Operating instructions
Maintenance instructions
Original operating instructions
BSS0134R
BMP 8500
S/N 101 720 11 1930 >
Catalogue No.
008 059 81
Multi-purpose compactor
08/2011
Foreword
Foreword
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 methods, such as lifetime tests of all important
components and highest quality demands
guarantee maximum reliability of your machine.
This manual comprises:
l Safety regulations
l Operating instructions
l Maintenance instructions
l Trouble shooting
Using these instructions will
l help you to become familiar with the machine.
l avoid malfunctions caused by unprofessional
operation.
Compliance with the maintenance instructions will
l enhance the reliability of the machine on con-
struction sites,
l prolong the lifetime of the machine,
l reduce repair costs and downtimes.
BOMAG GmbH will not assume liability for the
function of the machine
l if it is handled in a way that does not comply
with the usual modes of use,
l if it is used for purposes other than the ones it
is intended for (see safety regulations).
No warranty claims can be lodged in case of damage resulting from
l operating errors,
l insufficient maintenance and
l wrong fuels and lubricants.
Please note!
This manual was written for operators and maintenance 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 maintenance instructions are part of the machine.
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 Engineering Liability Association ”Safety Rules for
the Operation of Road Rollers and Soil Compactors” and all relevant accident prevention regulations.
For your own personal safety you should only
use original spare parts from BOMAG.
In the course of technical development we reserve the right for technical modifications
without prior notification.
These operating and maintenance instructions are
also available in other languages.
Furthermore, the spare parts catalogue is available from your BOMAG dealer against the serial
number of your machine.
Your BOMAG dealer will also supply you with information 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
FCC Notice
1)Changes or modifications not expressly approved by the party
responsible for compliance could void the user's authority to operate
the equipment.
2)This equipment has been tested and found to comply with the limits
for a Class B digital device, pursuant to part 15 of the FCC Rules.
These limits are designed to provide reasonable protection against
harmful interference in a residential installation. This equipment
generates, uses and can radiate radio frequency energy and, if not
installed and used in accordance with the instructions, may cause
harmful interference to radio communications. However, there is no
guarantee that interference will not occur in a particular installation. If
this equipment does cause harmful interference to radio or television
reception, which can be determined
by turning the equipment off and on, the user is encouraged to try to
correct the interference by one or more of the following measures:
—Reorient or relocate the receiving antenna.
—Increase the separation between the equipment and receiver.
—Connect the equipment into an outlet on a circuit different from that
to which the receiver is connected.
—Consult the dealer or an experienced radio/TV technician for help.
3)This device complies with part 15 of the FCC Rules. Operation is
subject to the following two conditions: (1) This device may not cause
harmful interference, and (2) this device must accept any interference
received, including interference that may cause undesired operation.
BOMAG 3BMP 8500
Foreword
i
Note
Please fill in
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine type (Fig. 1)
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Serial-number (Fig. 1 and 2)
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor type (Fig. 3)
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor number (Fig. 3)
Supplement the above data together with the commissioning protocol.
During commissioning our organisation will instruct you in the operation and maintenance of the
machine.
Please observe strictly the safety regulations and
all notes on risks and dangers!
Fig. 1
Fig. 2
Fig. 3
BOMAG4 BMP 8500
Table of Contents
Technical Data 7
Safety regulations 13
Indicators and Controls 23
3.1 General notes 26
3.2 Description of indicators and control elements 26
Operation 31
4.1 General 32
4.2 Tests before taking into operation 32
4.3 BOSS safety system 33
4.4 Starting the engine 34
4.5 Driving the machine (cable remote control) 36
4.6 Safety inspection for the cable remote control 39
4.7 Switching the vibration on and off 39
4.8 Shut down the engine 41
4.9 Shutting down the engine manually 42
4.10 Starting operation of the radio remote control 43
4.11 Replacing, recharging the radio remote control power pack 47
4.12 Safety inspection for the radio remote control 49
4.13 Switching off of the radio remote control in case of radio interferences 50
4.14 Switching ECO-mode on and off 50
4.15 Entering the machine type code 51
4.16 Teaching the BOSS safety system transponder 52
4.17 Assembling/removing the drum extension 53
4.18 Loading and transport 53
Maintenance 55
5.1 General notes on maintenance 56
5.2 Fuels and lubricants 57
5.3 Table of fuels and lubricants 60
5.4 Running-in instructions 61
5.5 Maintenance table 62
5.6 Check the engine oil level 65
5.7 Checking the hydraulic oil level 65
5.8 Checking the fuel level 66
5.9 Check the water separator 66
5.10 Checking the coolant level 67
5.11 Check the air intake hose 69
5.12 Changing engine oil and oil filter 69
5.13 Checking, tensioning, replacing the V-belt 71
5.14 Clean the cooling fins on engine and hydraulic oil cooler 72
5.15 Change the oil in the vibrator shaft housing 73
5.16 Checking the central screw of the drive hub 75
BOMAG 5BMP 8500
Table of Contents
5.17 Draining the fuel tank sludge 77
5.18 Changing the fuel pre-cleaner, bleeding the fuel system 77
5.19 Battery service, checking the main battery switch 79
5.20 Check the rubber buffers 80
5.21 Checking, adjusting the valve clearance 81
5.22 Safety field measurement of the Boss safety system 82
5.23 Change hydraulic oil and filter 83
5.24 Change the coolant 84
5.25 Change the fuel lines 86
5.26 Checking the injection pressure 86
5.27 Checking the fuel injection pump 87
5.28 Checking the fuel injection timing 87
5.29 Check, clean, replace the combustion air filter 89
5.30 Adjust the scrapers 92
5.31 Tightening torques for screws with metric unified thread 92
5.32 Engine conservation 93
Trouble shooting 95
6.1 General notes 96
6.2 Engine problems 97
6.3 Problems with remote control Hetronic with spiral cable 99
6.4 Problems with radio remote control Hetronic in radio operation 102
6.5 Faults in BOSS safety system 104
6.6 Fault indicator 105
6.7 Fault code 106
6.8 Input codes for BLM control 119
BOMAG6 BMP 8500
1 Technical Data
BOMAG 7BMP 8500
Technical Data
Dimensions in
A D H K L S W W
1
mm (inches)
BMP 8500
*
1000
(39.4)
520
(20.5)
1275
(50.2)
222
(8.7)
1897
(74.7)
25
(1.0)
850
(33.5)
610
(24.2)
BMP 8500
Weights
Operating weight (CECE) kg (lbs) 1595 (3516)
Basic weight kg 1585 (3494)
Mean axle load (CECE) kg 775 (1709)
Travel characteristics
Travel speed (1) forward/reverse km/h (mph) 1,3 (0.8)
Travel speed (2) forward/reverse km/h (mph) 2,5 (1.6)
Max. gradability without/with vibration (soil dependent) % 55/45
Drive
Engine manufacturer Kubota
Type D 1005
Cooling Water
Number of cylinders 3
Rated power ISO 9249 kW (hp) 14,5 (19.4)
Rated speed rpm 2600
Drive system hydrostatic
Driven drums front + rear
Brakes
Service brake hydrostatic
Parking brake mechanical
BOMAG8 BMP 8500
Technical Data
*
Steering
Type of steering Articulated joint
Steering operation hydrostatic
Vibration system
Vibrating drum front + rear
Drive system hydrostatic
Frequency Hz 42
Amplitude 1/2 mm (in) 1,12/0,56 (0.04/0.02)
Centrifugal force 1/2 kN (lbf) 72/36 (16186/8093)
Filling capacities
Fuel (diesel) l (gal us) 24 (6.3)
Hydraulic oil l (gal us) 17 (4.5)
Engine oil l (gal us) 4,7 (1.24)
Coolant l (gal us) 4,5 (1.19)
Vibration housing l (gal us) 2x 1,7 (2x 0.45)
Safety field system
Performance level PL c
Reach of the safety field infront of/behind the machine m (ft) > 1,20 (> 3,94)
BMP 8500
Safety field control
Voltage V 8 ... 30
Current consumption at 12 V A 1.5
Protection class IP 55
Safety field frequency kHz 125
Operating temperature °C (°F) -20 ... +80 (-4 ... +176)
Storage temperature °C (°F) -40 ... +85 (-40 ... +185)
Transponder in remote control
Voltage (cable operation) V 9 ... 30
Voltage (battery operation) V 3.6
Transmitting frequency range MHz 868/916
Operating temperature °C (°F) -20 ... +80 (-4 ... +176)
Storage temperature °C (°F) -40 ... +85 (-40 ... +185)
Safety field antenna
Protection class IP 55
Operating temperature °C (°F) -20 ... +80 (-4 ... +176)
Storage temperature °C (°F) -40 ... +85 (-40 ... +185)
Radio remote control
Manufacturer HETRONIC
Transmitter
Frequency band F-band
BOMAG 9BMP 8500
Technical Data
*
BMP 8500
Transmitting frequency range MHz 868 / 916
Number of channels 1
Reach, depending on environment m (ft) approx. 30 (98.4)
Current draw mA approx. 10
Weight kg (lbs) approx. 1.6 (3.5)
Receiver
Receiver frequency range MHz 868 / 916
Current draw mA approx. 10
Transmitter power pack
Voltage V 3.6
Capacity Ah 1.2
Battery charger
Operating voltage V (AC) 110/230
V (DC) 12 - 24
* The right for technical modifications remains reserved
BOMAG10 BMP 8500
Technical Data
!
Danger
The following noise and vibration data acc. to
- EC Machine Regulation edition 2006/42/EC
- the noise regulation 2000/14/EG, noise protection guideline 2003/10/EC
- Vibration Protection Regulation 2002/44/EC
were determined during conditions typical for this type of equipment and by application of harmonized standards.
During operation these values may vary because of the existing operating conditions.
Noise value
Sound pressure level on the place of the operator:
L
= 85 dB(A), determined acc. to ISO 11204 and EN 500
pA
Guaranteed sound power level:
L
= 103 dB(A), determined acc. to ISO 3744 and EN 500
WA
Wear your personal noise protection means (ear defenders) before starting operation.
BOMAG 11BMP 8500
Technical Data
BOMAG12 BMP 8500
2 Safety regulations
BOMAG 13BMP 8500
Safety regulations
General
This BOMAG machine has been built in compliance with the latest technical standard and
complies with the applicable regulations and
technical rules. However, dangers for persons
and property may arise from this machine, if:
l it is used for purposes other than the ones it is
intended for,
l it is operated by untrained personnel,
l it is changed or converted in an unprofessional
way,
l the safety instructions are not observed.
Each person involved in the operation, maintenance and repair of the machine must therefore read and comply with these safety
regulations. If necessary, this must be confirmed by obtaining the signature of the customer.
Furthermore, the following obviously also applies:
l applicable accident prevention instructions,
l generally accepted safety and road traffic reg-
ulations,
l country specific safety regulations. It is the
duty of the operator to be acquainted with
these instructions and to apply these accordingly. This applies also for local regulations
concerning different types of handling work.
Should the recommendations in these instructions 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:
l Compaction of cohesive soils in trench con-
struction
l Construction backfills
l Earthwork in sewer and pipeline construction
l Earthwork in railway and dam construction
l Earthwork in sanitary landfill construction
l Subbase and foundation work
The place of the operator is behind the machine.
When operating the machine from the opposite
side, actuation of travel controls will cause ma-
chine movements, which are not in compliance
with the movement of the control elements.
Fig. 4
l 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:
l work with vibration on hard concrete, cured bi-
tumen layers or extremely frozen ground
l driving on unstable subbases or insufficient
grip or too small contact area (danger of tipping over)
l using the machine on for towing
l 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 prohibited.
Remaining dangers, remaining risks
Despite careful work and compliance with standards and regulations it cannot be ruled out that further dangers may arise when working with and
handling the machine.
Both the machine as well as all other system components comply with the currently valid safety regulations. Nevertheless, remaining risks cannot be
ruled out completely, even when using the ma-
BOMAG14 BMP 8500
Safety regulations
!
Danger
!
Caution
i
Note
Environment
chine for the purpose it is intended for and following 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 (capable person) as required for the conditiosn the machine is working under, but at least once every
year.
Who is allowed to operate the machine?
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 machine 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 repair the machine.
Maintenance and repair work requires specific
knowledge and must therefore only be performed
by trained specialists.
Conversions and alterations to the machine
Unauthorized conversions to the machine are prohibited for safety reasons.
Original parts and accessories have been specially designed for this machine. We wish to make expressly clear that we have not tested or authorized
any original parts or special equipment not supplied by us. The installation and/or use of such
products can impair the active and/or passive driving safety. The manufacturer expressly excludes
any liability for damage resulting from the use of
non-original parts or accessories.
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 maintenance 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 machine.
Sections marked like this provide technical information concerning the optimal economical use of
the machine.
Sections marked like this highlight activities
for the safe and environmental disposal of fuels and lubricants as well as replaced parts.
Observe all environment protection regulations.
Loading the machine
Use only stable loading ramps of sufficient load
bearing capacity. The ramp inclination must be
less than the gradability of the machine.
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.
Use only safe lifting gear of sufficient load bearing
capacity Minimum lifting capacity of lifting gear:
see operating weight in chapter "Technical Data".
For lifting the machine attach the lifting gear only
to the lifting eye provided for this purpose.
BOMAG 15BMP 8500
Safety regulations
!
Danger
Check lifting eye for damage before use. Do not
use a damaged or in any other way impaired lifting
eye.
The machine must not swing about when being lifted.
Do not step or stand under suspended loads.
Lash the machine down, so that it is secured
against rolling, sliding and turning over.
Check the fastening of the central lifting hook before each use.
Recovering/towing the machine
The machine can be recovered by lifting it out of
the danger area.
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".
Do not take any loose objects with you or fasten
them to the machine.
Starting
For starting set all control levers to 'neutral position'.
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 electric system.
Do not start the engine by shorting the electric terminals 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 ensure an adequate supply of fresh air when starting
and operating in closed rooms and trenches!
Starting the machine
Before starting
When operating several machines with radio remote controls the system numbers of the individual control units must be checked.
Use only machines which are serviced at regular
intervals.
Become acquainted with the equipment, the control 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:
l persons or obstructions are near the machine
l the machine shows any obvious faults
l all guards and safety elements are in place
l brakes, control elements and horn are working
l engine hood is closed and locked
Do not start the machine with defective gauges,
control lights or control elements.
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 immediately 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 embankments and do not use working
methods that could impair the stability of the machine.
Do not work with vibration on hard concrete, cured
bitumen layers or extremely frozen ground.
BOMAG16 BMP 8500
Safety regulations
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 directly 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!
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, sewage, electric power),
if necessary stop compaction work with vibration.
Do not activate the vibration on hard (frozen, concrete) ground. Danger of bearing damage!
Parking the machine
Park the machine on horizontal, level, firm ground.
Before leaving the machine:
l shut the engine down, pull the ignition key off
l secure the machine against unintended use.
l Pull off the main battery switch.
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 tipping 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 accidents.
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. Ensure tight fit of the fuel tank cover, if necessary replace immediately.
Fire protection measures
Familiarise yourself with the location and the operation of fire fighting equipment. Observe all fire reporting and fire fighting possibilities.
BOMAG 17BMP 8500
Safety regulations
!
Caution
Maintenance work
Comply with the maintenance work described in
the operating and maintenance instructions, including the information concerning the replacement of parts.
Maintenance work must only be performed by
qualified and authorized persons.
Keep unauthorized persons away from the machine.
Do not perform maintenance work while the machine 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 battery switch.
Work on hydraulic lines
Relieve hydraulic pressures before working on hydraulic lines. Hydraulic oil escaping under pressure 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 system.
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 environmentally.
Always catch and dispose of hydraulic oils separately.
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.
l the hose shows deformations in pressurized
and depressurized condition, which do not
comply with the genuine shape of the hydraulic hose
l the hose shows deformations in bends, e.g.
squeezing, buckling, layer separation, formation of blisters
l parts of the hose are leaking.
l hoses are not correctly installed.
l the hydraulic hose has separated from the fit-
ting
l the fitting shows corrosion that impairs both
function and strength.
l hoses are mixed up by mistake.
l fittings are damaged or deformed, whereby
the function and strength of the hose/hose
connection is impaired.
Only genuine BOMAG replacement hydraulic hoses 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 dispose of environmentally.
Store used filters and other oil contaminated materials 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
Changing hydraulic hoses
Hydraulic hoses must be visually inspected at regular intervals.
Hydraulic hoses must be immediately replaced if:
l the outer layer is damaged down to the inlay
(e.g. chafing, cuts, cracks)
l the outer layer is brittle (formation of cracks in
the hose material)
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 machine disconnect the battery and cover it with insulating material.
Do not use fuses with higher ampere ratings and
do not repair fuses with a piece of wire. Fire hazard!
BOMAG18 BMP 8500
Safety regulations
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 – danger of short circuit and burning!
When recharging non-serviceable batteries remove all plugs, to avoid the accumulation of explosive 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 battery 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.
l Do not guide the water jet into the exhaust and
into the air filter.
After maintenance work
After all maintenance 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 machine, all electrical components must be disconnected from the power supply.
Repair work must only be performed by qualified
and authorized persons. Use our repair instructions for this work.
Exhaust gases are highly dangerous! Always ensure 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 remote 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 necessary
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 function. The connecting cable must be disconnected
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 system 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 19BMP 8500
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.
BOMAG20 BMP 8500
Safety regulations
Fig. 7
Stickers and decals
1 Warning sticker: Hand injuries and hot sur-
face, read operating instructions
2 Information sticker "Engine start"
3 Warning sticker "Danger of crushing"
4 Warning sticker "Hot surface"
5 Information sticker "Lifting point"
6 Information sticker "Diesel"
7 Information sticker "Battery disconnecting
switch"
8 Brief operating instructions
9 Instruction sticker: "Wear ear defenders"
10 Information sticker "Guaranteed sound capac-
ity level"
11 Maintenance sticker "High pressure cleaner"
12 Information sticker "Lashing points"
13 Information sticker "Safety field"
14 Information sticker "Hydraulic oil"
15 Maintenance sticker
BOMAG 21BMP 8500
Safety regulations
Fig. 8
Information sticker "Bio Hydraulic Oil"
*
Fig. 9
Information sticker "Panolin 46"
* Optional equipment
** Optional equipment
**
BOMAG22 BMP 8500
3 Indicators and Controls
BOMAG 23BMP 8500
Indicators and Controls
Fig. 10
BOMAG24 BMP 8500
Indicators and Controls
1 Display module
2 Fuse box
3 Toggle switch for cable remote control/radio
remote control
4 Main battery switch
5 Steering lever
6 Toggle switch, vibration automatic/manual
7 Toggle switch, travel ranges
8 Toggle switch, engine speed
9 Travel lever
10 Toggle switch for vibration high/low amplitude
11 Emergency stop switch
12 Control light data transfer/power pack radio re-
mote control
BOMAG 25BMP 8500
Indicators and Controls
h
720151
a
b
c
d
e
f
g
h
i
j
F1 F2
3.1 General notes
3.2 Description of indicators
and control elements
If you are not yet familiar with the control and display elements on this machine you should read
this section thoroughly before starting any operation on the machine. Here all functions are described in detail.
Section 4 "Operation" contains only brief descriptions of the individual control steps.
Fig. 11
No. 1 = Display module
a red = Engine oil pressure warning lamp
Lights if the engine oil pressure is too
low
Check engine oil level, repair the engine if necessary.
b yellow = Charge control lamp
Lights if the battery is not being
charged.
Check the 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 when the tipping angle of the
machine has reached > 45° in lateral
direction or > 60° in travel direction.
e = Preheating control
The machine will stop, vibration is
shut down.
Restart the machine and move it
carefully out of the danger area.
Preheating for starting at low temperatures.
BOMAG26 BMP 8500
f = Function key F2
i
Note
To enter code numbers in connection
with function key F1
g = Function key F1
To enter code numbers in connection
with function key F2
h = Operating hour meter
Counts the operating hours while the
engine is running.
All maintenance work must be performed according to the indicated operating hours.
Display of machine type code, remote 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 obstruction.
j = not used
Indicators and Controls
720164
Fig. 13
No. 3 = Toggle switch for cable remote con-
trol/radio remote control
Position left = Cable remote control
Position right = Radio remote control
*
Fig. 12
No. 2 = 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
F67 = (25A) Fuse control (potential 30)
F48 = (30A) Preheating
Fig. 14
No. 4 = Main battery switch
Disconnects the ground contact in the electric circuit 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.
* Optional equipment
BOMAG 27BMP 8500
Indicators and Controls
i
Note
720158
MIN
MAX
AUTOMATIC
720141
Fig. 15
No. 5 = Steering lever
Middle position = Straight ahead
Position left = Driving to the left
Position right = Driving to the right
Vibration switches off automatically when the travel lever is
returned to position "0"
Fig. 17
No. 7 = Toggle switch, travel ranges
Position "turtle" = 1. Travel speed range: 0 ... 1.3
km/h
Position "rabbit" = 2nd travel speed range: 0 ...
2.7 km/h, driving with vibration
not possible
Fig. 16
No. 6 = Toggle switch, vibration automatic/
manual
Position Manual = Vibration comes on when
switching on the toggle switch
for vibration in high/low amplitude.
Machine switches automatically to speed range 1
AUTOMATIC position = Vibration comes on automati-
cally when moving the travel
lever, after the toggle switch
for vibration with high/low amplitude has been actuated to
any desired position.
Fig. 18
No. 8 = Toggle switch, engine speed
Position "MIN" = idle speed of engine
Position "MAX" = maximum engine speed
BOMAG28 BMP 8500
Indicators and Controls
720159
MIN
MAX
AUTOMATIC
Fig. 19
No. 9 = Travel lever
Middle position = Stop position
Position front = Forward travel
Position rear = Reverse travel
Fig. 20
No. 10 = Toggle switch for vibration high/low
amplitude
Position "front" = high amplitude
Position "middle" = vibration switched off
Position "rear" = low amplitude
Fig. 21
No. 11 = Emergency stop push button
actuated = transmitter and diesel engine
will be switched off.
unlocked = switches the transmitter on
when the ignition is switched
on.
Fig. 22
No. 12 = 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.
BOMAG 29BMP 8500
Indicators and Controls
!
Caution
Fig. 23
No. 13 = Ignition switch
Position 0 = Ignition/engine off, key can be
pulled out
Position I = Ignition on, charge control and
oil pressure warning lights are
on.
Fig. 24
No. 14 = Start button
To start the engine in ignition switch position "I".
Fig. 25
No. 15 = Horn button
to signalize a danger situation.
Fig. 26
No. 16 = Main fuse for battery
80A = (F00)
Perform the starting process for maximum 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 shooting and rectify the cause.
BOMAG30 BMP 8500
4Operation
BOMAG 31BMP 8500
Operation
!
Danger
i
Note
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 described in detail in this chapter.
4.2 Tests before taking into operation
Before the everyday use or before a longer working 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 maintenance instructions.
l Park the machine on ground as level as possi-
ble.
l The operator must become acquainted with
the size of the safety field.
Check:
l fuel tank and fuel lines for leaks
l engine, radiator and hydraulic system for leaks
l screw joints for tight fit
l machine for condition, cleanliness, damage
l Function of remote control and emergency
stop.
l presence of the appropriate operating and
maintenance instructions
l proper maintenance of the machine
For a description of the following tasks refer to the
chapter "maintenance every 10 operating hours".
l Engine oil level, top up if necessary
l Hydraulic oil level, top up if necessary.
l Fuel level, top up if necessary.
l Fuel filter, drain water
l Coolant level, top up if necessary
BOMAG32 BMP 8500
Operation
!
Caution
!
Danger
4.3 BOSS safety system
Function
Fig. 27
The machine is surrounded by 2 spherical electromagnetic safety fields (Fig. 27). If the machine operator with the remote control enters into the field,
which stretches in travel direction, the machine will
stop immediately.
Danger of squashing!
Only operators carrying the associated remote
control are protected.
There is no protection for persons laying on
the ground.
l Shift the travel lever to neutral position and exit
the field, which corresponds with the travel direction.
l 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 operation.
If an operator is between 2 machines in both
safety fields, both corresponding travel directions 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 direction will be stopped.
BOMAG 33BMP 8500
Operation
! Danger
!
Danger
!
Caution
720162
720165
4.4 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 different control elements on the machine.
Fig. 29
l For cable operation of the machine switch the
toggle switch (Fig. 29) to the left.
l Open the rear hood.
Fig. 28
l Switch on the main battery switch (Fig. 28).
l Strap the control to your body and plug the spi-
ral cable into the remote control, if required.
Fig. 30
l For radio operation of the machine switch the
toggle switch (Fig. 30) to the right.
Fig. 31
l If necessary unlock the emergency stop switch
(Fig. 31).
BOMAG34 BMP 8500
Fig. 32
!
Caution
i
Note
i
Note
i
Note
i
Note
!
Caution
720153
0
720154
10s
720155
START
l Set the vibration toggle switch (Fig. 32) to po-
sition "0".
Operation
The control emits two short buzzer signals. This indicates that the control is ready for 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 engine cannot be started.
Fig. 33
l Switch on the ignition (Fig. 33).
l Under cold outside temperatures preheat for
Do not use any starting aid spray .
With the ignition switch in position "I" the machine
type code will appear in the display module for approx. 3 seconds.
The machine will emit a short horn signal. This indicates that the machine is ready for operation.
If the horn does not sound, there must be fault on
the machine.
Fig. 34
l Press the start button to start the engine(Fig.
34).
approx. 10 seconds before starting.
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
l Open the rear hood.
BOMAG 35BMP 8500
Operation
!
Caution
!
Danger
Fig. 35
l Switch on the main battery switch (Fig. 35).
Fig. 36
A wrong connection will cause severe damage
in the electric system.
l Bridge the machine only with a 12 Volt battery.
l When starting with an external battery connect
the plus poles (Fig. 36) first and the minus
poles (ground cable) after.
4.5 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 inclinations and slopes.
Do not drive up and down inclinations exceeding 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 apply 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 remote control strapped to the body.
The machine must only be operated within the
field of vision of the operator.
The minimum distance between operator and
machine must be 2 m.
l Do not overstretch the spiral cable.
l Start the engine as described above
l After starting disconnect the cable from the mi-
nus poles (ground cable) first and from the
plus poles last.
l Fold the control box back in and close the
hood.
BOMAG36 BMP 8500
Operation
i
Note
720162
720156
MAX
MIN
720157
Fig. 37
l Before starting the engine switch the toggle
switch for cable/radio remote control (Fig. 37)
to the left to position "Cable remote control"
l Start the engine.
Fig. 38
l Turn the rotary switch for engine speed (Fig.
38) to position MAX.
If the machine is not operated over a period of 10
seconds, the engine will be switched to "Ecomode" (low idle speed).
Fig. 39
l Switch the toggle switch for travel speed rang-
es (Fig. 39) to the desired speed range.
Fig. 40
l Actuate the travel lever (Fig. 40).
The machines drives with a speed which corresponds with the displacement of the travel control
levers.
Standstill = Travel lever in middle position
Forward travel = Shift the travel lever forward
Reverse travel = Pull the travel lever back
The engine will return to high idle as soon as either
the steering or travel lever is actuated.
BOMAG 37BMP 8500
Operation
!
Caution
Stopping the machine
Fig. 41
l Travel lever (Fig. 41) in middle position. The
machine will brake.
Steering the machine
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.
l After work clean the cable remote control with
a clean cloth or brush.
l Check the state of bellows and sealing caps at
regular intervals, have replaced by an expert,
if necessary.
Fig. 42
l Actuate the travel levers (Fig. 42) 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
Cleaning after use
Keep the cable remote control clean.
BOMAG38 BMP 8500
Operation
!
Danger
!
Caution
!
Danger
4.6 Safety inspection for the cable 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 released.
4.7 Switching the vibration on
and off
Risk of damage!
When compacting with vibration you must
check the effect of nearby buildings and underground 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
Fig. 43
l With the machine shut down actuate and hold
one of the travel levers 1 or 2 (Fig. 43).
l Try to start the diesel engine.
The diesel engine must not start.
l Return the travel lever to neutral position (rest
position).
l Start the engine and actuate the control lever
again.
The functions must now work as usual.
l Operate the emergency stop switch (3).
The machine must stop and the engine must be
shut down.
Fig. 44
l Set the vibration switch (Fig. 44) to "Automat-
ic".
Fig. 45
l Choose the amplitude (Fig. 45).
BOMAG 39BMP 8500
Operation
Fig. 46
l Move the travel lever (Fig. 46) 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
Fig. 47
l Set the vibration switch (Fig. 47) to position
”Manual”.
Fig. 48
l Choose the amplitude (Fig. 48).
Vibration switches on.
BOMAG40 BMP 8500
4.8 Shut down the engine
! Danger
l Switch the vibration off, if necessary.
Fig. 49
l Change to idle speed (Fig. 49) and let the en-
gine run for another few minutes for cooling.
Operation
Fig. 51
l Pull off the ignition key (Fig. 51) and store it in
a safe place.
Fig. 50
l Turn the ignition switch (Fig. 50) to position
"0".
Fig. 52
l Switch off and pull out the main battery switch
(Fig. 52).
l Plug the safety cap on the lock.
Danger of accident!
Secure the machine against unauthorized use.
BOMAG 41BMP 8500
Operation
!
Caution
!
Danger
!
Danger
4.9 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.
Fig. 53
l Turn the ignition switch (Fig. 53) to position
"0".
Fig. 55
l Keep the hand lever (Fig. 55) on the engine
depressed, until the engine shuts down.
l Open the rear hood.
Fig. 56
l Switch off and pull out the main battery switch
(Fig. 56).
l Remove the guard.
l Close engine hood and rear hood again.
Danger of accident!
Secure the machine against unauthorized use.
Fig. 54
l Pull off the ignition key (Fig. 54) and store it in
a safe place.
l Fold the engine hood open
BOMAG42 BMP 8500
4.10 Starting operation of the ra-
!
Danger
!
Caution
!
Caution
i
Note
!
Danger
dio remote control
The minimum distance between operator and
machine must be 2 m.
Use the transmitter only if the type approval
has been granted.
Operation
Fig. 58
l Turn the ignition switch to position "0" (Fig. 58)
and pull it off.
Fig. 57
l Set the toggle switch (Fig. 57) to remote con-
trol position.
Inserting the replacement power pack
Change the power pack only when the sender
is switched off.
Fig. 59
l Insert the replacement power pack into the re-
ceptacle (Fig. 59) 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.
BOMAG 43BMP 8500
Operation
i
Note
i
Note
i
Note
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 engine cannot be started.
l Strap the transmitter to your body, adjust the
belts accordingly.
Fig. 60
l If necessary unlock the emergency stop switch
(Fig. 60).
The radio remote control is equipped with a restart lock.
Fig. 62
l Switch on the ignition (Fig. 62).
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.
Fig. 61
l Set the vibration toggle switch (Fig. 61) 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).
Fig. 63
l Press the start button to start the engine (Fig.
63).
Run the engine warm for a short while before starting work.
BOMAG44 BMP 8500
Long distance shut-down
i
Note
! Danger
i
Note
!
Caution
Fig. 64
If the distance (Fig. 64) between and transmitter
and receiver exceeds 30 m, the machine will stop.
To continue travelling reduce the distance and restart the machine.
Operation
Fig. 65
If the battery voltage drops down to a too low level
during operation (power pack discharged), the red
warning light on the control (Fig. 65) 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
Work function
Life hazard!
Move the machine only when it is directly in
sight.
The functions of operating elements and controls are identical with the ones for the cable
remote control (see previous description).
Drive the machine to a safe place as soon as possible, so that it will not stop all of a sudden.
If necessary switch over to operation with cable remote control and plug the spiral cable into the remote 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 position "Min" for temperature equalization.
If the radio remote control is not going to be
used for a longer period of time we strictly recommend to take the batteries out of the transmitter and to recharge them approx. every four
weeks. This avoids complete discharging and
prolongs the lifetime of the power packs.
BOMAG 45BMP 8500
Operation
i
Note
!
Caution
Fig. 66
l Turn the ignition key (Fig. 66) to position "0".
Transmitter and engine will be switched off after
two seconds, the green control light on the transmitter goes out.
Fig. 67
l Switch off and pull out main battery switch 1
(Fig. 67).
l Plug the safety cap on the lock.
Fig. 68
l Pull off the ignition key (Fig. 68) and store it in
a safe place.
If the power pack of the remote control is to be recharged via the remote control cable, the main
battery switch (Fig. 67) 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.
l After work clean the transmitter with a clean
cloth or brush.
l Check the state of bellows and sealing caps at
regular intervals, have replaced by an expert,
if necessary.
BOMAG46 BMP 8500
Operation
i
Note
!
Danger
!
Caution
i
Note
i
Note
i
Note
4.11 Replacing, recharging the
radio remote control power
pack
As standard the power pack is recharged in the
machine through the spiral cable. A separate battery charger is available as an option. The recharging 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 energy source! Do not store charged power packs
in a tool box or similar, because metal parts
may cause a short circuit. Short circuits may
also be caused by keys etc. in a trouser pocket.
Charging the power pack in the machine
Fig. 69
l Switch off the transmitter (Fig. 69) with the ig-
nition key.
l Plug the spiral cable into the transmitter
Change the power pack only when the sender
is switched off.
Before connecting the battery charger make
sure that the mains voltage is in accordance
with the specifications mentioned on the battery charger.
Strictly follow the operating instructions for
the battery charger.
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 (holidays, bad weather) you should also disconnect the
charging unit from the mains supply or switch off
the main battery switch.
Fig. 70
l The main battery switch (Fig. 70) must be
switched on.
The power pack recharging time is approx. 6
hours.
BOMAG 47BMP 8500
Operation
i
Note
Charging the power pack with the external battery charger
Fig. 71
l Switch off the transmitter (Fig. 71) with the ig-
nition key.
Fig. 73
l Push lock 1 (Fig. 73) on the mains unit of the
battery charger forward and pull plug (2) upward out of the mains unit.
Fig. 72
l Press the power pack forward and lift it out of
the housing (Fig. 72).
Fig. 74
l Plug the corresponding plug (Fig. 74) onto the
mains unit of the battery charger.
The type of plug to be chosen depends on the
country. Observe local conditions and regulations.
BOMAG48 BMP 8500
Fig. 75
i
Note
!
Danger
!
Caution
l Insert the power pack into the battery charger
(Fig. 75).
Operation
4.12 Safety inspection for the radio 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 released.
Fig. 76
l Connect the battery charger to a power source
(Fig. 76).
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.
Fig. 77
l With the transmitter switched off actuate and
hold one of the travel levers 1 or 2 (Fig. 77).
l Switch on the transmitter and try to start the
diesel engine.
The diesel engine must not start.
l Return the travel lever to neutral position (rest
position).
l Start the engine and actuate the travel lever
again.
The functions must now work as usual.
l Operate the emergency stop switch (3).
The machine must stop and the engine must be
shut down.
BOMAG 49BMP 8500
Operation
!
Caution
h
720163
F
1
F
2
4.13 Switching off of the radio remote control in case of radio interferences
The radio remote control is automatically switched
off whenever the radio connection to the receiver
is interrupted or disturbed for more than 2 seconds.
Resetting the control after switching
off by radio interference
l Step into the radio transmission range of the
machine.
4.14 Switching ECO-mode on
and off
Input of code numbers
The code can only be entered when the engine
is shut down.
Fig. 78
l Switch on the ignition (Fig. 78) and restart the
machine.
Operation can be resumed.
Fig. 79
l Switch on the ignition (Fig. 79).
l Open the flap in the rear hood.
Fig. 80
l Keep both function keys F
the display module depressed for two seconds.
The display shows "0000", whereby the first digit is
flashing.
und F2 (Fig. 80) in
1
l The value of the flashing digit can be in-
creased by pressing the function key F
BOMAG50 BMP 8500
.
1
Operation
i
Note
!
Caution
i
Note
i
Note
l If the value "9" is displayed and the function
key F
is pressed again, the display will jump
1
back to the value "0".
l When pressing the function key F
the flashing
2
digit will move one digit to the right.
l If the fourth digit in the display is flashing func-
tion key F
is pressed again to confirm the en-
2
try.
The desired function is now executed or the desired value is displayed.
l To cancel the display function you must either
enter code number "0000" or switch off the ignition.
Setting ECO-mode
l Enter "5055" to start the procedure.
l Enter "5057" to switch off ECO-mode or
"5058" to switch on ECO-mode.
l Enter "5056" to finish the procedure.
Input code "5059" is used to display the status of
ECO-mode.
4.15 Entering the machine type
code
After replacing the machine control (BLM) the
machine type code must be entered again.
The machine must not be operated with a
wrong type settings, as otherwise the correct
function of the control can no longer be assured.
The code can only be entered when the engine
is shut down.
A description of the procedure for entering code
numbers can be found in the chapter "Switching
ECO-mode on or off".
l Enter "7010" to start the procedure.
This code number activates the function "Adjusting machine type“. The display module now permanently shows code "7010".
l Enter "7104".
Fig. 81
l Switch off the ignition (Fig. 81).
The display module now permanently shows code
"7104".
l Enter "7011" to finish the procedure.
This code number confirms the entered machine
type.
After having confirmed the machine type the control switches off, restarts automatically after 3 seconds and is then ready for starting.
Whenever switching the ignition on the machine
type will appear in the display module for 3 seconds.
BOMAG 51BMP 8500
Operation
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):
l Shut down the engine,
l switch off the main battery switch,
l replace defective components,
l switch on the main battery switch,
l plug the spiral cable into the remote control.
Fig. 83
l Turn the ignition switch to position I (Fig. 83),
charge control lamp and oil pressure control
lamp come on.
l Move the remote control out of the safety field.
l The safety field control lamp goes out at the
latest after 2 seconds.
Fig. 82
l Turn the tumbler switch for the cable remote
control to position "Left", cable operation (Fig.
82).
The machine is now ready for operation.
BOMAG52 BMP 8500
Operation
!
Caution
!
Danger
! Danger
4.17 Assembling/removing the
drum extension
Assembly
Fig. 84
l Attach drum extensions 2 (Fig. 84) to the
drums, turn three fastening screws (1) into
each drum and tighten.
Removal
l Unscrew the fastening screws and take off the
drum extensions.
l Turn the fastening screws back into the drum
and fasten.
4.18 Loading and transport
Danger of accident! Life hazard!
Use only stable loading ramps of sufficient
load bearing capacity. The ramp inclination
must be less than the gradability of the machine.
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.
Use only safe lifting gear of sufficient load
bearing capacity Minimum lifting capacity of
lifting gear: see operating weight in chapter
"Technical Data".
For lifting the machine attach the lifting gear
only to the lifting eye provided for this purpose.
Check lifting eye for damage before use. Do
not use a damaged or in any other way impaired lifting eye.
The machine must not swing about when being lifted.
Do not step or stand under suspended loads.
Lash the machine down, so that it is secured
against rolling, sliding and turning over.
In order to protect the threads turn the fastening 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.
Fig. 85
l After driving the machine on the transport ve-
hicle pull out the locking bolt (1) (Fig. 85) and
engage the articulation lock in the locking eye
(2). Let the locking bolt click into place.
BOMAG 53BMP 8500
Operation
!
Danger
Fig. 86
Use the central lifting facility (Fig. 86) to lift the machine.
Danger of accident!
The machine cannot be steered if the articulation lock is applied.
l After transport release the articulation lock
again and store it in the receptacle.
Fig. 87
l Position of centre of gravity (Fig. 87).
Fig. 88
l Drive the machine onto the transport vehicle
and lash it down by the two lashing eyes (Fig.
88).
BOMAG54 BMP 8500
5 Maintenance
BOMAG 55BMP 8500
Maintenance
Environment
5.1 General notes on maintenance
When performing maintenance work always comply with the appropriate safety regulations.
Thorough maintenance of the machine guarantees far longer safe functioning of the machine and
prolongs the lifetime of important components.
The effort needed for this work is only little compared with the problems that may arise when not
observing this rule.
The terms right/left correspond with travel direction forward.
l Always clean machine and engine thoroughly
before starting maintenance work.
l For maintenance work stand the machine on
level ground.
l Always remove the main battery switch for all
maintenance work.
l Perform maintenance work only with the motor
switched off.
l Relieve hydraulic pressures before working on
hydraulic lines.
l Before working on electric parts of the ma-
chine disconnect the battery and cover it with
insulation material.
l When working in the area of the articulated
joint attach the articulation lock (transport
lock).
During maintenance work catch all oils and fuels and do not let them seep into the ground or
into the sewage system. Dispose of oils and fuels 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.
l Keep fuel free of contaminants and water,
since this will damage the injection elements
of the engine.
l Drums with inside zinc lining are not suitable to
store fuel.
l When choosing the storage place for fuel
make sure that spilled fuel will not harm the environment.
l Do not let the hose stir up the slurry at the bot-
tom of the drum.
l The fuel drum must rest for a longer period of
time before drawing off fuel.
l The rest in the drum is not suitable for the en-
gine and should only be used for cleaning purposes.
Notes on the performance of the engine
On diesel engines both combustion air and fuel injection 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 of BOMAG or the
customer service of the engine manufacturer.
Notes on the cooling system
Prepare and check coolant with highest care,
since otherwise the engine may be damaged by
corrosion, cavitation and freezing.
The coolant is prepared by mixing a cooling system protection agent (ethylene glycol) into the
coolant.
Mixing with cooling system protection agent is
necessary in all climatic zones. It prevents corrosion, lowers the freezing point and raises the boiling point of the coolant.
Notes on the hydraulic system
During maintenance work on the hydraulic system
cleanliness is of major importance. Make sure that
no dirt or other contaminating substances can enter into the system. Small particles can produce
flutes in valves, cause pumps to seize, clog nozzles and pilot bores, thereby making expensive repairs inevitable.
l If, during the daily inspection of the oil level the
hydraulic oil level is found to have dropped,
check all lines, hoses and components for
leaks.
BOMAG56 BMP 8500
Maintenance
!
Caution
l Seal leaks immediately. If necessary inform
the responsible customer service.
l We recommend to use the BOMAG filling and
filtering unit with fine filter to fill the system.
This ensures finest filtration of the hydraulic
oil, prolongs the lifetime of the hydraulic oil filter and protects the hydraulic system.
l Clean fittings, filler covers and the area around
such parts before disassembly to avoid entering of dirt.
l Do not leave the tank opening unnecessarily
open, but cover it so that nothing can fall in.
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 (< 0.05%) is used, you must only
use engine oils of API
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 classification 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 operating location of the engine is of utmost importance when choosing the viscosity class (SAEclass) .
Optimal operating conditions can be achieved by
using the following oil viscosity chart as a reference.
*
-classification CF, CF-4,
Ambient temperature Viscosity
SAE 30
over 25 °C!
SAE10W-30
SAE 15W-40
SAE 20
0°C to 25°C
SAE10W-30
SAE 15W-40
below 0 °C SAE 10
SAE10W-30
SAE 15W-40
* American Petroleum Institute
BOMAG 57BMP 8500
Maintenance
!
Caution
!
Danger
Oil change intervals
The longest permissible time a lubrication oil
should remain in an engine is 1 year. If the following oil change intervals are not reached over a period of 1 year, the oil change should be performed
at least once per year, irrespective of the operating
hours reached.
API: CF, CF-4,
CG-4,CH-4 and
CI-4 = 250 operating hours
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 percentage (ppm) of sulphur the fuel used in the engine must comply with all relevant exhaust
emission regulations in the are of use of the engine.
It is highly recommended to use a fuel with a sulphur content of less than 0,10 % (1000 ppm).
When using a diesel fuel with a high sulphur content 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 destillate fuel with low volatility, which is especially suitable 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 exhaust emission standard of EPA
of low or ultra-low sulphur fuel is mandatory for
these engines, if the engines are operated within
the validity area of the EPA standard. As an alternative 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
*
-stage 4, the use
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 otherwise filter and injection lines need to be bled.
Winter fuel
Fire hazard!
Diesel fuels must never be mixed with gasoline.
For winter operation use only winter diesel fuel, to
avoid clogging because of paraffin separation. At
very low temperatures disturbing paraffin separation can also be expected when using winter diesel
fuel.
Coolant
Always use a mixture of anti-freeze agent and
clean, dehardened water with a mixing ratio of 1:1.
Under particularly extreme temperature conditions
you should consult the service representation of
the engine manufacturer with respect to the antifreeze 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 water. This procedure should be repeated two to
three times to clean the inside of radiator and engine block.
Mixing the anti-freeze agent: Prepare a mixture of
50 % anti-freeze agent and 50 % low mineral,
clean water. Stirr well before filling it into the radiator. 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.
BOMAG58 BMP 8500
!
Caution
Do not mix different coolants and additives of
Environment
!
Caution
any other kind.
Do not use any radiator cleaning agent after the
anti-freeze agent has been mixed in. The antifreeze 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 Viskosität von 46
2
mm
/s bei 40 °C und 8 mm2/s bei 100 °C betrieben. For topping up or for oil changes use only
high-quality hydraulic oil, type HVLP according to
DIN 51524, part 3, or hydraulic oils type HV according to ISO 6743/3. The viscosity index (VI)
should be at least 150 (observe information of
manufacturer).
Maintenance
Replace the hydraulic oil filter element every
500 operating hours.
Bio-degradable hydraulic oil
The hydraulic system can also be operated with a
synthetic ester based biodegradable hydraulic oil.
The biologically quickly degradable hydraulic 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 water and mineral oil.
BOMAG 59BMP 8500
Maintenance
5.3 Table of fuels and lubricants
Assembly Fuel or lubricant Quantity
Summer Winter Attention
Observe the level marks
Engine
- Engine oil Engine oil API: CF, CF-4, CG-4, CH-4 or CI-4 approx. 4.7 litres
SAE 10W-40 (-20 °C to +40 °C)
(BOMAG PN 009 920 06; 20 l)
SAE 10W-30 (-15 °C to +30 °C)
SAE 15W-40 (-15 °C to + 40 °C)
SAE 30 (+5 °C to +30 °C) SAE 10 (-30 °C to -5 °C)
- Fuel Diesel Winter diesel fuel (down
to -12°C)
- Coolant Mixture of water and anti-freeze agent
(BOMAG PN 009 940 08; 20 l)
Hydraulic system Hydraulic oil (ISO), HLP 46
(BOMAG PN 009 930 09; 20 l)
or
ester based biodegradable hydraulic oil
Vibration housing Engine oil SAE 15W/40 2 x 1.7 l
approx. 24 litres
approx. 4.0 litres
approx. 17 litres
BOMAG60 BMP 8500
Maintenance
i
Note
!
Caution
5.4 Running-in instructions
The maintenance plan inside the engine hood of
the machine assists you when servicing the machine!
The following maintenance work must be performed 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
l Change engine oil and filter
l Check the engine for leaks
l Retighten the fastening screws on air filter, ex-
haust and other attachments.
l Check screw connections on the machine,
retighten as necessary.
l Retighten fastening screws of engine mounts
l Check the central screw of the drive hub,
retighten if necessary
BOMAG 61BMP 8500
Maintenance
5.5 Maintenance table
No. Maintenance work Comment
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
every 10 operating hours, daily
every 250 oper. hours
every 500 oper. hours
every 1000 oper. hours
every 2000 oper. hours
every 3000 oper. hours
as required
5.9
Check the water separator X
5.10
Check the coolant level X
5.11
Check the air intake hose X
5.12
Change engine oil and oil filter
5.13
Check, tension, replace the V-belt X
5.14
Clean radiator cooling fins X
5.15
Change the oil in the vibrator shaft
housing
5.16
Check the central screw of the drive
**
hub
5.17
Drain the fuel tank sludge X
5.18
Change the fuel pre-cleaner, bleed
the fuel system
5.19
Service the battery, check the battery
main switch
5.20
Check the rubber buffers X
*
at least 1x per year
see foot note
min. 1x per year X
see foot note X
pole grease X
X
X
5.21
Check, adjust the valve clearance 0.145 ... 0.185 mm X
5.22
Check the safety field in front of/behind the machine
5.23
Change hydraulic oil and filter
***
at least every 2 years X
BOMAG62 BMP 8500
X
No. Maintenance work Comment
every 10 operating hours, daily
every 250 oper. hours
every 500 oper. hours
5.24
Change the coolant X
5.25
Changing the fuel lines X
5.26
Check the injection pressure X
5.27
Check the fuel injection pump X
5.28
Check the fuel injection timing X
Maintenance
every 1000 oper. hours
every 2000 oper. hours
every 3000 oper. hours
as required
5.29
Check, clean, change the combustion
min. 1x per year X
air filter
5.30
Adjust the scrapers X
5.31
Tightening torques X
5.32
Engine conservation X
* Running-in instructions: Oil change after 50 and 250 operating hours, then every 250 operating hours When using fuels with a sul-
phur content higher than 0.5% the oil change intervals must be halved.
** Running-in instructions: check tightening torque after 50 and 250 operating hours, then every 250 operating hours
*** Also in case of repair in the hydraulic system.
BOMAG 63BMP 8500
Maintenance
BOMAG64 BMP 8500
Every 10 operating hou rs
!
Caution
!
Caution
5.6 Check the engine oil level
The machine must be in horizontal position.
When the engine is warm, shut it down and
check the oil level after five minutes. With a
cold engine the oil level can be checked immediately.
For quality of oil refer to the "table of fuels and
lubricants".
Every 10 operating hours
5.7 Checking the hydraulic oil
level
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.
In hydraulic systems filled with Panolin HLP
Synth. 46 use only the same oil to top up. With
other ester based oils consult the lubrication
oil service of the respective oil manufacturer.
For quality of oil refer to the "table of fuels and
lubricants".
Fig. 89
l Pull the dipstick (Fig. 89) out, wipe it off with a
lint-free, clean cloth and reinsert it until it bottoms.
l Pull the dipstick back out.
The oil level must always be between the "MIN"and "MAX"-marks.
l If the oil level is too low top up oil immediately.
l If the oil level is too high, determine the cause
and drain the oil off.
Fig. 90
l Check the hydraulic oil level in the inspection
glass (Fig. 90) .
l If necessary remove the cover from the filter.
l Fill up hydraulic oil up to the MAX mark in the
inspection glass.
l Screw the cover back on.
BOMAG 65BMP 8500
Every 10 operating hours
! Danger
!
Caution
Environment
!
Caution
i
Note
Environment
5.8 Checking the fuel level
Fire hazard! Health hazard!
When working on the fuel system do not use
open fire, do not smoke, do not spill any fuel.
Do not refuel in closed rooms.
Do not inhale any fuel fumes.
Shut down the engine.
For quality and quantity of fuel refer to the "table of fuels and lubricants".
Catch running out fuel, do not let it seep into
the ground.
5.9 Check the water separator
The service intervals for the water separator depend 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 water separator every day for signs of
water.
Any fuel must be caught and disposed of in an
environmentally friendly manner.
Fig. 91
l Clean the area around the filler cover, unscrew
the filler cover (Fig. 91).
Contaminated fuel can cause malfunction or
even damage of the engine.
l Fill in fuel through a funnel with screen.
l Close the tank again.
Fig. 92
l Slacken the bleeding screw (1) (Fig. 92) for a
few turns.
l Slacken the drain plug (2) for a few turns and
catch running out fuel / water.
l Tighten drain and bleeding plugs again and
check for leaks, if necessary replace the seal
ring.
BOMAG66 BMP 8500
5.10 Checking the coolant level
! Danger
!
Caution
Danger of scalding!
Open the cap on the coolant compensation
tank only when the engine is cold.
If, during the daily inspection the coolant level
is found to have dropped, check all lines, hoses and engine for leaks.
For quality of coolant refer to "fuels and lubricants".
Every 10 operating hours
Fig. 93
l Check the coolant level (Fig. 93).
l To top up unscrew the filler cap and fill in cool-
ant up to the MAX-mark.
BOMAG 67BMP 8500
Every 10 operating hours
BOMAG68 BMP 8500
Every 250 operating hours
!
Danger
!
Caution
Environment
5.11 Check the air intake hose
Fig. 94
l Check the fastening of the hose clamps (Fig.
94), tighten if necessary.
l Check the condition of the air intake hose, re-
place if necessary.
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 filter.
The oil change at 250 operating hours refers to
the use of fuels with a sulphur content of less
than 0.5%. When using fuels with a sulphur
content higher than 0.5% the oil change intervals must be halved.
Drain the engine oil only when the engine is
warm.
For quality and quantity of oil refer to the "table
of fuels and lubricants".
Catch running out oil and dispose of environmentally together with the oil filter cartridge.
Fig. 95
l Unscrew the drain plug (Fig. 95) and catch
running out oil.
l Turn the drain plug tightly back in.
BOMAG 69BMP 8500
Every 250 operating hours
Fig. 96
l Unscrew the filter cartridge (1) (Fig. 96) using
an appropriate filter wrench.
l Clean the sealing face on the filter carrier from
any dirt.
Fig. 97
l Slightly oil the rubber seal on the new filter car-
tridge (Fig. 97).
l Turn the new filter cartridge on by hand, until
the seal contacts.
Fig. 98
l Fill in new engine oil (Fig. 98).
l Tighten the oil filler cap properly.
Fig. 99
l After a short test run check the oil level once
again (Fig. 99), if necessary top up to the top
mark (MAX).
l Tighten the filter element for another half turn.
BOMAG70 BMP 8500
Every 250 operating hours
!
Danger
5.13 Checking, tensioning, replacing the V-belt
Danger of accident!
Perform this work only with the engine shut
down.
Checking the V-belt
Tensioning the V-belt
Fig. 101
l Slacken the fastening screws 1 and 2 (Fig.
101) slightly.
l Press the generator in direction outward using
a lever, until the correct V-belt tension is
reached.
l Retighten all fastening screws and check the
V-belt tension once again.
Fig. 100
l Check the entire circumference of the V-belt
(Fig. 100) for damage and cracks. Replace
damaged or cracked V-belts.
l Check with thumb pressure whether the V-belt
can be depressed more than 7 to 9 mm between the V-belt pulleys, retighten if necessary.
Changing the V-belt
Fig. 102
l Slacken the fastening screws 1 and 2 (Fig.
102) slightly.
l Press the generator completely against the
engine.
l Take the old V-belt off.
l Fit the new V-belt to the V-belt pulleys.
l Tension the V-belt as previously described.
BOMAG 71BMP 8500
Every 250 operating hours
!
Caution
!
Danger
!
Caution
i
Note
i
Note
Check the V-belt tension again after a running
time of 30 minutes.
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 substantially 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 radiator and clean the cooling surfaces after.
Cleaning with compressed air
Start to blow out from the exhaust side.
Fig. 103
l Blow the cooler (Fig. 103) out with com-
pressed air from the air discharge side.
l Blow the cooler out with compressed air from
the air supply side.
BOMAG72 BMP 8500
Every 250 operating hours
!
Caution
!
Caution
Environment
!
Danger
Cleaning with cold cleansing agent
Protect electrical equipment such as generator
and starter against the direct water jet.
l 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 water jet.
l Run the engine warm for a while to avoid cor-
rosion.
5.15 Change the oil in the vibrator 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 environmentally.
Danger of injury!
Do not step under suspended loads.
Fig. 104
l Lift the machine up and support it safely (Fig.
104).
BOMAG 73BMP 8500
Every 250 operating hours
Fig. 105
l Unscrew the drain and filling plug on the front
drum (Fig. 105).
l Drain and catch all oil.
For quality and quantity of oil refer to the table
of fuels and lubricants.
l Screw the drain and ventilation plugs back in.
Fig. 108
l Unscrew the drain and ventilation plugs (Fig.
105) from the upper drum.
Fig. 106
l Jack up the opposite side of the machine and
secure it adequately (Fig. 106).
l Drain and catch all oil.
Fig. 109
l Jack up the opposite side of the machine and
secure it adequately (Fig. 104).
Fig. 107
l Top up oil through the oil drain hole in the bot-
tom drum.
BOMAG74 BMP 8500
Fig. 110
!
Caution
l Top up oil through the oil drain hole in the bot-
tom drum.
For quality and quantity of oil refer to the table
of fuels and lubricants.
l Screw the drain and ventilation plugs back in.
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. 111
l Check the tightening torque of the central
screw on all 4 drive hubs (Fig. 104).
BOMAG 75BMP 8500
Every 250 operating hours
BOMAG76 BMP 8500
Every 500 operating hours
!
Danger
!
Danger
Environment
i
Note
!
Danger
! Danger
Environment
5.17 Draining the fuel tank
Every 500 operating hours
5.18 Changing the fuel pre-
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.
l Fold out the rear frame
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
Fig. 112
l Place the suitable container under the fuel
tank drain plug(Fig. 112).
l Unscrew the plug and drain off fuel.
l Once all fuel has run out screw the drain plug
back in with a new seal ring.
l Fill the fuel tank with clean fuel.
Fig. 113
l Loosen and unscrew the fuel filter cartridge
(Fig. 113) using an appropriate filter wrench.
l Cleaning the sealing face on the filter head.
BOMAG 77BMP 8500
Every 500 operating hours
Fig. 114
l Apply a thin film of fuel to the seals and screw
the new filter cartridge (Fig. 114) on handtight.
Bleed the fuel system
Fig. 115
l Open the bleeding screw on the fuel filter (Fig.
115) and crank the engine with the starter, until fuel runs out without air bubbles.
Fig. 116
l Open the bleeding screw on the injection
pump (Fig. 116) and crank the engine with the
starter, until fuel runs out without air bubbles.
l Retighten the bleeding screw.
l Retighten the bleeding screw.
BOMAG78 BMP 8500
Every 500 operating hours
!
Danger
Environment
i
Note
!
Caution
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 battery to avoid the accumulation of highly explosive gases.
Dispose of the old batteries environmentally.
not forget to perform regular open-circuit voltage measurements.
Exhausted batteries (batteries with formation
of sulphate on the plates) are not covered under warranty!
l Open the maintenance flap and remove the
battery cover.
Maintenance free batteries also need care. Maintenance free only means that the fluid level does
not need to be checked. Each battery suffers under self-discharge, which may, in not checked occasionally, even cause damage to the battery as a
result of exhaustive discharge.
The following therefore applies for the service
life:
l Switch off all consumers.
l Check open-circuit voltage of the battery at
regular intervals. At least once per month.
Reference values: 12.6 V = fully charged; 12.3 V =
50% discharged.
l Recharge the battery immediately after an
open-circuit voltage of 12.25 V or less is
reached. Do not perform quick charging.
The open-circuit voltage of the battery occurs approx. 10 hours after the last charging process or
one hour after the last discharge.
l After each charging process allow the battery
to rest for one hour before taking it into service.
Fig. 117
l Clean the outside of the battery (Fig. 117).
l Clean battery poles and pole clamps and
grease them with pole grease (Vaseline).
l Check the fastening of the battery.
l On serviceable batteries check the acid level,
if necessary top up to the filling mark with distilled water.
Checking the main battery switch
l 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
machine.
l For resting periods of more than one month
you should always disconnect the battery. Do
BOMAG 79BMP 8500
Every 500 operating hours
5.20 Check the rubber buffers
Fig. 118
l Check all rubber buffers (Fig. 118) for tight fit,
cracks and damage and replace immediately if
damaged.
BOMAG80 BMP 8500
Every 1000 operating hours
!
Caution
i
Note
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.
l Disassemble cylinder head cover and glow
plug.
Every 1000 operating hours
Fig. 120
l Check the gap between rocker arm and valve
with a feeler gauge (Fig. 120).
Valve clearance for intake and exhaust valve:
0.145 - 0.185 mm
Fig. 119
Crankshaft position 1
IN = Intake valve
EX = Exhaust valve
l Crank the engine until both valves on cylinder
1 are “overlapping”.
l Perform the adjustment of the valve by follow-
ing the adjustment diagram 1"(Fig. 119), black
mark.
Fig. 121
Crankshaft position 2
IN = Intake valve
EX = Exhaust valve
l Turn the crankshaft one revolution (360 °) fur-
ther.
l Perform the adjustment of the valve by follow-
ing the adjustment diagram 2"(Fig. 121), black
mark.
l Assemble the cylinder head cover with a new
gasket.
After a short test run check the engine for leaks.
BOMAG 81BMP 8500
Every 1000 operating hours
!
Danger
! Danger
5.22 Safety field measurement of
the Boss safety system
Danger of injury!
The safety field of the machine must be measured at a height fo one meter, also after maintenance/repair work on the safety system.
A safety field length < 1.20 m is not permitted.
Fig. 122
l Step behind the machine with the remote con-
trol and allow the machine to move towards
you, until it stops.
l Measure the distance between machine and
remote control housing.
Nominal value:
>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.
l Repeat this inspection in front of the machine.
BOMAG82 BMP 8500
Every 2000 operating hours
i
Note
!
Danger
!
Caution
Environment
i
Note
5.23 Change hydraulic oil and filter
See also the notes on the hydraulic system in the
chapter "General notes on maintenance".
Danger of scalding!
Every 2000 operating hours
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 hydraulic oil.
Do not use any detergents to clean the system.
For quality and quantity of oil refer to the "table
of fuels and lubricants".
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.
Fig. 123
l Unscrew the plug (Fig. 123) and drain off all
hydraulic oil.
l Turn the plug tightly back in.
Fig. 124
l Unscrew the filter cover 1 (Fig. 124) and take
out the filter element.
Catch running out oil and dispose of environmentally.
l Drive the machine, until the hydraulic oil has
reached operating temperature.
l Shut down the engine.
We recommend to use the BOMAG filling and filtering unit with fine filter to fill the system. This ensures finest filtration of the hydraulic oil, prolongs
the lifetime of the hydraulic oil filter and protects
the hydraulic system.
l Fill in new hydraulic oil.
l Insert a new filter and reassemble the filter
cover.
l Replace the breather filter (2).
l Perform a test run and check the system for
leaks.
BOMAG 83BMP 8500
Every 2000 operating hours
! Danger
!
Caution
Environment
Fig. 125
l Check the oil level in the inspection glass (Fig.
125).
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 engine 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-freeze.
Do not mix different coolants and additives of
any other kind. If necessary flush the cooling
system 2-3 times with clear water.
For quality and quantity of coolant refer to the
"table of fuels and lubricants".
Catch running out coolant and dispose of environmentally.
Fig. 126
l Remove the radiator cap (Fig. 126).
BOMAG84 BMP 8500
Every 2000 operating hours
Fig. 127
l Unscrew the drain valve (Fig. 127) from the ra-
diator.
l Drain the coolant completely off and collect it.
l Screw the drain valve back in.
l Check the condition of radiator hoses, if nec-
essary replace all radiator hoses.
Fig. 128
l Open the drain valve (Fig. 128) on the engine.
l Drain the coolant completely off the engine
block and collect it.
l Close the drain tap again.
Fig. 129
l Fill in coolant until the level reaches the bottom
edge of the radiator filler socket (Fig. 129).
Fig. 130
l Fill in coolant up to the MAX mark (Fig. 130).
l Reattach the radiator cap and the cap of the
compensation tank.
l Start the diesel engine and run it warm to op-
erating temperature.
l Let the engine cool down and check the cool-
ant level again, if necessary top up in the compensation tank.
BOMAG 85BMP 8500
Every 2000 operating hours
i
Note
!
Danger
Environment
i
Note
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 not use
open fire, do not smoke and do not spill any fuel.
Do not inhale any fuel fumes.
Catch running out fuel, do not let it seep into
the ground.
5.26 Checking the injection pressure
This work must only be performed by authorized
service personnel.
Fig. 131 084
l Replace all fuel hoses (Fig. 131) including
their hose clips.
BOMAG86 BMP 8500
Every 3000 operating hours
i
Note
i
Note
5.27 Checking the fuel injection
Every 3000 operating hours
5.28 Checking the fuel injection
pump
This work must only be performed by authorized
service personnel.
timing
This work must only be performed by authorized
service personnel.
BOMAG 87BMP 8500
Every 3000 operating hours
BOMAG88 BMP 8500
As required
!
Caution
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 inspected with a torch for damage.
Dry air filter cartridges with damaged filter element or seal must be replaced in any case.
The dry air filter element must be replaced after 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 filter cartridge.
Incorrectly handled filter elements may become ineffective because of damage (e.g.:
cracks) and cause engine damage.
When working in dusty environments the filter
service may become due considerably earlier.
This my be noticed by a drop in engine power
and black exhaust fumes.
As required
Fig. 133
l Open both clamps 1 (Fig. 133).
l Remove the filter hood.
l Clean filter hood and dust discharge valve (2).
Fig. 132
Servicing of the dry air filter is necessary when the
yellow piston (Fig. 132) has reached the inscription "Service", but at the latest after one year.
After completion of the filter service reset the indicator back to "Zero" by pressing the button.
Fig. 134
l Carefully loosen the filter element.
The filter element is located directly on the outlet
tube, thereby providing a seal on the inside of the
filter 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. 134).
BOMAG 89BMP 8500
As required
!
Caution
Fig. 135
l Pull the filter element (Fig. 135) carefully out of
the housing.
Avoid contact between filter element and
housing.
Fig. 136
l Clean the sealing face on the outlet tube (Fig.
136).
Fig. 137
l Thoroughly clean the inside of the outlet tube
(Fig. 137) and the filter housing.
Dirt that may incidentally drop into the outlet tube
will reach the engine and cause wear.
l Check the old filter element.
The old filter element can be of help to discover
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 problem before installing a new filter element.
l Clean or replace the filter element.
l Examine the filter element thoroughly for dam-
age.
Before installing the new filter element check it for
possible damage from transport, cleaning or incorrect handling. Especially on the inside of the open
end (sealing area). Do not install a damaged filter
element.
Dust on the outer diameter of the outlet tube can
impair effective sealing.
Fig. 138
l Insert the filter element (Fig. 138).
BOMAG90 BMP 8500
The radial sealing area is located at the inside of
!
Caution
! Danger
i
Note
!
Caution
the open filter edge. This critical sealing area must
be under slight tension after the filter has been installed. In order to achieve a tight seal apply pressure to the outer edge of the filter and not to the
moveable centre.
l 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).
As required
Do not continue to use a damaged filter element. If in doubt use a new filter element.
Fig. 139
For cleaning purposes fit a tube to the compressed
air gun (Fig. 139), the end of which should be bent
for approx. 90°.
The length should reach down to the bottom of the
cartridge.
l Blow the cartridge out with compressed air
(max. 5 bar) from inside to outside by moving
the tube up and down inside the cartridge, until
it if free of dust.
l Examine the filter cartridge with a torch for
cracks and holes in the paper bellows.
BOMAG 91BMP 8500
As required
i
Note
i
Note
5.30 Adjust the scrapers
If the scrapers (2 per drum) are worn, they must be
adjusted or replaced.
Fig. 140
l Loosen the fastening screws (Fig. 140) on
both sides of the machine.
l Adjust the scrapers to a distance of approx. 5
mm to the drum.
l Tighten the fastening screws.
5.31 Tightening torques for
screws with metric unified
thread
Fig. 141
* Strength classes for screws with untreated, nonlubricated surface. Screw quality designations are
stamped on the screw heads.
8.8 = 8G
10.9 = 10K
12.9 = 12K
l Drum extension - drum
= 652 Nm
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 torques is checked with torque wrenches. When using MoS
torques do not apply.
lubricants the specified tightening
2
Self-locking nuts must always be replaced once
they have been unscrewed.
BOMAG92 BMP 8500
As required
i
Note
!
Caution
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 following conservation measures for the engine to
avoid corrosion:
l Clean the engine, including the cooling system
with cold cleansing agent and a water jet or,
even better, with a steam jet.
l Run the engine warm and shut it down.
l Drain the still warm engine oil and fill in anti-
corrosion engine oil.
l Drain the fuel from the fuel tank, mix it well with
10% anti-corrosion oil and fill it in again. Instead 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).
l Run the engine for 10 minutes until all lines, fil-
ter, pump and nozzles are filled with the conserving mixture and the new engine oil is
distributed to all parts.
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 attaching a clearly visible warning tag.
l 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.
l Crank the engine several times by hand (with-
out ignition) in order to spray the combustion
chamber.
l 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.
l Close the air intake opening on the air filter
and the exhaust opening.
Depending on weather conditions, these conserving measures will provide protection for approx. 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".
BOMAG 93BMP 8500
As required
BOMAG94 BMP 8500
6 Trouble shooting
BOMAG 95BMP 8500
Trouble shooting
! Danger
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 maintenance instructions.
Malfunctions are frequently caused by incorrect
operation of the machine or insufficient maintenance. Whenever a fault occurs you should therefore 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 dealers.
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.
BOMAG96 BMP 8500
6.2 Engine problems
Fault Possible cause Remedy
Trouble shooting
Engine does not
start
Poor starting of
engine or engine works irregularly with poor
power
Fuel tank empty Fill fuel tank
Fuel filter clogged, in winter due to paraffin separation
Fuel lines leaking Check all line connections for leaks and
Battery not charged or not connected Charge the battery, check the pole
Operating error see section “Starting the engine”
Incorrect valve clearance Adjust the valve clearance
Inclination switch has switched off Reduce the inclination
Battery power too low Have battery checked
Battery pole clamps loose or oxidized,
causing the starter to turn too slow
Especially in winter: use of too viscous engine oil
Fuel supply too low, fuel system clogged
by paraffin separation during winter
Change the filter, use winter fuel
tighten the fittings
clamps
Clean the pole clamps, tighten and cover
them with acid-free grease
Use an engine oil complying with the ambient temperatures
Change the fuel filter. Check the line connections for leaks and tighten the fittings.
Use winter fuel under cold conditions
Engine looses
power and
speed, excessive exhaust
smoke
The specified valve clearance is not correct
Injection valve or injection pump defective Have examined by a specialist
Engine oil level too high Drain the oil down to the top dipstick mark
Air filter dirty clean, if necessary use a new one
Poor compression due to burned or broken piston rings or incorrect valve clearance
Injection valve defective Have examined by a specialist
BOMAG 97BMP 8500
Adjust the valve clearance
Have piston rings and pistons examined
by a specialist, adjust the valve clearance
Trouble shooting
Fault Possible cause Remedy
Engine overheating, engine
must be shut
down immediately!
Engine has too
low oil pressure,
engine must be
immediately
shut down!
Charge control
light lights up
during operation
Cooling fins heavily soiled Clean the cooling fins
Injection valve defective Have examined by a specialist
Engine oil level too high Drain the oil down to the top dipstick mark
Injection pump displacement not correctly
adjusted
Lack of cooling air Remove any clogging from the cooling air
Leaks in the lubrication system, oil level
too low
Engine oil with wrong SAE viscosity class Change the engine oil
The generator does not charge the battery, because of defect on generator or
regular
Have corrected by a specialist
duct
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
Have examined by a specialist
BOMAG98 BMP 8500
6.3 Problems with remote control Hetronic with spiral cable
Fault Possible cause Remedy
Trouble shooting
Engine stops without
any reason
Engine oil pressure too low or engine oil pressure switch defective
(does the oil pressure controol
lamp light up while the engine is
running?)
Battery Check battery terminals for tight fit (inter-
Emergency stop push button Switch operated? Display off, pull button
Fuses F 54, F 67, F 103 defective Replace the fuses (may be damaged by
Toggle switch cable/radio S101 Check plug connections, bridge switch for
Relay K 11 Replace the relay
Check engine oil level or oil pressure
switch
mittent contact?)
Check the main battery switch
Replace the battery
out
Switch defective? replace
vibration)
testing
Check the plug connections in the relay
base
Spiral cables 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 while
the engine is running, especially close to
the plug connections
Check also the plug connections on the
regulator and the ground cable between
engine and frame.
Transmitter Replace the transmitter
BOMAG 99BMP 8500
Trouble shooting
Fault Possible cause Remedy
Inclination sensor Check the sensor signal, input code 1405
Bridge connections 5 and 6 on the plug for
the inclination sensor
If necessary replace the sensor
Regulator Pull off the four-pin plug above the regula-
tor, if OK, replace the regulator
A 70 module (BLM) Replace the module
Main wiring loom Replace the main wiring loom
Engine wiring harness Replace the engine wiring loom
Ignition on, display module on, but starting not
possible
Travel lever not in "0"-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 replace 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
After starting still no
function
A 70 module (BLM) Replace the module
All wiring looms Check all wiring looms for intermittent
contact, to do so wobble all cables, especially 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.
Not waited for horn signal before
starting
BOMAG100 BMP 8500
Press the horn button or wait fro the horn
signal before starting
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