Service - Manual

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

Multi-purpose compactor

Catalogue number.
008 915 77 08/2012
 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
Overall view of machine 27
2.1 Overall view of machine 29
BOMAG Multi-purpose compactor 31
3.1 BOMAG Multi-purpose compactor 32
Technical data 37
4.1 Technical data 38
Maintenance 43
5.1 General notes on maintenance 44
5.2 Fuels and lubricants 45
5.3 Table of fuels and lubricants 47
5.4 Running-in instructions 48
5.5 Maintenance table 49
E-Plan wiring diagrams 51
6.1 Understanding wiring diagrams 52
6.2 Circuit symbols in the circuit diagram 61
6.3 Designation of components in the wiring diagram 64
6.4 Terminal designations in wiring diagram 65
Electrics 67
7.1 Battery ground and analog ground 68
7.2 Processor signals 68
7.3 Current and voltage 69
7.4 Resistance 71
7.5 Series / parallel connection 73
7.6 Ohm's law 75
7.7 Electrical energy 75
7.8 Formula diagram 76
7.9 Metrology 77
7.10 Diodes, relays, fuses 81
7.11 Inductive proximity switches 84
7.12 Plug connectors 85
7.13 Deutsch plug, series DT and DTM 86
7.14 Batteries 90
7.15 Battery service, checking the main battery switch 92
7.16 Main battery switch 93
7.17 Main battery fuse 94
7.18 External starting 94
7.19 Generator 95
7.20 Generator repair 101
7.21 Electric starter 105
7.22 Repair of starter 111
7.23 Glow plugs 115

008 915 77 BOMAG 3

Table of Contents

7.24 Engine governor rod positioning solenoid 117

7.25 Engine shut-down solenoid 119
7.26 Oil pressure and low oil pressure circuitry 122
7.27 Coolant temperature and power reduction 124
7.28 Wiring looms 126
7.29 BLM - Power/Logic Module 129
7.30 Checking the voltage supply for the control unit 131
7.31 Diagnostics concept 139
7.32 Control elements 142
7.33 Fault display, P17 143
7.34 Fuses 143
7.35 Entering the machine type code 144
7.36 Replacing, recharging the radio remote control power pack 144
7.37 BOSS safety system 147
7.38 "Marriage" of transponder and protection field control 149
7.39 BOSS Service Mode 149
7.40 Safety field measurement of the Boss safety system 150
7.41 Problems with radio remote control Hetronic in radio operation 151
7.42 Problems with remote control Hetronic with spiral cable 153
7.43 Faults in BOSS safety system 156
Electronic control 157
8.1 with safety bow 159
8.2 with safety field control 191
8.3 Programmable start inhibitor 227
8.4 Logic 233
Hydraulics 241
9.1 Hydraulic circuit 242
9.2 Overview 244
9.3 Multiple gear pump 248
9.4 Vibration motor 251
9.5 Travel motor 253
9.6 Control valve block 255
9.7 Hoses 258
9.8 Travel system 261
9.9 Vibration 264
9.10 Checking the hydraulic oil level 267
9.11 Change hydraulic oil and filter 267
Engine 269
10.1 Kubota diesel engine 271
10.2 Check the engine oil level 273
10.3 Changing engine oil and oil filter 273
10.4 Checking the coolant level 275
10.5 Change the coolant 275
10.6 Checking, tensioning, replacing the V-belt 277
10.7 Clean the cooling fins on engine and hydraulic oil cooler 278
10.8 Changing the fuel pre-cleaner, bleeding the fuel system 279
10.9 Check the water separator 280
10.10 Change the fuel lines 280

4 BOMAG 008 915 77

 Table of Contents

10.11 Check, clean, replace the combustion air filter 281

10.12 Check the air intake hose 283
10.13 Checking the engine oil pressure 284
10.14 Checking the thermostat in disassembled state 284
10.15 Check the injection valves 285
10.16 Checking the start of commencement 287
10.17 Checking the fuel injection pump 288
10.18 Checking the compression 289
10.19 Checking, adjusting the valve clearance 290
10.20 Engine problems 292
Repair overview for drum 295
11.1 Repair overview for drum 296
Travel system 297
12.1 Special tools 298
12.2 Repairing the travel system 299
12.3 Assembling/removing the drum extension 306
Exciter unit 307
13.1 Special tools 308
13.2 Repairing the exciter unit. 309
13.3 Change the oil in the vibrator shaft housing 318
Suppliers documentation 321
14.1 Travel motor 323
Circuit diagrams 337
15.1 Hydraulic diagram 21 339
15.2 Hydraulic diagram 22 347
15.3 Wiring diagram 724 002 19 355
15.4 Wiring diagram 724 002 29 375
15.5 Wiring diagram 73 395

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 Service information

Use only genuine BOMAG spare parts.

Spare parts needed for repairs can be taken from the
spare parts catalogue for the machine.
This manual is not subject of an updating service; for
this reason we would like to draw your attention to our
additional "Technical Service Bulletins".
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

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.
10 BOMAG
Safety regulations
Operation of high-voltage systems
i Note
The rules and statutory regulations valid in the corre-
sponding do apply in addition to the notes given here.
!Caution
The high-voltage system must only be operated
and serviced by qualified and authorized person-
nel.
Before starting operation the operator must check
the proper condition of the system.
!Danger
Possibility of injury or even death caused by elec-
tric shock:
l if persons come into contact with live parts,
l in case of faulty insulation of live parts,
l
inadequate, unsuitable insulation,
l
if melted parts flake off in case of short circuits.
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-
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.
008 915 77
Safety regulations
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.
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.
008 915 77 BOMAG
1.2
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.
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.
11
1.2
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/-
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.
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.
12 BOMAG
Safety regulations
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.
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.
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. 1
! 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. 2
l
Lubricate the sealing lips (2) (Fig. 2) 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. 2)), 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. 2)) 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. 3
l
Press or knock the seal into the housing, until it is
flush with the housing surface.

i Note
Fig. 4
If possible, use a "bell" (1 (Fig. 3)), 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. 6

!Caution
When assembling the ball or roller bearing to the
shaft load must only be applied to the inner race 1
(Fig. 6).
When fitting the bearing into the housing load
must only be applied to the outer race (2).

Fig. 5
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. 7 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. 9 Identification of nuts in clock system

Fig. 8 Identification of nuts
In a connection with a screw, these nuts 1 (Fig. 8)
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. 9) 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. 8) 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. 8), 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. 11
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. 10

Screws
The screw head is marked with a stamped in, round
cavity 3 (Fig. 10).

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 thread*

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
* Coefficient of friction μ tot. = 0,14

Tightening torques for screws with metric unified fine thread*

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
* 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 240* (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
* 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) * **

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
* Coefficient of friction μ tot. = 0,14
** 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, * 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
* Coefficient of friction μ tot. = 0,14

Tightening torques for screws with UNF thread, * 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, * 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
* Coefficient of friction μ tot. = 0,14

26 BOMAG 008 915 77

 2 Overall view of machine

008 915 77 BOMAG 27

Simple servicing due to excellent accessibility

Fig. 12

28 BOMAG 008 915 77

Overall view of machine 2.1
2.1 Overall view of machine

Fig. 13 Overview

008 915 77 BOMAG 29

2.1 Overall view of machine

1 Steering pump 11 Hydraulic oil tank

2 Travel pump 12 Air filter
3 Vibration pump 13 Single point lifting facility
4 Exhaust system 14 Air filter service indicator
5 Diesel engine 15 Fuel filter
6 Cooler 16 Coolant compensation tank
7 Fuel tank 17 Engine oil filter
8 Central electrics 18 Hydraulic oil filter
9 Battery 19 Articulated joint
10 Hydraulic control valve block 20 Steering cylinder

30 BOMAG 008 915 77

 3 BOMAG Multi-purpose compactor

008 915 77 BOMAG 31

3.1 BOMAG Multi-purpose compactor

Added value by multi-purpose.

3.1 BOMAG Multi-purpose compactor

Secure and clean working above all under confined conditions, on difficult soils and in tipping endan-
gered areas – no problem with the BOMAG Multi-Purpose Compactor BMP 8500. As it has been specially
designed for earth work, it is particularly suitable for the compaction of cohesive soils in trench con-
struction, for construction backfills, in sewer and pipeline construction, for railway and dam construc-
tion, on sanitary landfill sites as well as for sub-base and foundation work.

Fig. 14
l High reliability and versatility
l Excellent compaction and work power
l
Low running costs,
l
Simple service and easy maintenance
l
High operating comfort
l
High safety standards

Robust, environmentally friendly, always ready for use.

A BOMAG multi-purpose compactor is an extremely hard-wearing helper for most difficult applications.
Robustness and high reliability a essential prerequisites for these applications, which are fully and also
environmentally fulfilled by BOMAG.
The BMP 8500 is powered by a powerful but still noticeably quiet Kubota engine – a guarantor for high reliability
and low service and repair costs.
The all-around protection hood made of highly impact resistant composite material contributes to the robustness
and resistance of the machine, even when used for extreme applications. The main components are thereby
effectively protected. At the same time the hood can be locked to protect against vandalism.
The special ECO mode additionally protects the engine and ensures a longer service life. If the remote control
does not send a control signal for a few seconds when in travel mode, the engine will automatically change to
idle speed. If an activation signal is received again, the engine speed is increased again within fractions of a
second, in contrast to conventional trench compactors. This results in lower fuel consumption while protecting
the environment and being immediately ready for operation.
For particularly sensitive applications, e.g. in aquifer protection zones, the BMP 8500 can optionally be operated
with a specially environmentally compatible hydraulic oil.

32 BOMAG 008 915 77

BOMAG Multi-purpose compactor 3.1

Fig. 15
With the optionally available drum extensions the working width can be modified to 610 mm or 850 mm, simply
and quick, directly on the construction site. Particularly beneficial for a wide range of applications.

Versatile and a real compaction expert.

The BMP 8500 is equipped with a double exciter system with directed vibrator. The user can choose from two
different amplitudes and two travel speeds and therefore has different compacting modes available.
Intelligent Vibration Control (IVC) automatically switches over to working speed when working with vibration and
thus guarantees constant compaction and reliable use.
The new BOMAG articulated steering prevents loosening of the already compacted surface caused by steering
movements and thus ensures high surface quality. A high level of running smoothness and the precise steering
do the rest. Breaking away from the track, even under most difficult soil conditions, will no longer occur.

Safe, reliable and operator friendly.

Multi-purpose compactors are particularly suitable in trench construction, under confined conditions and in dan-
ger zones. A reliable and safe remote control is indispensable for this purpose. The BMP 8500 comes with a
unique combination remote control with cable and radio. It enables work independently from outdoor conditions
like severe weather or poor access to the construction site.
With the intuitively operable remote control, which does not require any special training, the machine can be
electrically activated or deactivated, steered and both speed and vibration can be controlled. The BOMAG Op-
erator Safety System (BOSS) offers highest possible protection for the operator. If he steps into the nearby area
of the machine (1-2 meters) the travel system is automatically stopped in order to avoid accidents. BOSS works
with disturbance proof radio waves and is therefore safer and more reliable than conventional infrared remote
controls.

008 915 77 BOMAG 33

3.1 BOMAG Multi-purpose compactor

Fig. 16
Using the radio remote control not only enables the operator to keep an optimal distance to the trench compactor
or the danger zone, but the use of radio signals also provides maximum reliability. With conventional systems,
e.g. operated via infrared remote control, sudden insolation, an unfavourable position to the machine or even
smallest obstacles can adversely affect the reception and thus cause control problems or undesired standstill of
the machine. This does not apply for a radio remote control, with this technology the trench compactor always
remains under control and and achieves and optimal compaction quality. Result: disturbance free, speedy and
safe work – and work that protects your health. Because there is no hand-arm vibration at all.

Advantages of the radio remote control:

l
Disturbance free
l
Multi-functional
l
No hand-arm vibration
l Highest safety level at the work place
l
Highest safety level for the operator

Service friendly, cost effective and simple when it comes to maintenance

The multi-purpose compactor BMP 8500 convinces with its simple and quick solutions for service and mainte-
nance, the Easy Service Concept. Both machine hoods can be fully opened and therefore provide excellent ac-
cess to all service points and electronic components.

34 BOMAG 008 915 77

BOMAG Multi-purpose compactor 3.1

Fig. 17
A diagnostics module with error code display and operating hour meter ensures quick and exact fault diagnos-
tics, in many cases the fault rectification can be performed directly on site. This considerably reduces service
times and saves the company time and money. Besides the protection against external influences offered by the
fully closed protection hood made of highly impact resistant composite material, the engine itself has a protection
feature to protect against insufficient maintenance or turning over. The engine shuts down if the oil level is too
low or if the lateral tipping angle exceeds a certain limit. High service, repair and spare parts costs are most ef-
fectively avoided.

008 915 77 BOMAG 35

3.1 BOMAG Multi-purpose compactor

36 BOMAG 008 915 77

 4 Technical data

008 915 77 BOMAG 37

4.1 Technical data

4.1 Technical data

Dimensions in A D H K L S W W1
mm (inches)
BMP 8500 1000 520 1275 222 1897 25 850 610
(39.4) (20.5) (50.2) (8.7) (74.7) (1.0) (33.5) (24.2)

* BMP 8500
Weights
Operating weight (CECE) kg (lbs) 1595 (3516)
Basic weight kg 1585 (3494)
Mean axle load (CECE) kg 775 (1709)

Travel characteristics
Travel speed (1) forward/reverse km/h (mph) 1,3 (0.8)
Travel speed (2) forward/reverse km/h (mph) 2,5 (1.6)
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 (hp) 14,5 (19.4)
Rated speed rpm 2600
Drive system hydrostatic
Driven drums front + rear

Brakes
Service brake hydrostatic
Parking brake mechanical

Steering
Type of steering Articulated joint
Steering operation hydrostatic

Vibration system
Vibrating drum front + rear

38 BOMAG 008 915 77

Technical data 4.1
*
BMP 8500
Drive system hydrostatic
Frequency Hz 42
Amplitude 1/2 mm (in) 1,12/0,56 (0.04/0.02)
Centrifugal force 1/2 kN (lbf) 72/36 (16186/8093)

Filling capacities
Fuel (diesel) l (gal us) 24 (6.3)
Hydraulic oil l (gal us) 17 (4.5)
Engine oil l (gal us) 4,7 (1.24)
Coolant l (gal us) 4,5 (1.19)
Vibration housing l (gal us) 2x 1,7 (2x 0.45)

Safety field system

Performance level PL c
Reach of the safety field infront of/behind the machine m (ft) > 1,20 (> 3,94)

Safety field control

Voltage V 8 ... 30
Current consumption at 12 V A 1.5
Protection class IP 55
Safety field frequency kHz 125
Operating temperature °C (°F) -20 ... +80 (-4 ... +176)
Storage temperature °C (°F) -40 ... +85 (-40 ... +185)

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 (°F) -20 ... +80 (-4 ... +176)
Storage temperature °C (°F) -40 ... +85 (-40 ... +185)

Safety field antenna

Protection class IP 55
Operating temperature °C (°F) -20 ... +80 (-4 ... +176)
Storage temperature °C (°F) -40 ... +85 (-40 ... +185)

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 (ft) approx. 30 (98.4)
Current draw mA approx. 10
Weight kg (lbs) approx. 1.6 (3.5)

008 915 77 BOMAG 39

4.1 Technical data

*
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
* 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

40 BOMAG 008 915 77

Technical data 4.1
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 41

4.1 Technical data

The following noise and vibration data acc. to

- EC Machine Regulation edition 2006/42/EC

- the noise regulation 2000/14/EG, noise protection guideline 2003/10/EC

- Vibration Protection Regulation 2002/44/EC

were determined during conditions typical for this type of equipment and by application of harmonized
standards.

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

Noise value
Sound pressure level on the place of the operator:
LpA = 85 dB(A), determined acc. to ISO 11204 and EN 500

Guaranteed sound power level:

LWA = 103 dB(A), determined acc. to ISO 3744 and EN 500

! Danger
Wear your personal noise protection means (ear defenders) before starting operation.

42 BOMAG 008 915 77

 5 Maintenance

008 915 77 BOMAG 43

5.1
5.1 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.
44 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 5.2
5.2 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 API*-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 EPA**-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.

* American Petroleum Institute ** United States Environmental Protection Agency

008 915 77 BOMAG 45

5.2 Fuels and lubricants

Under particularly extreme temperature conditions In hydraulic systems filled with Panolin HLP Synth.46
you should consult the service representation of the always use the same oil to top up.
engine manufacturer with respect to the anti-freeze When changing from mineral oil based hydraulic oil to
agent to be used. an ester based biologically degradable oil, you should
There are various types of anti-freeze agents availa- consult the lubrication oil service of the oil manufactur-
ble. For this engine you should use ethylene glycol. er for details.
Before filling in the coolant mixed with anti-freeze
agent the radiator must be flushed with clean water. ! Caution
This procedure should be repeated two to three times
Check the filter more frequently after this change.
to clean the inside of radiator and engine block.
Mixing the anti-freeze agent: Prepare a mixture of Perform regular oil analyses for content of water
50 % anti-freeze agent and 50 % low mineral, clean and mineral oil.
water. Stirr well before filling it into the radiator. The Replace the hydraulic oil filter element every 500
method for mixing water and anti-freeze agent de- operating hours.
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 and 8 mm2/s at 100 °C. For topping up or for oil
changes use only high-quality hydraulic oil, type
HVLP according to DIN 51524, part 3, or hydraulic oils
type HV according 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.

46 BOMAG 008 915 77

Table of fuels and lubricants 5.3
5.3 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-40 (-20 °C to +40 °C)

(BOMAG PN 009 920 06; 20 l)

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. 4.0 litres

(BOMAG PN 009 940 08; 20 l)

Hydraulic system Hydraulic oil (ISO), HLP 46 approx. 17 litres

(BOMAG PN 009 930 09; 20 l)
or
ester based biodegradable hydraulic oil

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

008 915 77 BOMAG 47

5.4 Running-in instructions

5.4 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

48 BOMAG 008 915 77

Maintenance table 5.5
5.5 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 Check the water separator X
5.10 Check the coolant level X
5.11 Check the air intake hose X
5.12 Change engine oil and oil filter* 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
hub**
5.17 Drain the fuel tank sludge X
5.18 Change the fuel pre-cleaner, bleed X
the fuel system
5.19 Service the battery, check the battery pole grease X
main 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 filter*** at least every 2 years X
5.24 Change the coolant X
5.25 Changing 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 49

5.5 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
* 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.
** Running-in instructions: check tightening torque after 50 and 250 operating hours, then every 250 operating hours
*** Also in case of repair in the hydraulic system.

50 BOMAG 008 915 77

 6 E-Plan wiring diagrams

008 915 77 BOMAG 51

6.1 Understanding wiring diagrams

6.1 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"

52 BOMAG 008 915 77

Understanding wiring diagrams 6.1
Cover sheet
The cover sheet, see example (Fig. 18), contains general information.

Fig. 18 Example: Cover sheet

008 915 77 BOMAG 53

6.1 Understanding wiring diagrams

Table of contents
The table of contents, see example (Fig. 19), lists the individual functions and identifies the corresponding
sheets in the wiring diagram.

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54 BOMAG 008 915 77

Understanding wiring diagrams 6.1
Sheets with representations of functions
l
The main reading direction is sheet by sheet, from top to bottom and from left to right.
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. 20).

Structuring symbols
Relay cross-reference Potential cross-reference

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Mimic diagram of relay Current paths

Fig. 20 Example: Sheet with functions

Current paths (Fig. 20)

l Current paths are successively numbered from 0 to 9.

Potential cross references (Fig. 20)

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 55

6.1 Understanding wiring diagrams

Relay cross references (Fig. 20)

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.

56 BOMAG 008 915 77

Understanding wiring diagrams 6.1
List of component
The list of components, see example (Fig. 21), is the first evaluation list that follows the representation of func-
tion. This list contains all components used in the wiring diagram, except terminal strips and plugs.

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Fig. 21 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 57

6.1 Understanding wiring diagrams

Overview of terminal strips

The overview of terminal strips, see axample (Fig. 22), 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. 22 Example: Terminal strip overview X1

58 BOMAG 008 915 77

Understanding wiring diagrams 6.1
Overview of plugs
The overview of plugs, see example (Fig. 23), 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. 23 Example: Plug overview X0

008 915 77 BOMAG 59

6.1 Understanding wiring diagrams

Overview of pins
The overview of pins, see example (Fig. 24), informs about the type of inputs and outputs of the electronic con-
trols (E-BOX) used in the machine, as well as their signals and potentials.

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Fig. 24 Example: Overview of pins, control A66

60 BOMAG 008 915 77

Circuit symbols in the circuit diagram 6.2
6.2 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. 25 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. 25) 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 61

6.2 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. 26)

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. 26 Example: Central lubrication system

Identification of externally supplied documentation (Fig. 27)

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. 27 Example: Identification of externally supplied documentation

PLC representation(Fig. 28)

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

62 BOMAG 008 915 77

Circuit symbols in the circuit diagram 6.2
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. 28 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. 28)

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 63

6.3 Designation of components in the wiring diagram

6.3 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 6.4
6.4 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

6.4 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

 7 Electrics

008 915 77 BOMAG 67

7.1
7.1 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.
68 BOMAG
Battery ground and analog ground
7.2 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}'
008 915 77
Current and voltage 7.3
7.3 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

008 915 77 BOMAG 69

7.3 Current and voltage

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).

70 BOMAG 008 915 77

Resistance 7.4
7.4 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.
Resistance and voltage drop
While current flows through a conductor the current
Unnecessary resistances
flow is more or less inhibited by the conductor, this in-
hibitation is referred to as Resistance. 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.

008 915 77 BOMAG 71

7.4 Resistance

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

72 BOMAG 008 915 77

Series / parallel connection
7.5 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).
7.5
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.

008 915 77 BOMAG 73

7.5 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.
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.

74 BOMAG 008 915 77

Ohm's law 7.6
7.6 Ohm's law 7.7 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

008 915 77 BOMAG 75

7.8 Formula diagram

7.8 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

76 BOMAG 008 915 77

Metrology 7.9
7.9 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.

008 915 77 BOMAG 77

7.9 Metrology

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.

78 BOMAG 008 915 77

Metrology 7.9
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.

008 915 77 BOMAG 79

7.9 Metrology

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

80 BOMAG 008 915 77

Diodes, relays, fuses 7.10
7.10 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.

008 915 77 BOMAG 81

7.10 Diodes, relays, fuses

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

82 BOMAG 008 915 77

Diodes, relays, fuses 7.10
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

008 915 77 BOMAG 83

7.11 Inductive proximity switches

7.11 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.

84 BOMAG 008 915 77

Plug connectors 7.12
7.12 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)

008 915 77 BOMAG 85

7.13 Deutsch plug, series DT and DTM

7.13 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.

86 BOMAG 008 915 77

Deutsch plug, series DT and DTM 7.13
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.

008 915 77 BOMAG 87

7.13 Deutsch plug, series DT and DTM

DTM Series

Fig. 6 DTM Series

Fig. 7 Sectional drawing

Installing DTM contacts

Fig. 8
l Insert the contacts through the rubber grommet until they click into place.
l Insert the orange wedge, until it clicks into place.

88 BOMAG 008 915 77

Deutsch plug, series DT and DTM 7.13
!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.

Removing DTM contacts

Fig. 9
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.

008 915 77 BOMAG 89

7.14 Batteries

7.14 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.

90 BOMAG 008 915 77

Batteries 7.14
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.

008 915 77 BOMAG 91

7.15 Battery service, checking the main battery switch
Do not draw too much electrolyte into the pipe.
Make sure that the float is not obstructed in its move-
ment and hold the electrolyte tester at eye level.
The electrolyte tester must be read at the highest
electrolyte level.
l If the electrolyte temperature deviates from the
electrolyte tester calibration temperature, the indi-
cated value for the specific electrolyte weight must
be corrected acc. to the formula (reference) below.
Reference
The specific weight varies slightly with temperature.
To be exact, the specific weight drops by 0.0007 per 1
°C temperature increase (by 0.0004 per 1 °F) and in-
creases by 0,0007 per 1 °C temperature reduction (by
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-
mula.
l Specific weight at 20 °C = measuring value +
0,0007 × (electrolyte temperature: 20 °C)
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.
l
If the current consumption during charging is not 1/
20 of the nominal capacity (example 100 Ah battery:
100Ah x 1/20 = 5 A) or full recharging of the battery
results in a final electrolyte density of only 1.24 kg/
dm3 or less, the battery shows normal wear by ag-
ing. The battery was insufficient charging or ex-
haustive discharge.
92 BOMAG
7.15 Battery service, checking the
main battery switch
Danger
!
Danger of cauterisation ! Danger of explosion!
When working on the battery do not use open fire,
do not smoke!
The battery contains acid. Do not let acid come in
contact with skin or clothes!
Wear protective clothing!
Do not lay any tools on the battery!
For recharging remove the plugs from the battery
to avoid the accumulation of highly explosive gas-
es.
Environment
Dispose of the old batteries environmentally.
i Note
Maintenance free batteries also need care. Mainte-
nance free only means that the fluid level does not
need to be checked. Each battery suffers under self-
discharge, which may, in not checked occasionally,
even cause damage to the battery as a result of ex-
haustive discharge.
The following therefore applies for the service life:
l
Switch off all consumers.
l
Check open-circuit voltage of the battery at regular
intervals. At least once per month.
Reference values: 12.6 V = fully charged; 12.3 V =
50% discharged.
l Recharge the battery immediately after an open-cir-
cuit voltage of 12.25 V or less is reached. Do not
perform quick charging.
The open-circuit voltage of the battery occurs approx.
10 hours after the last charging process or one hour
after the last discharge.
l
After each charging process allow the battery to rest
for one hour before taking it into service.
l
For resting periods of more than one month you
should always disconnect the battery. Do not forget
to perform regular open-circuit voltage measure-
ments.
Caution
!
Exhausted batteries (batteries with formation of
sulphate on the plates) are not covered under war-
ranty!
l Open the maintenance flap and remove the battery
cover.
008 915 77
Main battery switch 7.16
7.16 Main battery switch

Fig. 6
l Clean the outside of the battery (Fig. 6).
Fig. 7
l Clean battery poles and pole clamps and grease
No. 1 = Main battery switch
them with pole grease (Vaseline).
Disconnects the ground contact in the electric circuit
l Check the fastening of the battery. of the machine.
l On serviceable batteries check the acid level, if nec-
essary top up to the filling mark with distilled water.
i Note
If the power pack of the radio remote control is to be
Checking the main battery switch charged, the main battery switch must remain
l Turn the main battery switch to "horizontal" position switched on when the engine is shut down.
and check by voltage measurement (ignition key
test) whether the batteries are disconnected from
the electric system of the machine.

008 915 77 BOMAG 93

7.17 Main battery fuse

7.17 Main battery fuse 7.18 External starting

Starting with jump wires

! Caution
A wrong connection will cause severe damage in
the electric system.
l Open the rear hood.

Fig. 8
No. 2 = Main fuse for battery
80A = (F00)

Fig. 9
l
Switch on the main battery switch (Fig. 9).

Caution
!

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.

94 BOMAG 008 915 77

Generator 7.19
7.19 Generator Three-phase generator
The AC-generator first of all produces AC-voltage /
General
AC-current.
The generator should be of light weight, have a high
rate of efficiency and supply all consumers in the ve- Why does AC-current need to be rectified?
hicle with electric current at a steady voltage already There are a few components for which can either be
at idling speed. operated with alternating current or direct current, be-
cause they work independently from the current flow
Terminal designations
direction.
l B61, L = charge control This includes :
l B+, B = battery plus, also with the designation "30" l
Incandescent lamps
l
B- = battery minus, also with the designation "31" l
Fluorescent lamps
l D+ = dynamo plus corresponds with terminal "61" l Glow lamps
and "L" l Electric heating elements.
l D- = dynamo minus (this designation is only found There are also a few components that could be oper-
on D.C. generators or A.C. generators with regula- ated either with alternating current, direct current or
tor removed) three-phase current, if the components were designed
accordingly.
l DF = dynamo field (this designation is only found on
D.C. generators or A.C. generators with regulator This includes :
removed). Note: The designation DF is also found l
Electric motors
on older alternators with externally arranged regula- l
Relays.
tor on the connection of the exciting coil to the reg-
ulator or on the regulator itself Finally, a variety of important components solely re-
quire direct current. These will under no circumstanc-
l
DF1 = dynamo field 1 es work with alternating or three-phase current.
l
DF2 = dynamo field 2 This includes :
l
IG = "15" ignition switch l
Accumulators
l
Control units
l
All electronics
l
Communication equipment.

Design and function

Fig. 11
1 Fan
2 Holding plate
3 Stator core
4 Stator winding
5 Brush

008 915 77 BOMAG 95

7.19 Generator

6 Brush holder
7 Rectifier
8 Bearing cover
9 Rotor winding
10Rotor
11V-belt pulley

Fig. 14 3-phase current

Fig. 12 Rotor with claw poles
In the generator the armature windings are located in-
side the stationary stator (Fig. 13), whereas the excit-
er winding is arranged on the internally revolving rotor
(Fig. 12).
The wiring diagram (Fig. 14) shows the 3 windings in
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. 13 Stator
The three stator windings (Fig. 13) are electrically off-
set to each other by 120°. The excitation of the mag-
netic field requires direct current, which is fed to the
rotor via two carbon brushes and slip rings.

96 BOMAG 008 915 77

Generator
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. 15) shows the current flow with the ignition
switched on, engine stopped.
7.19
Any other behaviour would indicate a defect on the
generator (rectifier, carbon brushes, regulator) or a
defect on the lamp, presumed the on-board battery is
not discharged.
A far more important function of the lamp is the transi-
tion and provision of field current. At standstill there is
no magnetic field in the de-energized generator. Since
this is necessary for the generation of electric current,
the rotor must be supplied with current, so that a weak
field can build up.
The current flows from the ignition switch via the
charge control light through the generator winding
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.
This type of machines can even start without charge
control light and produce current during operation.
However, this is an unintended effect and you should
not presume that a generator without charge control
light or external excitation can be started up.

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 97

7.19
Charge controller
The charge controller has the following functions
l To regulate the voltage generated by the generator
l To protect against overloads caused by too high
output current
l Protection against reverse current
If the output voltage or the output current of the gen-
erator exceeds the determined maximum values, the
field current and thus the electric power is reduced.
Electronic charge regulator
Fig. 17 Regulator, Kubota engine
In AC-generators the electrically generated exciter
field of the generator rotor is influenced by an at-
tached electronic charge regulator. Together with the
holder for the carbon brushes this regulator forms a
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.
98 BOMAG
Generator
Checking the generator
!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
Generator 7.19
replaced or the following trouble shooting procedure Measuring the charge current
must be performed. l All plug-and-socket connectors must be free of cor-
rosion and intermittent contact.
l The generator ground connection must be OK.
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.

008 915 77 BOMAG 99

7.19 Generator

Checking the regulator voltage with the generator Checking the regulator voltage with the multime-
tester ter
The battery and generator tester comes with an 8-line
LC display with background illumination and is able to
print out test results via an (optional) thermal printer.

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.
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.

100 BOMAG 008 915 77

Generator repair 7.20

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).

008 915 77 BOMAG 101

7.20 Generator repair

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.

102 BOMAG 008 915 77

Generator repair 7.20
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.

008 915 77 BOMAG 103

7.20 Generator repair

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

104 BOMAG 008 915 77

Electric starter
Regulator
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.
7.21
7.21 Electric starter
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.

008 915 77 BOMAG 105

7.21 Electric starter

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

106 BOMAG 008 915 77

Electric starter 7.21
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

008 915 77 BOMAG 107

7.21 Electric starter

Magnetic switch Freewheeling clutch

Fig. 15 Direct acting electric motor Fig. 17 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. 16 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

108 BOMAG 008 915 77

Electric starter 7.21
Trouble shooting "Starter" Testing and measuring the starter
Function control with the starter removed
i Note
The most frequent fault is definitely a fully discharged
Caution
!
battery.
Fasten the starter to make sure that it will not
If the starter rotates too slowly, either the brushes come loose during the test.
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. Fig. 18
Occasionally worn contacts are found on the magnetic l
Connect a jumper lead between start terminal (1)
return switch and battery plus (2).
Defects on the actual starter motor including pinion l
Connect a jumper cable instantaneously between
and carbon brushes are very rare. starter housing and battery minus (3).
With a trouble shooting chart the faults in the starter
system can be narrowed down. The starter system i Note
can only work when many conditions are fulfilled at
If the motor does not start, the starter is defective. Re-
the same time.
pair or replace the starter.
l Immobilizer deactivated?
l Ignition switch OK? Checking the magnetic switch
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?
Fig. 19
The sequence of these tests is generally of no signifi-
cance. It mainly depends on:
l
Connect a jumper lead between start terminal (1)
and battery plus (2).
l the experience of the specialist
l
Connect a jumper cable instantaneously between
l the failure probability of the component to be tested
starter housing and battery minus (3).
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- i Note
paired or replaced. If the pinion does not disengage, the magnetic switch
is defective. Repair or replace the starter.

008 915 77 BOMAG 109

7.21 Electric starter

Continuity test for the magnetic switch

Fig. 20
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 7.22

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

7.22 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 7.22
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

7.22 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 7.23
Field coil 7.23 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

7.23 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
7.24
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
7.24 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 7.25

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

7.25 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 7.25
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

7.26 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 7.26
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 With insufficient oil pressure, 49 kPa (0.5 kgf/cm2,
7 psi) or lower
5 Contact rivet
6 Contact With dropping oil pressure the diaphragm (4) will re-
turn, until the contact rivet (5) contacts again and the
7 Oil switch housing
electric circuit is closed.
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

7.27 Coolant temperature and power reduction

7.27 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.

124 BOMAG 008 915 77

Coolant temperature and power reduction 7.27

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

008 915 77 BOMAG 125

7.28 Wiring looms

7.28 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

126 BOMAG 008 915 77

Wiring looms 7.28

1 Wiring loom, safety bow

2 Proximity switches

008 915 77 BOMAG 127

7.28 Wiring looms

1 Wiring loom, Hytos solenoid valves

2 Spiral cable

128 BOMAG 008 915 77

BLM - Power/Logic Module 7.29
Control unit
7.29 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.

008 915 77 BOMAG 129

7.29 BLM - Power/Logic Module

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.

130 BOMAG 008 915 77

Checking the voltage supply for the control unit 7.30
7.30 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.

008 915 77 BOMAG 131

7.30 Checking the voltage supply for the control unit

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.

132 BOMAG 008 915 77

Checking the voltage supply for the control unit 7.30
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.

008 915 77 BOMAG 133

7.30 Checking the voltage supply for the control unit

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.

134 BOMAG 008 915 77

Checking the voltage supply for the control unit 7.30
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.

008 915 77 BOMAG 135

7.30 Checking the voltage supply for the control unit

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

136 BOMAG 008 915 77

Checking the voltage supply for the control unit 7.30
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

008 915 77 BOMAG 137

7.30 Checking the voltage supply for the control unit

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.

138 BOMAG 008 915 77

Diagnostics concept 7.31
7.31 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. 9

(1) Fault memorized in error log

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

(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, if the error log has not recorded a fault

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

008 915 77 BOMAG 139

7.31 Diagnostics concept

Localizing faults
Line or component?

Fig. 10
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

140 BOMAG 008 915 77

Diagnostics concept 7.31
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. 11

008 915 77 BOMAG 141

7.32 Control elements

15
16
17
Fig. 12 9 S133 Toggle switch, travel ranges
1 A67 Electronic immobilizer* 10 S134 Toggle switch, engine speed
2 P17 Display module 11 S138 Travel direction control lever
3 F05 - F119 Fuse box 12 S36 Toggle switch for vibration high/low amplitude
4 S101 Toggle switch for cable remote control/radio 13 S102 Emergency stop switch
remote control 14 H77 Control light data transfer/power pack radio
5 XS Socket remote control
6 S30 Main battery switch 15 S181 Key switch
7 S137 Steering control lever 16 S131 Engine start
8 S132 Toggle switch, vibration automatic/manual 17 S03 Horn button
* Optional equipment

142 BOMAG 008 915 77

Fault display, P17 7.33
7.33 Fault display, P17 7.34 Fuses

Fig. 13 Fig. 14
Faults are displayed in the display module h (Fig. 13) No. 3 = Fuse box
in form of flashing fault codes. If several faults occur F119 = (20A) Fuse for starter motor
at the same time, these will be indicated by flashing
F103 = (10A) Fuse potential 15
codes, one after the other.
F14 = (25A) Fuse for engine solenoid
F54 = (5A) Fuse for cable remote control
F67 = (25A) Fuse control (potential 30)
F48 = (30A) Preheating

008 915 77 BOMAG 143

7.35
7.35 Entering the machine type
code
Caution
! i
After replacing the machine control (BLM) the ma-
chine type code must be entered again.
The machine must not be operated with a wrong
type settings, as otherwise the correct function of
the control can no longer be assured.
The code can only be entered when the engine is
shut down.
i Note
A description of the procedure for entering code num-
bers can be found in the chapter "Switching ECO-
mode on or off".
l Enter "7010" to start the procedure.
This code number activates the function "Adjusting
machine type“. The display module now permanently
shows code "7010".
l Enter "7104".
The display module now permanently shows code
"7104".
l Enter "7011" to finish the procedure.
This code number confirms the entered machine type.
After having confirmed the machine type the control
switches off, restarts automatically after 3 seconds
and is then ready for starting.
i Note
Whenever switching the ignition on the machine type
will appear in the display module for 3 seconds.
144 BOMAG
Entering the machine type code
7.36 Replacing, recharging the ra-
dio remote control power pack
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
source! Do not store charged power packs in a
tool box or similar, because metal parts may
cause a short circuit. Short circuits may also be
caused by keys etc. in a trouser pocket.
! 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.
The full discharging capacity is only reached after sev-
eral charging cycles.
i Note
As the charging of the power pack succeeds, the
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
Replacing, recharging the radio remote control power pack 7.36
Charging the power pack in the machine Charging the power pack with the exter-
nal battery charger

Fig. 15
l Switch off the transmitter (Fig. 15) with the ignition Fig. 17
key. l Switch off the transmitter (Fig. 17) with the ignition
l Plug the spiral cable into the transmitter key.

Fig. 16 Fig. 18

l The main battery switch (Fig. 16) must be switched

l Press the power pack forward and lift it out of the
on. housing (Fig. 18).

i Note
The power pack recharging time is approx. 6 hours.

Fig. 19
l Push lock 1 (Fig. 19) on the mains unit of the battery
charger forward and pull plug (2) upward out of the
mains unit.

008 915 77 BOMAG 145

7.36 Replacing, recharging the radio remote control power pack

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.

Fig. 20
l Plug the corresponding plug (Fig. 20) onto the
mains unit of the battery charger.

i Note
The type of plug to be chosen depends on the country.
Observe local conditions and regulations.

Fig. 21
l
Insert the power pack into the battery charger (Fig.
21).

Fig. 22
l
Connect the battery charger to a power source (Fig.
22).
The two light emitting diodes on battery charger and
mains unit must light up.

146 BOMAG 008 915 77

BOSS safety system 7.37
7.37 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).

008 915 77 BOMAG 147

7.37 BOSS safety system

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!

148 BOMAG 008 915 77

"Marriage" of transponder and protection field control 7.38
7.38 "Marriage" of transponder and 7.39 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.

008 915 77 BOMAG 149

7.40 Safety field measurement of the Boss safety system

7.40 Safety field measurement of

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. 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.

150 BOMAG 008 915 77

Problems with radio remote control Hetronic in radio operation 7.41
7.41 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 151

7.41 Problems with radio remote control Hetronic in radio operation

152 BOMAG 008 915 77

Problems with remote control Hetronic with spiral cable 7.42
7.42 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 153

7.42 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

154 BOMAG 008 915 77

Problems with remote control Hetronic with spiral cable 7.42
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 155

7.43 Faults in BOSS safety system

7.43 Faults in BOSS safety system

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 chapter Safety equipment, teaching
been taught the BOSS safety system 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

! Danger
Danger of injury!
After maintenance and/or repair work on the safety system the safety field length must be checked
again, see corresponding chapter.

156 BOMAG 008 915 77

 8 Electronic control

008 915 77 BOMAG 157

158 BOMAG 008 915 77
 8.1 with safety bow

008 915 77 BOMAG 159

8.1 with safety bow

160 BOMAG 008 915 77

with safety bow 8.1

Documentation
BMP 8500
with
safety bar

008 097 xx

Author: VKS
Status: 06.06.2011

008 915 77 BOMAG 161

8.1 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

Page 3 / 30

008 915 77 BOMAG 163

8.1 with safety bow
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

Page 4 /30
164 BOMAG 008 915 77
with safety bow 8.1
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.

F1 F2

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.

Page 5 /30
008 915 77 BOMAG 165
8.1 with safety bow
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.

Page 7 /30
008 915 77 BOMAG 167
8.1 with safety bow
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.

Page 8 /30
168 BOMAG 008 915 77
 Description of the signals on the BML control

3 Description of the signals on the BML control

008 915 77
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.
with safety bow

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

BOMAG
Horn off ) 0 V, no consumer connected 2.9 V
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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8.1

169
170
Description of the signals on the BML control
8.1

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

BOMAG
X3:37 Activation input, cable remote control, S 101 Set selector switch for remote control type to cable, switch on remote
control, switch on ignition, emergency stop not operated ) 12 V
X3:38 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
with safety bow

008 915 77
Page 10 / 30
 Fault codes and warning messages of the BMP 8500 control

4 Fault codes and warning messages of the BMP 8500 control

008 915 77
4.1 Overview

Fault code : Function Group : Remark:

with safety bow

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
Page 11 / 30
8.1

171
172
Fault codes and warning messages of the BMP 8500 control
8.1

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
with safety bow

008 915 77
Page 12 / 30
 Fault codes and warning messages of the BMP 8500 control

Code Fault reaction Fault description Possible cause Terminal Input-

008 915 77
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
with safety bow

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

Page 13 / 30
8.1

173
174
Fault codes and warning messages of the BMP 8500 control
8.1

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
with safety bow

008 915 77
Page 14 / 30
 Fault codes and warning messages of the BMP 8500 control

4.3 Fault codes of work functions

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

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

Page 15 / 30
8.1

175
176
Fault codes and warning messages of the BMP 8500 control
8.1

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!
with safety bow

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

4.5 General fault codes diesel engine, machine

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

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.

Page 17 / 30
8.1

177
178
Fault codes and warning messages of the BMP 8500 control
8.1
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
with safety bow

008 915 77
Page 18 / 30
 Fault codes and warning messages of the BMP 8500 control
Code Fault reaction Fault description Possible cause Terminal Input-
on BLM code for

008 915 77
diagnose
5054 Input Aux – Signal rpm solenoid Y 46 ) 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 -
with safety bow

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.

Page 19 / 30
8.1

179
180
Fault codes and warning messages of the BMP 8500 control
8.1
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
nd
5101 2 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.
with safety bow

008 915 77
Page 20 / 30
 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
Page 21 / 30
8.1

181
182
Input codes for BLM control
8.1

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
with safety bow

008 915 77
Page 22 / 30
 Input codes for BLM control

Input code Description of display function Display values

008 915 77
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
with safety bow

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
Page 23 / 30
8.1

183
184
Input codes for BLM control
8.1

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
with safety bow

008 915 77
Page 24 / 30
 Input codes for BLM control

5.3 Inputs logic and power module

008 915 77
Input code Description of display function Display values
1400 Input signal L from generator regulator 12 V > Generator stopped
with safety bow

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
Page 25 / 30
8.1

185
186
Input codes for BLM control
8.1

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 sw itch
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
with safety bow

008 915 77
Page 26 / 30
 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

008 915 77
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
with safety bow

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

BOMAG
0001 = temperature alright

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

Page 27 / 30
8.1

187
188
Input codes for BLM control
8.1

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

BOMAG
0010 = Switch not operated, idle speed
2506 Position of button for horn, S 03 0000 = Button not operated
0001 = Button operated

With the input codes listed above it is possible to check the transfer of the individual switching signals from the remote controls to the central control unit. For 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!
with safety bow

008 915 77
Page 28 / 30
 Input codes for BLM control
5.6 Driving against the brake

008 915 77
Input code Description of display function Display values
0500 Driving against the brake Input code 500 desactivates the brake. The display shows code 500
with safety bow

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)

Page 29 / 30
8.1

189
190
Input codes for BLM control
8.1
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
with safety bow

008 915 77
Page 30 / 30
 8.2 with safety field control

008 915 77 BOMAG 191

8.2 with safety field control

192 BOMAG 008 915 77

with safety field control 8.2

Documentation
BMP 8500
with
Safety System BOSS

008 097 xx

Author: VK
Status: 20.07.2012

008 915 77 BOMAG 193

8.2 with safety field control

Table of contents

Table of contents

TABLE OF CONTENTS ............................................................................................. 2

1 CONFIRMATION OF CHANGES ......................................................................... 3

2 FUNCTIONS OF THE BLM CONTROL ............................................................... 4

2.1 Description of the Display Module ................................................................................................ 4
2.2 Input of code numbers .................................................................................................................. 4
NOTE: To verify work- and driving funktion with codes, the horn button needs to be pushed once. ..... 4
2.3 Display CtO ................................................................................................................................... 5
2.4 Showing stored faults ................................................................................................................... 5
2.5 Delete all stored faults .................................................................................................................. 5
2.6 How to activate the start blocking function ................................................................................... 5
2.6.1 Aktivation of the start blocking function before delivery ........................................................ 5
2.6.2 Release start function after the machine fell over ................................................................. 6
2.6.3 Desaktivation of the start blocking function before delivery .................................................. 6
2.6.4 Showing the status of the start blocking function .................................................................. 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 .............................................................................. 18
4.7 Fault codes safety system BOSS ............................................................................................... 23
4.8 Faults in parameterization .......................................................................................................... 24

5 INPUT CODES FOR BLM CONTROL ............................................................... 25

5.1 Outputs for travel functions ......................................................................................................... 25
5.2 Outputs for work functions .......................................................................................................... 27
5.3 Inputs logic and power module ................................................................................................... 28
5.4 Diesel engine, machine electrics ................................................................................................ 28
5.5 Checking the function of the remote controls ............................................................................. 31
5.6 Driving against the brake ............................................................................................................ 32
5.7 System information ..................................................................................................................... 32
5.8 Setting the remote control type ................................................................................................... 32
5.9 Fault log ...................................................................................................................................... 32
5.10 Safety system BOSS............................................................................................................... 33
5.11 Reading out the operating hour meter .................................................................................... 33
5.12 Setting the machine type ........................................................................................................ 33

Page 2 /30

194 BOMAG 008 915 77

with safety field control 8.2

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
7 20.07.2012 BMP 8500 mit BOSS Version 2.02, P/N 724 002 33 J.Kob

Page 3 /30

008 915 77 BOMAG 195

8.2 with safety field control

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.

F1 F2

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.

Page 4 /30

196 BOMAG 008 915 77

with safety field control 8.2

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.

2.4 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.

2.5 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.

2.6 How to activate the start blocking function

If the machine has tipped over and has been put back on the wheels, it is important to make sure that
there is no oil in front of the pistons of the Diesel engine. Otherwise the conrods and tappets can be
bent.
To make sure that the operator cannot start the engine now without checking this, you can preselect a
start blocking function before the machine is delivered to the site. If the start lock mode was selected
before delivery and the machine tips over now while the engine is running, the display shows codes
5092, 5091 one after the other. Now the operator can restart the engine only after he put in three
particular input codes.
The input codes are not listed in the operators manual, so the operator has to contact the
workshop now.
Now the work shop can make sure that the oil in the combustion chamber is removed, can type in the
input codes and after that he can restart the engine.

Note: The start lock is activated only, if the machine tipped over with the engine running.

2.6.1 Aktivation of the start blocking function before delivery

(Every time when the machine fell over, you can start the engine only if it is standing upright and the
release code has been entered)

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8.2 with safety field control

Functions of the BLM control

- Switch on the ignition + wait for 5 seconds

- Press both buttons (F1 and F2) of the display for 2 seconds
th
- Type in code 5035 (F1 changes the digit no, F2 goes to next digit / after the 4 digit press F2
once more)
- Press both buttons (F1 and F2) of the display for 2 seconds
- Type in code 5037
- Press both buttons (F1 and F2) of the display for 2 seconds
- Type in code 5036

2.6.2 Release start function after the machine fell over

(Machine must stand upright again)

- Switch on the ignition + wait for 5 seconds

- Press both buttons (F1 and F2) of the display for 2 seconds
th
- Type in code 5035 (F1 changes the digit no, F2 goes to next digit / after the 4 digit press F2
once more)
- Press both buttons (F1 and F2) of the display for 2 seconds
- Type in code 5034
- Press both buttons (F1 and F2) of the display for 2 seconds
- Type in code 5036

2.6.3 Desaktivation of the start blocking function before delivery

(You can start the engine after the machine fell over, as soon as the machine
stands upright again)

- Switch on the ignition + wait for 5 seconds

- Press both buttons (F1 and F2) of the display for 2 seconds
th
- Type in code 5035 (F1 changes the digit no, F2 goes to next digit / after the 4 digit press F2
once more)
- Press both buttons (F1 and F2) of the display for 2 seconds
- Type in code 5038
- Press both buttons (F1 and F2) of the display for 2 seconds
- Type in code 5036

2.6.4 Showing the status of the start blocking function

- Switch on the ignition + wait for 5 seconds

- Press both buttons (F1 and F2) of the display for 2 seconds
th
- Type in code 5039 (F1 changes the digit no, F2 goes to next digit / after the 4 digit press F2
once more)
1 = Start blocking function active,
0 = Start blocking function inactive

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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 7010 will be displayed when switching on the first time.

The following machine types can be adjusted:

Machine type Machine type code

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 4 )

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 4 ). 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.

Page 7 /30

008 915 77 BOMAG 199

8.2 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 0 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 0500 and the warning buzzer is activated.

To desactivate this function and to open the brake again you have to enter code 0501 or shutt off the
ignition once.

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

Page 8 /30

200 BOMAG 008 915 77

 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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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
with safety field control

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

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

Page 11 / 30
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8.2

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

Page 12 / 30
with safety field control

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
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

Page 14 / 30
with safety field control

008 915 77
 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, X3:19 -
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 X3:19 -
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 X3:19 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 X3:19 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, X3:21 -
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 X3:21 -
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 X3:21 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 X3:21 1010
Y 238 1011
Although the output is switched off, voltage 1012
is present

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8.2

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 at ) A remote control with cable and a
locked, horn sounds 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
outputs on control are switched off
Remote control emergency stop
Fault in data transfer between remote
control sender and receiver
Receive signal too weak
) Emergency stop on remote control
operated
) Battery empty
) Radio transmission disturbed
) Distance between sender an machine
too big
) Radio transmission disturbed
) Distance between sender an machine
too big

BOMAG
2611 Engine is stopped. Communication error between BLM modul ) Plug connector of spiral cable on one
and cable control box. end defective or loose
) Spiral cable broken
) BLM-modul defektive
) Cable control defektive
2612 Engine is stopped. Communication error between BLM modul ) Plug connector at radio receiver
and radio remote control. defective or loose
) Radio receiver defective
) BLM-modul defektive

2613 Engine is stopped. Communication error between BLM modul ) Plug connector at infrared receiver
and infra red control. defective or loose
) IR receiver defective
) BLM-modul defektive

Page 16 / 30
with safety field control

008 915 77
 Fault codes and warning messages of the BMP 8500 control
Code Fault reaction Fault description Possible cause Terminal Input-

008 915 77
on BLM code for
diagnose
2616 Engine is stopped. Communication error between BLM modul ) Plug connector on RFID-modul
and BOSS system (RFID). (BOSS) loose/defektive
) Plug connector on BLM-module
loose/defektive
) Wire harness between BLM- and
RFID-module defective
with safety field control

) BLM-modul defektive
) RFID-modul defektive

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

BOMAG
Page 17 / 30
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8.2

Fault codes and warning messages of the BMP 8500 control

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
) 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:

BOMAG
) Current path has short circuit to ground
) Engine oil level not correct
) Engine oil pump defective
) Pressure relief valve after engine oil
filter soiled
) Oil pressure switch defective
5021 Engine shut down by too low oil Input engine oil pressure, B 06 ) see fault code 5 0 2 0 X3:03 5020
pressure Fault 5 0 2 0 present longer than 8 seconds
) Engine is shut down
Faults or warning 5020 and 5021 are only evaluated and displayed when the engine is running.

Page 18 / 30
with safety field control

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
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
with safety field control

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
No or too low current flow out of this output 5042

BOMAG
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

Page 19 / 30
8.2

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8.2

Fault codes and warning messages of the BMP 8500 control

Code Fault reaction Fault description Possible cause Terminal Input-

on BLM code for
diagnose
5054 Input Aux – Signal rpm solenoid Y 46 ) 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!
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

BOMAG
is present
5070 Output switched off, engine cannot be Output relay K 39, starter ) Excessive current flow in current path, X3:06 -
started The current flow from this output is too high probably because of a defective coil or
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.

Page 20 / 30
with safety field control

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
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
with safety field control

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)
5091 Shut down of diesel engine Input inclination switch B 56 ) Wire breakage in current path X3:23 1405

BOMAG
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.
5092 Shut down of diesel engine Input inclination switch B 56 ) The switch is in actuated state X3:23 1405
The diesel engine is shut down because the (machine has turned over)
input on the control does not receive a
signal from the inclination sensor + start blocking function active

+ start blocking function active

) Wire breakage in current path

) Switch defective

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
Page 21 / 30
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8.2

Fault codes and warning messages of the BMP 8500 control

Code Fault reaction Fault description Possible cause Terminal Input-
on BLM code for
diagnose
nd
5101 2 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.

BOMAG
Page 22 / 30
with safety field control

008 915 77
 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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8.2

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
Page 24 / 30
with safety field control

008 915 77
 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

Page 25 / 30
8.2

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8.2

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
Page 26 / 30
with safety field control

008 915 77
 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
Page 27 / 30
8.2

219
220
8.2

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°
1409 Activation input, cable remote control, S 101 12 V > Operating mode cable remote control
1410 Activation input radio remote control, S 101 12 V > Operating mode wireless

5.4 Diesel engine, machine electrics

Input code Description of display function Display values

BOMAG
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°
5035 Activation of start blocking function See chapter 2.6
5037 Tipe in the three codes one after the other to activate the start
5036 blocking function.
5035 Desactivation of start blocking function See chapter 2.6
5038 Tipe in the three codes one after the other to desactivate the start
5036 blocking function.
5039 Check status of self blocking function If display shows 1, the blocking function is preselected, i fit shows 0,
the function is not preselected. See chapter 2.6
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
Page 28 / 30
with safety field control

008 915 77
 Input codes for BLM control

008 915 77
Input code Description of display function Display values
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
5052 Output relay K 114, engine speed solenoid 0000 = Output not triggered
Logic level of control 0001 = Output triggered
with safety field control

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

BOMAG
Logic level of control 0001 = Output triggered
5070 Output relay K 39, starter Display value = output voltage in Volt
Voltage at output
5071 Output relay K 39, starter Display value = output current in Amperè
Current at output
5072 Output relay K 39, starter 0000 = Output not triggered
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

Page 29 / 30
8.2

221
222
8.2

Input codes for BLM control

Input code Description of display function Display values
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

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

BOMAG
Page 30 / 30
with safety field control

008 915 77
 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!

Page 31 / 30
8.2

223
224
8.2

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 0500 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 0501 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)!

5.9 Fault log

Input code Description of display function Display values

0700 Switch on function „Show stored faults“ see adjustment instructions (page 5)
0701 Switch off function "Show stored faults" see adjustment instructions (page 5)
0710 Delete all stored faults see adjustment instructions (page 5)

Page 32 / 30
with safety field control

008 915 77
 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. (first put in code 6000 !)
with safety field control

6002 Switch off service mode (first put in code 6000 !)

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

7104 Preselect machine type BMP 8500 with BOSS 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)!

Page 33 / 30
8.2

225
8.2 with safety field control

226 BOMAG 008 915 77

 8.3 Programmable start inhibitor

008 915 77 BOMAG 227

8.3 Programmable start inhibitor

228 BOMAG 008 915 77

Programmable start inhibitor 8.3

6.43 Start lock mode when

machine is tipping over

Old: New:

Up to S/N 101720111929 :
Up to S/N 101720111929 the BMP 8500 shows code 5091 in the display, when the
machine tipped over with the engine running. However, after putting the machine back
on the wheels you can restart the engine directly.

The critical point:

If the machine tips over, engine oil is running from the crank case into the combustion
chamber through the gaps of the piston rings. If now the machine is put back on the
wheels and is started directly, the conrods and tappets can be bent.

From S/N 101720111930:

From S/N 101720111930 on , before delivering the machine to the site you can select a
start lock mode, to make sure that the engine cannot be started after the machine tipped
over. To select this mode you must put in three input codes before delivery (see below).
(So, you have to select the start lock mode yourself before delivery !)

If the start lock mode was selected before delivery and the machine tips over now while
the engine is running, the display shows codes 5092, 5091 one after the other. Now the
operator can restart the engine only after he put in three particular input codes.
The input codes are not listed in the operators manual, so the operator has to
contact the workshop now.
Now the work shop can make sure that the oil in the combustion chamber is removed,
can type in the input codes and after that he can restart the engine.

Note: The start lock is activated only, if the machine tipped over with the engine
running.

-1-

008 915 77 BOMAG 229

8.3 Programmable start inhibitor

If a machine with preselected start lock mode is tipping over, the display is showing
codes 5092, 5091 one after the other, and you cannot restart the engine.

Before restarting , you now must proceed as follows:

1. Loosen all three glow plugs

(BMP 8500)

-2-

230 BOMAG 008 915 77

Programmable start inhibitor 8.3

2. Then type in the input codes 5035, 5034, 5036 (see below)
By this the start lock is opened again.

3. Turn the starter for a few seconds.

By this, oil in the combustion chamber is blown out through the threads of the glow
plugs.

4. Retighten the glow plugs (BMP 8500)

5. Start the engine

-3-

008 915 77 BOMAG 231

8.3 Programmable start inhibitor

How to type in the input codes:

For typing a code, both buttons (F1 and F2) of the display have to be pushed at the
same time for 2 seconds, until the display shows 0000 (first digit blinking). Now you
can change the first digit by pushing the left button (F1). After you typed in the
required first digit you need to push the right button (F2) to come to the next digit.
After you have typed in all four digits in the same manner, you need to push the right
button (F2) once again to confirm the code.

For typing codes push

button F1 and F2 at the
same time for 2 seconds.

F1 F2 F1 F2

Selecting the start lock mode

On machines delivered ex works the start lock mode is not preselected. But you
can select the start lock mode with codes 5035; 5037; 5036. These codes have to be
typed one after the other. So, type the first code, then push F1 and F2 at the same
time for two seconds and then type in the next code and so on…., then switch off
ignition. Now the start lock mode is preselected unless you cancel the start lock
mode.

Checking the mode status

To check if the start lock mode is selected or not, you have to type in code 5039. If
the display shows 1, the start lock mode is selected, if it shows 0 it is not selected.

Cancelling the start lock mode

To cancel the start lock mode you have to type in code 5035; 5038; 5036 , one after
the other.

-4-

232 BOMAG 008 915 77

 8.4 Logic

008 915 77 BOMAG 233

8.4 Logic

234 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
8.4

235
236
8.4
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)
Logic

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)
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)
8.4

237
238
8.4
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
Logic

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)
100
101

BOMAG
8.4

239
8.4 Logic

240 BOMAG 008 915 77

 9 Hydraulics

008 915 77 BOMAG 241

9.1 Hydraulic circuit

9.1 Hydraulic circuit

Open circuit

Fig. 1 Open circuit

Open in this case means that the suction line of a pump) (Fig. 1) normally is situated below the fluid level, the
surface of which is in open contact with atmospheric pressure. Reliable equalization of pressure between the air
in the hydraulic oil tank and the ambient air ensures problem free suction of the pump.
In an open circuit the hydraulic fluid is fed to the consumer (2 or 3) and also returned to the tank through way
valves.

242 BOMAG 008 915 77

Hydraulic circuit 9.1
Closed circuit

Filter

Cooler (option)

Fig. 2 Closed circuit

One talks about a closed hydraulic system, when the hydraulic oil flows from the consumer (3) (Fig. 2) directly
back to the pump (2).
The closed circuit consists of a high and a low pressure side, depending on the load direction (take-off moment
on the consumer).
The high pressure side is protected by pressure relief valves (4), which release oil into the low pressure side.
The medium remains in the circuit.
Only the permanent leakage on pump and motor needs to be replenished. This is accomplished by a charge
pump (1), which permanently delivers a sufficient amount of fluid (charge capacity) through a check valve (5)
into the low pressure side of the closed circuit. Any excess oil delivered by the charge pump, which works in an
open circuit, runs through a charge pressure relief valve (6) back into the tank. Charging the low pressure side
enables the pump (2) to work with higher operating data.

008 915 77 BOMAG 243

9.2 Overview

9.2 Overview

Fig. 3 Overview

244 BOMAG 008 915 77

Overview 9.2

1 Steering pump 11 Hydraulic oil tank

2 Travel pump 12 Air filter
3 Vibration pump 13 Single point lifting facility
4 Exhaust system 14 Air filter service indicator
5 Diesel engine 15 Fuel filter
6 Cooler 16 Coolant compensation tank
7 Fuel tank 17 Engine oil filter
8 Central electrics 18 Hydraulic oil filter
9 Battery 19 Articulated joint
10 Hydraulic control valve block 20 Steering cylinder

The machine is equipped with four drums. For enhanced traction the drums are provided with padfeet.
In contrast to the previous model this machine is now equipped with
l Articulated joint
l two amplitudes
l and two travel motors
.

Fig. 4 Forward travel

The travel system consists of a gear pump (2) (Fig. 4) and two travel motors (21) . Once travel motor each
drives the two front and the two rear drums as pairs.

008 915 77 BOMAG 245

9.2 Overview

Fig. 5
The steering system is hydraulically operated. The steering angle is set by extending a hydraulic cylinder (2)
(Fig. 5).

Fig. 6 Vibration
The vibration system works with two exciter units (22) (Fig. 5) and (Fig. 6). One exciter unit per axle. Both ex-
citers are hydraulically driven by means of a common gear pump (3) (Fig. 4) and one gear motor (3) (Fig. 6) each.
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.

246 BOMAG 008 915 77

Overview 9.2

Fig. 7
The machine is operated by the control unit.
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.

008 915 77 BOMAG 247

9.3 Multiple gear pump

9.3 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.

248 BOMAG 008 915 77

Multiple gear pump 9.3

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.

008 915 77 BOMAG 249

9.3 Multiple gear pump

Travel pump
Vibration pump Steering pump

Fig. 4

250 BOMAG 008 915 77

Vibration motor 9.4
Vibration motors
9.4 Vibration motor

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. 5 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

9.4 Vibration motor

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. 6

252 BOMAG 008 915 77

Travel motor 9.5
Travel motor
9.5 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 253

9.5 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.

254 BOMAG 008 915 77

Control valve block 9.6
9.6 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

M1 Travel pressure, 250 bar M3 Steering pressure, 100 bar

M2 Vibration pressure, 250 bar M4 Brake pressure, 20 bar

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.

008 915 77 BOMAG 255

9.6 Control valve block

Fig. 2 Overview of ports on control valve block

The ports on the control valve block are numbered and can thereby easily assigned to the respective consumer
ports.

256 BOMAG 008 915 77

Control valve block 9.6

1.1 Pressure relief valve for travel circuit (250 bar) L2 Leak oil vibration
1.3.1 Retardation brake valve, rear A1 to rear travel motor port A1
1.3.2 Retardation brake valve, front B1 to front travel motor port B1
1.2 4/3 way solenoid valve travel direction valve, A2 to rear vibration motor port A2
(Y16 & Y17)
2.1 Pressure relief valve for vibration circuit B2 to front vibration motor port B2
2.2 4/3-way solenoid valve 2nd gear (Y03) A3 to steering cylinder port A3
2.3 4/3-way solenoid valve vibration (Y56 & Y57)- B3 to steering cylinder port B3
Magnetventil Vibration, Y56 & Y57)
2.4 Pre-loaded check valve BR to port on brake cylinder BR
3.1 Pressure relief valve for steering P1 Connection travel pump P2
3.2 Pressure relief valve for brake P2 Connection vibration pump P1
3.3 3/2-way solenoid valve for brake, Y04 P3 Connection steering pump P3
3.5 4/3-way solenoid valve steering, Y237 & Y238 T1 Return flow to tank via oil cooler
3.6 Pre-loaded check valve T2 Return flow to tank, direct
L1 Leak oil travel control

008 915 77 BOMAG 257

9.7 Hoses

9.7 Hoses

258 BOMAG 008 915 77

Hoses 9.7

1 Cooler 7 Steering cylinder

2 Hydraulic oil tank 8 Front cross-member
3 Return flow suction filter and breather filter 9 Steering pump
4 Control valve block 10 Travel pump
5 Rear cross-member 11 Vibration pump
6 Brake cylinder

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. 1 Rear cross-member

008 915 77 BOMAG 259

9.7 Hoses

Fig. 2 Rear cross-member

1 Rear travel motor 3 Rear vibration motor

2 Rear cross-member

260 BOMAG 008 915 77

Travel system 9.8
9.8 Travel system
The multi-purpose compactor BMP 8500 works with a hydrostatic travel system. The travel circuits are open hy-
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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008 915 77 BOMAG 261

262
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008 915 77
Travel system
Travel system 9.8

Fig. 3

1 Travel motor 4 Gear

2 Cylinder roller bearing 5 Cylinder roller bearing
3 Drive shaft 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.

008 915 77 BOMAG 263

9.9 Vibration

9.9 Vibration

Fig. 1 Rear cross-member, with exciter unit

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

The vibration system of the machine is hydraulically driven. The vibration system consists of:

264 BOMAG 008 915 77

Vibration 9.9
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. Both cross-members carry separate exciter units. The two vibration motors are connected in series and
drive the exciter shafts directly .
The exciter unit ((Fig. 1)) consists of two exciter shafts with an eccentric weight (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
exciter shaft to opposite direction.
By reversing the sense of rotation, two amplitudes can be realized.

high amplitude (Fig. 2)

Fig. 2 high amplitude

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

008 915 77 BOMAG 265

9.9 Vibration

low amplitude (Fig. 3)

Fig. 3 low amplitude

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

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.

266 BOMAG 008 915 77

Checking the hydraulic oil level 9.10
9.10 Checking the hydraulic oil lev- 9.11 Change hydraulic oil and filter
el
i Note
! Caution See also the notes on the hydraulic system in the
chapter "General notes on maintenance".
If, during the daily inspection of the oil level the
hydraulic oil level is found to have dropped, check
all lines, hoses and components for leaks. Danger
!

In hydraulic systems filled with Panolin HLP Danger of scalding!

Synth. 46 use only the same oil to top up. With oth- When draining off hot hydraulic oil!
er ester based oils consult the lubrication oil serv-
ice of the respective oil manufacturer.
! Caution
For quality of oil refer to the "table of fuels and lu-
bricants". The hydraulic oil must also be changed after ma-
jor repairs in the hydraulic system.
Perform the oil change when the hydraulic oil is
warm.
Replace the hydraulic oil filter element with every
hydraulic oil change.
Clean the area round hydraulic oil tank, filler
opening and breather filter.
Do not start the engine after draining the hydraulic
oil.
Do not use any detergents to clean the system.
For quality and quantity of oil refer to the "table of
fuels and lubricants".
Fig. 4 When changing from mineral oil based hydraulic
l
Check the hydraulic oil level in the inspection glass oil to an ester based biologically degradable oil,
(Fig. 4) . you should consult the lubrication oil service of
the oil manufacturer for details.
l
If necessary remove the cover from the filter.
l
Fill up hydraulic oil up to the MAX mark in the in-
Environment
spection glass.
Catch running out oil and dispose of environmen-
l
Screw the cover back on. tally.
l
Drive the machine, until the hydraulic oil has
reached operating temperature.
l Shut down the engine.

008 915 77 BOMAG 267

9.11 Change hydraulic oil and filter

Fig. 5 Fig. 7
l Unscrew the plug (Fig. 5) and drain off all hydraulic l Check the oil level in the inspection glass (Fig. 7).
oil.
l Turn the plug tightly back in.

Fig. 6
l Unscrew the filter cover 1 (Fig. 6) and take out the
filter element.

i Note
We recommend to use the BOMAG filling and filtering
unit with fine filter to fill the system. This ensures finest
filtration of the hydraulic oil, prolongs the lifetime of the
hydraulic oil filter and protects the hydraulic system.
l Fill in new hydraulic oil.
l Insert a new filter and reassemble the filter cover.
l
Replace the breather filter (2).
l Perform a test run and check the system for leaks.

268 BOMAG 008 915 77

 10 Engine

008 915 77 BOMAG 269

Simple servicing due to excellent accessibility

Fig. 8

270 BOMAG 008 915 77

Kubota diesel engine 10.1
10.1 Kubota diesel engine
Series D1005
The BMP 8500 is powered by a powerful but still no-
ticeably quiet Kubota engine – a guarantor for high re-
liability and low service and repair costs.

Fig. 2

Fig. 1
The special ECO mode additionally protects the en-
gine and ensures a longer service life. If the remote
control does not send a control signal for a few sec-
onds when in travel mode, the engine will automatical-
ly change to idle speed. If an activation signal is
received again, the engine speed is increased again
within fractions of a second, in contrast to convention-
al trench compactors. This results in lower fuel con-
sumption while protecting the environment and being
immediately ready for operation.

Fig. 3
1 Intake manifold
2 Speed control lever
3 (Engine shut-down lever
4 Injection pump
5 Fuel pump
6 Fan
7 V-belt pulley
8 Oil filter element
9 Water drain tap
10 (Cover of the oil filler opening
11 Exhaust manifold
12 Generator
13 Starter

008 915 77 BOMAG 271

10.1 Kubota diesel engine

14 Oil dipstick Closed crankcase ventilation

15 Oil pressure switch
16 Flywheel
17 Oil drain plug
18 Oil sump
19 Engine hook

Fig. 6
1 Valve cover
2 Ventilation hose
3 Bleeding valve
4 Oil separator
5 Rubber seal
Fig. 4
The engines are equipped with a closed crankcase
The cylinder sequence is No. 1, No. 2 and No. 3, start-
ventilation to prevent blow-by gases from escaping
ing from the timing gear side.
into the atmosphere. Once the oil vapours have been
separated by the oil separator (4) in the valve cover,
Engine block the blow-by gas is fed through the ventilation valve (3)
into the intake manifold to be combusted again.
Semi-floating valve cover

Fig. 7

Fig. 5
1 Valve cover
2 Rubber seal
A installed rubber seal ensures a distance of approx.
0.5 mm (0.02 inch) between valve cover and cylinder
head. This reduces the development of noise on the
cylinder head.

272 BOMAG 008 915 77

Check the engine oil level 10.2
10.2 Check the engine oil level 10.3 Changing engine oil and oil fil-
ter
! Caution
The machine must be in horizontal position. When Danger
!
the engine is warm, shut it down and check the oil
Danger of scalding!
level after five minutes. With a cold engine the oil
level can be checked immediately. When draining off hot oil.
For quality of oil refer to the "table of fuels and lu- By hot oil when unscrewing the engine oil filter.
bricants".
Caution
!

The oil change at 250 operating hours refers to the

use of fuels with a sulphur content of less than
0.5%. When using fuels with a sulphur content
higher than 0.5% the oil change intervals must be
halved.
Drain the engine oil only when the engine is warm.
For quality and quantity of oil refer to the "table of
fuels and lubricants".

Environment
Catch running out oil and dispose of environmen-
Fig. 8 tally together with the oil filter cartridge.
l
Pull the dipstick (Fig. 8) out, wipe it off with a lint-
free, clean cloth and reinsert it until it bottoms.
l
Pull the dipstick back out.
The oil level must always be between the "MIN"- and
"MAX"-marks.
l
If the oil level is too low top up oil immediately.
l
If the oil level is too high, determine the cause and
drain the oil off.

Fig. 9
l Unscrew the drain plug (Fig. 9) and catch running
out oil.
l
Turn the drain plug tightly back in.

008 915 77 BOMAG 273

10.3 Changing engine oil and oil filter

Fig. 10 Fig. 13

l Unscrew the filter cartridge (1) (Fig. 10) using an

l
After a short test run check the oil level once again
appropriate filter wrench. (Fig. 13), if necessary top up to the top mark (MAX).
l Clean the sealing face on the filter carrier from any
dirt.

Fig. 11
l
Slightly oil the rubber seal on the new filter cartridge
(Fig. 11).
l
Turn the new filter cartridge on by hand, until the
seal contacts.
l
Tighten the filter element for another half turn.

Fig. 12
l Fill in new engine oil (Fig. 12).
l Tighten the oil filler cap properly.

274 BOMAG 008 915 77

Checking the coolant level 10.4
10.4 Checking the coolant level 10.5 Change the coolant

! Danger ! Danger

Danger of scalding! Danger of scalding!

Open the cap on the coolant compensation tank
only when the engine is cold.
! Caution
If, during the daily inspection the coolant level is
found to have dropped, check all lines, hoses and
engine for leaks.
For quality of coolant refer to "fuels and lubri-
cants".
Change the coolant only when the engine is cold.
Do not remove the radiator cap when the engine is
still hot.
Always wear gloves when handling anti-freeze
agent.
! Caution
Always screw the radiator cap tightly back on
(second detent).
Always fill the engine cooling system with an anti-
freeze mixture (corrosion protection).
Do not use more than 50% anti-freeze.
Do not mix different coolants and additives of any
other kind. If necessary flush the cooling system
2-3 times with clear water.
For quality and quantity of coolant refer to the "ta-
ble of fuels and lubricants".

Environment
Catch running out coolant and dispose of environ-
mentally.
Fig. 14
l
Check the coolant level (Fig. 14).
l
To top up unscrew the filler cap and fill in coolant up
to the MAX-mark.

Fig. 15
l Remove the radiator cap (Fig. 15).

008 915 77 BOMAG 275

10.5 Change the coolant

Fig. 16 Fig. 19

l Unscrew the drain valve (Fig. 16) from the radiator.

l
Fill in coolant up to the MAX mark (Fig. 19).
l Drain the coolant completely off and collect it.
l
Reattach the radiator cap and the cap of the com-
pensation tank.
l Screw the drain valve back in.
l Start the diesel engine and run it warm to operating
l Check the condition of radiator hoses, if necessary temperature.
replace all radiator hoses.
l
Let the engine cool down and check the coolant lev-
el again, if necessary top up in the compensation
tank.

Fig. 17
l
Open the drain valve (Fig. 17) on the engine.
l
Drain the coolant completely off the engine block
and collect it.
l
Close the drain tap again.

Fig. 18
l
Fill in coolant until the level reaches the bottom
edge of the radiator filler socket (Fig. 18).

276 BOMAG 008 915 77

Checking, tensioning, replacing the V-belt 10.6
10.6 Checking, tensioning, replac- Changing the V-belt
ing the V-belt

Danger
!

Danger of accident!
Perform this work only with the engine shut down.

Checking the V-belt

Fig. 20
l
Check the entire circumference of the V-belt (Fig.
20) for damage and cracks. Replace damaged or
cracked V-belts.
l
Check with thumb pressure whether the V-belt can
be depressed more than 7 to 9 mm between the V-
belt pulleys, retighten if necessary.
Fig. 22
l Slacken the fastening screws 1 and 2 (Fig. 22)
slightly.
l Press the generator completely against the engine.
l Take the old V-belt off.
l Fit the new V-belt to the V-belt pulleys.
l Tension the V-belt as previously described.
Caution
!
Check the V-belt tension again after a running
time of 30 minutes.

Tensioning the V-belt

Fig. 21
l Slacken the fastening screws 1 and 2 (Fig. 21)
slightly.
l Press the generator in direction outward using a le-
ver, until the correct V-belt tension is reached.
l Retighten all fastening screws and check the V-belt
tension once again.

008 915 77 BOMAG 277

10.7 Clean the cooling fins on engine and hydraulic oil cooler

10.7 Clean the cooling fins on en- l Spray engine and cooler with a suitable cleansing
agent, e.g. cold cleanser, let it soak in for a while
gine and hydraulic oil cooler and spray it off with a strong water jet.
l Run the engine warm for a while to avoid corrosion.
Danger
!

Danger of injury!
Perform cleaning work only after the engine has
cooled down and with the engine stopped.

Caution
!

Do not damage any cooling fins on the cooler core

when cleaning.

i Note
Dirt on fan blades and radiator reduce the cooling ef-
fect. Dirt deposits in these areas are substantially sup-
ported by oil and fuel on these surfaces. For this
reason you should always seal any oil or fuel leaks in
the vicinity of the cooling fan or the radiator and clean
the cooling surfaces after.

Cleaning with compressed air

i Note
Start to blow out from the exhaust side.

Fig. 23
l Blow the cooler (Fig. 23) out with compressed air
from the air discharge side.
l Blow the cooler out with compressed air from the air
supply side.

Cleaning with cold cleansing agent

Caution
!

Protect electrical equipment such as generator

and starter against the direct water jet.

278 BOMAG 008 915 77

Changing the fuel pre-cleaner, bleeding the fuel system 10.8
10.8 Changing the fuel pre-cleaner,
bleeding the fuel system

Danger
!

Fire hazard!
When working on the fuel system do not use open
fire, do not smoke.
Do not spill any fuel.

Danger
!

Health hazard! Fig. 25

Do not inhale any fuel fumes.

l
Apply a thin film of fuel to the seals and screw the
new filter cartridge (Fig. 25) on hand-tight.

Environment
Bleed the fuel system
Catch running out fuel, do not let it seep into the
ground.
Dispose of the used fuel filter environmentally.

Change the fuel filter cartridge

Fig. 26
l
Open the bleeding screw on the fuel filter (Fig. 26)
and crank the engine with the starter, until fuel runs
out without air bubbles.
l
Retighten the bleeding screw.
Fig. 24
l Loosen and unscrew the fuel filter cartridge (Fig.
24) using an appropriate filter wrench.
l
Cleaning the sealing face on the filter head.

Fig. 27
l Open the bleeding screw on the injection pump
(Fig. 27) and crank the engine with the starter, until
fuel runs out without air bubbles.
l Retighten the bleeding screw.

008 915 77 BOMAG 279

10.9 Check the water separator

10.9 Check the water separator 10.10Change the fuel lines

i Note i Note
The service intervals for the water separator depend For safety reasons this work should be performed
on the water content in the fuel and can therefore not every two years.
be determined precisely. After taking the engine into
Hoses consist of rubber or plastic material and age
operation you should therefore check the water sepa-
over the course of time.
rator every day for signs of water.

Danger
!
Environment
Fire hazard!
Any fuel must be caught and disposed of in an en-
vironmentally friendly manner. When working on the fuel system do not use open
fire, do not smoke and do not spill any fuel.
Do not inhale any fuel fumes.

Environment
Catch running out fuel, do not let it seep into the
ground.

Fig. 28
l Slacken the bleeding screw (1) (Fig. 28) for a few
turns.
l Slacken the drain plug (2) for a few turns and catch
running out fuel / water.
l Tighten drain and bleeding plugs again and check
for leaks, if necessary replace the seal ring. Fig. 29 084
l Replace all fuel hoses (Fig. 29) including their hose
clips.

280 BOMAG 008 915 77

Check, clean, replace the combustion air filter 10.11
10.11Check, clean, replace the
combustion air filter

! Caution
Do not use gasoline or hot fluids to clean the filter
cartridge.
After cleaning the filter cartridge must be inspect-
ed with a torch for damage.
Dry air filter cartridges with damaged filter ele-
ment or seal must be replaced in any case.
The dry air filter element must be replaced after 3
Fig. 31
times cleaning, but at the latest after one year, ir-
respective of the operating hours. l Open both clamps 1 (Fig. 31).
Each cleaning interval must be marked with a l Remove the filter hood.
cross on the cover of the filter element. l Clean filter hood and dust discharge valve (2).
Cleaning does not make sense if the cartridge is
covered with a sooty deposit. Use a new filter car-
tridge.
Incorrectly handled filter elements may become
ineffective because of damage (e.g.: cracks) and
cause engine damage.
When working in dusty environments the filter
service may become due considerably earlier.
This my be noticed by a drop in engine power and
black exhaust fumes.

Fig. 32
l Carefully loosen the filter element.
The filter element is located directly on the outlet tube,
thereby providing a seal on the inside of the filter cov-
er. Carefully remove the filter element, in order to re-
duce the released amount of dust. To release the seal
pull the filter element carefully up, down and sideways
or turn it (Fig. 32).

Fig. 30
Servicing of the dry air filter is necessary when the yel-
low piston (Fig. 30) has reached the inscription "Serv-
ice", but at the latest after one year.
After completion of the filter service reset the indicator
back to "Zero" by pressing the button.

Fig. 33
l Pull the filter element (Fig. 33) carefully out of the
housing.

008 915 77 BOMAG 281

10.11 Check, clean, replace the combustion air filter

Caution
!

Avoid contact between filter element and housing.

Fig. 36
l Insert the filter element (Fig. 36).
The radial sealing area is located at the inside of the
Fig. 34
open filter edge. This critical sealing area must be un-
l
Clean the sealing face on the outlet tube (Fig. 34). der slight tension after the filter has been installed. In
order to achieve a tight seal apply pressure to the out-
Dust on the outer diameter of the outlet tube can im-
er edge of the filter and not to the moveable centre.
pair effective sealing.
l Reinstall the filter hood with the dust discharge
valve.

Caution
!

The dust discharge valve must point vertically

downwards.

Dry cleaning of the filter cartridge

Danger
!

Eye injury!
Wear protective clothing (goggles, gloves).
Fig. 35
l Thoroughly clean the inside of the outlet tube (Fig.
35) and the filter housing.
Dirt that may incidentally drop into the outlet tube will
reach the engine and cause wear.
l
Check the old filter element.
The old filter element can be of help to discover for-
eign particles on the sealing face, which could lead to
leaks. A dust strip on the clean air side of the filter may
be a sign for thisEliminate the problem before install-
ing a new filter element.
l Clean or replace the filter element.
l Examine the filter element thoroughly for damage. Fig. 37

Before installing the new filter element check it for

possible damage from transport, cleaning or incorrect i Note
handling. Especially on the inside of the open end For cleaning purposes fit a tube to the compressed air
(sealing area). Do not install a damaged filter element. gun (Fig. 37), the end of which should be bent for ap-
prox. 90°.
The length should reach down to the bottom of the
cartridge.

282 BOMAG 008 915 77

Check the air intake hose 10.12
l Blow the cartridge out with compressed air (max. 5 10.12Check the air intake hose
bar) from inside to outside by moving the tube up
and down inside the cartridge, until it if free of dust.
l Examine the filter cartridge with a torch for cracks
and holes in the paper bellows.

! Caution
Do not continue to use a damaged filter element.
If in doubt use a new filter element.

Fig. 38
l Check the fastening of the hose clamps (Fig. 38),
tighten if necessary.
l Check the condition of the air intake hose, replace
if necessary.

008 915 77 BOMAG 283

10.13 Checking the engine oil pressure

10.13Checking the engine oil pres- 10.14Checking the thermostat in

sure disassembled state
The thermostat serves the optimal temperature con-
trol of the coolant, in order to promote efficient com-
bustion and to bring the engine quickly to operating
temperature after starting. At temperatures below ap-
prox. 69.5°C to 72.5°C the thermostat is closed. Once
the coolant temperature has reached this tempera-
ture, the thermostat will start to open, at about 85° C it
is fully open. In this condition the full coolant flow is
guided through the radiator.

Fig. 1
l Remove the engine oil pressure switch and install a
measuring adapter.
l
Start the engine. Once operating temperature has
been reached check the oil pressure at idle speed
and at nominal speed.

i Note
Fig. 1
An oil pressure below the permissible limit may have
one of the following causes:
l Measure and write down the measurement "a" on
the thermostat (Fig. 1).
Engine oil level too low
Oil pump defective
i Note
Oil strainer clogged "a" = beginning of stroke at approx. 69.5°C to 72.5°C
Oil filter cartridge clogged (T1)
Oil gallery clogged "b" = end of stroke at approx. 85 °C (T2)
Excessive oil gap in crankshaft bearings
Foreign bodies in pressure relief valve

At idle speed: 0.50 bar

At nominal speed: 2.00 to 4.50 bar

Permissible limiting value at nominal speed: 1.50

bar
l Retighten the engine oil pressure switch with the
specified torque.

Tightening torque:

15 to 19 Nm
Fig. 2
l Warm up the thermostat in a water bath (Fig. 2).

i Note
In order to determine the exact start of opening the
temperature should be measured as close to the ther-
mostat as possible, but without touching it.
The water must thereby be stirred continuously, to en-
sure even temperature distribution.

284 BOMAG 008 915 77

Check the injection valves
The temperature increase should not exceed 1°C/
min, as otherwise the start of opening will be delayed
accordingly.
10.15
10.15Check the injection valves
! Caution
Ensure strict cleanliness when working on the in-
jection system. Use only clean testing oil acc. to
ISO 4113 or clean diesel fuel to test the injection
valves.

Danger
!

Keep your hands away from the nozzle spray jet.

Fuel will penetrate deeply into the flesh and may
cause blood poisoning.

Nozzle spray pattern

Fig. 3
l Measure and write down the measurement "b" on
the thermostat . (Fig. 3).
l Calculate the stroke.

Stroke = b - a

i Note
Stroke:
BMP8500 and BW80-100-5, at the given temperature
(T2) approx. 8 mm.
BW135-138-5, at the given temperature (T2) approx.
6 mm.
If the measured value is not within the factory specifi-
cation, the thermostat needs to be replaced.

Fig. 1

(a) (Fig. 1) Correct

b) Not correct
l Mount the injection nozzle to a nozzle tester and
check the nozzle spray pattern.

i Note
If the spray pattern is not ok, replace the nozzle ele-
ment.

008 915 77 BOMAG 285

10.15 Check the injection valves

Fuel injection pressure Leak tightness of the nozzle element

Fig. 2 Fig. 4
l Mount the injection valve to the nozzle tester (Fig. l Mount the injection valve to the nozzle tester (Fig.
2). 4).
l
Slowly operate the testing lever to measure the l
Increase the fuel pressure and hold it 130.0 bar
pressure at which fuel starts to emerge from the over a period of 10 seconds.
nozzle.
l If this measurement is not compliant with the factory i Note
specifications replace the adjusting shim (1) in the If a fuel leakage is detected, replace the nozzle ele-
nozzle holder in order to adjust the nozzle pressure. ment.
Nominal value: 140.0 to 150.0 bar

Fig. 3

i Note
0.01 mm (0.0004 inch) difference in the adjusting shim
thickness 1 (Fig. 3) results in a opening pressure dif-
ference of approx. 2.35 bar.

286 BOMAG 008 915 77

Checking the start of commencement 10.16
Nozzle holder 10.16Checking the start of com-
mencement

Fig. 1
l
Remove the injection lines.
l Remove the engine shut-down solenoid.
l Slowly turn the flywheel (viewed against the fly-
Fig. 5 wheel) in counter clockwise direction, until the fuel
1 Nozzle holder upper part supply for opening the pressure maintaining valve
2 Adjusting shim (3) (Fig. 2) reaches the first cylinder.
3 Compression spring l
Turn the flywheel back for 1.6 rad (90°) in clockwise
4 Pressure bolt direction.
5 Spacer block l
Now turn the flywheel in counter clockwise direction
6 Nozzle element up to approx. 0.44 rad (25°) before TDC.
7 Nozzle holder lower part l
Turn the flywheel slowly further in counter clockwise
direction, until fuel starts to rise.
l
Clamp the lower part of the nozzle holder (7) (Fig.
5) in a vice. l
Read the degree on the flywheel. The flywheel has
marks "1TC", "10" and "20", which indicate the
l
Unscrew the nozzle holder (1) and take out the in-
crankshaft angle before the top dead centre (TDC)
ternal parts.
of piston no. 1.
Tightening torques: l
Check whether the start of commencement angle
line matches the alignment mark (2) (Fig. 1) on the
Nozzle holder (upper/lower part): 35 to 39 Nm
flywheel.
Leak oil line retaining nut: 20 to 24 Nm

Nozzle holder assembly: 49 to 68 Nm i Note

If the start of commencement has been de-adjusted it
needs to be corrected using the shims (4) (Fig. 3).

Fig. 2
1 Mark for start of commencement
2 Alignment mark

008 915 77 BOMAG 287

10.17
3 Pressure retaining valve
4 Shim (soft metal washer)
5 Two holes 0.20 mm (0.0079 inch): Two holes
0.175 mm (0.00689 inch)
6 One hole: 0.25 mm (0.0098 inch)
7 Without hole: 0.30 mm (0.012 inch)
8 Three holes: 0.35 mm (0.014 inch)
Fig. 3
Start of delivery:
0.3011 to 0.3272 rad
(17.25 to 18.75 °) before TDC
i Note
No sealing compound is to be used for assembly:
Shims are available with thickness values 0.20 mm
(0.0079 inch), 0.25 mm (0.0098 inch), 0.30 mm (0.012
inch), 0.35 mm (0.014 inch) and 0.175 mm (0.00689
inch) and must be combined as required by the install-
er.
The start of commencement is adjusted by approx.
0.0044 rad (0.25°) by adding or removing a shim with
a thickness of 0.025 mm (0.00098 inch).
When installing or replacing the injection pump make
sure to use the same amount of new shims with iden-
tical thickness.
The 0.175mm (0.00689 inch) shim is only coated from
the bottom side, it must therefore not be used as top
shim in this combination of shims (injection pump
side), as otherwise oil may leak out.
288 BOMAG
Checking the fuel injection pump
10.17Checking the fuel injection
pump
1 Injection pump pressure tester
2 Injection nozzle
3 Protective covering for running out fuel
Fuel leak tightness of the pump element
Fig. 1
l Remove the engine shut-down solenoid.
l
Remove injection lines and glow plugs.
l Mount the injection pump pressure tester to the in-
jection pump.
l Install an injection nozzle (2) (Fig. 1) set according
to factory specifications to the second port of the in-
jection pump pressure tester (1).
l
Set the throttle control lever to max. speed.
l Operate the starter to crank the engine.
i Note
If the pump does not reach the permissible limiting
value replace the pump or have it repaired in a work-
shop approved by BOMAG.
Nominal value: 140.0 bar
! Caution
Never dismantle the injection pump yourself.
Have repairs solely carried out in workshops ap-
proved by BOMAG.
008 915 77
Checking the compression 10.18
Fuel leaks on the control valve 10.18Checking the compression
l Run the engine warm and shut it down.
l Actuate the emergency stop switch.

Measurement with injection nozzle adapter

Fig. 2
l
Remove the engine shut-down solenoid.
l Remove injection lines and glow plugs.
l
Install the injection pump pressure tester to the in-
jection pump. Fig. 3

l
Install an injection nozzle (2) (Fig. 2) set according
l
Remove the injection nozzles.
to factory specifications to the second port of the in- l
Install a compression tester with nozzle adapter in-
jection pump pressure tester (1). stead of the injection nozzle.
l
Operate the starter to increase the pressure. Measurement with glow plug adapter
l Switch off the starter when fuel emerges from the
injection nozzle. Subsequently turn the flywheel by
hand and increase the pressure to approx. 140.0
bar.
l Turn the flywheel back by approx. half a turn and
hold it in this position.
l
Measure the time by which the pressure has
dropped from 140.0 to 130.0 bar.

i Note
If the measured pressure is below the permissible lim-
iting value replace the pump or have it repaired in a
workshop approved by BOMAG.
Factory specification: 140.0 to 130.0 bar, 10 sec-
onds.
Permissible limit: 140.0 to 130.0 bar, 5 seconds.
Fig. 4
l Remove the glow plugs.
l
Install a compression tester with glow plug adapter
instead of the glow plug.
Measurement
1) Once you made sure that the stop lever is in stop
position (no injection) crank the engine with the starter
and measure the compression pressure.
2) Repeat step 1) for each cylinder.
3) If the measured value is below the permissible limit
apply some oil to the cylinder wall through the nozzle
or glow plug bore and measure the compression pres-
sure again.
4) If the compression pressure is still below the per-
missible limit, check the upper clearance, the valve
clearance and the cylinder head.
5) If the compression pressure increases after oil has
been injected, check piston wall and piston rings.

008 915 77 BOMAG 289

10.19 Checking, adjusting the valve clearance

i Note 10.19Checking, adjusting the valve

Check the compression with properly adjusted valve clearance
clearance.
Always use a fully charged battery to check the com- !Caution
pression.
We recommend to have this work carried out by
The deviation between the individual cylinder should trained personnel or our after sales service.
not exceed 10%.
Check and adjust only when the engine is cold.
If the measuring result is below the permissible limit,
check cylinder, piston, valves and cylinder head. Cylinder 1 is on the flywheel side.
l Disassemble cylinder head cover and glow plug.
Factory data: 38.0 to 42.0 bar

Permissible limit: 23.0 bar

Fig. 5

Crankshaft position 1
IN = Intake valve
EX = Exhaust valve
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).

290 BOMAG 008 915 77

Checking, adjusting the valve clearance 10.19
Valve clearance for intake and exhaust valve:
0.145 - 0.185 mm

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-
ket.

i Note
After a short test run check the engine for leaks.

008 915 77 BOMAG 291

10.20 Engine problems

10.20Engine problems

Fault Possible cause Remedy

Engine does not Fuel tank empty Fill fuel tank

start
Fuel filter clogged, in winter due to paraf- Change the filter, use winter fuel
fin separation

Fuel lines leaking Check all line connections for leaks and
tighten the fittings

Battery not charged or not connected Charge the battery, check the pole
clamps

Operating error see section “Starting the engine”

Incorrect valve clearance Adjust the valve clearance

Inclination switch has switched off Reduce the inclination

Poor starting of Battery power too low Have battery checked

engine or en-
gine works irreg- Battery pole clamps loose or oxidized, Clean the pole clamps, tighten and cover
ularly with poor causing the starter to turn too slow them with acid-free grease
power Especially in winter: use of too viscous en- Use an engine oil complying with the am-
gine oil bient temperatures

Fuel supply too low, fuel system clogged Change the fuel filter. Check the line con-
by paraffin separation during winter nections for leaks and tighten the fittings.
Use winter fuel under cold conditions

The specified valve clearance is not cor- Adjust the valve clearance
rect

Injection valve or injection pump defective Have examined by a specialist

Engine looses Engine oil level too high Drain the oil down to the top dipstick mark
power and
speed, exces- Air filter dirty clean, if necessary use a new one
sive exhaust Poor compression due to burned or bro- Have piston rings and pistons examined
smoke ken piston rings or incorrect valve clear- by a specialist, adjust the valve clearance
ance

Injection valve defective Have examined by a specialist

Engine over- Cooling fins heavily soiled Clean the cooling fins
heating, engine
must be shut Injection valve defective Have examined by a specialist
down immedi- Engine oil level too high Drain the oil down to the top dipstick mark
ately!
Injection pump displacement not correctly Have corrected by a specialist
adjusted

Lack of cooling air Remove any clogging from the cooling air
duct

Engine has too Leaks in the lubrication system, oil level Check fittings on oil lines and lubrication
low oil pressure, too low oil filter for leaks, if necessary tighten all
engine must be fittings Fill up engine oil up to the mark on
immediately the dipstick
shut down!
Engine oil with wrong SAE viscosity class Change the engine oil

292 BOMAG 008 915 77

Engine problems 10.20
Fault Possible cause Remedy

Charge control The generator does not charge the bat- Have examined by a specialist
light lights up tery, because of defect on generator or
during operation regular

008 915 77 BOMAG 293

10.20 Engine problems

294 BOMAG 008 915 77

 11 Repair overview for drum

008 915 77 BOMAG 295

11.1
Fig. 1
1 Travel motor
2 Middle frame
3 Drum
4 Cover/flange
5 Cylinder roller bearing
6 Vibration motor
296
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
 12 Travel system

008 915 77 BOMAG 297

12.1 Special tools

12.1 Special tools

1. Pressing mandrel

Fig. 1
2. Puller

BOMAG part-no.: 720 028 04

Fig. 2

298 BOMAG 008 915 77

Repairing the travel system 12.2
12.2 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 299

12.2 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

300 BOMAG 008 915 77

Repairing the travel system 12.2
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 301

12.2 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

302 BOMAG 008 915 77

Repairing the travel system 12.2
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 303

12.2 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

304 BOMAG 008 915 77

Repairing the travel system 12.2
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 305

12.3 Assembling/removing the drum extension

12.3 Assembling/removing the drum ex-

tension

Assembly

Fig. 15

l Attach drum extensions 2 (Fig. 15) to the

drums, turn three fastening screws (1) into
each drum and tighten.

Removal
l Unscrew the fastening screws and take off
the drum extensions.
l Turn the fastening screws back into the
drum and fasten.

!Caution
In order to protect the threads turn the fas-
tening screws into the drums, even after re-
moving the drum extensions.

Danger
!

Danger of turning over!

When using drums with a working width of
610 mm the second speed range must not
be switched on.

306 BOMAG 008 915 77

 13 Exciter unit

008 915 77 BOMAG 307

13.1 Special tools

13.1 Special tools

1. Pressing mandrel

Fig. 1
2. Puller

BOMAG part-no.: 720 028 04

Fig. 2

308 BOMAG 008 915 77

Repairing the exciter unit. 13.2
13.2 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 309

13.2 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

310 BOMAG 008 915 77

Repairing the exciter unit. 13.2
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 311

13.2 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

312 BOMAG 008 915 77

Repairing the exciter unit. 13.2
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 313

13.2 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

314 BOMAG 008 915 77

Repairing the exciter unit. 13.2
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 315

13.2 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

316 BOMAG 008 915 77

Repairing the exciter unit. 13.2
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 317

13.3 Change the oil in the vibrator shaft housing

13.3 Change the oil in the vibrator shaft

housing

!Caution
Change the oil at operating temperature. For
this purpose run the machine approx. half
an hour with vibration.

Environment
Catch running out oil and dispose of envi-
ronmentally.
Fig. 21
Danger
!
l Jack up the opposite side of the machine
Danger of injury! and secure it adequately (Fig. 21).
Do not step under suspended loads.

Fig. 22

Fig. 19 l Top up oil through the oil drain hole in the

l Lift the machine up and support it safely bottom drum.
(Fig. 19). For quality and quantity of oil refer to the ta-
ble of fuels and lubricants.
l Screw the drain and ventilation plugs back
in.

Fig. 20

l Unscrew the drain and filling plug on the

front drum (Fig. 20).
l Drain and catch all oil. Fig. 23

l Unscrew the drain and ventilation plugs

(Fig. 20) from the upper drum.
l Drain and catch all oil.

318 BOMAG 008 915 77

Change the oil in the vibrator shaft housing 13.3

Fig. 24

l Jack up the opposite side of the machine

and secure it adequately (Fig. 19).

Fig. 25

l Top up oil through the oil drain hole in the

bottom drum.

For quality and quantity of oil refer to the ta-

ble of fuels and lubricants.
l Screw the drain and ventilation plugs back
in.

008 915 77 BOMAG 319

13.3 Change the oil in the vibrator shaft housing

320 BOMAG 008 915 77

 14 Suppliers documentation

008 915 77 BOMAG 321

322 BOMAG 008 915 77
 14.1 Travel motor

008 915 77 BOMAG 323

14.1 Travel motor

324 BOMAG 008 915 77

Travel motor 14.1

® No. 7-124
Char-Lynn July, 1999

Hydraulic Motor

Repair Information

2000 Series
Disc Valve Geroler Motor 006

008 915 77 BOMAG 325

 14.1 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

326 BOMAG 008 915 77

Travel motor 14.1

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 327

 14.1 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.

328 BOMAG 008 915 77

Travel motor 14.1

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 329

 14.1 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.

330 BOMAG 008 915 77

Travel motor 14.1

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 331

14.1 Travel motor

332 BOMAG 008 915 77

Travel motor 14.1

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 333

 14.1 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

334 BOMAG 008 915 77

Travel motor 14.1

2000 Series Disc Valve Motors

Notes:

11

008 915 77 BOMAG 335

 14.1
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
336
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
 15 Circuit diagrams

008 915 77 BOMAG 337

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 15.1 Hydraulic diagram 21

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