO-principle. IPO stands for Input-Processing-Output. Sensors
are available for input. These determine a physical parameter like e.g. speed, pressure, temperature etc. This
value is then compared with a calculated or fixed nominal value that had been entered into the control unit. If
the measured value does not match the stored value, the control unit regulates the physical process by means
of actors, so that the measured actual values match the setpoint again. This means that the actors correctively
interfere with the ongoing process.
In current vehicles control units are linked via various system buses (CAN, LIN, MOST, Flexray). The units ex-
change information about operating states and other relevant data in vehicle across the system. Furthermore,
the on-board diagnostic or the diagnostic system of the vehicle is connected via such busses (and possible K-
lines). Furthermore, external diagnostic devices (alternatively Personal Computers or Notebooks plus matching
Interface) can communicate with the control units. In this case the system will be interrogated to find out whether
the permanent self tests of the control unit has revealed and registered any faults in itself or on the connected
sensors.

130 BOMAG 008 915 77

BLM - Power/Logic Module 6.31
CAN-bus, Controller Area Network
created by Bosch at the end of the eighties for auto-
mobile applications.

Development objectives:
Real-time critical, robust and low price communication
of control units, such as transmission and engine con-
trol, but also less time critical applications in the field
of convenience electronics, such as air conditioning.

Fig. 2

Why CAN?
l
Networking of control units for the realization of
complex functions.
l
Reduction of the extend of wiring and plug connec-
tions.
l
Better diagnostic possibilities (central diagnostics
socket).

Characteristics of CAN
It is a kind of serial data transmission. The individual
bits are transmitted one after the other, only 2 lines are
required.
CAN lines are twisted together 30 to 40 times per me-
tre. Electromagnetic interferences therefore always
occur simultaneously in both lines, the software is
thus able to filter out interfering signals more easily.
Wire (+) = cable colour blue
Wire (-) = cable colour yellow

Measuring on the CAN

Signals transmitted through the bus line can generally
not be measured with simple measuring instruments.
Testing is therefore quite complicated for the user.
Correct connection of lines can only be checked by
means of a continuity test. BOMAG display modules
are connected to the BUS to give engineers and user
the possibility to detect faults or to receive information
from the BUS.

008 915 77 BOMAG 131

6.32 Checking the voltage supply for the control unit

6.32 Checking the voltage supply for the control unit

Power supply for a control unit, general

All electronic switching and control units require an electric power supply to be able to work. If the plus or minus
supply is faulty, the control unit will work incorrectly or fail.

i Note
(Fig. 3) shows a simplified representation of how the control unit (ESX, 68 pole) is connected. The complete rep-
resentation can be found in the wiring diagram of the machine.

Fig. 3 Circuitry example

A70 = BLM - locig power module
F00 = Main fuse
F67 = Fuses potential 30
G01 = Battery
S30 = Main battery switch
W = Cable remote control
W02 = Radio receiver
Pin 14 = Voltage supply potential 30
Pin 28 = Voltage supply potential 30
Pin 42 = Voltage supply potential 30
Pin 1 = Ground supply for control
Pin 15 = Ground supply for control
Pin 37 = Activation input cable remote control, micro-controller starts.
Pin 39 = Activation input radio remote control, micro-controller starts.

132 BOMAG 008 915 77

Checking the voltage supply for the control unit 6.32
Fault in current supply, general
Clear interruptions in the plus or minus supply are relatively easy to detect. However, the plus and minus sides
of control units are in most cases connected to the vehicle mains supply via several cables, so that several par-
allel current branches exist. Checking the power supply is therefore slightly more difficult than expected. Another
point is the fact that every current branch has several plug connections, which could corrode over the years.
Corroded points are transition resistances and thus cause undesired voltage drops. In case of undesired voltage
drops the control unit is supplied with a lower voltage. This can lead to faulty reactions or even failure of the
control unit.

Fig. 4 Circuitry example

The arrows point to the contact locations, which may be the cause if a control unit only receives a reduced supply
voltage.
The following faults may occur:
l
Line interruption in a plus supply line
l high voltage drop in a plus supply line
l
line interruption on the minus side

Measuring principle for line testing

When a line conducts an electric current, a voltage drop will occur in the line (UV). The size of this voltage drop
UV depends on:
l the available amperage (I) and
l
the electric resistance (Rline) of the current branch being checked.
In order to have reliable comparison possibilities at hand one should always work with the same amperage. Iden-
tical marginal conditions are therefore used in all of the following examples:
12 Volt – vehicle battery as voltage source or 24 Volt in a 24 Volt vehicle network.
12 V / 21 W – lamp as load in a 12 Volt vehicle network.

Test steps
1. Switch off the ignition.

008 915 77 BOMAG 133

6.32 Checking the voltage supply for the control unit

2. Unplug the control unit from wiring loom.

3. If available connect the Pinbox to the plug of the wiring loom, do not connect the control unit with the Pinbox.
If no Pinbox is available, provide measuring cables with appropriate plug-in contacts, e.g. spade-type plugs.
4. Check with multimeter. If a setpoint is not reached, proceed step by step to identify the weak spot. Repair as
necessary. Repeat the measurement.

! Caution
The plug must not be pulled off or plugged on while the ignition is switched on. Switch off the ignition
first and then pull off or plug on the plug.
Only plug the wiring loom onto the control unit, when the actual value corresponds with the setpoint.

134 BOMAG 008 915 77

Checking the voltage supply for the control unit 6.32
General measuring setup to check a supply line (plus side)

Fig. 5 Measuring arrangement 12 Volt

1 = Supply line, plus side
2 = Plug contact in wiring loom plug of control
E = Lamp, 12V / 21 Watt
P = Multimeter
G01 = Battery as voltage source, 12V
UV = Voltage drop caused by the lamp current

Setpoint
The voltage drop UV should not exceed 0.5 V => USetpoint ≤ 0.5 V.

008 915 77 BOMAG 135

6.32 Checking the voltage supply for the control unit

General measuring setup to check a return line (minus side)

Fig. 6 Measuring arrangement 12 Volt

1 = Return line, minus side
2 = Plug contact in wiring loom plug of control
E = Lamp, 12V / 21 Watt
P = Multimeter
G01 = Battery as voltage source, 12V
UV = Voltage drop caused by the lamp current

Setpoint
The voltage drop UV should not exceed 0.5 V => USetpoint ≤ 0.5 V.

136 BOMAG 008 915 77

Checking the voltage supply for the control unit 6.32
Connection example to check the plus line between battery and plug pin 28

Fig. 7
X = Unplug the control unit from the wiring loom.
P = Multimeter
E = Setpoint : E is bright. UV max. 0.5 Volt

008 915 77 BOMAG 137

6.32 Checking the voltage supply for the control unit

Connection example to check the minus line between battery and plug pin 1

Fig. 8
P = Multimeter
X = Unplug the control unit from the wiring loom.
S30 = Main battery switch closed
E = Setpoint : E is bright. UV max. 0.5 Volt

138 BOMAG 008 915 77

Checking the voltage supply for the control unit 6.32
Test protocol for control
E lamp 12V / 21W in 12V vehicle network, to load the current branches.
G01, battery
P multimeter, measuring range: DC

Plug pin Note Setpoints

37, (39) Ignition ON
E between plug pin 37, (39) and battery minus E is bright.
P between battery plus and plug pin 37, (39) UV max. 0.5 Volt
37, (39) Ignition OFF
E between plug pin 37, (39) and battery plus E is dark.
P between battery minus and plug pin 37, (39) UV = 0 Volt
1, (15) Ignition OFF, main battery switch closed
E between plug pin 1, (15) and battery minus E is bright.
P between battery plus and plug pin 1, (15) UV max. 0.5 Volt
14, (28), (42) Ignition OFF
E between plug pin 14, (28), (42) and battery minus E is bright.
P between battery plus and plug pin 14, (28), (42) UV max. 0.5 Volt

i Note
If one or several setpoint(s) is (are) exceeded, one must make considerations which are related to the wiring
diagram.

Example 1:
In all supply lines to the pins 14, 28 and 42 the voltage drop is too high. There are two possible reasons. Either
all contacts are corroded, or the supply line between battery and fuse F67 has poor contact.

Example 2:
Only one measuring value exceeds the setpoint. In this case the fault must be located between the last branch
and the corresponding plug pin.

008 915 77 BOMAG 139

6.33 Controls

6.33 Controls

17 16 15

Fig. 9

140 BOMAG 008 915 77

Fuses 6.34
1 A67 Electronic immobilizer1 6.34 Fuses
2 P17 Display module
3 F05 - F119 Fuse box
4 S101 Toggle switch for cable remote control/radio
remote control
5 XS Socket
6 S30 Main battery switch
7 S137 Steering control lever
8 S132 Toggle switch, vibration automatic/manual
9 S133 Toggle switch, travel ranges
10 S134 Toggle switch, engine speed
11 S138 Travel direction control lever
12 S36 Toggle switch for vibration high/low amplitude
Fig. 10
13 S102 Emergency stop switch
No. 3 = Fuse box
14 H77 Control light data transfer/power pack radio
F119 = (20A) Fuse for starter motor
remote control
15 S181 Key switch F103 = (10A) Fuse potential 15
16 S131 Start engine F14 = (25A) Fuse for engine solenoid
17 S03 Horn button F54 = (5A) Fuse for cable remote control
F05 = (10A) Fuse for utility socket
F67 = (25A) Fuse control (potential 30)
F48 = (30A) Preheating
F68 = (5A) Immobilizer2

1 Optional equipment 2 Optional equipment

008 915 77 BOMAG 141

6.35 Entering the machine type code into the display module

6.35 Entering the machine type the key (F1/g) is pressed again, the display will
jump back to the value "0".
code into the display module l Pressing key (F2/f) moves the flashing digit one dig-
it to the right. If the fourth digit in the display is flash-
Caution
! ing, key (F2/f) is pressed again for confirmation.
After replacing the machine control (BLM) the The desired function is now executed or the desired
type code must be entered again. value is displayed.
The machine type code for the BMP 8500 is "7104" l To cancel the display function you must either enter
The machine must not be operated with a wrong code number "0000" or switch off the ignition.
type settings, as otherwise the correct function of
the control can no longer be assured. Entering the machine type code
The code can only be entered when the engine is l Enter code number "7010".
shut down.
This code number activates the function "Adjusting
machine type“.
The display module now permanently shows code
"7010".
l Enter code "7104".
The display module now permanently shows the en-
tered code.
l
Enter code number "7011".
This code number confirms the entered machine type.
After the confirmation of the machine type the control
switches off.
The control automatically switches on again is now
Fig. 11 ready for starting. The display module shows the ma-
l
Switch on the ignition (Fig. 11). chine type for 3 seconds.
l
Open the rear hood. Whenever switching the ignition on the machine type
will appear in the display module for 3 seconds.
Display module input functions
i Note
The machine type code can be checked by entering
the code "7010".

Fig. 12
l
Keep both keys (F1/g and F2/f) depressed for two
seconds (Fig. 12). The display shows „0000“,
whereby the first digit is flashing.
l The value of the flashing digit can be increased by
pressing key (F1/g). If the value "9" is displayed and

142 BOMAG 008 915 77

Replacing, recharging the radio remote control power pack 6.36
6.36 Replacing, recharging the ra- Charging the power pack in the machine
dio remote control power pack

i Note
As standard the power pack is recharged in the ma-
chine through the spiral cable. A separate battery
charger is available as an option. The recharging time
is approx. 6 hours.

! Danger
Operate the battery charger only in dry rooms at
temperatures of min. 0 °C to max. 40 °C!
A charged power pack is a concentrated energy
Fig. 13
source! Do not store charged power packs in a
tool box or similar, because metal parts may l Switch off the transmitter (Fig. 13) with the ignition
cause a short circuit. Short circuits may also be key.
caused by keys etc. in a trouser pocket. l Plug the spiral cable into the transmitter

! Caution
Change the power pack only when the sender is
switched off.
Before connecting the battery charger make sure
that the mains voltage is in accordance with the
specifications mentioned on the battery charger.
Strictly follow the operating instructions for the
battery charger.

i Note
Ageing of the power pack reduces the discharging ca-
pacity and therefore the operating time of the sender. Fig. 14

The full discharging capacity is only reached after sev- l The main battery switch (Fig. 14) must be switched
eral charging cycles. on.

i Note i Note
As the charging of the power pack succeeds, the The power pack recharging time is approx. 6 hours.
charging current drops, so that overcharging of the
power pack is almost impossible. However, if the con-
trol is switched off for a couple of days (holidays, bad
weather) you should also disconnect the charging unit
from the mains supply or switch off the main battery
switch.

008 915 77 BOMAG 143

6.36 Replacing, recharging the radio remote control power pack

Charging the power pack with the exter-

nal battery charger

Fig. 18
l Plug the corresponding plug (Fig. 18) onto the
mains unit of the battery charger.
Fig. 15
l Switch off the transmitter (Fig. 15) with the ignition
key.
i Note
The type of plug to be chosen depends on the country.
Observe local conditions and regulations.

Fig. 16
l Press the power pack forward and lift it out of the Fig. 19
housing (Fig. 16). l
Insert the power pack into the battery charger (Fig.
19).

Fig. 17
l Push lock 1 (Fig. 17) on the mains unit of the battery Fig. 20
charger forward and pull plug (2) upward out of the l
Connect the battery charger to a power source (Fig.
mains unit.
20).
The two light emitting diodes on battery charger and
mains unit must light up.

144 BOMAG 008 915 77

Replacing, recharging the radio remote control power pack 6.36
i Note
The power pack recharging time is approx. 6 hours.
When charging is completed the green LED on the
charger will start to flash.

008 915 77 BOMAG 145

6.37 BOSS safety system

6.37 BOSS safety system

Antenna 2
Antenna 1

Fig. 1 Club-shape electro-magnetic protection field

The BOMAG protection field control BOSS (Fig. 1) prevents the operator - and only the operator - from becom-
ing trapped between machine and wall. As the machine approaches the operator it will stop once the distance
between operator and machine becomes less than 1.2 m. This is irrespective of whether the operator is in front
of or behind the machine.
The engine keeps running and the steering is operable, but travelling towards the operator is no longer possible.
Travelling in the opposite direction (away from the operator) is still possible. To be able to continue travelling
towards the operator the distance to the machine must be increased and the travel lever must first be returned
to neutral, before travel operation is resumed.

Function
The machine is equipped with a protection field control, whereby each of the two protection field antennas emits
a spherical electro-magnetic field. This creates a spherical protection field around the machine (Fig. 1).

146 BOMAG 008 915 77

BOSS safety system 6.37

Remote control
Radio signal
Transmitter
868 MHz / 916
Transponder Radio transmitter
Radio receiver

Display /
Control unit
Spiral cables
Radio signal
Transponder CAN BUS
868 MHz / 916
Machine control

OUT 1 forward OUT 2 reverse

Protection field control (fixed LF-ID)

forward

Protection field logic 1. Shut down

reverse
Antenna 1

Feedback
Monitoring

Feedback valve
forward
forward

Test facility 2. Shut down

Antenna 2 reverse

valve
reverse

Fig. 2 Block diagram protection field control

The remote control of the machine is equipped with a transponder (small PCB) which sends a permanent control
signal to the protection field control in the machine. (Fig. 2)
Once the transponder enters into the protection field, it transmits an alarm to the protection field control. The
control then interrupts the electric power supply to the corresponding travel control valve and sends a stop com-
mand to the machine control (BLM), causing the machine to stop.
If the control signal emitted by the transponder is incorrect or does not exist, the machine will also be stopped.
Parallel to this the protection field logic of the protection field control is permanently monitored by a testing facil-
ity. In case of a fault in the protection field logic, the testing facility will switch off the travel control valves.

Communication of protection field system

Communication between transponder and protection field control either takes place via the spiral cable, or via
radio.
For the signal transmission via radio both the transponder and the protection field control are equipped with their
own transmitter, receiver and antenna.
This means that in radio mode the system works with two radio signals. One signal from transponder to protec-
tion field control and one signal from the radio transmitter to the receiver in the machine control.
Both systems must work with the same frequency (868 MHz for Europe - 916 MHz for USA). Please bear
this in mind when ordering spare parts!

008 915 77 BOMAG 147

6.38 "Marriage" of transponder and protection field control

6.38 "Marriage" of transponder and 6.39 BOSS Service Mode

protection field control In order to be able to check travel signals and valves
in case of repair work, the protection field control can
The control signal of the transponder is encrypted and
be disabled for 15 minutes by entering code 6000.
will only be accepted by the protection field control if
both the transponder and the protection field control In this service mode all machine functions are availa-
have the same encryption. ble for service and repair work.
The transponder inside the remote control must there-
fore always be "married" to the protection field control i Note
in the machine on occasion of initial commissioning, After switching off the ignition, but at the latest 15 min-
and after the replacement of one of the two compo- utes after entering the code 6000, the protection field
nents. The control will in this case check the encryp- control is enabled again.
tion with every start, and the fault display of the
machine will show an error code, should the encryp-
tion be wrong.
"Marrying" the transponder with the protection field
control:
l Switch on the main battery switch.

Fig. 3
l Set the tumbler switch S101 (cable / radio) to cable
remote control (Fig. 3).
l Plug the spiral cable into the remote control.
l Move at least 1.2 m away from the machine.

Fig. 4
l Set the ignition switch to position I (Fig. 4) and wait
until the horn sounds.

148 BOMAG 008 915 77

Safety field measurement of the Boss safety system 6.40
6.40 Safety field measurement of 6.41 Fault indicator
the Boss safety system

Danger
!

Danger of injury!
The safety field of the machine must be measured
at a height fo one meter, also after maintenance/
repair work on the safety system.
A safety field length < 1.20 m is not permitted.

Fig. 6
Faults are displayed in the display module h (Fig. 6) in
form of flashing fault codes. If several faults occur at
the same time, these will be indicated by flashing
codes, one after the other.

Fig. 5
l Step behind the machine with the remote control
and allow the machine to move towards you, until it
stops.
l Measure the distance between machine and re-
mote control housing.

Nominal value:
>1.20 m

Danger
!

Danger of injury!
If the safety distance is fallen short of stop the ma-
chine and have the safety system repaired. It is
not permitted to continue operation.
l Repeat this inspection in front of the machine.

008 915 77 BOMAG 149

6.42 Diagnostics concept

6.42 Diagnostics concept

Introduction
A correct and reliable diagnose is a general prerequisite for the detection of faults in system. For this to count
as a rule several points must be fulfilled. One of these points is the ability of the engine to run a systematic trouble
shooting procedure. However, this is only possible when a diagnostics concept is available and in practice. Trou-
ble shooting can generally be performed in various ways.

Fault description and questioning of the customer

After the customer has explained his complaint(s) the engineer has to ask further questions to track down the
cause of the fault. If the complaint is additionally related to electric/electronic components, the visual examina-
tion and a possible test drive must be subsequently followed by an interrogation of the error log. The further pro-
cedure in this case depends on the outcome of this interrogation.

Description of fault,
Questioning of customer

Visual inspection,
possible test drive

Interrogation of error log

(1)
Fault memorized in
error log
(2)
No fault memorized in
error log

Fig. 7

(1) Fault memorized in error log

Clear cause?
l If the fault message leaves no doubt, repair work may be started immediately.

150 BOMAG 008 915 77

Diagnostics concept 6.42
Line or component?

Fig. 8
l
In most cases the fault message does not clarify whether the fault is in the sensor or actor, or in one of the
connecting lines (2) between control unit and the mentioned component (1). For this purpose it makes sense
to check the component and the connecting lines between control unit and component separately.
l
Checking the voltage supply for the control unit
l
Checking the sensor lines
l
Checking the actor lines

Sequence after the fault is found

Fault found

Replace component or
repair the connecting line

Delete the error log, test drive

Read out the error log again

No fault memorized in
error log
Prepare the hand-over of the vehicle
Fault memorized in
error log
Check all work again,
rectify the fault

Fig. 9

008 915 77 BOMAG 151

6.42 Diagnostics concept

(2) No fault memorized in the error log at the time of initial questioning
Even if the fault is in the electric/electronic part of the vehicle, a control unit will very often not detect a fault. Right
from the start you should be aware of the fact that a high proportion of faults is caused by contacts. This even
gets worse in case of older and neglected vehicles.
In order to examine the electric/electronic part of an electronic system it is recommended to check the incoming
sensor information and outgoing command values on a control unit. This requires profound knowledge of system
and components.

Consideration, when the error log has not recorded a fault

l What could be the cause of the complaint?
l Which measuring possibilities are available?

152 BOMAG 008 915 77

Problems with radio remote control Hetronic in radio operation 6.43
6.43 Problems with radio remote
control Hetronic in radio oper- i Note
ation Assumed that the function is correct when using the
spiral cable.
Steel ropes or metal attachments on the frame can
disturb the radio connection.

Fault Possible cause Remedy

Machine does not re- Incorrect or defective aerial Replace the aerial (observe the frequency
spond of the aerial)
Check the plug connection between aerial
and receiver

The receiver is electrically not or Check the plug connection between re-
not correctly connected ceiver and machine

Receiver and tansmitter have dif- Installation of transmitter and receiver

ferent system numbers with identical system-no.

Power pack empty or defective Charge or replace the power pack

Distance between machine and Move closer to the machine

transmitter more than 30 m

Toggle switch radio/cable (S101) Check the plug connection

Bridge switch for testing

Transmitter or receiver defective Replace transmitter or receiver

Ignition on, display mod- Power pack empty or defective Charge or replace the power pack
ule on, but starting not
possible

Transmitter or receiver defective Replace transmitter or receiver

Engine stops without Power pack empty or defective Charge or replace the power pack
any reason

Disturbance caused by other radio Check whether the problem arises when
systems other radio signals are transmitted nearby
(airport, construction crane, etc.)
If necessary contine in cable operation

Incorrect or defective aerial Replace the aerial (observe the frequency

of the aerial)
Check the plug connection between aerial
and receiver

Distance between machine and Move closer to the machine

transmitter more than 30 m

Toggle switch radio/cable (S101) Check the plug connection

Bridge switch for testing

Emergency stop push button Switch operated? Display off, pull button
out
Switch defective? replace

Transmitter or receiver defective Replace transmitter or receiver

Main wiring loom Replace the main wiring loom

008 915 77 BOMAG 153

6.43 Problems with radio remote control Hetronic in radio operation

154 BOMAG 008 915 77

Problems with remote control Hetronic with spiral cable 6.44
6.44 Problems with remote control Hetronic with spiral cable

Fault Possible cause Remedy

Engine stops without Engine oil pressure too low or en- Check engine oil level or oil pressure
any reason gine oil pressure switch defective switch
Does the red oil pressure warning
lamp light up when the engine is
running?

Battery Check battery terminals for tight fit (inter-

mittent contact?)
Check the main battery switch
Replace the battery

Emergency stop push button Switch operated? Display off, pull button
out
Switch defective? replace

Fuses F 54, F 67, F 103 defective Replace the fuses (may be damaged by
vibration)

Toggle switch cable/radio S101 Check plug connections, bridge switch for
testing

Relay K 11 Replace the relay

Check the plug connections in the relay
base

Spiral cable Check the continuity of the individual ca-

bles
Check the cables for short circuit to the
housing
Replace the cables

All wiring looms Check all wiring looms for intermittent

contact, to do so wobble all cables, espe-
cially close to the plug connections, while
the engine is running
Check also the plug connections on the
regulator and the ground cable between
engine and frame.

Transmitter Replace the transmitter

Inclination sensor Check the sensor signal, input code 1405

Bridge connections 5 and 6 on the plug for
the inclination sensor
If necessary replace the sensor

Regulator Pull off the four-pin plug above the regula-

tor, if OK, replace the regulator

A 70 module (BLM) Replace the module

Main wiring loom Replace the main wiring loom

Engine wiring harness Replace the engine wiring loom

008 915 77 BOMAG 155

6.44 Problems with remote control Hetronic with spiral cable

Fault Possible cause Remedy

Generator Pull off the two-pin plug coming from the

generator and measure the a.c. voltage
between the two cables while the engine
is running (approx. 26 V at max. speed)
Check both cables for continuity and
check the ground connection

Ignition on, display mod- Travel lever not in "0“-position Actuate the travel lever and return it to "0"-
ule on, but starting not position
possible Check with input code 2500 and 2501

Fuse F 119 Replace the fuses (may be damaged by

vibration)

Battery A clicking sound on module A 70 indicates

that the battery is empty, if necessary re-
place the battery

Inclination sensor Check the sensor signal, (input code

1405)
Bridge connections 5 and 6 on the plug for
the inclination sensor
If necessary replace the sensor

Relay K 39 Check the relay control with code 5070

(start repetition lock!)
Replace the relay
Check the plug connections in the relay
base

Transmitter Replace the transmitter

A 70 module (BLM) Replace the module

All wiring looms Check all wiring looms for intermittent

contact, to do so wobble all cables, espe-
cially close to the plug connections, while
the engine is running
Check also the plug connections on the
regulator and the ground cable between
engine and frame.

After starting still no Not waited for horn signal before Press the horn button or wait fro the horn
function starting signal before starting

Emergency stop push button Switch operated? Display off, pull button
out
Switch defective? replace

Transmitter Replace the transmitter

Spiral cable Check the continuity of the individual ca-

bles
Check the cables for short circuit to the
housing
Replace the cables

A 70 module (BLM) Replace the module

156 BOMAG 008 915 77

Problems with remote control Hetronic with spiral cable 6.44
Fault Possible cause Remedy

Main wiring loom Replace the main wiring loom

Display module shows Spiral cable Check the continuity of the individual ca-
CTO when ignition is on bles
Check the cables for short circuit to the
housing
Replace the cables

Main wiring loom Check whether plug X3:30 or X3:31 is

loose
Check for short circuit between X24:6 and
7, or CAN+ und CAN- or 8 and 3 on the
display module

A 70 module (BLM) Replace the module

Engine not running at Toggle switch for speed S 134 Toggle switch in position "max“ ?
max. speed, otherwise Check with input code 2505
OK
If necessary replace the toggle switch

Fuse F 14 Replace the fuses (may be damaged by

vibration)

Engine solenoid Y 46 (adjustment) Adjust the engine solenoid if the fuse

keeps blowing

Relay K 114 Check the relay control with code 5050

Replace the relay
Check the plug connections in the relay
base

A 70 module (BLM) Replace the module

Main wiring loom Replace the main wiring loom

Engine wiring harness Replace the engine wiring loom

008 915 77 BOMAG 157

6.45 Faults in BOSS safety system

6.45 Faults in BOSS safety system

! Danger

Danger of injury!
After maintenance and/or repair work on the safety system the safety field length must be checked
again (see "Maintenance every 3000 operating hours").

Fault Possible cause Remedy

no travel move- The operator is inside the safety field Leave the safety field
ments, steering
is still possible
Transponder (in transmitter) has not see point 4.15 Teaching the
been taught transponder

Safety antenna front / rear Replace the antenna, check plug connec-
defective or not plugged in tion

Distance between machine and transmit- Move closer to the machine

ter
more than 30 m

Safety field control defective or not Replace the safety field control or
plugged in check the plug connection

Transmitter defective Replace the transmitter

Wiring loom for safety field antennas Replace the wiring loom for safety field
antennas

158 BOMAG 008 915 77

 7 Electronic control

008 915 77 BOMAG 159

160 BOMAG 008 915 77
 7.1 with safety bow

008 915 77 BOMAG 161

7.1 with safety bow

162 BOMAG 008 915 77

with safety bow 7.1

Documentation
BMP 8500
with
safety bar

008 097 xx

Author: VKS
Status: 12.01.2010

008 915 77 BOMAG 163

7.1 with safety bow

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

NOTE: To verify work- and driving funktion with codes, the horn button needs to be pushed
once. ....................................................................................................................................................... 5

2.3 Display CtO.............................................................................................................................. 6

2.4 Checking and setting the transfer rate ................................................................................. 6

2.5 Showing stored faults ............................................................................................................ 6

2.6 Delete all stored faults............................................................................................................ 6

2.7 Setting the machine type ....................................................................................................... 7

2.8 Adjusting the type of remote control .................................................................................... 8

2.9 Driving against the brake ....................................................................................................... 8

3 DESCRIPTION OF THE SIGNALS ON THE BML CONTROL ............................ 9

4 FAULT CODES AND WARNING MESSAGES OF THE BMP 8500 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 ................................................................................................... 21

5 INPUT CODES FOR BLM CONTROL ............................................................... 22

5.1 Outputs for travel functions................................................................................................. 22

5.2 Outputs for work functions.................................................................................................. 24

5.3 Inputs logic and power module ........................................................................................... 25

5.4 Diesel engine, machine electrics......................................................................................... 26

5.5 Checking the function of the remote controls ................................................................... 28

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Table of contents
5.6 Driving against the brake ..................................................................................................... 29

5.7 System information .............................................................................................................. 29

5.8 Setting the remote control type........................................................................................... 29

5.9 Fault log ................................................................................................................................. 29

5.10 Reading out the operating hour meter ............................................................................... 30

5.11 Setting the machine type ..................................................................................................... 30

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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
3 31.05.2005 Version 1.03 from software version 1.11 Ch. Fondel
4 07.12.2006 Version 1.04 from software version 1.21 Ch. Fondel
5 11.01.2010 BMP 8500 with safety bar J.Kob

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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 can be displayed. Higher values will trigger the display "9999".
Negative values are indicated by the "Minus LED" lighting up. 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, with the 1st digit 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.

NOTE: To verify work- and driving funktion with codes, the horn button needs to be pushed
once.

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Functions of the BLM control

2.3 Display CtO

If the display module shows the inscription 0 C t O , there is a fault in CAN Bus communication
between BLM-control and display module. The display value 0 C t O is not generated by the BLM-
control, but by the display itself.
This may have one of two possible reasons:
1. The CAN Bus communication line between display module and BLM-control is faulty, has been
mixed up by mistake or is interrupted. Refer to the wiring diagram.
2. The value for the transfer rate has been incorrectly set in the display module. In this case check
the transfer rate and, if necessary, set it to 100 KBaud.

2.4 Checking and setting the transfer rate

Switch off the ignition to check the transfer rate. Press both control buttons together before switching
the ignition back on Switch the ignition on with the buttons depressed. The currently set baud rate is
displayed. For correct operation the value 0 1 0 0 should be displayed. The value can be changed by
pressing the right hand button. All possible values are displayed one after the other. Keep pressing the
right hand button until the display shows 0 1 0 0 . This process is quit by pressing the left hand button.

2.5 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.

2.6 Delete 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.
Switch the ignition off

Note: The stored faults can only be deleted when the engine is not running.

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Functions of the BLM control

2.7 Setting 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. 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 8500 with safety bars 7103
BMP 8500 without safety bar 7104

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 setting, 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.

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Functions of the BLM control

2.8 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.

The following machine types can be adjusted:

Remote control type Type code

Radio remote control 0662

Note: Parameter adjustments can only be performed when the engine is not running!

Enter code number 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)

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.

2.9 Driving against the brake

After entering code 5 0 0 the brake will not be opened any more. When moving a travel lever forward
or reverse, the travel motors will be activated and the machine drives against the brake. At the same
time the display shows code 500 and the warning buzzer is activated.

To desactivate this function and to open the brake again you have to enter code 501 or shutt off the
ignition once.

Note: This function can only be activated / desactivated when the travel lever is in
neutral position.

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 Description of the signals on the BML control

008 915 77
3 Description of the signals on the BML control
Notes:
with safety bow

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 cooling water temperature sensor B 53 When temperature is too high, connected to ground.
(on +115°C, off +108 °C)
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
Relay off ) 0 V, no consumer connected 2.9 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

BOMAG
X3:09 Output relay K 114, solenoid for rotary speed regulation Relay on ) 12 V
Relay off ) 0 V, no consumer connected 2.9 V
X3:10 Output, holding coil shut off solenoid, Y 13 solenoid on ) 12 V
solenoid off ) 0 V, no consumer connected 2.9 V
X3:11 Output hydraulic valve 2nd gear, Y 03 Valve on ) 12 V
Valve off ) 0 V, no consumer connected 2.9 V
X3:12 Output small amplitude vibration, Y 56 Valve on ) 12 V
Valve off ) 0 V, no consumer connected 2.9 V
X3:13 Output big amplitude vibration, Y 57 Valve on ) 12 V
Valve off ) 0 V, no consumer connected 2.9 V
X3:14 Input voltage supply 12 V against ground
X3:15 Supply, 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 steering left, Y 237 Valve on ) 12 V
Valve off ) 0 V, no consumer connected 2.9 V

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Description of the signals on the BML control

BML terminal Signal description Nominal values (voltage / current)

X3:20 Control potential 15
X3:21 Output hydraulic valve steering right, Y 238 Valve on ) 12 V
Valve off ) 0 V, no consumer connected 2.9 V
X3:22 Output hydraulic valve driving forward, Y 16 Valve on ) 12 V
Valve off ) 0 V, no consumer connected 2.9 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 reverse, Y 17 Valve on ) 12 V
Valve off ) 0 V, no consumer connected 2.9 V
X3:27 Input proximity switch for safety bow backkward B 41 Switch sends positive signal, as long as the bow is not operated.
X3:28 Input voltage supply 12 V against ground
X3:29 Serial interface RS 232 BSL Measurement not possible!
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!
X3:34 Input proximity switch for safety bow forward B189 Switch sends positive signal, as long as the bow is not operated.
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

BOMAG
control, switch on ignition, emergency stop not operated ) 12 V
X3:38 Output relay K 14, pre-glow Relay on ) 12 V
Relay off ) 0 V, no consumer connected 2.9 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
X3:40 Output hydraulic valve brake Y 04 Valve on ) 12 V
Valve off ) 0 V, no consumer connected 2.9 V
X3:41 Input engine speed Measurement not possible!
X3:42 Input voltage supply 12 V against ground

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008 915 77
 Fault codes and warning messages of the BMP 8500 control

008 915 77
4 Fault codes and warning messages of the BMP 8500 control
4.1 Overview
with safety bow

Fault code : Function Group : Remark:

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

BOMAG
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Fault codes and warning messages of the BMP 8500 control

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 steering right, ) Excessive current flow in current path, X3:21 -
longer possible Y 237 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!
1011 Output is switched off, function no Output valve steering right, ) Short circuit to ground in current path X3:21 -
longer possible Y 237 ) Lines rubbed through
Short circuit current flowing from this output ) Valve defective
) output was switched off!
1012 Output is switched off, function no Output valve steering right, ) Wire breakage in current path X3:21 1020
longer possible Y 237 ) Current path connected to +12V 1021
No or too low current flow out of this output 1022
1013 Engine is shut down Output valve steering right, Y 237 ) Current path connected to +12V X3:21 1020
Although the output is switched off, voltage 1021
is present 1022

BOMAG
1020 Output is switched off, function no Output valve steering left, ) Excessive current flow in current path, X3:19 -
longer possible Y 238 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 steering left, ) Short circuit to ground in current path X3:19 -
longer possible Y 238 ) Lines rubbed through
Short circuit current flowing from this output ) Valve defective
) output was switched off!
1022 Output is switched off, function no Output valve steering left, ) Wire breakage in current path X3:19 1010
longer possible Y 238 ) Current path connected to +12V 1011
No or too low current flow out of this output 1012
1023 Engine is shut down Output valve steering left, ) Current path connected to +12V X3:19 1010
Y 238 1011
Although the output is switched off, voltage 1012
is present

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008 915 77
 Fault codes and warning messages of the BMP 8500 control

008 915 77
Code Fault reaction Fault description Possible cause Terminal Input-
on BLM code for
diagnose
with safety bow

1030 Output is switched off, function no Output valve driving forward, Y 16 ) Excessive current flow in current path, X3:22 -
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
1031 Output is switched off, function no Output valve driving forward, Y 16 ) Short circuit to ground in current path X3:22 -
longer possible Short circuit current flowing from this output ) Lines rubbed through
) output was switched off ! ) Valve defective
1032 Output is switched off, function no Output valve driving forward, Y 16 ) Wire breakage in current path X3:22 1030
longer possible No or too low current flow out of this output ) Current path connected to +12V 1031
1032
1033 Engine is shut down Output valve driving forward, Y 16 ) Current path connected to +12V X3:22 1030
Although the output is switched off, voltage 1031
is present 1032
1040 Output is switched off, function no Output valve driving reverse, Y 17 ) Excessive current flow in current path, X3:24 -
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
1041 Output is switched off, function no Output valve driving reverse, Y 17 ) Short circuit to ground in current path X3:24 -
longer possible Short circuit current flowing from this output ) Lines rubbed through

BOMAG
) output was switched off ! ) Valve defective
1042 Output is switched off, function no Output valve driving reverse, Y 17 ) Wire breakage in current path X3:24 1040
longer possible No or too low current flow out of this output ) Current path connected to +12V 1041
1042
1043 Engine is shut down Output valve driving reverse, Y 17 ) Current path connected to +12V X3:24 1040
Although the output is switched off, voltage 1041
is present 1042

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7.1

Fault codes and warning messages of the BMP 8500 control

Code Fault reaction Fault description Possible cause Terminal Input-

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 -
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
1051 Output is switched off, function no Output valve 2nd gear, Y 03 ) Short circuit to ground in current path X3:11 -
longer possible Short circuit current flowing from this output ) Lines rubbed through
) output was switched off ! ) Valve defective
1052 Output is switched off, function no Output valve 2nd gear, Y 03 ) Wire breakage in current path X3:11 1050
longer possible No or too low current flow out of this output ) Current path connected to +12V 1051
1052
1053 Output is switched off, engine runs Output valve 2nd gear, Y 03 ) Current path connected to +12V X3:11 1050
only with idle speed Although the output is switched off, voltage 1051
is present 1052
1060 Output is switched off, function no Output braking valve, Y 04 Excessive current flow in current path, X3:40
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
1061 Output is switched off, function no Output brakingvalve, Y 04 ) Short circuit to ground in current path X3:40

BOMAG
longer possible Short circuit current flowing from this output ) Lines rubbed through
) output was switched off ! ) Valve defective
1062 Output is switched off, function no Output braking valve, Y 04 ) Wire breakage in current path X3:40 1060
longer possible No or too low current flow out of this output ) Current path connected to +12V 1061
1062
1063 Output is switched off, engine runs Output braking valve, Y 04 ) Current path connected to +12V X3:40 1060
only with idle speed Although the output is switched off, voltage 1061
is present 1062

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008 915 77
 Fault codes and warning messages of the BMP 8500 control

008 915 77
4.3 Fault codes of work functions

Code Fault reaction Fault description Possible cause Terminal Input-

with safety bow

on BLM code for

diagnose
1305 Output is switched off, function no Output vibration small amplitude, Y 56 ) Excessive current flow in current path, X3:12 -
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
1306 Output is switched off, function no Output valve small amplitude, Y 56 ) Short circuit to ground in current path X3:12 -
longer possible Short circuit current flowing from this output ) Lines rubbed through
) output was switched off ! ) Valve defective
1307 Output is switched off, function no Output small amplitude, Y 56 ) Wire breakage in current path X3:12 1305
longer possible No or too low current flow out of this output ) Current path connected to +12V 1306
1307
1308 Output is switched off, engine runs Output small amplitude, Y 56 ) Current path connected to +12V X3:12 1305
only with idle speed, 2nd gear is Although the output is switched off, voltage 1306
locked is present 1307
1310 Output is switched off, function no Output big amplitude, Y 57 ) Excessive current flow in current path, X3:13 -
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

BOMAG
1311 Output is switched off, function no Output big amplitude, Y 57 ) Short circuit to ground in current path X3:13 -
longer possible Short circuit current flowing from this output ) Lines rubbed through
) output was switched off ! ) Valve defective
1312 Output is switched off, function no Output big amplitude, Y 57 ) Wire breakage in current path X3:13 1310
longer possible No or too low current flow out of this output ) Current path connected to +12V 1311
1312
1313 Output is switched off, engine runs Output big amplitude, Y 57 ) Current path connected to +12V X3:13 1310
only with idle speed, 2nd gear is Although the output is switched off, voltage 1311
locked is present 1312

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Fault codes and warning messages of the BMP 8500 control

4.4 Fault codes of remote control

Code Fault reaction Fault description Possible cause Terminal Input-

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 in the control is switched off, all
outputs on control are switched off
2601 Engine stopped, emergency stop
relay in the control is switched off, all
outputs on control are switched off
2605 Engine stopped, emergency stop
relay in the control is switched off, all
Remote control emergency stop ) Emergency stop on remote control
operated
Fault in data transfer between remote ) Battery empty
control sender and receiver ) Radio or infrared transmission
disturbed
) Distance between sender an machine
too big
Receive signal too weak ) Radio or infrared transmission
disturbed

BOMAG
outputs on control are switched off ) 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

Output of error code 2605 only with software version older than 1.11!

Page 16 / 30
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008 915 77
 Fault codes and warning messages of the BMP 8500 control

008 915 77
4.5 General fault codes diesel engine, machine

Code Fault reaction Fault description Possible cause Terminal Input-

with safety bow

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

BOMAG
) 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

Faults or warning 5020 and 5021 are only evaluated and displayed when the engine is running.

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7.1

Fault codes and warning messages of the BMP 8500 control

Code Fault reaction Fault description Possible cause Terminal Input-
on BLM code for
diagnose
5025 Engine running No rotary speed signal from the ) Generator regulator defective X3:41 5010
generator regulator ) Line between regulator and control
Only warning interrupted
5031 Machine standing Engine stopped or stalled ) Lack of fuel
) Engine stopped even though the BLM
control did not submit a corresponding
command
5040 Output is switched off, engine stops Output holding coil shut off solenoid, ) Excessive current flow in current path, X3:10 -
Y 13 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!
5041 Output is switched off, engine stops Output holding coil shut off solenoid, ) Short circuit to ground in current path X3:10 -
Y 13 ) Lines rubbed through
Short circuit current flowing from this output ) Valve defective
) output was switched off !
5042 Output is switched off, engine stops Output holding coil shut off solenoid, ) Wire breakage in current path X3:10 5040
Y 13 ) Current path connected to +12V 5041

BOMAG
No or too low current flow out of this output 5042
5043 Output is switched off, engine stops Output holding coil shut off solenoid, ) Current path connected to +12V X3:10 5040
Y 13 5041
Although the output is switched off, voltage 5042
is present
5050 Output is switched off, engine runs Output relay K 114, ) Excessive current flow in current path, X3:09 -
only 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
output ) was switched off!
5051 Output is switched off, engine runs Output relay K 114, ) Short circuit to ground in current path X3:09 -
only with idle speed Engine speed solenoid ) Lines rubbed through
Short circuit current flowing from this output
) output was switched off !
5052 Output is switched off, engine runs Output relay K 114, ) Wire breakage in current path X3:09 5050
only 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 Output relay K 114, ) Current path connected to +12V X3:09 5050
only with idle speed Engine speed solenoid 51051
output is switched off, but voltage present 5052

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008 915 77
 Fault codes and warning messages of the BMP 8500 control

008 915 77
Code Fault reaction Fault description Possible cause Terminal Input-
on BLM code for
diagnose
5054 Input Aux – Signal rpm solenoid Y 13 ) Wire breakage in current path X3:04
with safety bow

5060 Output switched off, no potential 15 Output relay K 11, changeover of ) Excessive current flow in current path, X3:07 -
on machine, control is working, engine potential 15 probably because of a defective coil or
is stopped or cannot be started The current flow from this output is too high a short circuit to ground
output ) was switched off!
5061 Output switched off, no potential 15 Output relay K 11, changeover of ) Short circuit to ground in current path X3:07 -
on machine, control is working, engine potential 15 ) Lines rubbed through
is stopped or cannot be started Short circuit current flowing from this output
) output was switched off !
5062 Output switched off, no potential 15 Output relay K 11, changeover of ) Wire breakage in current path X3:07 5060
on machine, control is working, engine potential 15 ) Current path connected to +12V 5061
is stopped or cannot be started No or too low current flow out of this output 5062

5063 Output switched off, no potential 15 Output relay K 11, changeover of ) Current path connected to +12V X3:07 5060
on machine, control is working, engine potential 15 5061
is 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 -

BOMAG
started 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
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
) output was switched off ! ) Lines rubbed through

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
5 0 7 3 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.

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7.1

Fault codes and warning messages of the BMP 8500 control

Code Fault reaction Fault description Possible cause Terminal Input-
on BLM code for
diagnose
5080 Output switched off, horn cannot Output horn, H 07 ) Excessive current flow in current path, X3:08 -
5085 sound The current flow from this output is too high probably because of a defective coil or X3:36
output ) was switched off! a short circuit to ground
5081 Output switched off, horn cannot Output horn, H 07 ) Short circuit to ground in current path X3:08 -
5086 sound Short circuit current flowing from this output ) Lines rubbed through X3:36
) output was switched off ! ) Horn defective
5082 Output switched off, horn cannot Output horn, H 07 ) Wire breakage in current path X3:08 5080
5087 sound 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
5090 Machine does not start Input inclination switch B56 ) Wire breakage in current path X3:23 1405
The machine cannot be started, because ) Switch defective
the input does not receive a signal from the ) The switch is in actuated state
inclination switch (incorrect installation position)

BOMAG
5091 Shut down of diesel engine Input inclination switch B 56 ) Wire breakage in current path X3:23 1405
The diesel engine is shut down because the ) Switch defective
input on the control does not receive a ) The switch is in actuated state
signal from the inclination sensor (machine has turned over) The
machine must first be shut down after it
has been placed in correct position.
5100 Horn sounds, just warning Input cooling water temperature B 53 ) deficit of cooling water X3:05 5100
Cooling water temperature is too high ) cooler broken
) sensor broken
5101 2nd gear and vibration is stopped Input cooling water temperature B 53 ) deficit of cooling water X3:05 5100
Cooling water temperature is too high for a ) cooler broken
longer period ) sensor broken

Due to the higher operating current two outputs are switched parallel for operation of the horn.

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008 915 77
 Fault codes and warning messages of the BMP 8500 control

008 915 77
4.6 Faults in parameterization
with safety bow

Code Fault reaction Fault description Possible cause Terminal Input-

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

When reading out the error log this error is usually present.

BOMAG
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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 steering right, Y 237 Display value = output voltage in Volt
Voltage at output
1011 Output valve steering right, Y 237 Display value = output current in Amperè
Current at output
1012 Output valve steering right, Y 237 0000 = Output not triggered
Logic level of control 0001 = Output triggered
1015 Valve control, steering 0100 = steering, left
0010 = valve not triggered
0011 = steering, right
1020 Output valve steering left, Y 238 Display value = output voltage in Volt
Voltage at output
1021 Output valve steering left, Y 238 Display value = output current in Amperè
Current at output
1022 Output valve steering left, Y 238 0000 = Output not triggered

BOMAG
Logic level of control 0001 = Output triggered
1030 Output valve driving forward, Y 16 Display value = output voltage in Volt
Voltage at output
1031 Output valve driving forward, Y 16 Display value = output current in Amperè
Current at output
1032 Output valve driving forward, Y 16 0000 = Output not triggered
Logic level of control 0001 = Output triggered
1035 Valve control, driving forward 0100 = Driving, forward
0010 = Drum stopped
0011 = Driving, reverse
1040 Output valve driving reverse, Y 17 Display value = output voltage in Volt
Voltage at output
1041 Output valve driving reverse, Y 17 Display value = output current in Amperè
Current at output
1042 Output valve driving reverse, Y 17 0000 = Output not triggered
Logic level of control 0001 = Output triggered

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008 915 77
 Input codes for BLM control

008 915 77
Input code Description of display function Display values
1050 Output valve 2nd gear, Y 03 Display value = output voltage in Volt
Voltage at output
with safety bow

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
Logic level of control 0001 = Output triggered
1060 Brake valve Y 04 Display value = output voltage in Volt
Voltage at output
1061 Brake valve Y 04 Display value = output current in Amperè
Current at output
1062 Brake valve Y 04 0000 = Output not triggered
Logic level of control 0001 = Output triggered

BOMAG
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Input codes for BLM control

5.2 Outputs for work functions

Input code Description of display function Display values

1305 Output valve vibration small amplitude, Y 56 Display value = output voltage in Volt
Voltage at output
1306 Output valve vibration small amplitude, Y 56 Display value = output current in Amperè
Current at output
1307 Output valve vibration small amplitude, Y 56 0000 = Output not triggered
Logic level of control 0001 = Output triggered
1310 Output valve vibration big amplitude, Y 57 Display value = output voltage in Volt
Voltage at output
1311 Output valve vibration big amplitude, Y 57 Display value = output current in Amperè
Current at output
1312 Output valve vibration big amplitude, Y 57 0000 = Output not triggered
Logic level of control 0001 = Output triggered

BOMAG
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008 915 77
 Input codes for BLM control

008 915 77
5.3 Inputs logic and power module

Input code Description of display function Display values

with safety bow

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°
1407 Input limit switch for safety bow, backward, B 41 12 V > Bow not operated
Ground , 0V > Bow operated
1408 Input limit switch for safety bow, forward, B189 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

BOMAG
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7.1

Input codes for BLM control

5.4 Diesel engine, machine electrics

Input code Description of display function Display values

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
Shows the switching state of the inclination switch defective
0001 = OK, inclination of machine less than 45°
5040 Output holding coil shut off solenoid, Y 13 Display value = output voltage in Volt
Voltage at output
5041 Output holding coil shut off solenoid, Y 13 Display value = output current in Amperè
Current at output
5042 Output holding coil shut off solenoid, Y 13 0000 = Output not triggered
Logic level of control 0001 = Output triggered
5050 Output relay K 114, engine speed solenoid Display value = output voltage in Volt
Voltage at output
5051 Output relay K 114, engine speed solenoid Display value = output current in Amperè

BOMAG
Current at output
5052 Output relay K 114, engine speed solenoid 0000 = Output not triggered
Logic level of control 0001 = Output triggered
5055 ECO mode deactivation temporarily ECO mode is deactivated as long as the engine is running
5056 Change ECO mode constantly
5057 ECO mode off Type in 5056 before !
5058 ECO mode on Type in 5056 before !
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
Logic level of control 0001 = Output triggered

Page 26 / 30
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008 915 77
 Input codes for BLM control

008 915 77
Input code Description of display function Display values
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
with safety bow

Current at output
5072 Output relay K 39, starter 0000 = Output not triggered
Logic level of control 0001 = Output 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
Logic level of control 0001 = Output 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
Logic level of control 0001 = Output triggered
5100 Cooling water temperature B 53 0000 = excess temperature
0001 = temperature alright

BOMAG
Due to the higher operating current two outputs are switched parallel for operation of the horn.

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Input codes for BLM control

5.5 Checking the function of the remote controls

Input code Description of display function Display values

2500 Actuation of hand travel lever on remote control, S 138 0100 = Travel lever shifted forward
0010 = Travel lever not moved
0001 = Travel lever shifted backward
2501 Actuation of joystick steering on remote control, S 137 0100 = Joystick shifted left
0010 = Joystick not moved
0001 = Joystick shifted right
2502 Position of switch for vibration, S 36 0100 = Switch operated to forward, vibration big amplitude
0010 = Switch not operated
0001 = Switch operated to backward, vibration small amplitude
2503 Position of switch for type of vibration, S 132 0100 = Switch operated to forward, automatic vibration
0010 = Switch not operated, manual operation
2504 Position of switch for fast speed, S 133 0100 = Switch operated to forward, fast speed selected
0010 = Switch not operated, fast speed disabled
2505 Position of switch for engine speed, S 134 0100 = Switch operated to forward, high speed
0010 = Switch not operated, idle speed

BOMAG
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 this
purpose start the machine or press the horn button to bring the remote control sender in operating mode for this function test.

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!

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 Input codes for BLM control

008 915 77
5.6 Driving against the brake

Input code Description of display function Display values

with safety bow

0500 Driving against the brake Input code 500 desactivates the brake. The display shows code 500
to remind that the function „driving against the brake“ is active. To
desactivate this function and to open the brake again you have to
enter code 501 or shutt off the ignition once.

5.7 System information

Input code Description of display function Display values

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

BOMAG
5.8 Setting the remote control type

Input code Description of display function Display values

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)!

5.9 Fault log

Input code Description of display function Display values

0700 Switch on function „Show stored faults“ see adjustment instructions (page 6)
0701 Switch off function "Show stored faults" see adjustment instructions (page 6)
0710 Delete all stored faults see adjustment instructions (page 6)

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Input codes for BLM control

5.10 Reading out the operating hour meter

Input code Description of display function Display values

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

5.11 Setting the machine type

Input code Description of display function Display values

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)!
7103 Preselect machine type BMP 8500 See adjustment instructions (page 7)!

BOMAG
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008 915 77
 7.2 with safety field control

008 915 77 BOMAG 193

7.2 with safety field control

194 BOMAG 008 915 77

with safety field control 7.2

Documentation
BMP 8500
with
Safety System BOSS

008 097 xx

Author: VKS
Status: 12.01.2010

008 915 77 BOMAG 195

7.2 with safety field control

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

NOTE: To verify work- and driving funktion with codes, the horn button needs to be pushed
once. ....................................................................................................................................................... 5

2.3 Display CtO.............................................................................................................................. 6

2.4 Checking and setting the transfer rate ................................................................................. 6

2.5 Showing stored faults ............................................................................................................ 6

2.6 Delete all stored faults............................................................................................................ 6

2.7 Setting the machine type ....................................................................................................... 7

2.8 Adjusting the type of remote control .................................................................................... 8

2.9 Driving against the brake ....................................................................................................... 8

3 DESCRIPTION OF THE SIGNALS ON THE BML CONTROL ............................ 9

4 FAULT CODES AND WARNING MESSAGES OF THE BMP 8500 CONTROL 11

4.1 Overview ................................................................................................................................ 11

4.2 Fault codes of travel functions............................................................................................ 12

4.3 Fault codes of work functions ............................................................................................. 14

4.4 Fault codes steering ............................................................................................................. 15

4.5 Fault codes of remote control ............................................................................................. 16

4.6 General fault codes diesel engine, machine ...................................................................... 17

4.7 Fault codes safety system BOSS ........................................................................................ 21

4.8 Faults in parameterization ................................................................................................... 22

5 INPUT CODES FOR BLM CONTROL ............................................................... 23

5.1 Outputs for travel functions................................................................................................. 23

5.2 Outputs for work functions.................................................................................................. 25

5.3 Inputs logic and power module ........................................................................................... 26

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Table of contents
5.4 Diesel engine, machine electrics......................................................................................... 27

5.5 Checking the function of the remote controls ................................................................... 29

5.6 Driving against the brake ..................................................................................................... 30

5.7 System information .............................................................................................................. 30

5.8 Setting the remote control type........................................................................................... 30

5.9 Fault log ................................................................................................................................. 30

5.10 Safety system BOSS............................................................................................................. 31

5.11 Reading out the operating hour meter ............................................................................... 31

5.12 Setting the machine type ..................................................................................................... 31

Page 3 / 30

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7.2 with safety field control

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
3 31.05.2005 Version 1.03 from software version 1.11 Ch. Fondel
4 07.12.2006 Version 1.04 from software version 1.21 Ch. Fondel
5 11.01.2010 BMP 8500 with safety bars J.Kob
6 15.09.2010 BMP 8500 with BOSS Version 2.0, P/N 724 002 33 J.Kob

Page 4 /30

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with safety field control 7.2

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 can be displayed. Higher values will trigger the display "9999".
Negative values are indicated by the "Minus LED" lighting up. 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, with the 1st digit 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.

NOTE: To verify work- and driving funktion with codes, the horn button needs to be pushed
once.

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7.2 with safety field control

Functions of the BLM control

2.3 Display CtO

If the display module shows the inscription 0 C t O , there is a fault in CAN Bus communication
between BLM-control and display module. The display value 0 C t O is not generated by the BLM-
control, but by the display itself.
This may have one of two possible reasons:
1. The CAN Bus communication line between display module and BLM-control is faulty, has been
mixed up by mistake or is interrupted. Refer to the wiring diagram.
2. The value for the transfer rate has been incorrectly set in the display module. In this case check
the transfer rate and, if necessary, set it to 100 KBaud.

2.4 Checking and setting the transfer rate

Switch off the ignition to check the transfer rate. Press both control buttons together before switching
the ignition back on Switch the ignition on with the buttons depressed. The currently set baud rate is
displayed. For correct operation the value 0 1 0 0 should be displayed. The value can be changed by
pressing the right hand button. All possible values are displayed one after the other. Keep pressing the
right hand button until the display shows 0 1 0 0 . This process is quit by pressing the left hand button.

2.5 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.

2.6 Delete 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.
Switch the ignition off

Note: The stored faults can only be deleted when the engine is not running.

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Functions of the BLM control

2.7 Setting 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. 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 8500 with safety bars 7103
BMP 8500 without safety bar 7104

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 setting, 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.

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008 915 77 BOMAG 201

7.2 with safety field control

Functions of the BLM control

2.8 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.

The following machine types can be adjusted:

Remote control type Type code

Radio remote control 0662

Note: Parameter adjustments can only be performed when the engine is not running!

Enter code number 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)

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.

2.9 Driving against the brake

After entering code 5 0 0 the brake will not be opened any more. When moving a travel lever forward
or reverse, the travel motors will be activated and the machine drives against the brake. At the same
time the display shows code 500 and the warning buzzer is activated.

To desactivate this function and to open the brake again you have to enter code 501 or shutt off the
ignition once.

Note: This function can only be activated / desactivated when the travel lever is in
neutral position.

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 Description of the signals on the BML control

008 915 77
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)

with safety field control

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 cooling water temperature sensor B 53 When temperature is too high, connected to ground.
(on +115°C, off +108 °C)
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
Relay off ) 0 V, no consumer connected 2.9 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

BOMAG
X3:09 Output relay K 114, solenoid for rotary speed regulation Relay on ) 12 V
Relay off ) 0 V, no consumer connected 2.9 V
X3:10 Output, holding coil shut off solenoid, Y 13 solenoid on ) 12 V
solenoid off ) 0 V, no consumer connected 2.9 V
X3:11 Output hydraulic valve 2nd gear, Y 03 Valve on ) 12 V
Valve off ) 0 V, no consumer connected 2.9 V
X3:12 Output small amplitude vibration, Y 56 Valve on ) 12 V
Valve off ) 0 V, no consumer connected 2.9 V
X3:13 Output big amplitude vibration, Y 57 Valve on ) 12 V
Valve off ) 0 V, no consumer connected 2.9 V
X3:14 Input voltage supply 12 V against ground
X3:15 Supply, 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 steering right, Y 237 Valve on ) 12 V
Valve off ) 0 V, no consumer connected 2.9 V

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7.2

Description of the signals on the BML control

BML terminal Signal description Nominal values (voltage / current)

X3:20 Control potential 15
X3:21 Output hydraulic valve steering left, Y 238 Valve on ) 12 V
Valve off ) 0 V, no consumer connected 2.9 V
X3:22 Output hydraulic valve driving forward, Y 16 Valve on ) 12 V
Valve off ) 0 V, no consumer connected 2.9 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 reverse, Y 17 Valve on ) 12 V
Valve off ) 0 V, no consumer connected 2.9 V

X3:28 Input voltage supply 12 V against ground

X3:29 Serial interface RS 232 BSL Measurement not possible!
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

BOMAG
control, switch on ignition, emergency stop not operated ) 12 V
X3:38 Output relay K 14, pre-glow Relay on ) 12 V
Relay off ) 0 V, no consumer connected 2.9 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
X3:40 Output hydraulic valve brake Y 04 Valve on ) 12 V
Valve off ) 0 V, no consumer connected 2.9 V
X3:41 Input engine speed Measurement not possible!
X3:42 Input voltage supply 12 V against ground

Page 10 / 30

008 915 77
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 Fault codes and warning messages of the BMP 8500 control

008 915 77
4 Fault codes and warning messages of the BMP 8500 control
4.1 Overview

Fault code : Function Group : Remark:

1000 – Travel system only 4-digit
1999
2000 – Steering only 4-digit
with safety field control

2499
2500 – Remote controls only 4-digit
2999
5000 – Diesel engine only 4-digit
5499
7000 – Input codes for machine parameterization only 4-digit
7499
7500 - Operating hour meter, load spectrum (input codes) only 4-digit
7999
8000 – severe software fault only 4-digit
8999
9000 - External IO nodes, joysticks, data collectors (CAN communication and hardware defects ) only 4-digit

BOMAG
9998
9999 Unknown fault, display value higher than +- 10000, is automatically displayed by the BMFSA only 4-digit

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205
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7.2

Fault codes and warning messages of the BMP 8500 control

4.2 Fault codes of travel functions

Code Fault reaction Fault description Possible cause Terminal Input-

on BLM code for
diagnose
1030 Output is switched off, function no Output valve driving forward, Y 16 ) Excessive current flow in current path, X3:22 -
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
1031 Output is switched off, function no Output valve driving forward, Y 16 ) Short circuit to ground in current path X3:22 -
longer possible Short circuit current flowing from this output ) Lines rubbed through
) output was switched off ! ) Valve defective
1032 Output is switched off, function no Output valve driving forward, Y 16 ) Wire breakage in current path X3:22 1030
longer possible No or too low current flow out of this output ) Current path connected to +12V 1031
1032
1033 Engine is shut down Output valve driving forward, Y 16 ) Current path connected to +12V X3:22 1030
Although the output is switched off, voltage 1031
is present 1032
1040 Output is switched off, function no Output valve driving reverse, Y 17 ) Excessive current flow in current path, X3:24 -
longer possible The current flow from this output is too high probably because of a defective coil or

BOMAG
output ) was switched off! a short circuit to ground
1041 Output is switched off, function no Output valve driving reverse, Y 17 ) Short circuit to ground in current path X3:24 -
longer possible Short circuit current flowing from this output ) Lines rubbed through
) output was switched off ! ) Valve defective
1042 Output is switched off, function no Output valve driving reverse, Y 17 ) Wire breakage in current path X3:24 1040
longer possible No or too low current flow out of this output ) Current path connected to +12V 1041
1042
1043 Engine is shut down Output valve driving reverse, Y 17 ) Current path connected to +12V X3:24 1040
Although the output is switched off, voltage 1041
is present 1042

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008 915 77
with safety field control
 Fault codes and warning messages of the BMP 8500 control

008 915 77
Code Fault reaction Fault description Possible cause Terminal Input-
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 -
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
1051 Output is switched off, function no Output valve 2nd gear, Y 03 ) Short circuit to ground in current path X3:11 -
longer possible Short circuit current flowing from this output ) Lines rubbed through
with safety field control

) output was switched off ! ) Valve defective

1052 Output is switched off, function no Output valve 2nd gear, Y 03 ) Wire breakage in current path X3:11 1050
longer possible No or too low current flow out of this output ) Current path connected to +12V 1051
1052
1053 Output is switched off, engine runs Output valve 2nd gear, Y 03 ) Current path connected to +12V X3:11 1050
only with idle speed Although the output is switched off, voltage 1051
is present 1052
1060 Output is switched off, function no Output braking valve, Y 04 Excessive current flow in current path, X3:40
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
1061 Output is switched off, function no Output brakingvalve, Y 04 ) Short circuit to ground in current path X3:40
longer possible Short circuit current flowing from this output ) Lines rubbed through

BOMAG
) output was switched off ! ) Valve defective
1062 Output is switched off, function no Output braking valve, Y 04 ) Wire breakage in current path X3:40 1060
longer possible No or too low current flow out of this output ) Current path connected to +12V 1061
1062
1063 Output is switched off, engine runs Output braking valve, Y 04 ) Current path connected to +12V X3:40 1060
only with idle speed Although the output is switched off, voltage 1061
is present 1062

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Fault codes and warning messages of the BMP 8500 control

4.3 Fault codes of work functions

Code Fault reaction Fault description Possible cause Terminal Input-

on BLM code for
diagnose
1305 Output is switched off, function no Output vibration small amplitude, Y 56 ) Excessive current flow in current path, X3:12 -
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
1306 Output is switched off, function no Output valve small amplitude, Y 56 ) Short circuit to ground in current path X3:12 -
longer possible Short circuit current flowing from this output ) Lines rubbed through
) output was switched off ! ) Valve defective
1307 Output is switched off, function no Output small amplitude, Y 56 ) Wire breakage in current path X3:12 1305
longer possible No or too low current flow out of this output ) Current path connected to +12V 1306
1307
1308 Output is switched off, engine runs Output small amplitude, Y 56 ) Current path connected to +12V X3:12 1305
only with idle speed, 2nd gear is Although the output is switched off, voltage 1306
locked is present 1307
1310 Output is switched off, function no Output big amplitude, Y 57 ) Excessive current flow in current path, X3:13 -
longer possible The current flow from this output is too high probably because of a defective coil or

BOMAG
output ) was switched off! a short circuit to ground
1311 Output is switched off, function no Output big amplitude, Y 57 ) Short circuit to ground in current path X3:13 -
longer possible Short circuit current flowing from this output ) Lines rubbed through
) output was switched off ! ) Valve defective
1312 Output is switched off, function no Output big amplitude, Y 57 ) Wire breakage in current path X3:13 1310
longer possible No or too low current flow out of this output ) Current path connected to +12V 1311
1312
1313 Output is switched off, engine runs Output big amplitude, Y 57 ) Current path connected to +12V X3:13 1310
only with idle speed, 2nd gear is Although the output is switched off, voltage 1311
locked is present 1312

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008 915 77
with safety field control
 Fault codes and warning messages of the BMP 8500 control

008 915 77
4.4 Fault codes steering

Code Fault reaction Fault description Possible cause Terminal Input-

on BLM code for
diagnose
with safety field control

20I0 Output is switched off, function no Output valve steering right, ) Excessive current flow in current path, X3:21 -
longer possible Y 237 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!
2011 Output is switched off, function no Output valve steering right, ) Short circuit to ground in current path X3:21 -
longer possible Y 237 ) Lines rubbed through
Short circuit current flowing from this output ) Valve defective
) output was switched off!
2012 Output is switched off, function no Output valve steering right, ) Wire breakage in current path X3:21 1020
longer possible Y 237 ) Current path connected to +12V 1021
No or too low current flow out of this output 1022
2013 Engine is shut down Output valve steering right, Y 237 ) Current path connected to +12V X3:21 1020
Although the output is switched off, voltage 1021

BOMAG
is present 1022
2020 Output is switched off, function no Output valve steering left, ) Excessive current flow in current path, X3:19 -
longer possible Y 238 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!
2021 Output is switched off, function no Output valve steering left, ) Short circuit to ground in current path X3:19 -
longer possible Y 238 ) Lines rubbed through
Short circuit current flowing from this output ) Valve defective
) output was switched off!
2022 Output is switched off, function no Output valve steering left, ) Wire breakage in current path X3:19 1010
longer possible Y 238 ) Current path connected to +12V 1011
No or too low current flow out of this output 1012
2023 Engine is shut down Output valve steering left, ) Current path connected to +12V X3:19 1010
Y 238 1011
Although the output is switched off, voltage 1012
is present

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Fault codes and warning messages of the BMP 8500 control

4.5 Fault codes of remote control

Code Fault reaction Fault description Possible cause Terminal Input-

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 in the control is switched off, all
outputs on control are switched off
2601 Engine stopped, emergency stop
relay in the control is switched off, all
outputs on control are switched off
2605 Engine stopped, emergency stop
relay in the control is switched off, all
Remote control emergency stop ) Emergency stop on remote control
operated
Fault in data transfer between remote ) Battery empty
control sender and receiver ) Radio or infrared transmission
disturbed
) Distance between sender an machine
too big
Receive signal too weak ) Radio or infrared transmission
disturbed

BOMAG
outputs on control are switched off ) 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

Output of error code 2605 only with software version older than 1.11!

Page 16 / 30

008 915 77
with safety field control
 Fault codes and warning messages of the BMP 8500 control

008 915 77
4.6 General fault codes diesel engine, machine

Code Fault reaction Fault description Possible cause Terminal Input-

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
with safety field control

) 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

BOMAG
) 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
Faults or warning 5020 and 5021 are only evaluated and displayed when the engine is running.

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Fault codes and warning messages of the BMP 8500 control

Code Fault reaction Fault description Possible cause Terminal Input-
on BLM code for
diagnose
5025 Engine running No rotary speed signal from the ) Generator regulator defective X3:41 5010
generator regulator ) Line between regulator and control
Only warning interrupted
5031 Machine standing Engine stopped or stalled ) Lack of fuel
) Engine stopped even though the BLM
control did not submit a corresponding
command
5040 Output is switched off, engine stops Output holding coil shut off solenoid, ) Excessive current flow in current path, X3:10 -
Y 13 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!
5041 Output is switched off, engine stops Output holding coil shut off solenoid, ) Short circuit to ground in current path X3:10 -
Y 13 ) Lines rubbed through
Short circuit current flowing from this output ) Valve defective
) output was switched off !
5042 Output is switched off, engine stops Output holding coil shut off solenoid, ) Wire breakage in current path X3:10 5040
Y 13 ) Current path connected to +12V 5041

BOMAG
No or too low current flow out of this output 5042
5043 Output is switched off, engine stops Output holding coil shut off solenoid, ) Current path connected to +12V X3:10 5040
Y 13 5041
Although the output is switched off, voltage 5042
is present
5050 Output is switched off, engine runs Output relay K 114, ) Excessive current flow in current path, X3:09 -
only 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
output ) was switched off!
5051 Output is switched off, engine runs Output relay K 114, ) Short circuit to ground in current path X3:09 -
only with idle speed Engine speed solenoid ) Lines rubbed through
Short circuit current flowing from this output
) output was switched off !
5052 Output is switched off, engine runs Output relay K 114, ) Wire breakage in current path X3:09 5050
only 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 Output relay K 114, ) Current path connected to +12V X3:09 5050
only with idle speed Engine speed solenoid 51051
output is switched off, but voltage present 5052

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008 915 77
with safety field control
 Fault codes and warning messages of the BMP 8500 control

008 915 77
Code Fault reaction Fault description Possible cause Terminal Input-
on BLM code for
diagnose
5054 Input Aux – Signal rpm solenoid Y 13 ) Wire breakage in current path X3:04
5060 Output switched off, no potential 15 Output relay K 11, changeover of ) Excessive current flow in current path, X3:07 -
on machine, control is working, engine potential 15 probably because of a defective coil or
is stopped or cannot be started The current flow from this output is too high a short circuit to ground
output ) was switched off!
with safety field control

5061 Output switched off, no potential 15 Output relay K 11, changeover of ) Short circuit to ground in current path X3:07 -
on machine, control is working, engine potential 15 ) Lines rubbed through
is stopped or cannot be started Short circuit current flowing from this output
) output was switched off !
5062 Output switched off, no potential 15 Output relay K 11, changeover of ) Wire breakage in current path X3:07 5060
on machine, control is working, engine potential 15 ) Current path connected to +12V 5061
is stopped or cannot be started No or too low current flow out of this output 5062

5063 Output switched off, no potential 15 Output relay K 11, changeover of ) Current path connected to +12V X3:07 5060
on machine, control is working, engine potential 15 5061
is 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 -

BOMAG
started 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
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
) output was switched off ! ) Lines rubbed through

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
5 0 7 3 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.

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Fault codes and warning messages of the BMP 8500 control

Code Fault reaction Fault description Possible cause Terminal Input-
on BLM code for
diagnose
5080 Output switched off, horn cannot Output horn, H 07 ) Excessive current flow in current path, X3:08 -
5085 sound The current flow from this output is too high probably because of a defective coil or X3:36
output ) was switched off! a short circuit to ground
5081 Output switched off, horn cannot Output horn, H 07 ) Short circuit to ground in current path X3:08 -
5086 sound Short circuit current flowing from this output ) Lines rubbed through X3:36
) output was switched off ! ) Horn defective
5082 Output switched off, horn cannot Output horn, H 07 ) Wire breakage in current path X3:08 5080
5087 sound 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
5090 Machine does not start Input inclination switch B56 ) Wire breakage in current path X3:23 1405
The machine cannot be started, because ) Switch defective
the input does not receive a signal from the ) The switch is in actuated state
inclination switch (incorrect installation position)

BOMAG
5091 Shut down of diesel engine Input inclination switch B 56 ) Wire breakage in current path X3:23 1405
The diesel engine is shut down because the ) Switch defective
input on the control does not receive a ) The switch is in actuated state
signal from the inclination sensor (machine has turned over) The
machine must first be shut down after it
has been placed in correct position.
5100 Horn sounds, just warning Input cooling water temperature B 53 ) deficit of cooling water X3:05 5100
Cooling water temperature is too high ) cooler broken
) sensor broken
5101 2nd gear and vibration is stopped Input cooling water temperature B 53 ) deficit of cooling water X3:05 5100
Cooling water temperature is too high for a ) cooler broken
longer period ) sensor broken

Due to the higher operating current two outputs are switched parallel for operation of the horn.

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008 915 77
with safety field control
 Fault codes and warning messages of the BMP 8500 control

008 915 77
4.7 Fault codes safety system BOSS
with safety field control

Code Fault reaction Fault description Possible cause Terminal Input-

Machine drives without safety system
6001 BOSS for 15 min. Attention: Only for
service purposes!
6010 No travel functions, only steering
6011 No travel functions, only steering
6012 No travel functions, only steering
on BLM code for
diagnose
Servicemode ) Servicemode through input code -
active active.
Defective BOSS antenna front (W12) ) Wire breakage in current path. -
Defective BOSS antenna in the
frontfront
Defective BOSS antenna rear (W13) ) Wire breakage in current path
Defective BOSS antenna in the rear
Defective transponder (no answer back) ) Radio transmission of transponder in
transmitter does not work.

BOMAG
6013 No travel functions, only steering Defective transponder in transmitter ) Internal defect of transponder
6014 No travel functions, only steering Defective BOSS control (A115) ) Internal defect of BOSS control.
6015 No travel functions, only steering CAN bus communication between ) Wire breakage in current path
transponder and BOSS control does not
work.
6016 Quality of reception safety system

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Fault codes and warning messages of the BMP 8500 control

4.8 Faults in parameterization

Code Fault reaction Fault description Possible cause Terminal Input-

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

When reading out the error log this error is usually present.

BOMAG
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008 915 77
with safety field control
 Input codes for BLM control

008 915 77
5 Input codes for BLM control
5.1 Outputs for travel functions

Input code Description of display function Display values

1010 Output valve steering right, Y 237 Display value = output voltage in Volt
Voltage at output
1011 Output valve steering right, Y 237 Display value = output current in Amperè
with safety field control

Current at output
1012 Output valve steering right, Y 237 0000 = Output not triggered
Logic level of control 0001 = Output triggered
1015 Valve control, steering 0100 = steering, left
0010 = valve not triggered
0011 = steering, right
1020 Output valve steering left, Y 238 Display value = output voltage in Volt
Voltage at output
1021 Output valve steering left, Y 238 Display value = output current in Amperè
Current at output
1022 Output valve steering left, Y 238 0000 = Output not triggered
Logic level of control 0001 = Output triggered

BOMAG
1030 Output valve driving forward, Y 16 Display value = output voltage in Volt
Voltage at output
1031 Output valve driving forward, Y 16 Display value = output current in Amperè
Current at output
1032 Output valve driving forward, Y 16 0000 = Output not triggered
Logic level of control 0001 = Output triggered
1035 Valve control, driving forward 0100 = Driving, forward
0010 = Drum stopped
0011 = Driving, reverse
1040 Output valve driving reverse, Y 17 Display value = output voltage in Volt
Voltage at output
1041 Output valve driving reverse, Y 17 Display value = output current in Amperè
Current at output
1042 Output valve driving reverse, Y 17 0000 = Output not triggered
Logic level of control 0001 = Output triggered

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7.2

Input codes for BLM control

Input code Description of display function Display values

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
Logic level of control 0001 = Output triggered
1060 Brake valve Y 04 Display value = output voltage in Volt
Voltage at output
1061 Brake valve Y 04 Display value = output current in Amperè
Current at output
1062 Brake valve Y 04 0000 = Output not triggered
Logic level of control 0001 = Output triggered

BOMAG
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008 915 77
with safety field control
 Input codes for BLM control

008 915 77
5.2 Outputs for work functions

Input code Description of display function Display values

1305 Output valve vibration small amplitude, Y 56 Display value = output voltage in Volt
Voltage at output
1306 Output valve vibration small amplitude, Y 56 Display value = output current in Amperè
Current at output
with safety field control

1307 Output valve vibration small amplitude, Y 56 0000 = Output not triggered
Logic level of control 0001 = Output triggered
1310 Output valve vibration big amplitude, Y 57 Display value = output voltage in Volt
Voltage at output
1311 Output valve vibration big amplitude, Y 57 Display value = output current in Amperè
Current at output
1312 Output valve vibration big amplitude, Y 57 0000 = Output not triggered
Logic level of control 0001 = Output triggered

BOMAG
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7.2

Input codes for BLM control

5.3 Inputs logic and power module

Input code Description of display function Display values

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°
1407 Input limit switch for safety bow, backward, B 41 12 V > Bow not operated
Ground , 0V > Bow operated
1408 Input limit switch for safety bow, forward, B189 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

BOMAG
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008 915 77
with safety field control
 Input codes for BLM control

008 915 77
5.4 Diesel engine, machine electrics

Input code Description of display function Display values

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
with safety field control

Shows the switching state of the inclination switch defective

0001 = OK, inclination of machine less than 45°
5040 Output holding coil shut off solenoid, Y 13 Display value = output voltage in Volt
Voltage at output
5041 Output holding coil shut off solenoid, Y 13 Display value = output current in Amperè
Current at output
5042 Output holding coil shut off solenoid, Y 13 0000 = Output not triggered
Logic level of control 0001 = Output triggered
5050 Output relay K 114, engine speed solenoid Display value = output voltage in Volt
Voltage at output
5051 Output relay K 114, engine speed solenoid Display value = output current in Amperè
Current at output

BOMAG
5052 Output relay K 114, engine speed solenoid 0000 = Output not triggered
Logic level of control 0001 = Output triggered
5055 ECO mode deactivation temporarily ECO mode is deactivated as long as the engine is running
5056 Change ECO mode constantly
5057 ECO mode off Type in 5056 before !
5058 ECO mode on Type in 5056 before !
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
Logic level of control 0001 = Output triggered

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Input codes for BLM control

Input code Description of display function Display values
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
Logic level of control 0001 = Output 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
Logic level of control 0001 = Output 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
Logic level of control 0001 = Output triggered
5100 Cooling water temperature B 53

BOMAG
0000 = excess temperature
0001 = temperature alright

Due to the higher operating current two outputs are switched parallel for operation of the horn.

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008 915 77
with safety field control
 Input codes for BLM control

008 915 77
5.5 Checking the function of the remote controls

Input code Description of display function Display values

2500 Actuation of hand travel lever on remote control, S 138 0100 = Travel lever shifted forward
0010 = Travel lever not moved
0001 = Travel lever shifted backward
2501 Actuation of joystick steering on remote control, S 137 0100 = Joystick shifted left
with safety field control

0010 = Joystick not moved

0001 = Joystick shifted right
2502 Position of switch for vibration, S 36 0100 = Switch operated to forward, vibration big amplitude
0010 = Switch not operated
0001 = Switch operated to backward, vibration small amplitude
2503 Position of switch for type of vibration, S 132 0100 = Switch operated to forward, automatic vibration
0010 = Switch not operated, manual operation
2504 Position of switch for fast speed, S 133 0100 = Switch operated to forward, fast speed selected
0010 = Switch not operated, fast speed disabled
2505 Position of switch for engine speed, S 134 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

BOMAG
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 this
purpose start the machine or press the horn button to bring the remote control sender in operating mode for this function test.

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!

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7.2

Input codes for BLM control

5.6 Driving against the brake

Input code Description of display function Display values

0500 Driving against the brake Input code 500 desactivates the brake. The display shows code 500
to remind that the function „driving against the brake“ is active. To
desactivate this function and to open the brake again you have to
enter code 501 or shutt off the ignition once.

5.7 System information

Input code Description of display function Display values

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

BOMAG
5.8 Setting the remote control type

Input code Description of display function Display values

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)!

5.9 Fault log

Input code Description of display function Display values

0700 Switch on function „Show stored faults“ see adjustment instructions (page 6)
0701 Switch off function "Show stored faults" see adjustment instructions (page 6)
0710 Delete all stored faults see adjustment instructions (page 6)

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with safety field control
 Input codes for BLM control

008 915 77
5.10 Safety system BOSS

Input code Description of display function Display values

6000 Switch on service mode 6000
6001 Service mode active. Machine drives without safety system 6001 = Service mode active.
BOSS for 15 min.
6002 Switch off service mode
with safety field control

5.11 Reading out the operating hour meter

Input code Description of display function Display values

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

BOMAG
5.12 Setting the machine type

Input code Description of display function Display values

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)!
7103 Preselect machine type BMP 8500 See adjustment instructions (page 7)!

Page 31 / 30
7.2

225
7.2 with safety field control

226 BOMAG 008 915 77

 7.3 Logic

008 915 77 BOMAG 227

7.3 Logic

228 BOMAG 008 915 77

 Kob, 12.01.2010
Logic

LOGIC Hetronic control with BLM modul (A 70) for BMP 8500

008 915 77
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 : 6)
7 Voltage on monitoring module (P18 : 7)

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

BOMAG
15 Ground on X3:1, X3:15
16 Aktivation signal X3:39 or X3:37 (12 V from transmitter)
17 Initializing program finished ( 2sec after Aktivation signal X3:39 or X3:37 (constantly 12 V)) >> Horn
18 Travel levers in neutral
19 Slope sensor signal 12 V (X3:23)
20 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
21 [L] on ground, X3:41 [W] lower than 100 Hz, X3:3 [p] on ground
22 Key switch start signal through Can - and Can + [digital>>no constant voltage]
23 code for machine type needs to be adjusted
24
Holding coil of shutt
off solenoid Y13
energized before
25 starting Power supply X3:14, X3:28, X3:42
26 Ground on X3:1, X3:15
7.3

229
230
7.3
Kob, 12.01.2010
LOGIC Hetronic control with BLM modul (A 70) for BMP 8500

For (see below) The following is necessary (see below)

27 Aktivation signal X3:39 or X3:37 (12 V from transmitter)
28 Initializing program finished ( 2sec after Aktivation signal X3:39 or X3:37 (constantly 12 V)) >> Horn
29
30
Holding coil of shutt
off solenoid Y13
energized after
31 starting Power supply X3:14, X3:28, X3:42
32 Ground on X3:1, X3:15
33 Aktivation signal X3:39 or X3:37 (12 V from transmitter)
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.

BOMAG
37
38 Travel forward Power supply X3:14, X3:28, X3:42
39 Ground on X3:1, X3:15
40 Aktivation signal X3:39 or X3:37 (12 V from transmitter)
Starter switch must have been turned to start position or horn button pushed at least once after
41 ignition on and initializing phase >>> horn

42 Travel lever S 138 in forward position (signal through Can - and Can + [digital>>no constant voltage])
43 proximity switch safety bar in front 12 V (X3: 34)
44
45 Travel revers Power supply X3:14, X3:28, X3:42
46 Ground on X3:1, X3:15
47 Aktivation signal X3:39 or X3:37 (12 V from transmitter)
Starter switch must have been turned to start position or horn button pushed at least once after
48 ignition on and initializing phase >>> horn
49 Proximity switch revers protection bow 12 V (X3:27)

008 915 77
Logic
 Kob, 12.01.2010
Logic

LOGIC Hetronic control with BLM modul (A 70) for BMP 8500

008 915 77
For (see below) The following is necessary (see below)
50 Travel lever S138 in revers position (signal through Can - and Can + [digital>>no constant voltage])
51
52
53
54
55
56 high engine rpm Power supply X3:14, X3:28, X3:42
57 Ground on X3:1, X3:15
58 Aktivation signal X3:39 or X3:37 (12 V from transmitter)
Starter switch must have been turned to start position or horn button pushed at least once after
59 ignition on and initializing phase >>> horn
60 Switch S 134 on (signal through Can - and Can + [digital>>no constant voltage])
61 code 0500 must not be activated
During starting of the engine the engine rpm solenoid is generally activated (K114) as long as the
62 NOTE >>> starter is activated.

BOMAG
If there is no signal to travel, vibration or steering for more than 20 seconds, the rpm
63 NOTE >>> falls down (ECO mode)
64
65 2nd speed travel Power supply X3:14, X3:28, X3:42
66 Ground on X3:1, X3:15
67 Activation signal X3:39 or X3:37 (12 V from transmitter)
Starter switch must have been turned to start position or horn button pushed at least once after
68 ignition on and initializing phase >>> horn
69 Switch S 133 on 2nd speed (signal through Can - and Can + [digital>>no constant voltage])
70 code 0500 must not be activated
71 cooling water temperature sensor must not be connected to ground.
72 Note >>>> 2 sec delay
73
74 steering right power supply X3:14, X3: 28, X3: 42
75 Ground on X3:1, X3:15
76 Activation signal X3:39 or X3:37 (12 V from transmitter)
7.3

231
232
7.3
Kob, 12.01.2010
LOGIC Hetronic control with BLM modul (A 70) for BMP 8500

For (see below) The following is necessary (see below)

Starter switch must have been turned to start position or horn button pushed at least once after
77 ignition on and initializing phase >>> horn
steering lever S137 held to the right hand side (signal through Can - and Can + [digital>>no constant
78 voltage]
79
80 steering left power supply X3:14, X3: 28, X3: 42
81 Ground on X3:1, X3:15
82 Activation signal X3:39 or X3:37 (12 V from transmitter)
Starter switch must have been turned to start position or horn button pushed at least once after
83 ignition on and initializing phase >>> horn
steering lever S137 held to the left hand side (signal through Can - and Can + [digital>>no constant
84 voltage]
85
Vibration low

BOMAG
86 amplitude power supply X3:14, X3: 28, X3: 42
87 Ground on X3:1, X3:15
88 Activation signal X3:39 or X3:37 (12 V from transmitter)
Starter switch must have been turned to start position or horn button pushed at least once after
89 ignition on and initializing phase >>> horn
90 cooling water temperature sensor must not be connected to ground.
91 toggle switch S36 switched to low amplitude
92
Vibration high
93 amplitude power supply X3:14, X3: 28, X3: 42
94 Ground on X3:1, X3:15
95 Activation signal X3:39 or X3:37 (12 V from transmitter)
Starter switch must have been turned to start position or horn button pushed at least once after
96 ignition on and initializing phase >>> horn
97 cooling water temperature sensor must not be connected to ground.
98 toggle switch S36 switched to high amplitude
99

008 915 77
Logic
 Kob, 12.01.2010
Logic

LOGIC Hetronic control with BLM modul (A 70) for BMP 8500

008 915 77
For (see below) The following is necessary (see below)
100
101

BOMAG
7.3

233
7.3 Logic

234 BOMAG 008 915 77

 8 Service Training

008 915 77 BOMAG 235

Simple servicing due to excellent accessibility .....

Fig. 10

236 BOMAG 008 915 77

General 8.1
8.1 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 inside the machine are exceptionally well protected against damage caused by collision
with trench walls and by falling down stones, etc.
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 mounted to the front of the rear frame. With this lifting hook the machine can
be easily lowered into and lifted out of the trench.
The machine is equipped with four drums. The machine is driven by two travel motors. Once travel motor each
drives the two front and the two rear drums as pairs.
The two travel motors per machine side are connected in series, whereby slippage between front and rear drums
is avoided.
Unlike the previous model, this machine is equipped with an articulated joint. The steering system is hydraulically
operated. The steering angle is set by extending a hydraulic cylinder next to the articulated joint.
In contrast to the previous model BMP 8500 this machine is now equipped with
l
two travel motors
l
an articulated joint
l
two amplitudes
.
For enhanced traction the drums are provided with padfeet.
The vibration system works with two exciter units. One exciter unit per axle. Both exciters are hydraulically driven
by means of a common gear pump and one gear motor each.
When driving without vibration this oil flow is also available for the travel system.
The machine is operated via two travel levers, one for steering and one for travel direction, a tumbler switch to
choose the vibration mode (high/low amplitude) and a tumbler switch for high and low travel speed range.
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".
With a tumbler switch the operator can choose between low and high amplitude. The tumbler switch is linked
with a 4/3-way valve, which reverses the sense of rotation of the hydraulic motor. In combination with change-
over weights, two amplitudes are realized this way.
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 lever forward the machine
can then be moved away from the obstruction.

008 915 77 BOMAG 237

8.1 General

Fig. 11 Overview

238 BOMAG 008 915 77

General 8.1
1 Steering pump
2 Travel pump
3 Vibration pump
4 Exhaust system
5 Diesel engine
6 Cooler
7 Fuel tank
8 Central electrics
9 Battery
10 Hydraulic control valve block
11 Hydraulic oil tank
12 Air filter
13 Single point lifting facility
14 Air filter service indicator
15 Fuel filter
16 Coolant compensation container
17 Engine oil filter
18 Hydraulic oil filter

008 915 77 BOMAG 239

8.2 Travel system

The multi-purpose compactor BMP 8500 works with a hydrostatic travel system. The travel circuits are open hy-
8.2 Travel system

draulic circuits and consist mainly of

l
Travel pump
l Travel motors
l Control valve block
and the connecting pressure hoses. The machine is equipped with two hydraulic motors connected in series.
One motor each drives the two drums of an axle.
This series connection avoids slipping of only one drum under severe soil conditions.
Both travel motors are supplied from a travel pump. Together with the vibration pump and the steering pump this
travel pump forms a triple pump unit.
This pump combination is directly driven by the engine with full engine speed.
The travel pump draws the hydraulic oil through a suction filter in the hydraulic oil tank and delivers it to the con-
trol valve block. When the travel lever is not actuated, the oil flows back to the tank.
l When the travel lever is actuated, the travel direction control valves are controlled according to the chosen
travel direction. The two travel motors receive an hydraulic oil flow that is determined by the position of the
control valves.
When working without vibration the oil flow delivered by the vibration pump is also directed to the travel circuits
through a 4/2-way valve. This increases the travel speed of the machine. This "2nd travel speed range" is nor-
mally 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 vibration motors is then interrupted by
the 4/2-way valve and guided to the vibration motor through the 4/3-way solenoid valve.
Pressure relief valves limit the pressure in the travel circuits to 250 bar.

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Fig. 1 List of components

240 BOMAG 008 915 77

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008 915 77
    
Travel system

Fig. 2 Hydraulic diagram

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8.2

241
8.2 Travel system

Fig. 3
1 Travel motor
2 Cylinder roller bearing
3 Drive shaft
4 Gear
5 Cylinder roller bearing
6 Pinion travel motor
The travel motor 1 (Fig. 3) is hydraulically driven. The pinion (6) is directly connected with the travel motor and
drives the gear (4). This gear is fitted to the drive shaft (3) by means of a feather key. Both ends of the drive shaft
rest in cylinder roller bearings (2) in the cover of the centre frame.

242 BOMAG 008 915 77

Travel motor 8.3
Travel motor
8.3 Travel motor

The drums are the BMP 8500 are driven by two Eaton Geroller hydraulic motors. Geroller motors are slow run-
ning hydraulic motors with high torque. The series 2000 enables torques of up to 845 Nm, the approved design
is reliable and suitable for a long service life.
With a given oil flow and a given pressure the displacement of the motor (nominal size of motor) determines both
the speed and the torque.
This means:
a) that the speed is determined by the supplied oil flow and
b) the torque depends on the available pressure.

Fig. 1
The plate or distributor valve is arranged on the side of the drive set. The distributor valve is driven synchronous-
ly with the gear set, so that filling and emptying of the individual chambers takes place precisely and without
losses. This valve is separated from the drive shaft and is separately driven by a short universal shaft.
Displacement:
l 75 l/min. continuous
l
115 l/min. intermittent
Speed up to 1042 rpm.
Pressure difference:
l 200 bar continuous
l
300 bar intermittent
Torque:

008 915 77 BOMAG 243

8.3 Travel motor

l 845 Nm continuous
l 930 Nm intermittent

Fig. 2
The drive sets of the hydraulic motors consist of a housing section with internal gearing and a gear wheel, the
centre of which during rotation orbits around the centre of the ring gear.
l Geroller hydraulic motors are characterized by a very robust and compact design.
l Applications are mainly found in areas where high torques with relatively low rotary speeds are required.
l The housing contains a fixed, integrated ring gear.
l Long service life.
l Highly power output.
l Excellent volumetric and mechanical rate of efficiency due to the fixed integrated ORBITAL unit.
l Suitable for short-term operation with medium pressure.
l Excellently suitable for permanentb operation at medium pressure.

244 BOMAG 008 915 77

Multiple gear pump 8.4
8.4 Multiple gear pump

Design, external-gear pump

The external-gear pump mainly consists of the friction bearing mounted gear pair and the housing with front and
rear covers. The drive shaft, which is sealed with a radial seal, protrudes from the front cover. The bearing forces
are absorbed by friction bearings. These have been designed for high pressures and have excellent antifriction
properties - particularly at low speeds. The gears have 12 teeth each. This keeps flow pulses and noise emis-
sions at a low level.

Axial seal Outer pressure field Inner pressure field Radial seal

Sealing zone
Cover Flange Compensation forces
Fig. 1 Axial compensation of gear pump
Internal sealing of the pressure chambers is achieved by flow volume dependent forces. This results in an ex-
cellent rate of efficiency. On the rear side the moveable bearing bushings are pressurized and thus tightly
pressed against the gears. The pressurized pressure fields are thereby limited by special seals. Sealing around
the circumference of the gears to the housing is assured by small gaps, which appears between gears and hous-
ing in dependence on the pressure.

Function

Fig. 2
The increasing volume caused by a tooth exiting a tooth gap results in a vacuum in the suction chamber. The
pressure fluid is transported into the pressure chamber. There the meshing of teeth and tooth gaps displaces
the pressure fluid into the upper supply line.

008 915 77 BOMAG 245

8.4 Multiple gear pump

Fig. 3

1 Cover 6 Gear (driven)

2 Seals and gaskets 7 Shaft
3 Housing 8 Flange
4 Gear (driving) 9 Bearing plate
5 Displacement chamber 10 Bearing plate

Multiple gear pump

Gear pumps are most suitable for multiple pump arrangements, whereby the drive shaft of the first pump is ex-
tended to a second and third pump. The shafts are connected by drivers in between. The individual pump stages
are sealed to each other, i.e. the suction ports are separated from each other.

Vibration pump
The vibration pump is a directly driven gear pump. The vibration pump is the first pump section, viewed from the
drive side.
The vibration pump transports the hydraulic oil from the tank through the control valve block to the vibration mo-
tor and from there back to the tank.

Travel pump
The travel pump is a directly driven gear pump, which is connected with the vibration pump via a coupling.
The travel pumps deliver the hydraulic oil from the tank through the control valve block to the travel motors and
back to the tank.

Steering pump
The steering pump also is a directly driven gear pump, which is connected with the travel pump via a coupling.

246 BOMAG 008 915 77

Multiple gear pump 8.4

Travel pump
Vibration pump Steering pump

Fig. 4

008 915 77 BOMAG 247

8.5 Vibration

8.5 Vibration
The vibration system of the machine is also hydraulically driven. The vibration system consists of:
l a vibration pump
l two vibration motors
l two exciters
l a 4/2-way valve to select the travel speed range
l a 4/3-way valve for amplitude control.
The design of the vibration control system enables perfect adaptation of the vibration to all possible require-
ments.
Each axle has a separate exciter unit, which is carried by the centre frame. The two vibration motors are con-
nected in series and drive the exciter shafts directly .
An exciter unit ((Fig. 5)) consists of two exciter shafts with an eccentric (5) and a change-over weight (4).
The exciter shaft is driven by the coupling (3) of the vibration motor (6). The two gears (1) drive the second ex-
citer shaft to opposite direction.
The entire exciter unit (7) rest in cylinder roller bearings (2) in the centre frame.

248 BOMAG 008 915 77

Vibration 8.5

Fig. 5 Exciter unit

1 Gear
2 Cylinder roller bearing
3 Coupling, vibration motor
4 Change-over weight
5 Eccentric
6 Vibration motor
7 Exciter unit

008 915 77 BOMAG 249

8.5 Vibration

By reversing the sense of rotation, two amplitudes can be realized.

high amplitude (Fig. 6)

The exciter shaft rotates clockwise. Both eccentrics add up and generate a higher resultant centrifugal force.

Fig. 6 high amplitude

low amplitude (Fig. 7)

The exciter shafts rotate anti-clockwise. The eccentric weight (2) swings over. The centrifugal forced generated
by the two eccentrics are subtracted from one another resulting in a lower resultant centrifugal force

Fig. 7 low amplitude

250 BOMAG 008 915 77

Vibration 8.5
Vibration motors
The vibration motors are reversible gear motors. Both vibration motors are connected to the corresponding ex-
citer shaft in the two centre frames via curved tooth couplings and drive the exciter shafts with output speed.

Fig. 1 Reversible gear motor

The displacement principle of external gear motors is reversed when compared with the principle of a pump.
A special design are the reversible motors. Due to their symmetric construction the high or low pressure spaces
are separated from the bearing and radial seal area. Any amounting leak oil is returned through a separate leak
oil port in the housing cover. This leak oil return port enables reversing of the motor, which allow installation in
series connection. Due to the connection between radial seal and low pressure side standard motors and pumps
can be loaded with a pressure of up to approx. 3 bar.

008 915 77 BOMAG 251

8.5 Vibration

When the gear motor is supplied with pressure oil, a torque can be taken off the protruding output shaft. A dif-
ferentiation is thereby made between motors for one direction of rotation and reversible motors.

Output shaft

for one
direction of rotation

Counter-clockwise rotation Clockwise rotation

reversible
Fig. 2

252 BOMAG 008 915 77

Vibration 8.5
Vibration control
The vibration control elements are integrated in the same valve block as the control elements for the travel sys-
tem. The vibration control is linked with the travel system control as follows:
l If the machine is driven with high travel speed, a 2/4-way solenoid valve will cut off the oil flow to the vibration
motor and directs it additionally to the travel circuit.
When the vibration is switched on, the oil flow from the vibration pump must first start rotation of the resting ex-
citer shaft. The pressure (starting pressure) caused by this high starting resistance of the resting exciter shaft is
limited to max. 250 bar by a pressure relief valve inside the control valve block.
Once the final speed of the exciter shafts is reached, the resistance of the exciter shafts becomes lower and the
pressure drops down to a value (operating pressure) which is influenced by external effects (degree of compac-
tion, soil condition, etc.).
The sense of rotation of the vibration motors can be reversed by actuation of a 4/3-way valve. This way the am-
plitude adjustment is realized.

008 915 77 BOMAG 253

8.6 Control valve block

8.6 Control valve block

The control valve block contains all control and safety elements needed in the both travel and vibration circuits.
These are:
l 1 pressure relief valve (250 bar) for the travel circuit
l 1 pressure relief valve (250 bar) for the vibration circuit
l 1 3/2-way solenoid valve to operate the brake
l 1 4/2-way solenoid valve to switch the travel speed ranges
l 2 load lowering valves
l 1 4/3-way solenoid valve for travel circuit control
l 1 4/3-way solenoid valve to control the vibration.
l 1 4/3-way solenoid valve to operate the steering cylinder
l 1 pressure relief valve (100 bar) for the steering
l 1 pressure relief valve (20 bar) for the brake pressure

Fig. 1 Control valve block

When starting the engine with all control valves set to initial position, hydraulic oil will flow from the travel pump
to the travel direction valve and from there back to the tank.
When switching the travel speed range selector valve to high travel speed, the pump flow from the vibration
pump is also fed to both travel motors. However, in this case the machine cannot be operated with vibration. The
line between the 4/2-way valve and the travel direction valve is fitted with a check valve. This valve prevents oil
flowing out of the travel circuit into the vibration circuit.
With the engine shut down no pressure is applied to the brake cylinder. Due to the internal springs the brake
cylinder is in this case extended and thus prevents rolling of the machine. When the engine is started the steering
pump will direct a hydraulic oil flow through Y04 to the brake cylinder and open the brake.
The ports on the control valve block are numbered and can thereby easily assigned to the respective consumer
ports.

254 BOMAG 008 915 77

Control valve block 8.6

Fig. 2 Overview of ports on control valve block

1.1 Pressure relief valve for travel circuit (250 bar)
1.3.1 Load lowering valve rear
1.3.2 Load lowering valve front
1.2 Travel direction valve (4/3-way solenoid valve)
2.1 Pressure relief valve for vibration circuit
2.2 Valve 2nd gear (4/3-way solenoid valve)
2.3 Vibration valve (4/3-way solenoid valve)
2.4 Pre-loaded check valve

008 915 77 BOMAG 255

8.6 Control valve block

3.1 Pressure relief valve for steering

3.2 Pressure relief valve for brake
3.3 3/2-way solenoid valve for brake
3.5 4/3-way solenoid valve for steering
3.6 Pre-loaded check valve
L1 Leak oil travel control
L2 Leak oil vibration
A1 to rear travel motor port A
B1 to front travel motor port B
A2 to rear vibration motor port A
B2 to front vibration motor port B
A3 to steering cylinder port A
B3 to steering cylinder port B
BR to port on brake cylinder
P1 Connection travel pump
P2 Connection vibration pump
P3 Connection steering pump
T1 Return flow to tank via oil cooler
T2 Return flow to tank, direct

256 BOMAG 008 915 77

Hose connection centre frame 8.7
8.7 Hose connection centre frame
In order to be able to work without routing the hydraulic hoses through the endangered area between the drums,
the hydraulic oil is directed through deep drilled holes in the centre frame.
Inside the centre frame hydraulic hoses connect the deep drilled holes with the travel motors, the vibration mo-
tors and the brake cylinder.

Fig. 3 Connection overview centre frame

008 915 77 BOMAG 257

8.8 Hydraulic lines

8.8 Hydraulic lines

258 BOMAG 008 915 77

Hydraulic lines 8.8

008 915 77 BOMAG 259

8.8 Hydraulic lines

260 BOMAG 008 915 77

Hydraulic lines 8.8

008 915 77 BOMAG 261

8.8 Hydraulic lines

262 BOMAG 008 915 77

Hydraulic lines 8.8

008 915 77 BOMAG 263

8.8 Hydraulic lines

i Note
The brake is located in the rear tarverse on the right hand side.

264 BOMAG 008 915 77

 9 Engine

008 915 77 BOMAG 265

Simple servicing due to excellent accessibility .....

Fig. 4

266 BOMAG 008 915 77

Checking, adjusting the valve clearance 9.1
9.1 Checking, adjusting the valve Valve clearance for intake and exhaust valve:
0.145 - 0.185 mm
clearance

!Caution
We recommend to have this work carried out by
trained personnel or our after sales service.
Check and adjust only when the engine is cold.
Cylinder 1 is on the flywheel side.
l Disassemble cylinder head cover and glow plug.

Fig. 7

Crankshaft position 2
IN = Intake valve
EX = Exhaust valve
l Turn the crankshaft one revolution (360 °) further.
l Perform the adjustment of the valve by following the
adjustment diagram 2"(Fig. 7), black mark.
l Assemble the cylinder head cover with a new gas-
Fig. 5
ket.
Crankshaft position 1
IN = Intake valve i Note
EX = Exhaust valve After a short test run check the engine for leaks.
l
Crank the engine until both valves on cylinder 1 are
“overlapping”.
l
Perform the adjustment of the valve by following the
adjustment diagram 1"(Fig. 5), black mark.

Fig. 6
l Check the gap between rocker arm and valve with
a feeler gauge (Fig. 6).

008 915 77 BOMAG 267

9.1 Checking, adjusting the valve clearance

268 BOMAG 008 915 77

 10 Repair overview for drum

008 915 77 BOMAG 269

10.1
Fig. 1
1 Travel motor
2 Middle frame
3 Drum
4 Cover/flange
5 Cylinder roller bearing
6 Vibration motor
270
Repair overview for drum
7 Vibrator shaft
8 Gear exciter shaft
9 Drive shaft
10 Cylinder roller bearing
11 Gear drive shaft
12 Pinion travel motor
BOMAG 008 915 77
 11 Travel system

008 915 77 BOMAG 271

11.1 Special tools

11.1 Special tools

1. Pressing mandrel

Fig. 1
2. Puller

BOMAG part-no.: 720 028 04

Fig. 2

272 BOMAG 008 915 77

Repairing the travel system 11.2
11.2 Repairing the travel system

Environment
Catch running out oil and dispose of environ-
mentally.

! Danger
Danger of injury!
Do not step under suspended loads.
1. Enter input code 500 (see chapter 7) and drive
the machine, until the brake engages.

Dismantling
2. Lift the machine up and support it safely.
3. Unscrew the fastening screws and remove the
drums on both sides.

Fig. 1
4. Unscrew fastening screw 1 (Fig. 2) and replace it
with a grub screw.

Fig. 2
5. Remove backing ring 1 (Fig. 3) and seal (2).

Fig. 3

008 915 77 BOMAG 273

11.2 Repairing the travel system

6. Attach a puller (Fig. 4) and extract the hub.

i Note
At the rear always remove the left hand hub,
when viewed in travel direction.
At the front always remove the right hand hub,
when viewed in travel direction.

Fig. 4

i Note
Disassemble drum and cover on the opposite
machine side as described under 1. - 6.
7. Unscrew the fastening screw 1 (Fig. 5) from the
cover.
8. Turn the fastening screws into the bores (2) and
force off the cover.

Fig. 5
9. Check the Nilos ring 1 (Fig. 6) for damage, re-
place if necessary.

Fig. 6
10. Pull out the drive shaft 1 (Fig. 7).

Fig. 7

274 BOMAG 008 915 77

Repairing the travel system 11.2
11. Loosen the hydraulic hoses and disassemble the
travel motor 1 (Fig. 8).

Fig. 8
12. Remove circlip 1 (Fig. 9).
13. Pull the bearing (2) out of the cover.
14. Take out the Nilos ring (3).

Fig. 9
15. Remove circlip 3 (Fig. 10) dfrom the drive shaft.
16. Pull off the gear (4) and remove the feather key
(2) from the keyway.

Fig. 10

008 915 77 BOMAG 275

11.2 Repairing the travel system

Assembly
1. Assemble pinion 1 (Fig. 1) with copper paste to
the travel motor.
2. Turn in the threaded socket.

Fig. 1
3. Install the travel motor 1 (Fig. 2) and connect the
hydraulic hoses.

Fig. 2
4. Place the Nilos ring 1 (Fig. 3) into the cover.
5. Knock in the bearing (2).
6. Assemble circlip (3).

Fig. 3
7. Fill the bearing with grease (Fig. 4).

Fig. 4

276 BOMAG 008 915 77

Repairing the travel system 11.2
8. Pull the bearing shell 1 (Fig. 5) over the hub (2).

Fig. 5
9. Fill the radial seal with grease (Fig. 6).

Fig. 6
10. Place the radial seal 1 (Fig. 7) into the cover.

Fig. 7
11. Assemble hub 1 (Fig. 8).

! Caution
Clean the hub thoroughly.
The inner ring must be free of grease!

Fig. 8

008 915 77 BOMAG 277

11.2 Repairing the travel system

12. Assemble the circlip 3 (Fig. 9) to the shaft (2).

13. Insert the feather key (1) into the keyway and
slide the gear (4) over the shaft.

Fig. 9
14. Insert the drive shaft into the hub.
15. Apply some grease to the gear (Fig. 10).

Fig. 10
16. Turn in fastening screw 3 (Fig. 11) with washer
(1) and spring washer (2).

Fig. 11
17. Clean the sealing face and apply a coat of OMNI-
FIT FD10 (P/N 009 700 16) and assemble the
new O-ring.
18. Assemble cover and drive shaft and insert a new
sealing ring (Fig. 12).

Fig. 12

278 BOMAG 008 915 77

Repairing the travel system 11.2
19. Turn in the fastening screw 1 (Fig. 13) and tight-
en with 900 Nm.
20. Reassemble the drums.

Fig. 13
21. Assemble the backing ring 1 (Fig. 14) with a new
seal (2).

Fig. 14

008 915 77 BOMAG 279

11.2 Repairing the travel system

280 BOMAG 008 915 77

 12 Exciter unit

008 915 77 BOMAG 281

12.1 Special tools

12.1 Special tools

1. Pressing mandrel

Fig. 1
2. Puller

BOMAG part-no.: 720 028 04

Fig. 2

282 BOMAG 008 915 77

Repairing the exciter unit. 12.2
12.2 Repairing the exciter unit.

Environment
Catch running out oil and dispose of environ-
mentally.

! Danger
Danger of injury!
Do not step under suspended loads.
1. Enter input code 500 (see chapter 7) and drive
the machine, until the brake engages.

Dismantling
2. Lift the machine up and support it safely.
3. Unscrew the fastening screws and remove the
drums on both sides.

Fig. 1
4. Unscrew fastening screw 1 (Fig. 2) and replace it
with a grub screw.

Fig. 2
5. Remove backing ring 1 (Fig. 3) and seal (2).

Fig. 3

008 915 77 BOMAG 283

12.2 Repairing the exciter unit.

6. Attach a puller (Fig. 4) and extract the hub.

i Note
At the rear always remove the left hand hub,
when viewed in travel direction.
At the front always remove the right hand hub,
when viewed in travel direction.

Fig. 4

i Note
Disassemble drum and cover on the opposite
machine side as described under 1. - 6.
7. Unscrew the fastening screw 1 (Fig. 5) from the
cover.
8. Turn the fastening screws into the bores (2) and
force off the cover.

Fig. 5
9. Check the Nilos ring 1 (Fig. 6) for damage, re-
place if necessary.

Fig. 6
10. Pull out the drive shaft 1 (Fig. 7).

Fig. 7

284 BOMAG 008 915 77

Repairing the exciter unit. 12.2
11. Loosen the hydraulic hoses and disassemble the
vibration motor 1 (Fig. 8).

Fig. 8
12. Unscrew the locking cap 1 (Fig. 9) from the centre
frame.

Fig. 9
13. Unscrew the fastening screws 1 (Fig. 10) from the
cover.
14. Turn the fastening screws into the bores (2) and
force off the cover.
15. Also disassemble the cover from the opposite
side.

Fig. 10
16. Pull the exciter shafts out of the housing.

Fig. 11

008 915 77 BOMAG 285

12.2 Repairing the exciter unit.

17. Remove circlip 2 (Fig. 12) and knock the bearing

(1) out of the housing.

Fig. 12
18. Pull the bearing 1 (Fig. 13) out of the flange.

Fig. 13

286 BOMAG 008 915 77

Repairing the exciter unit. 12.2
Assembly
1. Press the bearing (Fig. 1) into the centre frame.

Fig. 1
2. Assemble the circlip 1 (Fig. 2).

i Note
Repeat steps 1. - 2. on the opposite side of the
centre frame.

Fig. 2
3. Assemble gear 3 (Fig. 3) with feather key (2) to
the exciter shaft.
4. Pull the bearing shell (1) over the shaft end.

Fig. 3
5. Fasten coupling 1 (Fig. 4) with fastening screws
(2) to the exciter shaft on the motor side.

Fig. 4

008 915 77 BOMAG 287

12.2 Repairing the exciter unit.

6. Align the exciter shafts in such a way (Fig. 5), that

the eccentrics are hanging down.
7. Mark the position of the gears.

Fig. 5
8. Insert the exciter shaft without coupling.

Fig. 6
9. Fill 1.7 l of engine oil into the exciter housing.

Fig. 7

! Danger
Danger of squashing!
10. Guide the exciter shaft 1 (Fig. 8) on the motor
side into the exciter housing using a suitable tube
(2).

Fig. 8

288 BOMAG 008 915 77

Repairing the exciter unit. 12.2
11. Check the correct positioning of the gears.

Fig. 9
12. Press bearing 1 (Fig. 10) into the flange.
13. Assemble the new O-ring (2).
14. Clean the sealing face (3) and apply a coat of
OMNIFIT FD10 (P/N 009 700 16).

Fig. 10
15. Assemble the flange and tighten the fastening
screws 1 (Fig. 11).

i Note
repeat steps 12. - 16. with the second flange.

Fig. 11
16. Knock the locking cap 1 (Fig. 12) into the housing.

Fig. 12

008 915 77 BOMAG 289

12.2 Repairing the exciter unit.

17. Insert the circlip 2 (Fig. 13) into the curved tooth
coupling.

Fig. 13
18. Plug the curved tooth coupling (Fig. 14) on the vi-
bration motor.
19. Assemble the new O-ring.
20. Clean the sealing face and apply a coat of OMNI-
FIT FD10 (P/N 009 700 16).

Fig. 14
21. Install the vibration motor 1 (Fig. 15).

! Caution
The coupling should engage!
22. Connect the hydraulic hoses.

Fig. 15
23. Clean the sealing face and apply a coat of OMNI-
FIT FD10 (P/N 009 700 16) and assemble the
new O-ring.
24. Assemble cover and drive shaft and insert a new
sealing ring (Fig. 16).

Fig. 16

290 BOMAG 008 915 77

Repairing the exciter unit. 12.2
25. Turn in the fastening screw 1 (Fig. 17) and tight-
en with 900 Nm.
26. Reassemble the drums.

Fig. 17
27. Assemble the backing ring 1 (Fig. 18) with a new
seal (2).

Fig. 18

008 915 77 BOMAG 291

12.2 Repairing the exciter unit.

292 BOMAG 008 915 77

 13 Suppliers documentation

008 915 77 BOMAG 293

294 BOMAG 008 915 77
 13.1 Travel motor

008 915 77 BOMAG 295

13.1 Travel motor

296 BOMAG 008 915 77

Travel motor 13.1

® No. 7-124
Char-Lynn July, 1999

Hydraulic Motor

Repair Information

2000 Series
Disc Valve Geroler Motor 006

008 915 77 BOMAG 297

 13.1 Travel motor

2000 Series Disc Valve Motors

Valve
Plate
Seal

Splined Geroler
Drive
Shaft
Face Seal Seal
Wear
Bearing and Plate
Shaft
Shaft
Seal
Assembly
Key
Bearing Back-up
Housing Washer Valve
Drive O-ring/
Seal Plug S/A
Valve
Exclusion Housing Tie
Dash Pot
Seal Spring Bolt
Outer Spring
Face Seal
Poppet
Balance
Seal Piston
Ring
Valve Poppet
Spring
Dash Pot
O-ring/ O-ring/
Pin
Plug S/A Plug S/A
Inner
Face Seal Shuttle Vave Option

Tools required for disassembly and reassembly.

Torque wrench 57Nm [500 lb-in] capacity

300-450 [12-16]* breaker bar
9/16 socket
Small screwdriver 150-200 x 6,5 [6-8 x 1/4] blade
3/16 Allen wrench
Press
* Unless indicated otherwise, measurements
are given in mm [inches]
** Shaft seal installation tool (600496)
** Bullet (600465) for 1 diameter shafts
The following tools are not necessary for disassembly and reassem-
bly, but are extremely helpful.
Alignment studs (2)

Alignment studs (2)

200,0 [8.00]

Approx. 13,0 [.50] 25,0 [1.00]

9,5 [.375] Dia. Steel Rod

8,0 [.312]
3/8-24 UNF thread
Grind flat spots on each side

298 BOMAG 008 915 77

 Travel motor 13.1

2000 Series Disc Valve Motors

Disassembly

Cleanliness is extremely important when repairing a hydraulic motor. 2 Remove 4 bolts from motor.
Work in a clean area. Before disconnecting the lines, clean the port
area of the motor thoroughly. Use a wire brush to remove foreign
material and debris from around the exterior joints of the motor.
Check the shaft and key slot, remove all nicks, burrs or sharp edges
that might damage the bearing housing seals when installing the shaft
and bearing assembly. Before starting the disassembly procedures,
drain the oil from inside the motor.

Figure 3

3 Lift valve housing straight up. If done carefully the pins, springs,
balance ring assembly, and valve will remain on the valve plate.

Figure 1

1 Place the motor in a vise with the output shaft down. Clamp
across the mounting flange of the motor not the housing. Excessive
clamping pressure will cause distortion. When clamping, use some
protective device on the vise, such as special soft jaws, pieces of hard
rubber or board.
Although not all drawings show the motor in a vise, we recommend Seal Seal Case Drain Plug
that you keep the motor in the vise during disassembly and reas-
sembly. Follow the clamping procedures explained throughout the Figure 4
manual.

4 Carefully remove 76,0 [3.00] diameter seal from valve housing.

5 Remove case drain plug—with seal, from valve housing.
6 Remove 2 pins and 2 springs from balance ring assembly, see
Figure 5.

Tie Bolts

Figure 2

008 915 77 BOMAG 299

 13.1 Travel motor

2000 Series Disc Valve Motors

Disassembly

15 Remove the 76,0 [3.00] diameter seal from wear plate,

Outer Face Seal
see Figure 7.

Bearing Seal Wear

Housing Plate

Pin (2) and

Spring (2)
Inner
Face Seal
Shaft Face Seal
Valve Balance Ring

Figure 5 Figure 8

7 Remove balance ring assembly. 16 Remove the wear plate.

8 Remove inner and outer face seals from balance ring. 17 Remove the shaft face seal from the wear plate.
9 Remove the valve. 18 Remove the 76,0 [3.00] diameter seal from bearing housing.

Valve Drive Bearing

Housing

Shaft and
Bearing
Assembly
Seal Valve Plate

Figure 9
Figure 6

19 You may need a press to remove shaft and bearing assembly from
bearing housing. (Key must be removed before removing shaft.)
10 Remove the valve plate.
11 Remove the 76,0 [3.00] diameter seal from valve plate.
12 Remove the valve drive. Bearing Housing Shaft Seal

Exclusion
Seal
Seal

Back-up Washer

Seal Geroler
Figure 10

Figure 7 20 Use a small screwdriver to remove shaft seal, back-up washer and
exclusion seal from bearing housing, see Figure 10. Do not damage
13 Remove the Geroler. Be sure to retain the rollers in the outer ring bore of housing.
if they are loose. Note: Individual parts of shaft and bearing assembly are not sold
14 Remove the drive. separately. Replace as a unit.

300 BOMAG 008 915 77

Travel motor 13.1

2000 Series Disc Valve Motors

Reassembly
Check all mating surfaces. Replace any parts that have scratches or
burrs that could cause leakage. Clean all metal parts in clean solvent.
Blow dry with air. Do not wipe dry with cloth or paper towel because
lint or other matter can get in the hydraulic system and cause damage.
Do not use a coarse grit or try to file or grind these parts. Check
around the keyway and chamfered area of the shaft for burrs, nicks or
sharp edges that can damage the seals when reassembling the bearing
housing.
Note: Lubricate all seals (prior to installation) with petroleum jelly such
as Vaseline. Use new seals when reassembling this motor. Refer to
parts list (6-129) for proper seal kit number.
21 Use a press to install exclusion seal in outer bore of bearing
housing. Lip of seal must face outward. See Figure 11. If a press is
not available use a plastic or rubber hammer, being careful not to
damage or cock seal in the bore.
Shaft Face
Shaft Seal Shaft Face
Seal
26 Alignment studs can be very helpful in reassembly of the motor.
See special tool listing page 2. If you use studs, install 2 studs
diagonally opposed in the bearing housing.
27 Install the shaft face seal in the wear plate as shown in Figure 11.
Do not distort seal.
28 Install the wear plate, see Figure 11.
29 Apply a light film of petroleum jelly to the 76,0 [3.00] diameter seal
and install seal in the wear plate.
30 Install the drive into the output shaft.
31 Align the notch on the outside of the Geroler with the notch on the
wear plate. Install the Geroler against the wear plate. Be sure to retain
the rollers in the outer ring if they are loose.
32 Install the valve drive in the Geroler.
Note: Installation at this time involves 3 steps in the timing of the
motor. Timing determines the direction of rotation of the output shaft.
Timing parts include:
1. Geroler
2. Valve Drive
3. Valve Plate
4. Valve

Wear Plate

Back-up
Washer

Exclusion Seal
Seal
Geroler Valve Plate Valve
Valve
Shaft and Drive Drive Rotate
Bearing Valve
Assembly Clockwise
1/2 tooth max.
to Engage Spline

Figure 11
Anyone of
22 Place back-up washer into seal bore. Place shaft seal onto Largest Alignment 6 Ports Open
installation tool (600496) and press seal into seal bore of the Open Pocket Ref. Only to Ouside of Vave
housing.
23 Clamp housing in vise, see Figure 1. Figure 12 Timing Alignment
24 Place protective bullet (see note below) over shaft. Apply
petroleum jelly to inside diameter of dust and shaft seal. You may
need a press to install shaft and bearing assembly. Do not distort
Timing Step # 1 — Locate the largest open pocket in the Geroler and
shaft seal. Damage to this seal will cause leakage.
mark it on the outside edge of the Geroler.
Note: Bullet (600465), for 1inch dia. shafts, available— by special
33 Apply a light film of petroleum jelly to the 76,0 [3.00] diameter
order. Use tape over other shafts to prevent cutting the seals.
seal. Install seal in groove of valve plate.
25 Apply petroleum jelly to the 76,0 [3.00] diameter seal. Install
seal into the bearing housing.

008 915 77 BOMAG 301

 13.1 Travel motor

2000 Series Disc Valve Motors

Reassembly
34 Align the notch on the outside of the valve plate with the notch on
the Geroler as shown in Figure 12.
Important: Install face seals in the positions shown in Figure 15, or the
Timing Step # 2 — Locate the slot opening in the valve plate which is motor will not operate properly. Do not force or bend the face seals.
in line with the largest open pocket of the Geroler. Any damage to these seals will affect the operation of the motor.
Timing Step # 3 — Locate any one of the side openings of the valve
and align this opening with the open slot of the valve plate that is in Outer Seal Inner Seal Pin Notch
line with the largest open pocket of the Geroler. Install the valve by
rotating it clockwise until the spine teeth engage (1/2 spine tooth
max.). This will provide the proper rotation when pressurized as
shown in Figure 13.

Balance Ring
Figure 15

38 Align pin notches in balance ring with pins in bore of valve housing.
Install balance ring assembly in valve housing.

Clockwise
Rotation

Balance
Counter Ring
Clockwise
Rotation

Figure 13 Valve
Housing

Figure 16

Spring and Pin

Alignment
Valve
Studs
Seal Housing

Figure 14 Valve
Plate

35 Install 2 springs and 2 pins in the holes located in the bore of the
valve housing, as shown in Figure 14.
36 Apply a light film of petroleum jelly to the 76,0 [3.00] diameter
seal. Install seal in the valve housing.
37 Apply petroleum jelly to inner and outer face seals. Install seals
on balance ring as shown in Figure 15.
Figure 17
39 Insert your finger through port of valve housing. Apply pressure
to side of balance ring as shown in Figure 16. Hold ring in position
until valve housing is in place against valve plate (see Figure 17).
Note: After installing the valve housing on the valve plate check for
proper placement. Push down on the valve housing. You should
get a slight spring action.

302 BOMAG 008 915 77

Travel motor 13.1

2000 Series Disc Valve Motors

Reassembly

40 Install tie bolts. If you use alignment Studs, install 2 bolts opposite
the studs. Finger tighten the bolts. Remove the alignment studs and Tie Bolts
replace with the two remaining bolts. Torque all four bolts alternately
to 50 Nm [450 lb-in].
41 Install seal on case drain plug then install in valve housing. Torque Case Drain Plug with Seal
to 6 Nm [50 lb-in.]
Figure 18

Wheel Motor Shaft and Bearing

Assembly
Shaft Seal

Bearing Housing

Shaft Face Seal

Castle Nut

Back-up Washer
Seal

Exclusion Seal
Figure 19

On wheel motors, a different bearing housing is used, see Figure 19.

Other than this the parts are the same as the standard motor and the
same disassembly and reassembly procedures apply.

Housing with Seal Guard Groove

Exclusion Seal

Seal Guard

Wheel Motor
with Seal Guard 4,40[.177]
Installation of Seal Guard:
After completing assembly of the shaft and bearing assembly into the
bearing housing, press the seal guard onto the shaft with a tool that
will provide an even push over the seal. This tool must bottom out
against the bearing housing and provide a 4,5 mm [.177 inch] stop for
the seal guard.

008 915 77 BOMAG 303

13.1 Travel motor

304 BOMAG 008 915 77

 Travel motor 13.1

2000 Series Disc Valve Motors

Reassembly —
Speed Sensor

1 Rotate the motor shaft until a (gear/target)

tooth is centered in the speed sensor port. If
this is not done, the sensor may be damaged
during the operation of the motor.

2 Make sure the lock nut and its threads are

clean and dry for the proper torque. Position
the lock nut against the alignment nut as
shown in Figure 22.

3 Move the washer and the o-ring up against

Speed Sensor Installation
the speed sensor body threads as shown in
Figure 22. Speed Sensor Body
4 By hand, lightly thread the speed sensor Alignment Nut
body into the housing until the sensor
Lock Nut
touches against the motor (gear/target) tooth.
Do not force the sensor against the (gear/
target) tooth, damage may occur. Make sure Washer
the o-ring or the washer do not touch the
housing — see Figure 23. O-ring
5 Turn the speed sensor body out one quarter Speed Sensor Port
Figure 22 Figure 23
turn (CCW) plus the additional amount (CCW)
needed to make the alignment notches
perpendicular to the motor shaft centerline
(90° +/-5 degrees from the motor shaft
centerline — Figure 24 and 25). Housing

6 Maintain the speed sensor body alignment

(Figure 25), and tighten the lock nut to 8,5-14
Nm [75-125 lb-in.] (torque values are for
clean dry threads). Gear/Target
Tooth
7 Check the speed sensor body for correct
alignment (Figure 25), reinstall the sensor if it
is not correct.
Alignment Notch

Alignment Notchs
haft
Perpendicular to
l w ith otor S
Centerline of Motor lle fM
Alignment Notch Para erline o
en t
C
Alignment Nut
Figure 24 Figure 25 9/16 inch
90° Hex Head

Back out
Lock Nut
11/16 inch
Hex Head Alignment Notch

008 915 77 BOMAG 305

 13.1 Travel motor

2000 Series Disc Valve Motors

Product Identification

For Additional Literature Contact Eaton Corp. Hydraulics Char-Lynn ® Date Code
Division 15151 Highway 5 Eden Prairie, MN 55344. Product number 00 00
Specifications and performance data, Catalog No. 11-878
Week of Last
Replacement part numbers and kit information — Parts Eaton Corp. Hydraulics Div. Year 01 Number(s)
Eden Prairie, MN 55344
Information No. 6-129 Thru 52 of Year
Product Number
How to Order Replacement Parts 000 0000 000

Each Order Must Include the Following: Product Line Product Engineering
1. Product Number 4. Part Number Identification Identification Change
2. Date Code 5. Quantity of Parts Number Number Code
3. Part Name

Product Numbers—2000 Series Use digit prefix —104-, 105-, or 106- plus four digit number from charts 104-1007
for complete product number—Example 106-1039.
Displacement cm3/r [ in3/r ] and Product Number
80 100 130 160 195 245 305 395 490
Mounting Shaft Ports [ 4.9] [ 6.2] [ 8.0] [ 9.6] [11.9] [14.9] [18.7] [24.0] [29.8]
7/8-14 O-ring Staggered 104-1001 -1002 -1003 -1004 -1005 -1006 -1007 -1143 —
1 inch Straight
1-1/16—12 O-ring 180° Apart 104-1037 -1038 -1039 -1040 -1041 -1042 -1043 -1044 —
2 Bolt 7/8-14 O-ring Staggered 104-1022 -1023 -1024 -1025 -1026 -1027 -1028 -1228 -1420
SAE A 1-1/4 Inch Straight
Flange 1-1/16—12 O-ring 180° Apart 104-1061 -1062 -1063 -1064 -1065 -1066 -1067 -1068 -1421
1-1/4 Inch 7/8-14 O-ring Staggered 104-1029 -1030 -1031 -1032 -1033 -1034 -1035 -1229 -1422
14 T Splined 1-1/16—12 O-ring 180° Apart 104-1087 -1088 -1089 -1090 -1091 -1092 -1093 -1094 -1423
1-1/4 Inch Straight 7/8-14 O-ring Staggered 104-1200 -1201 -1202 -1203 -1204 -1205 -1206 -1207 —
2 Bolt
SAE B 1-1/4 In. Involute SAE C Splined 7/8-14 O-ring Staggered 104-1208 -1209 -1210 -1211 -1212 -1213 -1214 -1215 —
Flange 1 Inch SAE 6B Splined 7/8-14 O-ring Staggered 104-1193 -1194 -1195 -1196 -1197 -1198 -1199 — —
7/8 Inch SAE B Splined 7/8-14 O-ring Staggered 104-1216 -1217 -1218 -1219 -1220 — — — —
Standard 32 mm Straight G 1/2 (BSP) 104-1384 -1385 -1386 -1387 -1388 -1389 -1390 -1391 —
with 4 Bolt
Square 1-1/4 Inch
Flange G 1/2 (BSP) 104-1376 -1377 -1378 -1379 -1380 -1381 -1382 -1383 —
14 T Splined
7/8-14 O-ring Staggered 105- — — — — — — — — -1148
1-1/4 Inch Straight
1-1/16—12 O-ring 180° Apart 105- — — — — — — — — -1149
32 mm Straight G 1/2 (BSP) 105-1134 -1135 -1136 -1137 -1138 -1139 -1140 -1141 —
Wheel
Motor 1-1/4 Inch 7/8-14 O-ring Staggered 105-1001 -1002 -1003 -1004 -1005 -1006 -1007 -1060 -1152
Tapered
1-1/16—12 O-ring 180° Apart 105-1071 -1072 -1073 -1074 -1075 -1076 -1077 -1078 —
1-1/4 Inch 7/8-14 O-ring Staggered 105-1029 -1030 -1031 -1032 -1033 -1034 -1035 -1096 —
14 T Splined 1-1/16—12 O-ring 180° Apart 105-1079 -1080 -1081 -1082 -1083 -1084 -1085 -1086 —
7/8-14 O-ring Staggered 106-1008 -1009 -1010 -1011 -1012 -1013 -1014 -1015 -1047
Bearingless
G 1/2 (BSP) 106-1038 -1039 -1040 -1041 -1042 -1043 -1044 -1045 —

10

306 BOMAG 008 915 77

Travel motor 13.1

2000 Series Disc Valve Motors

Notes:

11

008 915 77 BOMAG 307

 13.1
2000 Series Disc Valve Motors
Eaton Corporation
Hydraulics Division
15151 Hwy. 5
Eden Prairie, MN 55344
Telephone: 612/937-7254
Fax: 612/937-7130
Sumitomo Eaton
Hydraulic Company Ltd.
Ooi-Cho Kameoka-Shi
621-0017 Kyoto
Japan
Telephone: [+81] 771-22-9601
Fax: [+81] 771-29-2020
www.eatonhydraulics.com
Form No. 7-124
308
Eaton Ltd.
Hydraulics Division
Glenrothes, Fife
Scotland, KY7 4NW
Telephone: [+44] (0)1592-771-771
Fax: [+44] (0)1592-773-184
Eaton Ltd.
7th Floor, Woo Duk Building
832-2 Yeoksam-Dong, Kangnam-Ku
Soeul 135-750
Korea
Telephone: [+82] 2-557-0595
Fax: [+82] 2-557-1634
Copyright Eaton Corporation, 1985, 1988, 1994, 1996, 1997 and 1999
All Rights Reserved
Printed in USA
Eaton B.V.
Boeing Avenue 11
1119 PC Schiphol-Rijk
The Netherlands
Telephone: [+31] (0)20-655 6776
Fax: [+31] (0)20-655 6800
Eaton Hydraulics (Shanghai) Co. Ltd.
388 Aidu Road, Waigaogiao FTZ
Pudong New Area
Shanghai 200137
Peoples Republic of China
Telephone: [+86] 21-5046 0758
Fax: [+86] 21-5046 0767
BOMAG
Travel motor
Sumitomo Eaton Hydraulic Co.
8 Temasek Blvd.
42-01 Suntec Tower Three
Singapore 03988
Telephone: [+65] 832-7727 ACCREDITED BY
THE DUTCH COUNCIL
Fax: [+65] 832-7733 FOR CERTIFICATION
Reg. No. 24
ISO-9001 CERTIFICATED FIRM
Jining Eaton Hydraulic Co. Ltd. DET NORSKE VERITAS INDUSTRY BV, THE NETHERLANDS
6 Ji Da Road
Qualitiy System Certified
Jining City Products in this catalog are manufactured
Shandong Province 272131 in an ISO-9001-certified site.
Peoples Republic of China
Telephone: [+86] 537-2221288
Fax: [+86] 537-2221557
008 915 77
 14 Circuit diagrams

008 915 77 BOMAG 309

310 BOMAG 008 915 77
 14.1 Hydraulic diagram 21

008 915 77 BOMAG 311

14.1 Hydraulic diagram 21

312 BOMAG 008 915 77

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008 915 77
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14.1 Hydraulic diagram 21

318 BOMAG 008 915 77

 14.2 Wiring diagram 724 002 09

008 915 77 BOMAG 319

14.2 Wiring diagram 724 002 09

S/N Wiring diagram 724 00 209

S/N 101 720 111 001 ⇔ 101 720 111 009

320 BOMAG 008 915 77

Inhaltsverzeichnis: BMP 8500 Feldtest

008 915 77
table of contents: BMP 8500 field test
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing  no.
001 724 002 09 Stromlaufplan Circuit Diagram
002 724 002 09 Stromlaufplan circuit diagram
003 724 002 09 Stromlaufplan circuit diagram
004 724 002 09 Stromlaufplan circuit diagram
005 724 002 09 Stromlaufplan circuit diagram
Wiring diagram 724 002 09

101 724 002 09 Bauteilliste component listing

201 724 002 09 Zentralelektrik EBox

BOMAG
25.9.2008
001 001
Nallin Stromlaufplan 724 002 09
25.9.2008
14.2

321
circuit diagram 001
Rau 2002
 322
30S
3:14
15 3:1

B
F X8:5 X8:1
14.2

1 10A F103 F67 X10:8

W 15GPS 5:15
2:11 V05 25A 6
X9:9 2
2
1 X6:A X7:A B56
30
K11
X9:6 R09

X9:11
82 Ohm 2:10
X8:6 X8:2

BR/BN
BR/BN
X12:3 2 87 87a

X9:1
signal pot 15

cable activation
2:4

radio activation

X12:2
W L

Signal Pot 15
B41 BL/BU B189
IG BL/BU B53 B06

3:14
3:1
3:1
LGPS

3:7
3:3
aux
3:14
3:14
2:2
5:14

SW/BK
SW/BK
B X6:C X6:B X7:C X7:B

3:14
B+ t P
M
M

G01 X10:11 X10:7 X9:11 X9:10

BSL
W

CAN 
CAN +
Funk Aktivierung
Kabel Aktivierung
RS 232 Rx
RS 232 Tx

RS 232 gnd
X9:4 X9:2

X9:3
31 31
slope sensor

X3:2 X3:32 30 31 39 37 4 X3:20 29 16 17 41 X3:14 28 42 X3:27 X3:34 X3:23 X3:5 X3:3

Neigungsschalter

engine running: 12V

G01
Sicherheitsbügel hinten Sicherheitsbügel vorn Kühlmitteltemperatur
engine off: gndpotential
Motor läuft: 12V
Security bow rear Security bow rear collant temperature

2:2
Motor steht: Masse geschaltet
E A70 Modul Logik/Leistung Motoröldruck
A70 Modul, logic/power engine oil pressure
F05 30Laden

10A
5 3:3
+
XS
30 K 3:7
 12V
F54 4
5A
D

BOMAG
X3:1 15
X3:8

A C

X3:6
X3:9
X3:7
X3:36

X11:A F119
X3:24

X3:11

X3:10
X3:13
X3:19

X3:12
X3:21

X3:38
X3:22

X3:40

20A F14
50 5:4 5:5
1 3 25A 2:2 A115:5 A115:7
F00 1 30

2:2
K39

X9:5
80A 30 X9:12
2 2:8 30 K14
K97
X10:1

X10:3
X10:5
X10:6

X10:2
X10:4

Y13

G01
87 87a 2:9 2:7 A115:6 A115:8
2 2 1 5:4 5:6
+ X13:3 87 87a 87 87a X9:8
X10:9 X10:10
50 X9:7 HW 1 1 1 1 1 1 1 1
G01 X13:1 2 V01 1 AW
 2
3 30 50 2:11 2:8 2 2 2 2 2 2 2 2
Y16
Y17

M01 86 86 86 86
Y57
Y56
Y03
Y04

S30 R02
Y237
Y238

AW/HW
H07

aux
4  2 + Y46 K14 K39 K97 K11 V03

3x12A 10s
M V04
X:Massepunkt 2:5 1  2:2 M 85 85 85 85 X10:11 X10:12 X9:11
X11:B X13:4 31 3:1

2:5 2:3 2:4 2:6 Motorabschaltung Vibration klein Fahren links Bremse Fahren vorwärts Signalhorn
Batterie Starter Motordrehzahl engine shut off vibration low traveling lh. brake traveling forw. signal horn
battery starter engine rpm

Motorstart Umschaltung Pot 30/15 Vibration, groß 2. Gang Fahren rechts Fahren rückwärts
engine start switch pot.30/15 vibration, high 2nd speed range traveling rh traveling backw.
Glühen Motordrehzahl
glowing engine rpm

18.09.2008

008 915 77
Wiring diagram 724 002 09

Nallin Stromlaufplan 724 002 09

Rau
25.09.08 2002 circuit diagram 002
2:20 15 15 5:1

2:7 CAN + CAN + 5:1

008 915 77
2:6 CAN  CAN  5:1

2:6 BSL

2:10 RS 232 Rx

2:10 RS 232 Tx
30 K
2:3 RS 232 gnd
2:9
2 2:19 30S
Wiring diagram 724 002 09

S101 Antenne
W05 antenna
R1 Umschalter Kabel/Drahtlos
switch, cable / wireless 1 3

R2

(3) (8)
Can P18 Can+
Kabel Aktivierung Funk Aktivierung
2:8 2:7

nur ZA/NS Funk

only option radio
radio activation nicht belegt (IR)
30Laden

BOMAG
2:3
F1 F2

X22:7
X22:8
X22:6
X22:4
X22:2
X22:1
X22:3
X22:5
X23:4
X23:8
X23:6
X23:11
X23:12
X23:9
X23:10
X23:3
X23:5
X26:1
X24:2
X24:3
X24:4
X24:5
X24:8
X24:6
X24:7
X24:1

 +
Kabelsteuerung W02 Empfänger Funk Diagnose (6) (7)
cable control receiver Radio diagnostics
oder / or in ( ) Belegung
ZA / option Rundanzeige
X22:16

Spiralkabel
4:2
Spiral cable

2:20 31 31 5:1

Anzeigemodul
monitoring module

16.09.2008
Nallin Stromlaufplan 724 002 09
Rau
14.2

323
25.09.08 2002 circuit diagram 003
 324
Vibration man/auto
Vibration man/auto
Motordrehzahl Vibr. klein/0/groß Signal Horn
engine rpm Vibr. auto/0/auto signal horn
14.2

Lenkhebel (li.) 2. Gang NOTSTOP Fahrhebel v/r (r) Schlüsselschalter

steering lever 2nd speed range emergency off travel lever Key switch

W07
Fernsteuerung , Kabel/Funk
Gelbes Gehäuse
R0V Remote Control, Cable/Radio
R0V R0V Yellow Body
a0a 0 1 S131
0 0 01

S181
S55 S08 S42 S127 S01 S36 S75 S03

ignition on (K11)
Zündung ein (K11)
Engine start
Motorstart

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
H78 Warnsummer radio
warning buzzer A69 Elektronik CANBus
A69 elektronic CANbus G05

BOMAG
 +

gnd

Can 
Can 
Can +
Can +
supply

activation
Aktivierung
Versorgung
Akku laden
battery charging

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:Ax
Attention: charging of the battery is only possible
Spiralkabel
3:5 with connected spiral cable and
battery disconnect switch in position "on"
Spiral cable

16.09.2008

008 915 77
Wiring diagram 724 002 09

Nallin Stromlaufplan 724 002 09

Rau
25.09.08 2002 circuit diagram 004
 3:20 15
3:19 CAN +

3:19 CAN 

008 915 77
15GPS
2:10

gelb

weiß
X67:1
LGPS

X67:4
2:4
X115:1 3 4

grün
X67:3
1 3 4

antenna, front
antenna, back
Antenne hinten

X116:1
X117:1

X114:1
X115:9

Antenne vorne
X114:3
9 11

X115:11
Modul RFID A115 A92
A67
10 2 12
Wiring diagram 724 002 09

A116 A117 Tastatur

5 6 7 8
keyboard
at the moment zur Zeit in

braun

X114:2
X114:4
zur Zeit in Entwicklung

X115:10
X115:12

X116:2
X117:2
under way Entwicklung
at the moment under way

X67:2
Brücke/bridge Brücke/bridge

X115:5 6 X115:7 8

A115:5 A115:7
2:17 2:19
A115:6 A115:8 zur Zeit in
Entwicklung
2:17 2:19

BOMAG
at the moment
under way

3:20 31

ZA Diebstahlschutz
option burglary protection

16.09.2008
Nallin Stromlaufplan 724 002 09
25.09.08
14.2

325
2002 circuit diagram 005
Rau
 Name Bl. Pf. Benennung title TYP

14.2 A67
A69
A70
005
004
002
12
13
8
Eingabeeinheit
Elektronik CANBus
Modul Logik/Leistung
Keyboard
Electronic CANBus
Modul Logic/power
Wiring diagram 724 002 09
A92 005 15 GPS Receiver GPS receiver
A115 005 4 Modul Personenschutz RFID Modul, operator protection RFID
A116 005 1 RFID Antenne vorn RFID antenna front
A117 005 8 RFID Antenne hinten RFID antenna rear

B06 002 20 Druckschalter Motoroel Pressure switch, engine oil 12V 5W NC

B41 002 14 Naeherungsinitiator Sicherheitsbuegel hinten Proximity switch, security bow, back
B53 002 19 Temperaturgeber Kuehlmittel Temperature switch, collant NO
B56 002 18 Neigungsschalter Slope sensor
B189 002 16 Naeherungsinitiator Sicherheitsbuegel vorn Proximity switch , security bow, front
Rau
29.09.08
Nallin
29. 9. 8

F00 002 1 Hauptsicherung Batterie Fuse, main, battery 80A

F05 002 1 Sicherung Steckdose Fuse, socket 10A
F14 002 4 Sicherung Hubmagnet Motor Fuse, shut off solenoid, engine 25A
F54 002 3 Sicherung Kabelsteuerung Fuse, cable control 5A
F67 002 12 Sicherung Steuerung (Potential 30) Fuse, controller (pot.30) 25A
F103 002 6 Sicherung Potential 15 fuse, potential 15 10A
F119 002 3 Sicherung Motor Fuse, motor 20A

G01 002 1 Batterie Battery 12V/61Ah

G01 002 2 Batterie Battery
G05 004 18 Akku Recharchable Battery NiMH3,6V/1,2AhAkku

H07 002 20 Warnsummer Betriebsstoerung Warning buzzer, breakdown 4A

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 10 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHW

K14 002 7 Relais Vorgluehen Relay, glow plug system BOSCHW
K39 002 8 Relais Anlasser Relay, starter BOSCHW
K97 002 9 Lastrelais load relay BOSCHW

M01 002 2 Starter Starter Aw45A/HW10A

P18 003 18 Diagnose Diagnostics

R02 002 5 Gluehkerze Glow plug 3x12A 10s

R09 002 4 Vorwiderstand Dropping resistor 82 Ohm

S01 004 6 Schalter NOT AUS Switch, emergency off

component listing

S03 004 11 Taster Signalhorn Push button, warning horn

S08 004 4 Vibrationsschalter man./autom. Switch, vibration, man./autom.
Bauteilliste

S30 002 1 Batterietrennschalter Switch, battery disconnect

S36 004 7 Vibrationsschalter Switch, vibration
S42 004 4 Stufenumschalter schnelllangsam Speed range selector, fastslow
S55 004 2 Schalter Fahrhebel Switch, travel control lever
S75 004 9 Schalter Fahrhebel Switch, travel control lever
S101 003 7 Schalter Kabel/Fernsteuerung Switch cable/remote control
S127 004 5 Schalter Motordrehzahl Switch, engine rpm
S131 004 16 Schalter Start Switch, start
S181 004 15 Schalter Zündung switch ignition

V01 002 10 Diode Diode FE5B

V03 002 19 Diode Diode FE5B
V04 002 3 Diode Diode FE5B
V05 002 4 Diode Diode FE5B

W02 003 8 Empfaenger Funk Receiver Radio

W05 003 13 Antenne Antenna
W07 004 17 Fernsteuerung, Kabel/Funk Remote Control, Cable/Radio

X2:1 004 3 Spiralkabel Spiral cable

X2:2 004 2 Spiralkabel Spiral cable
X2:3 004 4 Spiralkabel Spiral cable
X2:4 004 1 Spiralkabel Spiral cable
X2:5 004 4 Spiralkabel Spiral cable
X2:6 004 6 Spiralkabel Spiral cable
X2:Ax 004 3 Spiralkabel Spiral cable
X3:1 002 6 Modul A70 Modul A70
X3:2 002 4 Modul A70 Modul A70
X3:3 002 20 Modul A70 Modul A70
X3:4 002 8 Modul A70 Modul A70
X3:5 002 19 Modul A70 Modul A70
X3:6 002 8 Modul A70 Modul A70
X3:7 002 10 Modul A70 Modul A70
X3:8 002 20 Modul A70 Modul A70
X3:9 002 9 Modul A70 Modul A70
X3:10 002 11 Modul A70 Modul A70
X3:11 002 14 Modul A70 Modul A70
1

X3:12 002 13 Modul A70 Modul A70

X3:13 002 12 Modul A70 Modul A70
X3:14 002 12 Modul A70 Modul A70
X3:15 002 6 Modul A70 Modul A70
X3:16 002 10 Modul A70 Modul A70
3

X3:17 002 10 Modul A70 Modul A70

X3:19 002 15 Modul A70 Modul A70
X3:20 002 9 Modul A70 Modul A70
X3:21 002 15 Modul A70 Modul A70
724 002 09

X3:22 002 17 Modul A70 Modul A70

X3:23 002 17 Modul A70 Modul A70
X3:24 002 19 Modul A70 Modul A70
X3:27 002 14 Modul A70 Modul A70
X3:28 002 12 Modul A70 Modul A70
101

X3:29 002 9 Modul A70 Modul A70

X3:30 002 6 Modul A70 Modul A70
326 X3:31 002 7 Modul A70 BOMAG
Modul A70 008 915 77
 Name Bl. Pf. Benennung title TYP
X3:32

X3:36
002
Wiring diagram 724 002 09
X3:34 002
002
6
16
20
Modul A70
Modul A70
Modul A70
Modul A70
Modul A70
Modul A70
14.2
X3:37 002 8 Modul A70 Modul A70
X3:38 002 7 Modul A70 Modul A70
X3:39 002 7 Modul A70 Modul A70
X3:40 002 16 Modul A70 Modul A70
X3:41 002 11 Modul A70 Modul A70
X3:42 002 12 Modul A70 Modul A70
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
Rau
29.09.08
Nallin
29. 9. 8

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X8:1 002 18 B56 B56
X8:2 002 18 B56 B56
X8:5 002 17 B56 B56
X8:6 002 17 B56 B56
X9:1 002 3 G01 G01
X9:2 002 20 Deutsch Deutsch
X9:3 002 8 Motorsignale engine signals
X9:4 002 19 Deutsch Deutsch
X9:5 002 11 Deutsch Deutsch
X9:6 002 2 Deutsch Deutsch
X9:7 002 4 Deutsch Deutsch
X9:8 002 20 Deutsch Deutsch
X9:9 002 5 Deutsch Deutsch
X9:10 002 16 Deutsch Deutsch
X9:11 002 1 Deutsch Deutsch
X9:11 002 15 Deutsch Deutsch
X9:11 002 20 Deutsch Deutsch
X9:12 002 11 Deutsch Deutsch
XS 002 1 Steckdose Socket
X10:1 002 14 Deutsch Deutsch
X10:2 002 13 Deutsch Deutsch
X10:3 002 12 Deutsch Deutsch
X10:4 002 15 Deutsch Deutsch
X10:5 002 15 Deutsch Deutsch
X10:6 002 16 Deutsch Deutsch
X10:7 002 14 Deutsch Deutsch
X10:8 002 14 Deutsch Deutsch
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X10:11 002 12 Deutsch Deutsch
Bauteilliste

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X11:A 002 1 MTA MTA
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X13:1 002 5 Starten starting unit
X13:2 002 5 Starten starting unit
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X13:4 002 4 Deutsch Deutsch
X22:1 003 4 Spiralkabel Spiral cable
X22:16 003 4 Spiralkabel Spiral cable
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X22:3 003 5 Spiralkabel Spiral cable
X22:4 003 3 Spiralkabel Spiral cable
X22:5 003 5 Spiralkabel Spiral cable
X22:6 003 3 Spiralkabel Spiral cable
X22:7 003 1 Spiralkabel Spiral cable
X22:8 003 2 Spiralkabel Spiral cable
X23:3 003 11 Empfänger Receiver
X23:4 003 8 Empfänger Receiver
X23:5 003 12 Empfänger Receiver
X23:6 003 9 Empfänger Receiver
X23:8 003 8 Empfänger Receiver
X23:9 003 10 Empfänger Receiver
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X23:11 003 9 Empfänger Receiver
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X24:1 003 17 Diagnose diagnostics
X24:2 003 14 Diagnose diagnostics
X24:3 003 14 Diagnose diagnostics
X24:4 003 15 Diagnose diagnostics
X24:5 003 15 Diagnose diagnostics
X24:6 003 16 Diagnose diagnostics
X24:7 003 17 Diagnose diagnostics
X24:8 003 16 Diagnose diagnostics
X26:1 003 13 Antenne Antenna
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X67:1 005 11 weiß white

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Y04 002 16 Magnetventil Bremse Solenoid valve, brake
Y13 002 11 Hubmagnet Motor Shut off solenoid, engine AW HW
Y16 002 17 Magnetventil Fahrtrichtung vorwaerts Solenoid valve, travel direction forw.
Y17 002 19 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw.
Y46 002 4 Magnetventil Regelstange Motor Solenoid valve, governor rod, engine m.60A 1s, 0.8A
Rau
29.09.08
Nallin
29. 9. 8

Y56 002 13 Vibration klein Vibration low

Y57 002 12 Vibration gross Vibration high
Y237 002 15 Magnetventil Fahrtrichtung links Solenoid valve, travel direction lh
Y238 002 15 Magnetventil Fahrtrichtung rechts Solenoid valve, travel direction rh
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