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Operating instructions Maintenance instructions - AL Del

1. nected to 12V 5061 machine control is tential 15 working engine is 5062 j Although the output stopped or cannot be is switched off volt started age is present 5070 Output switched off Output relay K 39 Excessive current X3 06 engine cannot be starter ee ae Too ae current flow a defective coil ora out or inis output short circuit to Output was switched ground off 5071 Output switched off Output relay K 39 Wire breakage in X3 06 engine cannot be starter a nn started Short circuit current I bacon i nected to 12V flow out of this output Lines rubbed Output was switched through off 5072 Output switched off Output relay K 39 Wire breakage in X3 06 5070 engine cannot be starter current path 5071 started Nasroolow sarene o Sit path con nected to 12V 5072 flow out of this output 5073 All outputs switched Output relay K 39 Current path con X3 06 5070 off engine stopped starter nected to 12V 5071 safety relay switched er y retay Although the output 5072 is switched off volt age is present 120 BOMAG BMP 8500 Trouble shooting Code Fault reaction Description of fault Possible cause Terminal Input on BLM code for diagnose 5080 Output switched off Output horn H 07 a ee X3 08 ow in current pat 5085 horncannotsound Too high current flow X3 36 t t ie Stu probably because of P a defective coil or a Output was switched short circui
2. BOMAG fa FAYAT GROUP Operating instructions Maintenance instructions Original operating instructions BMP 8500 S N 101 720 11 1082 bis 101 720 11 1091 S N 101 720 11 1112 bis 101 720 11 1116 S N 101 720 11 1121 gt Multi purpose compactor Catalogue No 008 059 81 09 2010 If the machine is equipped with a battery CALIFORNIA Proposition 65 Warning _ Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling If the machine is equipped with a diesel engine CALIFORNIA Proposition 65 Warning The engine exhaust and some of its constituents are known to the state of California to cause cancer birth defects and other reproductive harm BOMAG machines are products from the wide range of BOMAG compaction equipment BOMAG s vast experience in connection with state of the art production and testing meth ods such as lifetime tests of all important components and highest quality demands guarantee maximum reliability of your ma chine This manual comprises e Safety regulations e Operating instructions e Maintenance instructions J Trouble shooting Using these instructions will e help you to become familiar with the machine e avoid malfunctions caused by unprofessional operation Compliance with the maintenance instructions will
3. Driven drums Brake Service brake Parking brake Steering 8 BOMAG 25 850 km h km h kW rpm 720039 Wy 610 BMP 8500 1595 1585 775 0 to 1 3 0 to 2 5 55 45 Kubota D 1005 Water 3 14 5 2600 hydrostatic front rear hydrostatic mechanical BMP 8500 Type of steering Steering operation Vibration system Vibrating drum Drive system Frequency Amplitude Centrifugal force Filling capacities Fuel diesel Hydraulic oil Engine oil Coolant Vibration housing Safety field system Performance level Reach of the safety field infront of behind the machine Safety field control Voltage Current consumption 12 V Protection class Safety field frequency Operating temperature Storage temperature Transponder in remote control Voltage cable operation Voltage battery operation Transmitting frequency range Operating temperature Storage temperature Safety field antenna Protection class Operating temperature Storage temperature Radio remote control Manufacturer Transmitter Frequency band Transmitting frequency range Number of channels Reach depending on environment BMP 8500 BOMAG Technical Data BMP 8500 Articulated joint hydrostatic front rear hydrostatic Hz 42 mm 1 12 0 56 kN 72 36 24 l 17 4 7 4 5 2x 1 7 PLc m gt 1 20 V 8 30 A 1 5 IP 55 kHz 125 C 20 80 C 40 85 V 9 30 V 3 6 MHz
4. G 723161 Fig 33 Fig 36 e For radio operation of the machine switch the e Switch on the ignition Fig 36 toggle switch Fig 33 to the right With the ignition key in position 1 the machine type code will appear in the display module for a few seconds The machine will emit a short horn signal This in dicates that the machine is ready for operation Q If the horn does not sound there must be fault on the machine The control emits two short buzzer signals This in dicates that the control is ready for operation 723153 Fig 34 e If necessary unlock the emergency stop switch Fig 34 BMP 8500 BOMAG 37 Operation If the buzzer does not sound there must be a fault in the control or the power pack of the control is empty All normal work functions can only be operated from a defined neutral position i e the respective control elements must be in rest position when switching the sender on If this is not true the en gine cannot be started Fig 37 e Press the start button to start the engine Fig 37 Run the engine warm for a short while before starting work Do not rev up a cold engine to high idle speed full load speed Starting with jump wires A wrong connection will cause severe damage in the electric system e Open the rear hood 38 BOMAG 720 113 e Switch on the main battery switch Fig 38 Only use a 12 volt battery for jump starting Fig 39
5. If the radio remote control is not going to be used for a longer period of time we strictly rec ommend to take the batteries out of the trans mitter and to recharge them approx every four weeks This avoids complete discharging and prolongs the lifetime of the power packs BMP 8500 Operation Fig 70 e Turn the ignition key Fig 70 to position 0 Transmitter and engine will be switched off after two seconds the green control light on the trans mitter goes out 720 113 Fig 71 e Switch off and pull out main battery switch 1 Fig 71 e Plug the safety cap on the lock BMP 8500 Fig 72 e Pull off the ignition key Fig 72 and store it in a safe place If the power pack of the remote control is to be re charged via the remote control cable the main battery switch Fig 71 must be switched on Cleaning after use Keep the radio remote control clean Rests of concrete clay or mortar may damage the bellows on travel levers and sealing caps on toggle switches so that water can enter Do not use a water jet or a high pressure or steam cleaner for cleaning e After work clean the transmitter with a clean cloth or brush e Check the state of bellows and sealing caps at regular intervals have replaced by an expert if necessary BOMAG 49 Operation 4 12 Replacing recharging the radio remote control power pack As standard the power pack is recharged in the machine through the
6. e enhance the reliability of the machine on con struction sites e prolong the lifetime of the machine e reduce repair costs and downtimes BOMAG GmbH will not assume liability for the function of the machine e if itis handled in a way that does not comply with the usual modes of use e if itis used for purposes other than the ones it is intended for see safety regulations No warranty claims can be lodged in case of dam age resulting from e operating errors e insufficient maintenance and e wrong fuels and lubricants Please note This manual was written for operators and mainte nance personnel on construction sites Always keep this manual close at hand e g in the tool compartment of the machine or in a specially provided container These operating and mainte nance instructions are part of the machine BMP 8500 Foreword You should only operate the machine after you have been instructed and in compliance with these instructions Strictly observe the safety regulations Please observe also the guidelines of the Civil En gineering Liability Association Safety Rules for the Operation of Road Rollers and Soil Compac tors and all relevant accident prevention regula tions For your own personal safety you should only use original spare parts from BOMAG In the course of technical development we re serve the right for technical modifications without prior notification These operating and m
7. 6 12 months The conserving oil must be replaced by engine oil according to the API MIL classification before taking the machine into operation Refer to the section Fuels and lubricants BMP 8500 As required Anti corrosion oils are those that comply with the specification MIL L 21260 B or TL 9150 037 2 or Nato Code C 640 642 Mark a machine with a conserved engine by at taching a clearly visible warning tag BOMAG 97 As required 98 BOMAG BMP 8500 BMP 8500 6 Trouble shooting BOMAG 99 Trouble shooting 6 1 General notes The following work must only be carried out by qualified and trained personnel or by the BOMAG sales service Please observe strictly the safety regulations in chapter 2 of these operating and mainte nance instructions Malfunctions are frequently caused by incorrect operation of the machine or insufficient mainte nance Whenever a fault occurs you should there fore thoroughly read these instruction on correct operation and maintenance If you cannot locate the cause of a fault or rectify it yourself by following the trouble shooting chart you should contact the service departments at our branch offices or deal ers On the following pages you will find a selection of fault remedies It goes without saying that not all possible reasons for faults could be listed Danger of injury Do not touch rotating parts of the engine 100 BOMAG BMP 8500
8. 6 2 Engine problems Trouble shooting Fault Possible cause Remedy Engine does not start Fuel tank empty Fuel filter clogged in winter due to paraf fin separation Fuel lines leaking Battery not charged or not connected Operating error Incorrect valve clearance Fill fuel tank Change the filter use winter fuel Check all line connections for leaks and tighten the fittings Charge the battery check the pole clamps see section Starting the engine Adjust the valve clearance Inclination switch has switched off Reduce the inclination Poor starting of engine or en gine works irreg ularly with poor power Battery power too low Battery pole clamps loose or oxidized causing the starter to turn too slow Especially in winter use of too viscous en gine oil Fuel supply too low fuel system clogged by paraffin separation during winter The specified valve clearance is not cor rect Injection valve or injection pump defective Have battery checked Clean the pole clamps tighten and cover them with acid free grease Use an engine oil complying with the am bient temperatures Change the fuel filter Check the line con nections for leaks and tighten the fittings Use winter fuel under cold conditions Adjust the valve clearance Have examined by a specialist Engine looses power and speed exces sive exhaust smoke Engine oil level too high Air fi
9. 10 Toggle switch engine speed Position MIN idle speed of engine Position MAX maximum engine speed BMP 8500 Indicators and Controls No 11 Travel direction control lever Middle position Stop position Position front Forward travel Position rear Backwards travel 0 wi Fig 22 No 12 Toggle switch for vibration high low amplitude Position front high amplitude Position mid dle vibration switched off Position rear low amplitude BOMAG 29 Indicators and Controls 5 723153 Fig 23 No 13 Emergency stop push button actuated transmitter and diesel engine will be switched off unlocked switches the transmitter on when the ignition is switched on 720041 Fig 24 No 14 Control light data transfer power pack radio remote control Flashes green when the transmitter is switched on Lights red when the accumulator voltage drops too low 30 BOMAG Fig 25 No 15 Start button to start the engine Perform the starting process formaximum 15 to 20 seconds without interruption and pause for about 1 minute between starting attempts Should the engine not start in this time perform trouble shoot ing and rectify the cause Fig 26 No 16 Ignition switch Position 0 Insert or pull out key ignition engine off Position Ignition on charge and oil pressure control lamps light up BMP 8500 Indicators and Controls Fig 2
10. 121 Trouble shooting Code Fault reaction Description of fault Possible cause Terminal Input on BLM code for diagnose 5101 Vibration and 2 gear Input coolant tem Lack of coolant X3 05 5100 switched off B53 perature sensor Coolant temperature too high over a long er period of time Radiator defective Sensor defective Fault in BOSS safety system Code Fault reaction Description of fault Possible cause 6001 Machine travels for 15min Warning that service mode is Service mode activated via in without activated BOSS safe active put code ty system Attention Only for servicing purposes 6010 Travel movement not possi Fault of front safety field an Wire breakage in current ble only steering tenna W12 path front safety field anten na defective 6011 Travel movement not possi Fault of rear safety field an Wire breakage in current ble only steering tenna W13 path rear safety field antenna defective 6012 Travel movement not possi Transponder fault no feed Fault in radio link of safety ble only steering back system transponder of re mote control defective 6013 Travel movement not possi Transponder fault Internal fault in transponder of ble only steering remote control 6014 Travel movement not possi Fault in safety field control Internal fault in safety field ble only steering A115 control 6015 Travel movement not possi Fault
11. 2 6 3 6 4 6 5 6 6 6 7 6 8 Draining the fuel tank sludge Changing the fuel pre cleaner bleeding the fuel system Battery service checking the main battery switch Check the rubber buffers Checking adjusting the valve clearance Safety field measurement of the Boss safety system Change hydraulic oil and filter Change the coolant Change the fuel lines Checking the injection pressure Checking the fuel injection pump Checking the fuel injection timing Check clean replace the combustion air filter Adjust the scrapers Tightening torques for screws with metric unified thread Engine conservation General notes Engine problems Problems with remote control Hetronic with spiral cable Problems with radio remote control Hetronic in radio operation Faults in BOSS safety system Fault indicator Fault code Input codes for BLM control BOMAG 81 81 83 84 85 86 87 88 90 90 91 91 93 96 96 97 99 100 101 103 107 109 110 111 124 BMP 8500 BMP 8500 1 Technical Data BOMAG Technical Data Dimensions in A D H K B mm BMP 8500 1000 520 1275 222 1897 Weights Operating weight CECE Basic weight Mean axle load CECE Travel characteristics Travel speed 1 forward reverse Travel speed 2 forward reverse Max gradability without with vibration soil dependent Drive Engine manufacturer Type Cooling Number of cylinders Rated power ISO 9249 Rated speed Drive system
12. 2 Fig 105 slightly Press the generator completely against the engine Take the old V belt off Fit the new V belt to the V belt pulleys Tension the V belt as previously described 75 Every 250 operating hours Check the V belt tension again after a running time of 30 minutes 76 BOMAG 5 14 Clean the cooling fins on engine and hydraulic oil cooler Danger of injury Perform cleaning work only after the engine has cooled down and with the engine stopped Do not damage any cooling fins on the cooler core when cleaning Dirt on fan blades and radiator reduce the cooling effect Dirt deposits in these areas are substantial ly supported 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 radia tor and clean the cooling surfaces after Cleaning with compressed air Start to blow out from the exhaust side Fig 106 e Blow the cooler Fig 106 out with com pressed air from the air discharge side e Blow the cooler out with compressed air from the air supply side BMP 8500 Cleaning with cold cleansing agent Protect electrical equipment such as generator and starter against the direct water jet e Spray engine and cooler with a suitable cleansing agent e g cold cleanser let it soak in for a while and spray it off with a strong wa ter jet e Run the engine warm for a while to avoid cor rosion BMP 85
13. 5050 off engine runs only engine speed sole Nected to 12V 5051 with idle speed noid 5052 Although the output is switched off volt age is present 5054 Input AUX signal Wire breakage in X3 04 engine solenoid Y Current path 13 5060 Output switched off Output relay K 11 Excessive current X3 07 no potential 15 on changeover of po flow in current path machine controlis tential 15 probably because of working engine is Too high current flow lt a stoppedorcannotbe out of this output short circuit to started p ground Output was switched off BMP 8500 BOMAG 119 Trouble shooting Code Fault reaction Description of fault Possible cause Terminal Input on BLM code for diagnose 5061 Output switched off Output relay K 11 Short circuit to X3 07 no potential 15 on changeover of po ground in the current machine controlis tential 15 path working engine is Shorscreuiteunene one stopped or cannotbe flow out of this output trough started Output was switched off 5062 Output switched off Output relay K 11 Wire breakage in X3 07 5060 no potential 15 on changeover of po Current path 5061 machine control is tential 15 Current path con working engine is Nooriociowemment ee ee stoppedorcannotbe flow out of this output started 5063 Output switched off Output relay K 11 Current path con X3 07 5060 no potential 15 on changeover of po
14. 868 916 C 20 80 C 40 85 IP 55 C 20 85 C 40 85 HETRONIC F band MHz 868 916 1 m approx 30 9 Technical Data Current draw Weight Receiver Receiver frequency range Current draw Transmitter power pack Voltage Capacity Battery charger Operating voltage The right for technical modifications remains reserved BOMAG mA kg MHz mA BMP 8500 approx 10 approx 1 6 868 916 approx 10 110 230 12 24 BMP 8500 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 harmo nized standards During operation these values may vary because of the existing operating conditions Noise value Sound pressure level on the place of the operator Loa 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 Wear your personal noise protection means ear defenders before starting operation BMP 8500 BOMAG 11 Technical Data BOMAG BMP 8500 BMP 8500 2 Safety regulations BOMAG 13 Safety regulations General This BOMAG machine has been built in com pliance with the latest technical standard
15. O K 600034 Fig 121 e Check all rubber buffers Fig 121 for tight fit cracks and damage and replace immediately if damaged 84 BOMAG BMP 8500 5 21 Checking adjusting the valve clearance We recommend to have this work carried out by trained personnel or our after sales service Check and adjust only when the engine is cold Cylinder 1 is on the flywheel side e Disassemble cylinder head cover and glow plug Fig 122 Crankshaft position 1 IN Intake valve EX Exhaust valve e Crank the engine until both valves on cylinder 1 are overlapping e Perform the adjustment of the valve by follow ing the adjustment diagram 1 Fig 122 black mark BMP 8500 Every 1000 operating hours 0 145 0 185 mm 0 006 0 007 inch Fig 123 e Check the gap between rocker arm and valve with a feeler gauge Fig 123 Valve clearance for intake and exhaust valve 0 145 0 185 mm 462089 Fig 124 Crankshaft position 2 IN Intake valve EX e Turn the crankshaft one revolution 360 fur ther e Perform the adjustment of the valve by follow ing the adjustment diagram 2 Fig 124 black mark Exhaust valve e Assemble the cylinder head cover with a new gasket After a short test run check the engine for leaks BOMAG 85 Every 1000 operating hours 5 22 Safety field measurement of the Boss safety system Danger of injury The safety field of the machine must be
16. Stirr well before filling it into the radi ator The method for mixing water and anti freeze agent depends on the brand of the anti freeze agent In this respect see standard SAE J1034 and also the standard SAE J814c Add anti freeze agent If the coolant level drops because 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 BMP 8500 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 mixes with cleaning agent it may cause the development of sludge which could damage the cooling system Anti freeze concentration 50 37 C 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 mm s at 40 C For topping up or for oil chang es 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 in dex VI should be at least 150 observe informa tion of manufacturer Bio degradable hydraulic oil The hydraulic system can also be operated with a synthetic ester based biodegradable hydraulic oil The biologically quickly degradable hydra
17. Turn the fastening screws back into the drum and fasten In order to protect the threads turn the fasten ing screws into the drums even after removing the drum extensions Danger of turning over When using drums with a working width of 610 mm the second speed range must not be switched on 56 BOMAG 4 18 Loading and transport Danger of accident Use only stable loading ramps of sufficient load bearing capacity Make sure that persons are not endangered by the machine tipping or sliding off Always engage the articulation lock before loading lifting and transporting the machine Lash the machine down so that no persons are endangered by the machine falling off sliding about or turning over Lift the machine only with suitable lifting gear Weights see chapter Technical Data Always use shackles on the lifting points for loading tying or lifting the machine Do not step or stand under suspended loads The machine must not swing about when be ing lifted Check the lifting eye before lifting the machine It must be free of cracks Fig 88 e After driving the machine on the transport ve hicle pull out the locking knob 1 Fig 88 and engage the articulation lock in the locking eye 2 Let the locking knob click into place BMP 8500 Fig 89 Use the central lifting facility Fig 89 to lift the ma chine 512mm 475 mm 720 109 Fig 90 e Posi
18. and complies with the applicable regulations and technical rules However dangers for persons and property may arise from this machine if e itis used for purposes other than the ones it is intended for e itis operated by untrained personnel e itis changed or converted in an unprofessional way e the safety instructions are not observed Each person involved in the operation mainte nance and repair of the machine must there fore read and comply with these safety regulations If necessary this must be con firmed by obtaining the signature of the cus tomer Furthermore the following obviously also applies e applicable accident prevention instructions e generally accepted safety and road traffic reg ulations e country specific safety regulations It is the duty of the operator to be acquainted with these instructions and to apply these accord ingly This applies also for local regulations concerning different types of handling work Should the recommendations in these instruc tions be different from the regulations valid in your country you must comply with the safety regulations valid in your country Intended use This machine must only be used for e Compaction of cohesive soils in trench con struction Construction backfills Earthwork in sewer and pipeline construction Earthwork in railway and dam construction Earthwork in sanitary landfill construction Subbase and foundation work The place of
19. e When starting with an external battery connect the plus poles Fig 39 first and the minus poles ground cable after Switch the vibration off Start the engine as described above After starting disconnect the cable from the mi nus poles ground cable first and from the plus poles last e Fold the control box back in and close the hood BMP 8500 Starting under low temperatures Fig 40 Do not use any starting aid spray Fig 40 BMP 8500 Operation 4 6 Driving the machine cable remote control Danger of accident Before starting to drive make sure that the drive range is absolutely safe Wet and loose soils considerably reduce the ground adhesion of the machine on inclina tions and slopes Do not drive up and down inclinations exceed ing the maximum gradability of the machine see technical data Slowly return the travel lever towards neutral when driving down slopes Before starting to drive check the function of the remote control During operation of the machine with remote control the operator must always stay behind or beside the machine Specified directions ap ply only if the operator is standing behind the machine If the operator is standing in front of the machine all machine movements will be opposite to the movement of the control lever The machine must only be operated with re mote control strapped to the body The machine must only be operated within the field of visi
20. engine and cause wear e Check the old filter element The old filter element can be of help to discover foreign 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 prob lem before installing a new filter element e Clean or replace the filter element e Examine the filter element thoroughly for dam age Before installing the new filter element check it for possible damage from transport cleaning or incor rect handling Especially on the inside of the open end sealing area Do not install a damaged filter element Fig 141 e Insert the filter element Fig 141 BMP 8500 The radial sealing area is located at the inside of the open filter edge This critical sealing area must be under slight tension after the filter has been in stalled In order to achieve a tight seal apply pres sure to the outer edge of the filter and not to the moveable centre e Reinstall the filter hood with the dust discharge valve The dust discharge valve must point vertically downwards Dry cleaning of the filter cartridge Eye injury Wear protective clothing goggles gloves For cleaning purposes fit a tube to the compressed air gun Fig 142 the end of which should be bent for approx 90 The length should reach down to the bottom of the cartridge e Blow the cartridge out with compressed air max 5 bar from inside to
21. gt Bow operated 1408 Input limit switch for safety bow front 12 V gt Bow not operated B 189 Ground OV gt Bow operated 1409 Activation input cable remote con 12 V gt Operating mode cable remote control trol S 101 1410 Activation input infrared remote con 12 V gt Operating mode wireless trol S 101 Diesel engine machine electrics Input code Description of display function Display values 5010 Engine speed Engine speed 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 Shows the switching state of the inclina 457 or switch defective tion switch 0001 OK inclination of machine less than 457x 5040 Output bia winding of shut down sole Display value output voltage in Volt noid Y 13 Voltage at output 5041 Output bia winding of shut down sole Display value output current in AmperD noid Y 13 Current at output 5042 Output bia winding of shut down sole 0000 Output not triggered noid Y 13 0001 Output triggered Logic level of control 5050 Output relay K 114 engine speed so Display value output voltage in Volt lenoid Voltage at output 126 BOMAG BMP 8500 Trouble shooting Input code Description of display function Display values 5
22. leave the tank opening unnecessarily open but cover it so that nothing can fall in BMP 8500 Maintenance 5 2 Fuels and lubricants Engine oil Quality Lubrication oils are classified according to their performance and quality class Oils according to other comparable specifications may be used If low sulphur fuel lt 0 05 is used you must only use engine oils of API classification CF CF 4 CG 4 CH 4 and CI 4 For operation of an engine with high sulphur fuels it is recommended to use an engine oil of classifi cation CF or higher with a total base number of at least 10 Engine oils of classification CJ 4 must not be used Oil viscosity Since lubrication oil changes its viscosity with the temperature the ambient temperature at the oper ating location of the engine is of utmost impor tance when choosing the viscosity class SAE class Optimal operating conditions can be achieved by using the following oil viscosity chart as a refer ence Ambient temperature Viscosity SAE 30 SAE10W 30 SAE 15W 40 over 25 C SAE 20 SAE10W 30 SAE 15W 40 0 C to 25 C below 0 C SAE 10 SAE10W 30 SAE 15W 40 American Petroleum Institute BOMAG 61 Maintenance Oil change intervals The longest permissible time a lubrication oil should remain in an engine is 1 year If the follow ing oil change intervals are not reached over a pe riod of 1 year the oil change shou
23. oil level top up if necessary e Hydraulic oil level top up if necessary e Fuel level top up if necessary e Coolant level top up if necessary e Water level top up if necessary BOMAG BMP 8500 4 3 BOSS safety system Function Fig 29 The machine is surrounded by 2 spherical electro magnetic safety fields Fig 29 If the machine op erator with the remote control enters into the field which stretches in travel direction the machine will stop immediately e Shift the travel lever to neutral position and exit the field which corresponds with the travel di rection e Operate the machine to the opposite direction picture so that the operator is no longer in the safety field of the machine The operator must become acquainted with the size of the safety field before he starts op eration If an operator is between 2 machines in both safety fields both corresponding travel direc tions of the associated machines will be stopped The operator must leave the safety field to be able to move the machine again The minimum distance between operator and machine must be 2 m When falling short of a distance of 1 2 m the corresponding travel di rection will be stopped BMP 8500 Operation Danger of squashing Only operators carrying the associated remote control are protected There is no protection for persons laying on the ground BOMAG 35 Operation 4 4 Electronic immobilizer Before star
24. outside by moving the tube up and down inside the cartridge until it if free of dust e Examine the filter cartridge with a torch for cracks and holes in the paper bellows BMP 8500 BOMAG As required Do not continue to use a damaged filter ele ment If in doubt use a new filter element 95 As required 5 30 Adjust the scrapers Ifthe scrapers 2 per drum are worn they must be adjusted or replaced Fig 143 e Loosen the fastening screws Fig 143 on both sides of the machine e Adjust the scrapers to a distance of approx 5 mm to the drum e Tighten the fastening screws 96 BOMAG 5 31 Tightening torques for screws with metric unified thread Tightening torques Nm Bolt dimensions Ber Loe 3 5 5 6 9 Fig 144 Strength classes for screws with untreated non lubricated surface Screw quality designations are stamped on the screw heads 8 8 8G 10 9 10K 12 9 12K e Drum extension drum 652Nm The values result in a 90 utilization of the screw s yield point at a coefficient of friction total 0 14 Compliance with the specified tightening tor ques is checked with torque wrenches When us ing MoS lubricants the specified tightening torques do not apply Self locking nuts must always be replaced once they have been unscrewed BMP 8500 5 32 Engine conservation If the engine is to be shut down for a longer period of time e g during winter we recommend the
25. perform maintenance work while the ma chine is driving or the engine is running Park the machine on horizontal level firm ground Pull off the ignition key and switch off the main bat tery switch Work on hydraulic lines Relieve hydraulic pressures before working on hy draulic lines Hydraulic oil escaping under pres sure can penetrate the skin and cause severe injury When being injured by hydraulic oil consult a medical doctor immediately as otherwise this may cause severe infections Do not step in front of or behind the drums when performing adjustment work in the hydraulic sys tem Do not change the setting of pressure relief valves Drain the hydraulic oil at operating temperature danger of scalding Catch running out hydraulic oil and dispose of en vironmentally Always catch and dispose of hydraulic oils sepa rately Do not start the engine after draining the hydraulic oil Once all work is completed with the system still depressurized check all connections and fittings for leaks Changing hydraulic hoses Hydraulic hoses must be visually inspected at reg ular intervals Hydraulic hoses must be immediately replaced if e the outer layer is damaged down to the inlay e g chafing cuts cracks e the outer layer is brittle formation of cracks in the hose material 18 BOMAG e the hose shows deformations in pressurized and depressurized condition which do not comply with the genu
26. repair fuses with a piece of wire Fire haz ard BMP 8500 Working on the battery When working on the battery do not smoke do not use open fire Do not let acid come in contact with hands or clothes When injured by acid flush off with clear water and seek medical advice Metal objects e g tools rings watch straps must not come in contact with the battery poles dan ger of short circuit and burning When recharging non serviceable batteries re move all plugs to avoid the accumulation of explo sive gases Observe the applicable instructions when starting with an auxiliary battery Dispose of old batteries according to regulations Switch off the charging current before removing the charging clamps Ensure sufficient ventilation especially if the bat tery is to be charged in a closed room Working on the fuel system Do not inhale any fuel fumes Avoid open fire do not smoke do not spill any fuel Catch running out fuel do not let it seep into the ground and dispose off environmentally Cleaning work Do not perform cleaning work while the motor is running Do not use gasoline or other easily inflammable substances for cleaning When cleaning with steam cleaning equipment do not subject electrical parts and insulation material to the direct jet of water or cover it beforehand e Do not guide the water jet into the exhaust and into the air filter After maintenance work After all maintenance
27. vibration on and off Risk of damage When compacting with vibration you must check the effect of nearby buildings and un derground supply lines gas water sewage electric power if necessary stop compaction with vibration Do not activate the vibration on hard frozen concrete ground Danger of bearing damage Automatic AUTOMATI 720 143 Fig 48 e Set the vibration switch Fig 48 to Automat ic 720 094 Fig 49 e Choose the amplitude Fig 49 BMP 8500 Fig 50 e Move the travel lever Fig 50 forward or back The machine starts to move and the vibration switches on automatically The vibration will switch off when the machine comes to a halt Manual AUTOMATIC 720 144 Fig 51 e Set the vibration switch Fig 51 to position Manual BMP 8500 Operation WW A we e Choose the amplitude Fig 52 Fig 52 Vibration switches on BOMAG 43 Operation 4 9 Shut down the engine e Switch the vibration off if necessary Fig 55 e Pull off the ignition key Fig 55 and store it in a safe place Fig 53 e Change to idle speed Fig 53 and let the en gine run for another few minutes for cooling 720 113 Fig 56 e Switch off and pull out the main battery switch Fig 56 e Plug the safety cap on the lock Fig 54 e Turn the ignition switch Fig 54 to position o Danger of accident Secure the machine agains
28. work is completed reinstall all guards and safety installations Repair Mark a defective machine by attaching a warning tag to the dashboard Before starting electric welding work on the ma chine all electrical components must be discon nected from the power supply BMP 8500 Safety regulations Repair work must only be performed by qualified and authorized persons Use our repair instruc tions for this work Exhaust gases are highly dangerous Always en sure an adequate supply of fresh air when starting in closed rooms Test The safety of compaction equipment must be checked by a specialist as required in dependence on the application and the operating conditions however at least once every year Radio remote control The machine must only be operated within the field of vision of the operator The radio remote control must only be used by trained and authorized persons The safety features incorporated in the radio re mote control must be checked at regular intervals A defective radio remote control must no longer be used In case of radio interferences watch the fault code display and switch to cable remote control if nec essary The machine will stop when the reach of the radio remote control is exceeded In case of defects the radio remote control must be immediately taken out of service The transmitter must be switched off via the emergency stop func tion The connecting cable must be disco
29. 0 Optional equipment BMP 8500 BOMAG 10 11 12 13 14 Indicators and Controls Toggle switch vibration automatic manual Toggle switch travel ranges Toggle switch engine speed Travel direction control lever Toggle switch for vibration high low amplitude Emergency stop switch Control light data transfer power pack radio re mote control 25 Indicators and Controls 3 1 General notes If you are not yet familiar with the control and dis play elements on this machine you should read this section thoroughly before starting any opera tion on the machine Here all functions are de scribed in detail Section 4 Operation contains only brief descrip tions of the individual control steps 26 BOMAG 3 2 Description of indicators and control elements 720042 Fig 11 No 1 Electronic immobilizer Before starting the engine the anti theft protection must be disarmed by entering a code Fig 12 No 2 Display module a red Warning light engine oil pressure Lights if the engine oil pressure is too low Check engine oil level repair the en gine if necessary b yellow Charge control light Lights if the battery is not being Optional equipment BMP 8500 charged Check V belt if necessary repair the generator c red Coolant temperature warning light Lights red if the temperature of the engine coolant is too high d Tipping angle warning indicator Lights
30. 00 Every 250 operating hours 5 15 Change the oil in the vibra tor shaft housing Change the oil at operating temperature For this purpose run the machine approx half an hour with vibration Catch running out oil and dispose of environ mentally Danger of injury Do not step under suspended loads 720128 Fig 107 e Lift the machine up and support it safely Fig 107 BOMAG 77 Every 250 operating hours For quality and quantity of oil refer to the table of fuels and lubricants e Screw the drain and ventilation plugs back in Fig 108 e Unscrew the drain and filling plug on the front drum Fig 108 e Drain and catch all oil Fig 111 e Unscrew the drain and ventilation plugs Fig 108 from the upper drum e Drain and catch all oil Fig 109 e Jack up the opposite side of the machine and secure it adequately Fig 109 720128 Fig 112 e Jack up the opposite side of the machine and secure it adequately Fig 107 Fig 110 e Drain of oil through the oil drain bore in the bot tom drum 78 BOMAG BMP 8500 Every 250 operating hours 5 16 Checking the central screw of the drive hub Check the tightening torque of the central screw on all 4 drive hubs Tightening torque 900 Nm Fig 113 e Drain of oil through the oil drain bore in the bot tom drum For quality and quantity of oil refer to the table of fuels and lubricants e Screw the drai
31. 051 Output relay K 114 engine speed so Display value output current in AmperD lenoid Current at output 5052 Output relay K 114 engine speed so 0000 Output not triggered lenoid 0001 Output triggered Logic level of control 5053 Status diesel engine 0000 Engine OFF Shows the status of the diesel engine 0001 Engine ON The state is determined on basis of sig nal L from generator oil pressure and en gine speed signal 5055 Ecomode diesel engine Temporary deactivation while the engine is run ning 5056 Ecomode diesel engine Permanent deactivation release 5057 off Permanent deactivation release 5058 on 5060 Output relay K 11 potential changeo Display value output voltage in Volt ver Voltage at output 5061 Output relay K 11 potential changeo Display value output current in AmperD ver Current at output 5062 Output relay K 11 potential changeo 0000 Output not triggered Ver 0001 Output triggered Logic level of control 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 AmperD 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 AmperD Current at output 5082 Output horn H 07 0000 Output not trigger
32. 25015 Desenzano del Garda BS ITALY Tel 39 030 9127263 Fax 39 030 9127278 e mail italy bomag com BOMAG GmbH 300 Beach Road The Concourse 18 06 Singapore 199555 SINGAPORE Tel 65 294 1277 Fax 65 294 1377 e mail singapore bomag com sg BOMAG Niederlassung Boppard Hellerwald 56154 Boppard GERMANY Tel 49 6742 100360 Fax 49 6742 100392 e mail nlboppard bomag de BOMAG Niederlassung M nchen Otto Hahn Ring 3 85301 Schweitenkirchen GERMANY Tel 49 8444 91840 Fax 49 8444 918420 e mail nimuenchen bomag de BOMAG CANADA INC 3455 Semenyk Court Mississauga Ontario LSC 4P9 CANADA Tel 1 905 361 9961 Fax 1 905 361 9962 e mail canada bomag com BOMAG S A F 2 avenue du G n ral de Gaulle 91170 Viry Chatillon FRANCE Tel 33 1 69578600 Fax 33 1 69962660 e mail france bomag com BOMAG Polska Sp z o o Ul Szyszkowa 52 02 285 Warzawa Poland Tel 48 22 482 0400 Fax 48 22 482 04 01 e mail poland bomag com BOMAG Americas Inc 2000 Kentville Road Kewanee Illinois 61443 U S A Tel 1 309 8533571 Fax 1 309 8520350 e mail usa bomag com BOMAG mm FAYAT GROUP BOMAG Niederlassung Chemnitz QuerstraRe 6 09247 Chemnitz GERMANY Tel 49 3722 51590 Fax 49 3722 515951 e mail nichemnitz bomag de BOMAG Niederlassung Stuttgart Uferstra e 22 73630 Remshalden Grunbach GERMANY Tel 49 7151 986293 Fax 49 7151 9862959 e mail nistut
33. 7 Horn button No 17 to signalize a danger situation Fig 28 Main fuse for battery No 18 31 BOMAG BMP 8500 Indicators and Controls 32 BOMAG BMP 8500 BMP 8500 4 Operation BOMAG 33 Operation 4 1 General If you are not yet acquainted with the controls and indicating elements on this machine you should thoroughly read chapter 3 Indicators and control elements before starting work All indicators and control elements are de scribed in detail in this chapter 34 4 2 Tests before taking into op eration Before the everyday use or before a longer work ing period the following tests and inspections must be performed Danger of injury Please observe strictly the safety regulations in chapter 2 of these operating and mainte nance instructions e Park the machine on ground as level as possi ble e The operator must become acquainted with the size of the safety field Check e fuel tank and fuel lines for leaks engine radiator and hydraulic system for leaks screw joints for tight fit Machine for condition cleanliness damage Function of remote control and emergency stop e presence of the appropriate operating and maintenance instructions proper maintenance of the machine e Air pressure in rubber tires only AC ma chines For a description of the following tasks refer to the chapter maintenance every 10 operating hours e Engine
34. Check the coolant level Fill up coolant only when the engine is cold If during the daily inspection the coolant level is found to have dropped check all lines hos es and engine for leaks e Check the coolant level Fig 96 e Totop up unscrew the filler cap and fill in cool ant up to the MAX mark For quality of coolant refer to the chapter 5 2 fuels and lubricants BMP 8500 BOMAG Every 10 operating hours 71 Every 10 operating hours 72 BOMAG BMP 8500 5 11 Check the air intake hose e Check the fastening of the hose clamps Fig 97 tighten if necessary e Check the condition of the air intake hose re place if necessary BMP 8500 Every 250 operating hours 5 12 Changing engine oil and oil filter Danger of scalding When draining off hot oil By hot oil when unscrewing the engine oil fil ter 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 inter vals 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 Catch running out oil and dispose of environ mentally together with the oil filter cartridge 720 086 Fig 98 e Unscrew the drain plug Fig 98 and catch running out oil e Turn the drain plug tightly back in BOMAG 73 Every 250
35. Fig 67 e Press the start button to start the engine Fig 67 Run the engine warm for a short while before start ing work BOMAG 47 Operation Long distance shut down STOP ca 30m approx 33 yd Fig 68 If the distance Fig 68 between and transmitter and receiver exceeds 30 m the machine will stop To continue travelling reduce the distance and re start the machine Work function Life hazard Move the machine only when it is directly in sight The functions of operating elements and con trols are identical with the ones for the cable remote control see previous description 48 BOMAG 723160 If the battery voltage drops down to a too low level during operation power pack discharged the red warning light on the control Fig 69 will light up approx 10 minutes before the engine is shut down The warning buzzer starts to sound approx 1 minute before the shut down Drive the machine to a safe place as soon as pos sible so that it will not stop all of a sudden If necessary switch over to operation with cable re mote control and plug the spiral cable into the re mote control During cable operation of the machine the power pack is automatically charged Replace or recharge the power pack Switching off the transmitter engine Do not shut the engine down all of a sudden from full load but let it idle for a while in posi tion Min for temperature equalization
36. Nopen Slave radio re communication mote control has not sent a node guarding answer 2613 Engine is shut down CANopen fault in bus CANopen Slave infrared re communication mote control has not sent a node guarding answer 116 BOMAG BMP 8500 General fault codes diesel engine ma Trouble shooting chine Code Fault reaction Description of fault Possible cause Terminal Input on BLM code for diagnose 5015 Only warning horn Potential 15 miss Fuse F 103 defective X3 20 not sounds ing Relay K11 defective possible display module is Control has switched Cable breakage in dark relay K11 no voltage wiring loom 5016 Output is switched Battery voltage too Battery acid level too 0561 off function low low no longer possible Battery voltage al Battery defective ready below 11 Volt Battery discharged when switching on 5020 Only warning horn Input engine oil The oil pressure X3 03 5020 sounds pressure B 06 switch has measured Oil pressure switch amp t00 low oil pres delivers the signal sure The engine no engine oil pres may be shut down sure Should this message be displayed even though the engine is not running the fol lowing faults should be examined Current path has short circuit to ground Engine oil level not correct Engine oil pump de fective Pressure relief valve after engine oil filter soiled Oil pressure switch defective 5021 Engine shut down by Input engin
37. S 137 0100 Joystick actuated to the left 0010 Joystick not moved 0001 Joystick actuated to the right 2502 Position of switch for vibration S 36 0100 Switch operated to forward vibration high amplitude 0010 Switch not operated 0001 Switch operated to reversed vibration low amplitude 2503 Position of switch for type of vibra 0100 Switch operated to forward automatic tion S 132 operation 0010 Switch not operated manual operation 2504 Position of switch for fast speed S 0100 Switch operated to forward fast speed 133 selected 0010 Switch not operated fast speed disa bled 128 BOMAG BMP 8500 Trouble shooting Input code Description of display function Display values 2505 Position of switch for engine speed S 0100 Switch operated to forward high engine 134 speed 0010 Switch not operated idle speed 2506 Position of button for horn S 03 0000 Button not operated 0001 Button operated System information Input code Description of display function Display values 0555 Software Version 3 digit version number Shows the software version number 0561 Supply voltage Display value voltage in V Shows the voltage value Setting the remote control type Input code Description of display function Display values 0660 Switches on function Set remote See adjustment instructions control type 0661 confirms th
38. X3 19 off function no long ing left Y 237 ground in the current er possible Short circuit current path flow out of this output Lines rubbed through Output was switched Valve defective off 2012 Output is switched Output valve steer Wire breakage in cur X3 19 1010 off function no long ing left Y 237 rent path 1011 er possible No or too low current Current path con 1012 flow out of this output nected to 12V 2013 Engine is shut down Output valve steer Current path con X3 19 1010 ing left Y 237 nected to 12V 1011 Although the output is 1012 switched off voltage is present 2020 Output is switched Output valve steer Excessive current X3 21 off function no long ing right Y 238 flow in current path er possible Too high current flow probably because of out of this output Out 2 defective coil or a put was switched off Short circuit to ground 2021 Output is switched Output valve steer Short circuit to X3 21 off function no long ing right Y 238 ground in the current er possible Short circuit current path flow out of this output Lines rubbed through Output was switched Valve defective off 2022 Output is switched Output valve steer Wire breakage in cur X3 21 1020 off function no long ing right Y 238 rent path 1021 er possible No or too low current Current path con 1022 flow out of this output nected to 12V BMP 8500 BOMAG 115 Trouble shooting Code Fault reaction De
39. aintenance instructions are also available in other languages Furthermore the spare parts catalogue is availa ble from your BOMAG dealer against the serial number of your machine Your BOMAG dealer will also supply you with in formation about the correct use of our machines in soil and asphalt construction The above notes do not constitute an extension of the warranty and liability conditions specified in the general terms of business of BOMAG GmbH We wish you successful work with your BOMAG machine BOMAG GmbH Printed in Germany Copyright by BOMAG BOMAG 3 Foreword Please fill in Motor number Fig 3 Supplement the above data together with the com missioning protocol During commissioning our organisation will in struct you in the operation and maintenance of the machine Please observe strictly the safety regulations and all notes on risks and dangers BOMAG Fig 1 BMP 8500 Technical Data Safety regulations Indicators and Controls Operation Maintenance BMP 8500 3 1 3 2 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 Table of Contents General notes Description of indicators and control elements General Tests before taking into operation BOSS safety system Electronic immobilizer Starting the engine Driving the machine cable remote control Safety inspection for the cable remote c
40. al IO node joystick data collector 9999 Unknown fault displayed value higher than 10000 automatic output by the BMFSA Fault codes of travel functions Code Fault reaction Description of fault Possible cause Terminal Input on BLM code for diag nose 1030 Output is switched Output valve travel Excessive current X3 22 off function ling forward Y 16 flow in current path no longer possible Too high current flow Probably because of out of this output Out 4 defective coil or a put was switched off Short circuit to ground 1031 Output is switched Output valve travel Short circuit to X3 22 off function no long ling forward Y 16 ground in the current er possible Short circuit current path flow out of this output Lines rubbed through Output was switched Valve defective off 1032 Output is switched Output valve travel Wire breakage in cur X3 22 1030 off function no long ling forward Y 16 rent path 1031 er possible No or too low current Current path con 1032 flow out of this output nected to 12V BMP 8500 BOMAG 111 Trouble shooting Code Fault reaction Description of fault Possible cause Terminal Input on BLM code for diag nose 1033 Engine is shut down Output valve travel Current path con X3 22 1030 ling forward Y 16 nected to 12V 1031 Although the output is 1032 switched off voltage is present 1040 Outp
41. aning after use Keep the cable remote control clean BMP 8500 Operation Rests of concrete clay or mortar may damage the bellows on travel levers and sealing caps on toggle switches so that water can enter Do not use a water jet or a high pressure or steam cleaner for cleaning e After work clean the cable remote control with a clean cloth or brush e Check the state of bellows and sealing caps at regular intervals have replaced by an expert if necessary BOMAG 41 Operation 4 7 Safety inspection for the ca ble remote control This safety inspection must be performed regularly once every week especially after longer breaks Danger of injury Make sure that there are no persons within the danger zone Rests of mortar or concrete may restrict the movement of the travel control levers Check from time to time with the sender switched off whether both travel control levers return reliably to their neutral position when being re leased Fig 47 e With the machine shut down actuate and hold one of the travel levers 1 or 2 Fig 47 e Try to start the diesel engine The diesel engine must not start e Return the travel lever to neutral position rest position e Start the engine and actuate the control lever again The functions must now work as usual e Operate the emergency stop switch 3 The machine must stop and the engine must be shut down 42 BOMAG 4 8 Switching the
42. ankments and do not use working methods that could impair the stability of the ma chine Do not work with vibration on hard concrete cured bitumen layers or extremely frozen ground BMP 8500 Driving on inclinations and slopes Fig 5 Do not drive on gradients exceeding the maximum gradability of the machine On slopes drive extremely careful and always di rectly up or down the slope Change to a lower gear before starting to drive Wet and loose soils considerably reduce the ground adhesion of the machine on inclinations and slopes Higher risk of accident Inclination Fig 6 The tipping angle was measured in static condition on level hard ground with the machine stopped no steering and without vibration With loose soil acceleration deceleration running vibration steering or attached accessoriies the tip ping angle may be considerably lower Driving across slopes should therefore be strictly avoided because of the high risk of tipping over and the related risk of severe or even fatal acci dents BMP 8500 Safety regulations You should therefore always drive straight up or down a slope Behaviour in traffic Match the speed to the working conditions Always give way to loaded transport vehicles Keep away from edges and embankments Checking the effect of vibration When compacting with vibration you must check the effect on nearby buildings and underground supply lines gas water sewag
43. ay value output current in AmperD Y 56 Current at output 1307 Output valve vibration low amplitude 0000 Output not triggered Y 56 0001 Output triggered Logic level of control 1309 Vibration valve control 0100 Vibration low amplitude 0010 No vibration 0011 Vibration high amplitude 1310 Output valve vibration high ampli Display value output voltage in Volt tude Y 57 Voltage at output 1311 Output valve vibration high ampli Display value output current in AmperD tude Y 57 Current at output 1312 Output valve vibration high ampli 0000 Output not triggered tude Y 57 Logic level of control 0001 Output triggered Inputs logic and power module Input code Description of display function Display values 1400 Input signal L from generator regula tor 12 V gt Generator stopped Ground 0 V gt Generator running BMP 8500 BOMAG 125 Trouble shooting Input code Description of display function Display values 1401 Input oil pressure switch B 06 12 V gt No oil pressure Ground 0 V gt Oil pressure 1402 Input limit switch engine speed sole 12 V gt Solenoid retracted noid Aux OV Ground gt Solenoid not in end position 1405 Input inclination sensor B 56 12 V gt Inclination less than 45 x OV Ground gt Inclination higher than 45 x 1407 Input limit switch for safety bow rear 12 V gt Bow not operated B41 Ground OV
44. ca Trouble shooting ble 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 BMP 8500 BOMAG 103 Trouble shooting Fault Possible cause Remedy Inclination sensor Check the sensor signal input code 1405 Bridge connections 5 and 6 on the plug for t
45. d cover it with insulation material e When working in the area of the articulated joint attach the articulation lock transport lock During maintenance work catch all oils and fu els and do not let them seep into the ground or into the sewage system Dispose of oils and fu els environmentally 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 e Keep fuel free of contaminants and water since this will damage the injection elements of the engine 60 BOMAG e Drums with inside zinc lining are not suitable to store fuel e When choosing the storage place for fuel make sure that spilled fuel will not harm the en vironment e Donotlet the hose stir up the slurry at the bot tom of the drum e The fuel drum must rest for a longer period of time before drawing off fuel e The rest in the drum is not suitable for the en gine and should only be used for cleaning pur poses Notes on the performance of the en gine On diesel engines both combustion air and fuel in jection 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 consult the customer service
46. d within the validity area of the EPA standard As an alter native to no 2 D you may also use diesel fuel no 2 D S500 or S15 with ambient temperatures be United States Environmental Protection Agency 62 BOMAG low 10 C the diesel fuel no 1 D S500 or S15 should be used fir no 1 D The fuel level should always be topped up in due time so that the fuel tank is never run dry as oth erwise filter and injection lines need to be bled Winter fuel Fire hazard Diesel fuels must never be mixed with gaso line For winter operation use only winter diesel fuel to avoid clogging because of paraffin separation At very low temperatures disturbing paraffin separa tion 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 Under particularly extreme temperature conditions you should consult the service representation of the engine manufacturer with respect to the anti freeze agent to be used There are various types of anti freeze agents available For this engine you should use ethylene glycol Before filling in the coolant mixed with anti freeze agent the radiator must be flushed with clean wa ter This procedure should be repeated two to three times to clean the inside of radiator and en gine block Mixing the anti freeze agent Prepare a mixture of 50 anti freeze agent and 50 low mineral clean water
47. 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 135 Servicing of the dry air filter is necessary when the yellow piston Fig 135 has reached the inscrip tion Service but at the latest after one year After completion of the filter service reset the indi cator back to Zero by pressing the button BMP 8500 As required Fig 136 e Open both clamps 1 Fig 136 e Remove the filter hood e Clean filter hood and dust discharge valve 2 723 037 Fig 137 e 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 cover Carefully remove the filter element in order to reduce the released amount of dust To release the seal pull the filter element carefully up down and sideways or turn it Fig 137 BOMAG 93 As required Fig 138 e Pull the filter element Fig 138 carefully out of the housing Avoid contact between filter element and housing Fig 139 e Clean the sealing face on the outlet tube Fig 139 Dust on the outer diameter of the outlet tube can impair effective sealing 94 BOMAG Fig 140 e Thoroughly clean the inside of the outlet tube Fig 140 and the filter housing Dirt that may incidentally drop into the outlet tube will reach the
48. e electric power if necessary stop compaction work with vibration Do not activate the vibration on hard frozen con crete ground Danger of bearing damage Parking the machine Park the machine on horizontal level firm ground Before leaving the machine e shut the engine down pull the ignition key off e secure the machine against unintended use e Pull off the main battery switch Mark machines which could be in the way with a clearly visible sign Refuelling Do not inhale any fuel fumes Refuel only with the engine shut down Do not refuel in closed rooms No open fire do not smoke Monitor the entire refuelling process Do not spill any fuel Catch running out fuel do not let it seep into the ground Wipe off spilled fuel Keep dirt and water away from the fuel A leaking fuel tank can cause an explosion En sure tight fit of the fuel tank cover if necessary re place immediately Fire protection measures Familiarise yourself with the location and the oper ation of fire fighting equipment Observe all fire re porting and fire fighting possibilities BOMAG 17 Safety regulations Maintenance work Comply with the maintenance work described in the operating and maintenance instructions in cluding the information concerning the replace ment of parts Maintenance work must only be performed by qualified and authorized persons Keep unauthorized persons away from the ma chine Do not
49. e entered remote control See adjustment instructions type 0662 Preselect radio remote control de See adjustment instructions fault setting Fault log Input code Description of display function Display values 0700 Switch on function A Show stored See adjustment instructions faults Au 0701 Switch off function Show stored See adjustment instructions faults 0662 Delete all stored faults See adjustment instructions Safety system Input code Description of display function Display values 6000 Enable service mode 6000 BMP 8500 BOMAG 129 Trouble shooting Input code Description of display function Display values 6001 Service mode active machine travels for 15min without activated BOSS safety system Attention Only for servicing purpos es 6001 service mode active 6002 Service mode inactive Reading out the operating hour meter Input code Description of display function Display values 7500 Display of hours operating hour me The full hours are displayed ter 7501 Display of minutes operating hour The minute digits of the operating hour meter meter are displayed Setting the machine type Input code Description of display function Display values 7101 Preselect machine type BMP 851 See adjustment instructions 7102 Preselect machine type BPH 80 65s See adj
50. e machine assists you when servicing the ma chine The following maintenance work must be per formed when running in new machines or overhauled engines Up to approx 250 operating hours check the engine 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 e Change engine oil and filter e Check the engine for leaks e Retighten the fastening screws on air filter ex haust and other attachments e Check screw connections on the machine retighten as necessary e Retighten fastening screws of engine mounts e Check the central screw of the drive hub retighten if necessary BOMAG 65 Maintenance 5 5 Maintenance table z S gt n n n e 2 2 515 35 ala 32 2 12 No Maintenance work Comment ele e Si o o alalea oe 2 2 0 10 o 2 0 o o o o o 3 olo s s s 5 e oO 1O O So oO oO N 1O N M Pi gt 2 gt 2 gt 2 2 8 os 0o o o i0o o gt gt gt gt gt gt gt o oe 2 oa oo ojoje 5 6 Check the engine oil level Dipstick mark x 5 7 Check the hydraulic oil level Inspection glass x 5 8 Check the fuel level X 5 9 Fuel filter draining off water x 5 10 Check the coolant level x 5 11 Check the air intake hose 5 12 Change engine oil and oil filt
51. e oil see fault code 5020 X3 03 5020 too low oil pressure pressure B 06 Fault 5 0 2 0 present longer than 8 sec onds Engine is shut down BMP 8500 BOMAG 117 Trouble shooting Code Fault reaction Description of fault Possible cause Terminal Input on BLM code for diagnose 5022 Oil pressure switch Input engine oil Engine oil pressure X3 03 defective pressure B 06 switch defective The machine had Cable breakage to oil niot been started and pressure switch does not run howev Fault code inactive er there is still an oil since version 1 10 pressure signal 5025 Engine running No rotary speed Generator regulator X3 41 z signal from the defective generator regulator Line between regula Only warning tor and control inter rupted 5031 Machine standing Engine stops en Lack of fuel gine stalled Engine stopped even though the BLM con trol did not submit a corresponding com mand 5040 Output is switched Output HW shut Excessive current X3 10 off engine stops down solenoid Y flow in current path 13 probably because of Too high til a defective coil or a ee re ar t OW short circuit to out of this outpu ground Output was switched off 5041 Output is switched Output HW shut Short circuit to X3 10 off engine stops down solenoid Y ground in the current 13 path oes Lines rubbed Short circuit current through flow out of this output Valve d
52. ed Logic level of control 0001 Output triggered BMP 8500 BOMAG 127 Trouble shooting Input code Description of display function Display values 5085 Output 2 horn H 07 Voltage at output Display value output voltage in Volt 5086 Output 2 horn H 07 Current at output Display value output current in AmperD 5087 Output 2 horn H 07 Logic level of control 0000 Output not triggered 0001 Output triggered 5100 Coolant temperature sensor B 53 0000 Temperature too high excessive tem perature 0001 Temperature OK Checking the function of the remote controls With the input codes listed above it is possible to check the transfer of the individual switching sig nals from the remote controls to the central control unit For this purpose start the machine and sub sequently press the horn button to bring the re mote 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 Input code Description of display function Display values 2500 Actuation of 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 steering joystick on re mote control
53. efective Output was switched off 5042 Outputis switched Output HW shut Wire breakage in X3 10 5040 off engine stops down solenoid Y current path 5041 13 Current path con nected to 12V 5042 No or too low current flow out of this output 118 BOMAG BMP 8500 Trouble shooting Code Fault reaction Description of fault Possible cause Terminal Input on BLM code for diagnose 5043 Output is switched Output HW shut Current path con X3 10 5040 off engine stops down solenoid y nected to 12V 5041 13 5042 Although the output is switched off volt age is present 5050 Output is switched Output relay K 114 Excessive current X3 09 off engine runs only engine speed sole flow in current path with idle speed noid probably because of fecti il Too high current flow er oe out of this output ground Output was switched off 5051 Output is switched Output relay K 114 Short circuit to X3 09 i off engine runs only engine speed sole ground in the current with idle speed noid p TEM Short circuit current OEN l through flow out of this output Output was switched off 5052 Output is switched Output HW shut Wire breakage in X3 10 5050 off engine runs only down solenoid Y current path 5051 with idle speed 13 Current path con nected to 12V 5052 No or too low current flow out of this output 5053 Output is switched Output relay K 114 Current path con X3 09
54. efective off 112 BOMAG BMP 8500 Trouble shooting Code Fault reaction Description of fault Possible cause Terminal Input on BLM code for diag nose 1052 Output is switched Output valve 2 gear Wire breakage in cur X3 11 1050 off function no long Y 03 rent path 1051 er possible No or too low current Current path con 1052 flow out of this output nected to 12V 1053 Output is switched Output valve 2 gear Current path con X3 11 1050 off engine runs only Y 03 nected to 12V 1051 with idle speed Although the output is 1052 switched off voltage is present 1060 Output is switched Output brake valve Y Excessive current X3 40 off function no long 04 flow in current path er possible Too high current flow probably because of out of this output Out 4 defective coil or a put was switched off Short circuit to ground 1061 Output is switched Output brake valve Y Short circuit to X3 40 off function no long 04 ground in the current er possible Short circuit current path flow out ofthis output Lines rubbed through Output was switched Valve defective off 1062 Output is switched Output brake valve Y Wire breakage in cur X3 40 1060 off function no long 04 rent path 1061 er possible No or too low current Current path con 1062 flow out of this output nected to 12V 1063 Output is switched Output brake valve Y Current path con X3 40 1060 off engine r
55. er at least 1x per year see foot note 5 13 Check tension replace the V belt 5 14 Clean radiator cooling fins 5 15 Change the oil in the vibrator shaft min 1x per year housing 5 16 Check the central screw of the drive see foot note x hub 5 17 Drain the fuel tank sludge 5 18 Change the fuel pre cleaner bleed the fuel system 5 19 Battery service checking the main pole grease x battery switch 5 20 Check the rubber buffers x 5 21 Check adjust the valve clearance 0 145 0 185 mm 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 66 BOMAG BMP 8500 Maintenance gt T os d gt n n n e 2 2 5 5 5 i s 5 0 60 6 e cz No Maintenance work Comment a ae io s cela ol 2o l2o lo0o o0 o amp 0 o o o 3 lo oe ls s s s Q Te So oO m N 1O N M S Piel el ele e o oe oo o o sos o gt gt gt gt gt gt 2 gt ao oo oo o o o o s 5 24 Change the coolant X 5 25 Change the fuel lines X 5 26 Check the injection pressure x 5 27 Check the fuel injection pump 5 28 Check the fuel injection timing 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 ev
56. ery 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 BMP 8500 BOMAG 67 Maintenance 68 BOMAG BMP 8500 5 6 Check the engine oil level Park the machine on level ground so that the en gine is in horizontal position It Ais N e Shut down the engine e Pull the dipstick Fig 92 out wipe it off with a lint free clean cloth and reinsert it until it bot toms e Pull the dipstick back out again e The oil level should reach the upper mark MAX on the dipstick e Ifthe oil level is too low top up oil immediately For quality and quantity of oil refer to the table of fuels lubricants and filling capacities BMP 8500 Every 10 operating hours 5 7 Check the hydraulic oil level In hydraulic systems filled with Panolin HLP Synth 46 always use the same oil to top up With other ester based oils consult the lubrica tion oil service of the respective oil manufac turer 720 081 e Check the hydraulic oil level in the inspection glass Fig 93 Hydraulic oil is not consumed like engine oil If during the daily inspection of the oil level the hydraulic oil level is found to have dropped check all lines hoses and compo nents for leaks e f necessary remove t
57. eze 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 table of fuels and lubricants Catch running out coolant and dispose of envi ronmentally e Remove the radiator cap Fig 129 BOMAG BMP 8500 Every 2000 operating hours e Unscrew the drain valve Fig 130 from the ra e Fill in coolant until the level reaches the bottom diator edge of the radiator filler socket Fig 132 e Drain the coolant completely off and collect it e Screw the drain valve back in e Check the condition of radiator hoses if nec essary replace all radiator hoses Fill in coolant up to the MAX mark Fig 133 e Reattach the radiator cap and the cap of the compensation tank Fig 131 e Start the diesel engine and run it warm to op e Open the drain valve Fig 131 on the engine erating temperature e Let the engine cool down and check the cool ant level again if necessary top up in the com pensation tank e Drain the coolant completely off the engine block and collect it e Close the drain tap again BMP 8500 BOMAG 89 Every 2000 operating hours 5 25 Change the fuel lines For safety reasons this work should be performed every two years Hoses consist of rubber or plastic material and age over the course of time Fire hazard When working on the fuel system do
58. fol lowing conservation measures for the engine to avoid corrosion e Clean the engine including the cooling system with cold cleansing agent and a water jet or even better with a steam jet e Run the engine warm and shut it down e Drain the still warm engine oil and fill in anti corrosion engine oil e Drain the fuel from the fuel tank mix it well with 10 anti corrosion oil and fill it in again In stead of mixing anti corrosion oil with the fuel it is also possible to fill the tank with injection pump testing oil with anti corrosive properties e g Calibration Fluid B e Run the engine for 10 minutes until all lines fil ter pump and nozzles are filled with the con serving mixture and the new engine oil is distributed to all parts e After this test run remove the cylinder head covers and the lateral cover of the injection pump spray the rocker chambers and the spring chamber in the injection pump with a mixture of diesel fuel with 10 anti corrosion oil Reassemble hoods and covers e Crank the engine several times by hand with out ignition in order to spray the combustion chamber e Take the V belt off and spray the grooves in the pulleys with anti corrosion oil Remove the anti corrosion oil before taking the machine into operation e Close the air intake opening on the air filter and the exhaust opening Depending on weather conditions these conserv ing measures will provide protection for approx
59. h Brief operating instructions Instruction sticker Wear ear defenders BMP 8500 Safety regulations aR Sg SRO OTE ER 720068 10 Information sticker Guaranteed sound capac ity level 11 Maintenance sticker High pressure cleaner 12 Information sticker Lashing points 13 Information sticker Hydraulic oil 14 Maintenance sticker BOMAG 21 Safety regulations Fig 8 Information sticker Bio Hydraulic Oil Bio Synthetic Ester Panolin HLP Synth 46 Diese Anlage ist mit Bio Hydraulik l bef llt Bei Verwendung von anderen len den Schmiertechnischen Dienst des jeweiligen lherstellers ansprechen This system is filled with Bio Hydraulic Oil When using other brand oils please contact the lubrication service department of the oil manifacturer for information Ce syst me est rempli avec cette huile hydr biologique Lors de Vutilisation d autres huiles Contacter le Service des lubrifiants du fabricant respectif Fig 9 Information sticker Panolin 46 Optional equipment Optional equipment 22 BOMAG BMP 8500 BMP 8500 3 Indicators and Controls BOMAG 23 Indicators and Controls i Caan ao omy i A 720 124 Fig 10 BMP 8500 BOMAG 24 Electronic immobilizer Display module Fuse box RwWD Toggle switch for cable remote control radio remote control Socket Main battery switch Steering control lever N OO
60. h er possible Too high current flow probably because of out of this output Out a defective coil or a put was switched off Short circuit to ground 1311 Output is switched Output valve vibra Short circuit to X3 13 off function no long tion high ampl Y 57 ground in the current er possible Short circuit current path flow out of this output Lines rubbed through Output was switched Valve defective off 1312 Output is switched Output valve vibra Wire breakage in cur X3 13 1310 off function no long tion high ampl Y 57 rent path 1311 er possible No or too low current Current path con 1312 flow out of this output nected to 12V 1313 Output is switched Output valve vibra Current path con X3 13 1310 off engine runs only tion high ampl Y 57 nected to 12V 1311 with idle speed 2nd Although the output is ear is inhibited 1312 g switched off voltage is present 114 BOMAG BMP 8500 Fault codes steering Trouble shooting Code Fault reaction Description of fault Possible cause Terminal Input on BLM code for diag nose 2010 Output is switched Output valve steer Excessive current X3 19 1010 off function no long ing left Y 237 flow in current path er possible Too high current flow probably because of out of this output Out 4 defective coil or a put was switched off Short circuit to ground 2011 Output is switched Output valve steer Short circuit to
61. he cover from the filter e Fill in hydraulic oil up to the MAX mark of the inspection glass e Screw the cover back on For quality and quantity of oil refer to the table of fuels and lubricants BOMAG 69 Every 10 operating hours 5 8 Check the fuel level Fire hazard When working on the fuel system do not use open fire do not smoke Do not refuel in closed rooms Do not inhale any fuel fumes Contaminated fuel can cause malfunction or even damage of the engine If necessary fill in fuel through a funnel with screen filter 720 082 e Clean the area around the filler opening un screw the cover check the filling level and fill in fuel as necessary Fig 94 For quality of fuel refer to the table of fuels and lubricants 70 BOMAG 5 9 Fuel filter draining off water The service intervals for the water separator de pend on the water content in the fuel and can therefore not be determined precisely After taking the engine into operation you should therefore check the filter bowl initially every day for signs of water Catch running out fuel and dispose of environ mentally y AG i fs exes y a ATIU 720 083 Fig 95 e Slacken bleeding screw 1 Fig 95 for a few turns e Slacken drain plug 2 for a few turns and catch running out fuel water e Tighten drain and bleeding plugs again and check for leaks if necessary replace the seal ring BMP 8500 5 10
62. he 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 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 ule on but starting not possible Travel lever not in O position Actuate the travel lever and return it to 0 position 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 104 BOMAG BMP 8500 Trouble shooting Fault Possible cause Remedy All wi
63. ial equipment not sup plied by us The installation and or use of such products can impair the active and or passive driv ing safety The manufacturer expressly excludes any liability for damage resulting from the use of non original parts or accessories BMP 8500 Safety regulations Damage deficiencies misuse of safety installations Machines which are not safe to operate or in traffic must be immediately taken out of service and shall not be used until these deficiencies have been properly rectified Safety installations and switches must neither be removed nor must they be made ineffective Safety notes in the operating and main tenance instructions Sections marked like this point out possible dangers for persons Sections marked like this point out possible dangers for the machine or for parts of the ma chine Sections marked like this provide technical infor mation concerning the optimal economical use of the machine Sections marked like this highlight activities for the safe and environmental disposal of fu els and lubricants as well as replaced parts Observe all environment protection regula tions Loading the machine Check the fastening of the central lifting hook be fore each use Use only stable loading ramps of sufficient load bearing capacity The ramp inclination must be less than the gradability of the machine Secure the machine against tipping or slipping off Secure the machine o
64. ilter head BOMAG 81 Every 500 operating hours Fig 117 Fig 119 e Apply a thin film of fuel to the seals and screw e Open the bleeding screw on the injection the new filter cartridge Fig 117 on hand pump Fig 119 and crank the engine with the tight starter until fuel runs out without air bubbles e Retighten the bleeding screw Bleed the fuel system 9 e Open the bleeding screw on the fuel filter Fig 118 and crank the engine with the starter un til fuel runs out without air bubbles e Retighten the bleeding screw 82 BOMAG BMP 8500 5 19 Battery service checking the main battery switch 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 bat tery to avoid the accumulation of highly explo sive gases Dispose of the old batteries environmentally Maintenance free batteries also need care Main tenance free only means that the fluid level does not need to be checked Each battery suffers un der self discharge which may in not checked oc casionally even cause damage to the battery asa result of exhaustive discharge The following therefore applies for the service life e Switch off all consumers e Check open circuit voltage of the batter
65. in bus communication Wire breakage in current path ble only steering between safety field control and transponder 6016 Reception quality safety field control Faults in parameterization 122 BOMAG BMP 8500 Trouble shooting Code Fault reaction Description of fault Possible cause Terminal Input on BLM code for diagnose 7010 Machine cannot be No machine type set Module is new pa 0725 started module is not completely initial ized rameters were deleted BMP 8500 BOMAG 123 Trouble shooting 6 8 Input codes for BLM control Outputs for travel functions Input code Description of display function Display values 1010 Output valve steering left Y 237 Display value output voltage in Volt Voltage at output 1011 Output valve steering left Y 237 Display value output current in AmperD Current at output 1012 Output valve steering left Y 237 0000 Output not triggered Logic level of control 0001 Output triggered 1015 Valve control right 0100 steering to the left 0010 Valve not triggered 0011 steering to the right 1020 Output valve steering right Y 238 Display value output voltage in Volt Voltage at output 1021 Output valve steering right Y 238 Display value output current in AmperD Current at output 1022 Output valve steering right Y 238 0000 Output not triggered Logic level of co
66. ine shape of the hydrau lic hose e the hose shows deformations in bends e g squeezing buckling layer separation forma tion of blisters e parts of the hose are leaking e hoses are not correctly installed e the hydraulic hose has separated from the fit ting e the fitting shows corrosion that impairs both function and strength e hoses are mixed up by mistake e fittings are damaged or deformed whereby the function and strength of the hose hose connection is impaired Only genuine BOMAG replacement hydraulic hos es ensure that the correct hose type pressure range is used at the right location Working on the engine Shut the engine down before opening the engine hood Drain the engine oil at operating temperature danger of scalding Wipe off spilled oil catch running out oil and dis pose of environmentally Store used filters and other oil contaminated ma terials in a separate specially marked container and dispose of environmentally Do not leave any tools or other objects that could cause damage in the engine compartment Working on electric parts of the machine Disconnect the minus pole first and the plus pole after Connect the battery in reverse order Connect the plus pole first and the minus pole after Before starting to work on electric parts of the ma chine disconnect the battery and cover it with insu lating material Do not use fuses with higher ampere ratings and do not
67. is now ready for starting The display module shows the machine type for 3 seconds Whenever switching the ignition on the machine type will appear in the display module for 3 sec onds The machine type code can be checked by enter ing the code 7010 BMP 8500 4 16 Teaching the BOSS safety system transponder When replacing a defective remote control only units with a completely black housing must be used Please follow the described procedure when installing new components of the radio system or the safety system BOSS e Shut down the engine switch off the main battery switch replace defective components switch on the main battery switch plug the spiral cable into the remote control 723192 Fig 85 e Turn the tumbler switch for the cable remote control to position Left cable operation Fig 85 BMP 8500 BOMAG Operation Fig 86 e Turn the ignition switch to position Fig 86 charge control lamp and oil pressure control lamp come on e Move the remote control out of the safety field e The safety field control lamp goes out at the latest after 2 seconds The machine is now ready for operation 55 Operation 4 17 Assembling removing the drum extension Assembly Fig 87 e Attach drum extensions 2 Fig 87 to the drums turn three fastening screws 1 into each drum and tighten Removal e Unscrew the fastening screws and take off the drum extensions
68. ked again see Maintenance every 3000 operating hours Fault Possible cause Remedy no travel move ments steering is still possible The operator is inside the safety field Transponder in transmitter has not been taught Safety antenna front rear defective or not plugged in Distance between machine and transmit ter more than 30 m Safety field control defective or not plugged in Transmitter defective Wiring loom for safety field antennas Leave the safety field see point 4 15 Teaching the transponder Replace the antenna check plug connec tion Move closer to the machine Replace the safety field control or check the plug connection Replace the transmitter Replace the wiring loom for safety field antennas BMP 8500 BOMAG 109 Trouble shooting 6 6 Fault indicator Fig 145 Faults are displayed in the display module h Fig 145 in form of flashing fault codes If several faults occur at the same time these will be indicated by flashing codes one after the other 110 BOMAG BMP 8500 6 7 Fault code Trouble shooting Overview Fault code Function group 1000 1999 Travel system 2000 2499 Steering 2500 2999 Remote controls 5000 5499 Diesel engine 7000 7499 Input codes for machine parameterization 7500 7999 Operating hour meter load spectrum input codes 8000 8999 Severe software error 9000 9998 extern
69. l Position left Cable remote control Position right Radio remote control Optional equipment BOMAG 27 Indicators and Controls 590113 Fig 15 No 5 12 V socket 12 V vehicle voltage when main battery switch is switched on N re ER KIN gt Y No 6 Main battery switch Disconnects the ground contact in the electric cir cuit of the machine If the power pack of the radio remote control is to be charged the main battery switch must remain switched on when the engine is shut down 28 BOMAG Fig 17 No 7 Steering control lever Middle position Straight ahead Position left Driving to the left Position right Driving to the right AUTOMATIC 3c 720141 Fig 18 No 8 Toggle switch vibration automatic manual Position Manu al Vibration switches on when shifting the control lever for high low amplitude Machine switches automatically to speed range 1 Position Auto matic Vibration comes on when moving the travel lever to for ward reverse after the control lever for high low amplitude has been actuated to any de sired position BMP 8500 Vibration switches off with travel lever in position 0 Fig 19 No 9 Toggle switch travel ranges Position turtle 1 Travel speed range 0 1 3 km h Position rab bit 2nd travel speed range 0 2 7 km h driving with vibration not possible S MIN 723197 Fig 20 No
70. ld be performed at least once per year irrespective of the operating hours reached API CF CF 4 CG 4 CH 4 and Cl 4 250 operating hours Fuels Quality Cetan index number The recommended minimum index number for the Cetan value is 45 A Cetan index number higher than 50 should preferably be used especially at ambient temperatures below 20 C and when working at altitudes of 1500 m and more Diesel fuel specifications With respect to the per centage ppm of sulphur the fuel used in the en gine must comply with all relevant exhaust emission regulations in the are of use of the en gine It is highly recommended to use a fuel with a sul phur content of less than 0 10 1000 ppm When using a diesel fuel with a high sulphur con tent of 0 50 5000 ppm to 1 0 10 000 ppm the engine oil change intervals must behalved Do not use any fuels with a sulphur content of more than 1 0 10000 ppm It is recommended to use diesel fuel that complies with the specifications EN590 or ASTM D975 Diesel fuel with the designation no 2 D is a destil late fuel with low volatility which is especially suit able for industrial engines and heavy duty commercial vehicles SAE J313 JUN87 Since KUBOTA diesel engines with a rated power of less than 56 kW 75 HP comply with the ex haust emission standard of EPA stage 4 the use of low or ultra low sulphur fuel is mandatory for these engines if the engines are operate
71. ld consult the lubrication oil serv ice of the oil manufacturer for details Catch running out oil and dispose of environ mentally e Drive the machine until the hydraulic oil has reached operating temperature e Shut down the engine BMP 8500 Every 2000 operating hours 720 089 Fig 126 e Unscrew the plug Fig 126 and drain off all hydraulic oil e Turn the plug tightly back in Fig 127 e Unscrew the filter cover 1 Fig 127 and take out the filter element We recommend to use the BOMAG filling and fil tering unit with fine filter to fill the system This en sures finest filtration of the hydraulic oil prolongs the lifetime of the hydraulic oil filter and protects the hydraulic system e Fill in new hydraulic oil e Insert a new filter and reassemble the filter cover e Replace the breather filter 2 e Perform a test run and check the system for leaks BOMAG 87 Every 2000 operating hours 720 081 Fig 128 e Check the oil level in the inspection glass Fig 128 88 5 24 Change the coolant Danger of scalding Change the coolant only when the engine is cold Do not remove the radiator cap when the en gine is still hot Always wear gloves when handling anti freeze agent 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 fre
72. lter dirty Poor compression due to burned or bro ken piston rings or incorrect valve clear ance Injection valve defective Drain the oil down to the top dipstick mark clean if necessary use a new one Have piston rings and pistons examined by a specialist adjust the valve clearance Have examined by a specialist BMP 8500 BOMAG 101 Trouble shooting Fault Possible cause Remedy Engine over heating engine must be shut down immedi ately Cooling fins heavily soiled Injection valve defective Engine oil level too high Injection pump displacement not correctly adjusted Lack of cooling air Clean the cooling fins Have examined by a specialist Drain the oil down to the top dipstick mark Have corrected by a specialist Remove any clogging from the cooling air duct Engine has too low oil pressure engine must be immediately shut down Leaks in the lubrication system oil level too low Engine oil with wrong SAE viscosity class Check fittings on oil lines and lubrication oil filter for leaks if necessary tighten all fittings Fill up engine oil up to the mark on the dipstick Change the engine oil Charge control light lights up during operation The generator does not charge the bat tery because of defect on generator or regular Have examined by a specialist 102 BOMAG BMP 8500 6 3 Problems with remote con trol Hetronic with spiral
73. meas ured at a height fo one meter also after main tenance repair work on the safety system A safety field length lt 1 20 m is not permitted ou Ge Bs er gt 1 20 m 1 12 amp So 720 148 Fig 125 e Step behind the machine with the remote con trol and allow the machine to move towards you until it stops e Measure the distance between machine and remote control housing Nominal value gt 1 20 m Danger of injury If the safety distance is fallen short of stop the machine and have the safety system repaired It is not permitted to continue operation e Repeat this inspection in front of the machine 86 BOMAG BMP 8500 5 23 Change hydraulic oil and fil ter See also the notes on the hydraulic system in the chapter General notes on maintenance Danger of scalding When draining off hot hydraulic oil The hydraulic oil must also be changed after major 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 hy draulic oil Do not use any detergents to clean the system For quality and quantity of oil refer to the table of fuels and lubricants When changing from mineral oil based hydrau lic oil to an ester based biologically degradable oil you shou
74. n Engine solenoid Y 46 adjustment Adjust the engine solenoid if the fuse keeps blowing BMP 8500 BOMAG 105 Trouble shooting Fault Possible cause Remedy 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 106 BOMAG BMP 8500 6 4 Problems with radio remote control Hetronic in radio op eration Trouble shooting Assumed that the function is correct when using the spiral cable Steelropes or metal attachments on the frame can disturb the radio connection Fault Possible cause Remedy Machine does not re spond Incorrect or defective aerial Replace the aerial observe the frequency of the aerial Check the plug connection between aerial and receiver The receiver is electrically not or not correctly connected Check the plug connection between re ceiver and machine Receiver and tansmitter have dif ferent system numbers Installation of transmitter and receiver with identical system no Power pack empty or defective Charge or replace the power pack Distance between machine and transmitter more than 30 m Move closer to the machine Toggle switch radio cable S101 Check the plug connection Bridge switch for
75. n and ventilation plugs back in Fig 114 e Check the tightening torque of the central screw on all 4 drive hubs Fig 107 BMP 8500 BOMAG 79 Every 250 operating hours 80 BOMAG BMP 8500 5 17 Draining the fuel tank sludge Fire hazard When working on the fuel system do not use open fire do not smoke Do not spill any fuel Health hazard Do not inhale any fuel fumes Catch running out fuel do not let it seep into the ground When performing this work the fuel tank shall only hold max 5 litres of fuel pump off if necessary e Fold out the rear frame Fig 115 e Place the suitable container under the fuel tank drain plug Fig 115 e Unscrew the plug and drain off fuel e Once all fuel has run out screw the drain plug back in with a new seal ring e Fill the fuel tank with clean fuel BMP 8500 Every 500 operating hours 5 18 Changing the fuel pre cleaner bleeding the fuel system Fire hazard When working on the fuel system do not use open fire do not smoke Do not spill any fuel Health hazard Do not inhale any fuel fumes Catch running out fuel do not let it seep into the ground Dispose of the used fuel filter environmentally Change the fuel filter cartridge C EN E gt gt I Y 720 085 Fig 116 e Loosen and unscrew the fuel filter cartridge Fig 116 using an appropriate filter wrench e Cleaning the sealing face on the f
76. n the transport vehicle against rolling slipping and turning over Persons are highly endangered if BOMAG 15 Safety regulations e they step or stand under loads being lifted e they remain in the drive range of the machine during an instruction and during loading The machine must not swing about when being lift ed Use only safe lifting gear of sufficient load bearing capacity Fasten the lifting gear only at the specified lifting points Recovering towing the machine The machine can be recovered by lifting it out of the danger area Life hazard Lift the machine only with suitable lifting gear Weight see chapter Technical Data Starting the machine Before starting When operating several machines with radio re mote controls the system numbers of the individu al control units must be checked Use only machines which are serviced at regular intervals Become acquainted with the equipment the con trol elements the working principle of the machine and the working area Wear your personal protective outfit hard hat safety boots etc Before starting the machine check whether persons or obstructions are near the machine the machine shows any obvious faults all guards and safety elements are in place brakes control elements and horn are working engine hood is closed and locked Do not start the machine with defective gauges control lights or control elements Do not take any loose
77. nnected from the machine related socket on the receiver The radio remote control must only be repaired by the manufacturer or specialists authorized by the manufacturer When working on plug connections the machine battery must be disconnected or the connecting cable of the receiver pulled off All work related with the initial installation of a sys tem or with repair work must only be performed by qualified personnel The person performing the work is fully liable for professional execution of repair and maintenance work in compliance with the regulations of the manufacturer Warranty on spare parts can only be granted if these parts were installed in compliance with our regulations and instructions and by personnel au BOMAG 19 Safety regulations thorized by us We will not assume liability for changes and modifications not performed by us Information and safety stickers decals on the machine Keep safety stickers in good and legible condition see parts manual and comply with their meaning Replace damaged and illegible stickers decals 20 BOMAG BMP 8500 Fig 7 Stickers and decals 1 NO OO FB WwW PD Warning sticker Hand injuries and hot sur face read operating instructions Information sticker Engine start Warning sticker Danger of crushing Warning sticker Hot surface Information sticker Lifting point Information sticker Diesel Information sticker Battery disconnecting switc
78. not use open fire do not smoke and do not spill any fu el Do not inhale any fuel fumes Catch running out fuel do not let it seep into the ground Fig 134 084 e Replace all fuel hoses Fig 134 including their hose clips 90 BOMAG 5 26 Checking the injection pres sure This work must only be performed by authorized service personnel BMP 8500 Every 3000 operating hours 5 27 Checking the fuel injection 5 28 Checking the fuel injection pump timing This work must only be performed by authorized This work must only be performed by authorized service personnel service personnel BMP 8500 BOMAG 91 Every 3000 operating hours 92 BOMAG BMP 8500 5 29 Check clean replace the combustion air filter Do not use gasoline or hot fluids to clean the filter cartridge After cleaning the filter cartridge must be in spected 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 af ter 3 times cleaning but at the latest after one year irrespective of the operating hours Each cleaning interval must be marked with a cross on the cover of the filter element Cleaning does not make sense if the cartridge is covered with a sooty deposit Use a new fil ter cartridge Incorrectly handled filter elements may be come ineffective because of damage e g cracks and cause engine
79. ntrol 0001 Output triggered 1030 Output valve travelling forward Y 16 Display value output voltage in Volt Voltage at output 1031 Output valve travelling forward Y 16 Display value output current in AmperD Current at output 1032 Output valve travelling forward Y 16 0000 Output not triggered Logic level of control 0001 Output triggered 1035 Valve control travel system 0100 Driving forward 0010 Drum stopped 0011 Driving reverse 1040 Output valve travelling reverse Y 17 Display value output voltage in Volt Voltage at output 1041 Output valve travelling reverse Y 17 Display value output current in AmperD Current at output 1042 Output valve travelling reverse Y 17 0000 Output not triggered Logic level of control 0001 Output triggered 124 BOMAG BMP 8500 Trouble shooting Input code Description of display function Display values 1050 Output valve 2 gear Y 03 Display value output voltage in Volt Voltage at output 1051 Output valve 2 gear Y 03 Display value output current in AmperD Current at output 1052 Output valve 2 gear Y 03 0000 Output not triggered Logic level of control 0001 Output triggered Outputs for work functions Input code Description of display function Display values 1305 Output valve vibration low amplitude Display value output voltage in Volt Y 56 Voltage at output 1306 Output valve vibration low amplitude Displ
80. objects with you or fasten them to the machine 16 BOMAG Starting For starting set all control levers to neutral posi tion Do not use any starting aids like start pilot or ether After starting check all gauges and control lights Starting with jump wires Connect positive with positive and negative with negative ground cable always connect the ground strap last and disconnect it first A wrong connection will cause severe damage in the elec tric system Do not start the engine by shorting the electric ter minals on the starter motor because the machine may start to drive immediately Do not use any starting aids like start pilot or ether Starting and operation of the machine is closed rooms and trenches Exhaust gases are highly dangerous Always en sure an adequate supply of fresh air when starting and operating in closed rooms and trenches Driving the machine Persons in the danger area Before taking up work also after breaks you should always convince yourself that the danger zone is free of persons or obstructions especially when driving in reverse Give warning signals if necessary Stop work im mediately if persons remain in the danger zone despite the warning Driving Do not use the machine to transport persons In case of unusual noises and development of smoke perform trouble shooting and have the fault corrected Always keep a sufficient distance to excavation walls and emb
81. 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 sys tem protection agent ethylene glycol into the coolant Mixing with cooling system protection agent is necessary in all climatic zones It prevents corro sion lowers the freezing point and raises the boil ing 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 en ter into the system Small particles can produce flutes in valves cause pumps to seize clog noz zles and pilot bores thereby making expensive re pairs inevitable e 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 BMP 8500 e Seal leaks immediately If necessary inform the responsible customer service e 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 fil ter and protects the hydraulic system e Clean fittings filler covers and the area around such parts before disassembly to avoid enter ing of dirt e Do not
82. on of the operator The minimum distance between operator and machine must be 2 m e Do not overstretch the spiral cable BOMAG 39 Operation 723144 Fig 41 e Before starting the engine switch the toggle switch Fig 41 to the left to position Cable operation e Start the engine see chapter Starting the en gine Fig 42 e Set the toggle switch Fig 42 to maximum en gine speed If the machine is not operated over a period of 20 seconds the engine will be switched to ecomode low idle speed The engine will return to high idle as soon as either the steering or travel lever is actuated 40 BOMAG K Or Sr 723143 Fig 43 e Set the toggle switch Fig 43 to the desired travel stage g 720 115 Fig 44 Actuate the travel lever Fig 44 The machines drives with a speed which corresponds with the displacement of the travel control levers Standstill Travel lever in middle position Forward travel 1 Reverse travel 2 Shift the travel lever forward Pull the travel lever back BMP 8500 Stopping the machine Fig 45 e Travel lever Fig 45 in middle position The machine will brake Steering the machine Fig 46 e Actuate the travel levers Fig 46 accordingly Straight ahead Steering lever in middle posi tion To drive to the right Move the travel lever to the right To drive to the left Move the travel lever to the left Cle
83. ontrol Switching the vibration on and off Shut down the engine 4 10 Shutting down the engine manually 4 11 Starting operation of the radio remote control 4 12 Replacing recharging the radio remote control power pack 4 13 Safety inspection for the radio remote control 4 14 Switching off of the radio remote control in case of radio interferences 4 15 Entering the machine type code into the display module 4 16 Teaching the BOSS safety system transponder 4 17 Assembling removing the drum extension 4 18 Loading and transport 5 1 5 2 5 3 5 4 5 5 5 6 5 7 5 8 5 9 5 10 5 11 5 12 5 13 5 14 5 15 5 16 General notes on maintenance Fuels and lubricants Table of fuels and lubricants Running in instructions Maintenance table Check the engine oil level Check the hydraulic oil level Check the fuel level Fuel filter draining off water Check the coolant level Check the air intake hose Changing engine oil and oil filter Checking tensioning replacing the V belt Clean the cooling fins on engine and hydraulic oil cooler Change the oil in the vibrator shaft housing Checking the central screw of the drive hub BOMAG 13 23 26 26 33 34 34 35 36 36 39 42 42 44 45 46 50 52 53 53 55 56 56 59 60 61 64 65 66 69 69 70 70 71 73 73 75 76 77 79 Table of Contents Trouble shooting 5 17 5 18 5 19 5 20 5 21 5 22 5 23 5 24 5 25 5 26 5 27 5 28 5 29 5 30 5 31 5 32 6 1 6
84. operating hours Q N N A Fig 99 Fig 101 e Unscrew the filter cartridge 1 Fig 99 using e Fill in new engine oil Fig 101 an appropriate filter wrench e Tighten the oil filler cap properly e Clean the sealing face on the filter carrier from any dirt Fig 102 e After a short test run check the oil level once again Fig 102 if necessary top up to the top e Slightly oil the rubber seal on the new filter car mark MAX tridge Fig 100 e Turn the new filter cartridge on by hand until the seal contacts Fig 100 e Tighten the filter element for another half turn 74 BOMAG BMP 8500 5 13 Checking tensioning re placing the V belt Danger of accident Perform this work only with the engine shut down Checking the V belt Fig 103 e Check the entire circumference of the V belt Fig 103 for damage and cracks Replace damaged or cracked V belts e Check with thumb pressure whether the V belt can be depressed more than 7 to 9 mm be tween the V belt pulleys retighten if neces sary BMP 8500 Every 250 operating hours Tensioning the V belt Slacken the fastening screws 1 and 2 Fig 104 slightly Press the generator in direction outward using a lever until the correct V belt tension is reached Retighten all fastening screws and check the V belt tension once again Changing the V belt Fig 105 BOMAG Slacken the fastening screws 1 and
85. otherwise the correct function of the control can no longer be as sured The code can only be entered when the engine is shut down Fig 83 e Switch on the ignition Fig 83 e Open the rear hood BOMAG 53 Operation Display module input functions 720 138 Fig 84 e Keep both keys F1 g and F2 f depressed for two seconds Fig 84 The display shows A 0000 Au whereby the first digit is flashing e The value of the flashing digit can be in creased by pressing key F1 g If the value 9 is displayed and the key F1 g is pressed again the display will jump back to the value o e Pressing key F2 f moves the flashing digit one digit to the right If the fourth digit in the display is flashing key F2 f is pressed again for confirmation The desired function is now executed or the de sired value is displayed e Tocancel the display function you must either enter code number 0000 or switch off the ig nition Entering the machine type code e Enter code number 7010 This code number activates the function Adjust ing machine type Au The display module now permanently shows code 7010 e Enter code 7104 The display module now permanently shows the entered code e Enter code number 7011 This code number confirms the entered machine type 54 BOMAG After the confirmation of the machine type the con trol switches off The control automatically switches on again
86. restrict the movement of the travel control levers Check from time to time with the sender switched off whether both travel control levers return reliably to their neutral position when being re leased Fig 81 e With the transmitter switched off actuate and hold one of the travel levers 1 or 2 Fig 81 e Switch on the transmitter and try to start the diesel engine The diesel engine must not start e Return the travel lever to neutral position rest position e Start the engine and actuate the travel lever again The functions must now work as usual e Operate the emergency stop switch 3 The machine must stop and the engine must be shut down BMP 8500 4 14 Switching off of the radio re mote control in case of ra dio interferences The radio remote control is automatically switched off whenever the radio connection to the receiver is interrupted or disturbed for more than 2 sec onds Resetting the control after switching off by radio interference e Step into the radio transmission range of the machine Fig 82 e Switch on the ignition Fig 82 and restart the machine Operation can be resumed BMP 8500 Operation 4 15 Entering the machine type code into the display mod ule After replacing the machine control BLM the type code must be entered again The machine type code for the BMP 8500 is 7104 The machine must not be operated with a wrong type settings as
87. ring 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 function Not waited for horn signal before starting Press the horn button or wait fro the horn 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 Main wiring loom Replace the main wiring loom Display module shows CTO when ignition is on Spiral cable Check the continuity of the individual ca 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 max speed otherwise OK Toggle switch for speed S 134 Toggle switch in position max Check with input code 2505 If necessary replace the toggle switch Fuse F 14 Replace the fuses may be damaged by vibratio
88. scription of fault Possible cause Terminal Input on BLM code for diag nose 2023 Engine is shut down Output valve steer Current path con X3 21 1020 ing right Y 238 nected to 12V 1021 Although the output is 1022 switched off voltage is present Fault codes of remote control Code Fault reaction Description of fault Possible cause 2500 Engine is stopped all func Operation of two remote A remote control with cable tions are locked horn control system atthe same and a wireless remote con sounds time trol are operated at the same time 2600 Engine stopped emergency Remote control emergen Emergency stop on remote stop relay in the control is cy stop control operated switched off all outputs on control are switched off 2601 Engine stopped emergency Fault in data transfer be Battery empty stop relay in the control is tween remote control Radio or infrared transmis switched off all outputs on sender and receiver sion disturbed control are switched off i Distance between sender an machine too big 2605 Engine stopped emergency Receive signal too weak Radio or infrared transmis stop relay in the control is sion disturbed switched off all outputs on Distance between sender an control are switched off machine too big 2611 Engine is shut down CANopen fault in bus CANopen Slave cable con communication trol has not sent a node guarding answer 2612 Engine is shut down CANopen fault in bus CA
89. sert the replacement power pack into the re ceptacle Fig 63 and let it click into place Make sure the power pack clicks into place Duty time with a fully charged power pack approx 100 hours Switching on the transmitter Life hazard In order to avoid unauthorized operation of the machine do not leave the activated transmitter unattended Operate the transmitter only if the machine is in your field of vision BMP 8500 All normal work functions can only be operated from a defined neutral position i e the respective control elements must be in rest position when switching the sender on If this is not true the en gine cannot be started e Strap the transmitter to your body adjust the belts accordingly Q e If necessary unlock the emergency stop switch Fig 64 RUN wy 723153 Fig 64 720 094 Fig 65 e Set the vibration toggle switch Fig 65 to po sition 0 Starting the engine Before starting the engine both travel levers and the vibration control lever must be in rest position neutral BMP 8500 Operation The radio remote control is equipped with a re start lock Fig 66 e Switch on the ignition Fig 66 The green control light on the transmitter starts to flash and a buzzer signal sounds The transmitter is ready for operation After a period of approx 5 to 10 seconds the signal horn on the machine starts to sound The machine is now ready for operation
90. sing the ma BMP 8500 chine for the purpose it is intended for and follow ing all information given in the operating instructions A remaining risk can also not be excluded beyond the actual danger zone of the machine Persons remaining in this area must pay particular attention to the machine so that they can react immediately in case of a possible malfunction an incident or failure etc All persons remaining ion the area of the machine must be informed about the dangers that arise from the operation of the machine Regular safety inspections Have the machine inspected by an expert proper ly trained person once every year Who is allowed to operate the ma chine Only trained instructed and authorized persons of at least 18 years of age are permitted to drive and operate this machine For operation of the ma chine the responsibilities must be clearly specified and complied with Persons under the influence of alcohol medicine or drugs are not allowed to operate service or re pair the machine Maintenance and repair work requires specific knowledge and must therefore only be performed by trained specialists Conversions and alterations to the ma chine Unauthorized conversions to the machine are pro hibited for safety reasons Original parts and accessories have been special ly designed for this machine We wish to make ex pressly clear that we have not tested or authorized any original parts or spec
91. spiral cable A separate bat tery charger is available as an option The re charging time is approx 6 hours 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 ener gy 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 pock et 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 bat tery charger Strictly follow the operating instructions for the battery charger Ageing of the power pack reduces the discharging capacity and therefore the operating time of the sender The full discharging capacity is only reached after several charging cycles 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 control is switched off for a couple of days holi days bad weather you should also disconnect the charging unit from the mains supply or switch off the main battery switch 50 BOMAG Charging the power pack in the ma chine Fig 73 e Switch off the transmitter Fig 73 with the ig nition key e Plug the spiral cable into the transmitter 720 113 Fig 74 e The main batter
92. t to off ground 5081 Output switched off Output horn H07 Short on to X3 08 int t 5086 horn cannot sound short circuit current ah EU ET flow out of this output Lines rubbed Output was switched through off Horn defective 5082 Output switched off Output horn H07 Wire TR in X3 08 5080 current pat 5087 hormcannot sound No or too low current Cis cath Bi X3 36 5081 flow out of this output nected to 12V 5082 5083 Horn may sound Output horn H 07 Current path con X3 08 5080 Soe Continuously Although the output nected to 12V X3 36 5081 is switched off volt 5082 age is present 5090 Machine does not Input inclination Wire breakage in X3 23 1405 start switch B56 current path Th hi Switch defective 8 a cannot The switch is in actu A vel a i ated state incorrect iTA o installation position the inclination switch 5091 Shut down of diesel Input inclination Wire breakage in X3 23 1405 engine switch B56 current path The diesel RB Switch defective Ye diesel engine is The switch is in actu ut down Se ated state machine i pe on the con has turned over tro ae a The machine must nn rom the in first be shut down af clination sensor ter it has been placed in correct po sition 5100 Warning horn Input coolant tem Lack of coolant X3 05 5100 sounds only warn ing perature sensor B53 Coolant temperature too high Radiator defective Sensor defective BMP 8500 BOMAG
93. t unauthorized use 44 BOMAG BMP 8500 4 10 Shutting down the engine manually If the engine is not automatically shut down when turning the ignition switch to position 0 you may switch it off manually You should immediately investigate the cause for the engine not shutting down and repair the machine accordingly nel NS A Sa Fig 57 e Turn the ignition switch Fig 57 to position o Fig 58 e Pull off the ignition key Fig 58 and store it in a safe place e Fold the engine hood open BMP 8500 Operation e Keep the hand lever Fig 59 on the engine depressed until the engine shuts down e Open the rear hood 720 113 e Switch off and pull out the main battery switch Fig 60 e Remove the guard e Close engine hood and rear hood again Danger of accident Secure the machine against unauthorized use BOMAG 45 Operation 4 11 Starting operation of the ra dio remote control The minimum distance between operator and machine must be 2 m A Caution Use the transmitter only if the type approval has been granted cand 723161 Fig 61 e Set the toggle switch Fig 61 to remote con trol position Inserting the replacement power pack Change the power pack only when the sender is switched off 46 BOMAG Fig 62 e Turn the ignition switch to position 0 Fig 62 and pull it off 723154 Fig 63 e In
94. testing Transmitter or receiver defective Replace transmitter or receiver Ignition on display mod ule on but starting not possible Power pack empty or defective Charge or replace the power pack Transmitter or receiver defective Replace transmitter or receiver Engine stops without any reason Power pack empty or defective Charge or replace the power pack Disturbance caused by other radio systems Check whether the problem arises when 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 transmitter more than 30 m Move closer to the machine Toggle switch radio cable S101 Check the plug connection Bridge switch for testing BMP 8500 BOMAG 107 Trouble shooting Fault Possible cause Remedy 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 108 BOMAG BMP 8500 6 5 Faults in BOSS safety sys tem Danger of injury Trouble shooting After maintenance and or repair work on the safety system the safety field length must be chec
95. tgart bomag de BOMAG China Compaction Machinery Co Ltd No 2808 West Huancheng Road Shanghai Comprehensive Industrial Zone Fengxian Shanghai 201401 CHINA Tel 86 21 33655566 Fax 86 21 33655508 e mail china bomag com BOMAG GREAT BRITAIN LTD Sheldon Way Larkfield Aylesford Kent ME20 6SE GREAT BRITAIN Tel 44 1622 716611 Fax 44 1622 718385 e mail gb bomag com BOMAG RUS 000 Klyazma block h 1 g 141400 Khimki RUSSIA Tel 7 495 287 92 90 Fax 7 495 287 92 91 e mail russia bomag com Printed in Germany
96. the operator is behind the machine When operating the machine from the opposite side actuation of travel controls will cause ma 14 BOMAG chine movements which are not in compliance with the movement of the control elements ca 1000mm Fig 4 e The remote control must be carried in front of the body as intended Fig 4 Unintended use Danger may arise from the machine if it is used for purposes other than the one it is intended for Any danger caused by unintended use is the sole responsibility of the customer or driver operator the manufacturer cannot be made liable Examples for unintended use are e work with vibration on hard concrete cured bi tumen layers or extremely frozen ground e driving on unstable subbases or insufficient grip or too small contact area danger of tip ping over e using the machine on for towing e operating the machine without visual contact The transport of persons is prohibited Starting and operation of the machine in explosive environments and in underground mining is pro hibited Remaining dangers remaining risks Despite careful work and compliance with stand ards and regulations it cannot be ruled out that fur ther dangers may arise when working with and handling the machine Both the machine as well as all other system com ponents comply with the currently valid safety reg ulations Nevertheless remaining risks cannot be ruled out completely even when u
97. ting the engine the anti theft protection must be disarmed by entering a code 920390 Fig 30 With the electronic immobilizer armed the light emitting diode a Fig 30 flashes slowly e Slowly enter the six digit user code When entering the code the light emitting diode 6 lights up with every digit e Press the diamond button e The electronic immobilizer is now disarmed and the engine can be started within the next 30 seconds After entering the service code for maintenance work the electronic immobilizer remains switched off Optional equipment 36 BOMAG 4 5 Starting the engine Wear your personal noise protection means ear defenders before starting operation Exhaust gases are highly dangerous Always ensure an adequate supply of fresh air when starting and operating in closed rooms and trenches In this chapter it is assumed that the operator is fully acquainted with the function of the dif ferent control elements on the machine e Open the rear hood E aA INN P 720 113 Fig 31 e Switch on the main battery switch Fig 31 e Strap the control to your body and plug the spi ral cable into the remote control if required BMP 8500 Operation 723144 720 094 Fig 32 Fig 35 e For cable operation of the machine switch the e Set the vibration toggle switch Fig 35 to po toggle switch Fig 32 to the left sition 0
98. tion of centre of gravity Fig 90 Loading weight see technical data Fig 91 e Drive the machine onto the transport vehicle and lash it down by the two lashing eyes Fig 91 BMP 8500 BOMAG Operation Weights See technical data Danger of accident The machine cannot be steered if the articula tion lock is applied e After transport release the articulation lock again and store it in the receptacle 57 Operation 58 BOMAG BMP 8500 BMP 8500 5 Maintenance BOMAG 59 Maintenance 5 1 General notes on mainte nance When performing maintenance work always com ply with the appropriate safety regulations Thorough maintenance of the machine guaran tees far longer safe functioning ofthe machine and prolongs the lifetime of important components The effort needed for this work is only little com pared with the problems that may arise when not observing this rule The terms right left correspond with travel direc tion forward e Always clean machine and engine thoroughly before starting maintenance work e For maintenance work stand the machine on level ground e Always remove the main battery switch for all maintenance work e Perform maintenance work only with the motor switched off e Relieve hydraulic pressures before working on hydraulic lines e Before working on electric parts of the ma chine disconnect the battery an
99. ulic oil Panolin HLP Synth 46 meets all demands of a mineral oil based hydraulic oil according to DIN 51524 In hydraulic systems filled with Panolin HLP Synth 46 always use the same oil to top up When changing from mineral oil based hydraulic oil to an ester based biologically degradable oil you should consult the lubrication oil service of the oil manufacturer for details Check the filter more frequently after this change Perform regular oil analyses for content of wa ter and mineral oil Replace the hydraulic oil filter element every 500 operating hours BMP 8500 BOMAG Maintenance 63 Maintenance 5 3 Table of fuels and lubri cants Assembly Fuel or lubricant Quantity Summer Winter Attention Observe the level marks Engine Engine oil Engine oil API CF CF 4 CG 4 CH 4 or CI 4 approx 4 7 litres SAE 10W 30 15 C to 30 C SAE 15W 40 15 C to 40 C SAE 30 5 C to 30 C SAE 10 30 C to 5 C Fuel Diesel Winter diesel fuel down approx 24 litres to 12 C Coolant Mixture of water and anti freeze agent approx 4 5 litres Hydraulic system Hydraulic oil ISO HV46 kinem viscosity 46 mm s at 40 C or ester based biodegradable hydraulic oil approx 17 litres Vibration housing Engine oil SAE 15W 40 2x 1 71 64 BOMAG BMP 8500 BMP 8500 Maintenance 5 4 Running in instructions The maintenance plan inside the engine hood of th
100. uns only 04 nected to 12V 1061 with idle speed Although the output is 1062 switched off voltage is present 1305 Output is switched Output valve vibra Excessive current X3 12 off function no long tion low ampl Y 56 flow in current path er possible Too high current flow probably because of out of this output Out 4 defective coil or a put was switched off Short circuit to ground BMP 8500 BOMAG 113 Trouble shooting Code Fault reaction Description of fault Possible cause Terminal Input on BLM code for diag nose 1306 Output is switched Output valve vibra Short circuit to X3 12 off function no long tion low ampl Y 56 ground in the current er possible Short circuit current path flow out of this output Lines rubbed through Output was Valve defective switched off 1307 Output is switched Output valve vibra Wire breakage in cur X3 12 1305 off function no long tion low ampl Y 56 rent path 1306 er possible No or too low current Current path con 1307 flow out of this output nected to 12V 1308 Output is switched Output valve vibra Current path con X3 12 1305 off engine runs only tion low ampl Y 56 nected to 12V 1306 with idle speed 2nd Although the output is ear is inhibited 1902 g switched off voltage is present 1310 Output is switched Output valve vibra Excessive current X3 13 off function no long tion high ampl Y 57 flow in current pat
101. ustment instructions 7010 Switches on function Set machine See adjustment instructions type 7011 Confirms entered machine type See adjustment instructions 7104 Preselect machine type BMP 8500 See adjustment instructions 130 BOMAG BMP 8500 We will help you immediately Operating maintenance repair instructions and spare parts catalogues e e in situ Safe and simple trouble shooting e Secure access to required spare parts Easy to understand from experts for users Contact us or your BOMAG distributor 4 i t 4 1 E 4 a ds a gt englisch Head Office Hauptsitz BOMAG Hellerwald 56154 Boppard GERMANY Tel 49 6742 100 0 Fax 49 6742 3090 e mail germany bomag com www bomag com BOMAG Niederlassung Berlin Gewerbestra e 3 15366 Hoppegarten GERMANY Tel 49 3342 369410 Fax 49 3342 369436 e mail niberlin bomag de BOMAG Niederlassung Hannover Dieselstra e 44 30827 Garbsen Berenbostel GERMANY Tel 49 5131 70060 Fax 49 5131 6766 e mail nlhannover bomag de BOMAG Maschinenhandelsgesellschaft m b H Porschestra e 9 1230 Wien AUSTRIA Tel 43 1 69040 0 Fax 43 1 69040 20 e mail austria bomag com BOMA Equipment Hong Kong LTD Room 1003 10 F Charm Centre 700 Castle Peak Road Kowloon Hong Kong Tel 852 2721 6363 Fax 852 2721 3212 e mail bomaghk bomag com BOMAG Italia Srl Z l Via Mella 6
102. ut is switched Output valve travel Excessive current X3 24 off function no long ling reverse Y 17 flow in current path er possible Too high current flow probably because of out of this output Out 4 defective coil or a put was switched off Short circuit to ground 1041 Output is switched Output valve travel Short circuit to X3 24 off function no long ling reverse Y 17 ground in the current er possible Short circuit current path flow out of this output Lines rubbed through Output was switched Valve defective off 1042 Output is switched Output valve travel Wire breakage in cur X3 24 1040 off function no long ling reverse Y 17 rent path 1041 er possible No or too low current Current path con 1042 flow out of this output nected to 12V 1043 Engine is shut down Output valve travel Current path con X3 24 1040 ling reverse Y 17 nected to 12V 1041 Although the output is 1042 switched off voltage is present 1050 Output is switched Output valve 2 gear Excessive current X3 11 off function no long Y 03 flow in current path er possible Too high current flow probably because of out of this output Out 4 defective coil or a put was switched off Short circuit to ground 1051 Output is switched Output valve 2 gear Short circuit to X3 11 off function no long Y 03 ground in the current er possible Short circuit current path flow out of this output Lines rubbed through Output was switched Valve d
103. when the tipping angle of the machine is gt 45 The machine will stop vibration is shut down Restart the machine and move it carefully out of the danger area e Preheating control Preheating for starting at low temper atures f Function key F1 To enter code numbers in connection with function key F2 g Function key F2 To enter code numbers in connection with function key F1 h Operating hour meter Counts the operating hours while the engine is running All maintenance work must be per formed according to the indicated op erating hours Display of machine type code re mote control code and fault codes i Display of safety field system Lights when the operator is within the safety field The machine stops Move the travel lever accordingly to free the machine from the obstruc tion j Indication that the electronic immobi lizer is active Enter the required code to deacti vate Optional equipment BMP 8500 Indicators and Controls F119 F 103 F144 E54 Fo Fer F Fe 720132 Fig 13 No 3 Fuse box F119 20A Fuse for starter motor F103 10A Fuse potential 15 F14 25A Fuse for engine solenoid F54 5A Fuse for cable remote control F05 10A Fuse for utility socket F67 25A Fuse control potential 30 F48 30A Preheating F68 5A Immobilizer CD 723192 Fig 14 No 4 Toggle switch for cable remote con trol radio remote contro
104. y at regular intervals At least once per month Reference values 12 6 V fully charged 12 3 V 50 discharged Every 500 operating hours not forget to perform regular open circuit volt age measurements Exhausted batteries batteries with formation of sulphate on the plates are not covered un der warranty e Open the maintenance flap and remove the battery cover YAZ 720 113 Fig 120 e Clean the outside of the battery Fig 120 e Clean battery poles and pole clamps and grease them with pole grease Vaseline e Check the fastening of the battery e Onserviceable batteries check the acid level if necessary top up to the filling mark with dis tilled water Checking the main battery switch e Turn the main battery switch to horizontal position and check by voltage measurement ignition key test whether the batteries are disconnected from the electric system of the e Recharge the battery immediately after an machine open circuit voltage of 12 25 V or less is reached Do not perform quick charging The open circuit voltage of the battery occurs ap prox 10 hours after the last charging process or one hour after the last discharge e After each charging process allow the battery to rest for one hour before taking it into service e For resting periods of more than one month you should always disconnect the battery Do BMP 8500 BOMAG 83 Every 500 operating hours 5 20 Check the rubber buffers
105. y switch Fig 74 must be switched on The power pack recharging time is approx 6 hours BMP 8500 Operation Charging the power pack with the ex ternal battery charger Fig 77 e Push lock 1 Fig 77 on the mains unit of the battery charger forward and pull plug 2 up Fig 75 ward out of the mains unit e Switch off the transmitter Fig 75 with the ig nition key Fig 78 e Plug the corresponding plug Fig 78 onto the Fig 76 mains unit of the battery charger e Press the power pack forward and lift it out of the housing Fig 76 The type of plug to be chosen depends on the country Observe local conditions and regulations BMP 8500 BOMAG 51 Operation ver Battery cy ren ERY Crane tee charac Ym 7231 84a Fig 79 e Insert the power pack into the battery charger Fig 79 Fig 80 e Connect the battery charger to a power source Fig 80 The two light emitting diodes on battery charger and mains unit must light up The power pack recharging time is approx 6 hours When charging is completed the green LED on the charger will start to flash 52 BOMAG 4 13 Safety inspection for the ra dio remote control This safety inspection must be performed regularly once every week especially after longer breaks Danger of injury Make sure that there are no persons within the danger zone Rests of mortar or concrete may

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