FCC ID: QLXBSS0134R Schutzfeld-Steuerung / Reader (BSS-R)

 

Operating instructions Maintenance instructions Original operating instructions BSS0134R BMP 8500 S/N 101 720 11 1930 >

Multi-purpose compactor Catalogue No. 008 059 81 08/2011 F orewordBOMAG machines are products from the wide range of BOMAG compaction equipment. BOMAGs vast experience in connection with state-of-the-art production and testing meth-

ods, such as lifetime tests of all important components and highest quality demands guarantee maximum reliability of your ma-

chine. This manual comprises:

l Safety regulations l Operating instructions l Maintenance instructions l Trouble shooting Using these instructions will l l help you to become familiar with the machine. avoid malfunctions caused by unprofessional operation. l Compliance with the maintenance instructions will enhance the reliability of the machine on con-

struction sites, prolong the lifetime of the machine, reduce repair costs and downtimes. l l BOMAG GmbH will not assume liability for the function of the machine l l if it is handled in a way that does not comply with the usual modes of use, 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 dam-

age resulting from l l operating errors, insufficient maintenance and l wrong fuels and lubricants. Please note!

This manual was written for operators and mainte-

nance personnel on construction sites. Always keep this manual close at hand, e.g. in the tool compartment of the machine or in a specially provided container. These operating and mainte-

nance instructions are part of the machine. Foreword You should only operate the machine after you have been instructed and in compliance with these instructions. Strictly observe the safety regulations. Please observe also the guidelines of the Civil En-

gineering Liability Association Safety Rules for the Operation of Road Rollers and Soil Compac-

tors and all relevant accident prevention regula-

tions. For your own personal safety you should only use original spare parts from BOMAG. In the course of technical development we re-

serve the right for technical modifications without prior notification. These operating and maintenance instructions are also available in other languages. Furthermore, the spare parts catalogue is availa-

ble from your BOMAG dealer against the serial number of your machine. Your BOMAG dealer will also supply you with in-

formation about the correct use of our machines in soil and asphalt construction. The above notes do not constitute an extension of the warranty and liability conditions specified in the general terms of business of BOMAG GmbH. We wish you successful work with your BOMAG machine. BOMAG GmbH Printed in Germany Copyright by BOMAG 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. BMP 8500 BOMAG 3 Foreword Please fill in

. Machine type (Fig. 1)

. Serial-number (Fig. 1 and 2)

. Motor type (Fig. 3)

. Motor number (Fig. 3) i Note Supplement the above data together with the com-

missioning protocol. During commissioning our organisation will in-

struct you in the operation and maintenance of the machine. Please observe strictly the safety regulations and all notes on risks and dangers!

Fig. 1 Fig. 2 Fig. 3 4 BOMAG BMP 8500 Table of Contents Technical Data Safety regulations Indicators and Controls 3.1 General notes 3.2 Description of indicators and control elements Operation Maintenance 4.1 General 4.2 Tests before taking into operation 4.3 BOSS safety system 4.4 Starting the engine 4.5 Driving the machine (cable remote control) 4.6 Safety inspection for the cable remote control 4.7 Switching the vibration on and off 4.8 Shut down the engine 4.9 Shutting down the engine manually 4.10 Starting operation of the radio remote control 4.11 Replacing, recharging the radio remote control power pack 4.12 Safety inspection for the radio remote control 4.13 Switching off of the radio remote control in case of radio interferences 4.14 Switching ECO-mode on and off 4.15 Entering the machine type code 4.16 Teaching the BOSS safety system transponder 4.17 Assembling/removing the drum extension 4.18 Loading and transport 5.1 General notes on maintenance 5.2 Fuels and lubricants 5.3 Table of fuels and lubricants 5.4 Running-in instructions 5.5 Maintenance table 5.6 Check the engine oil level 5.7 Checking the hydraulic oil level 5.8 Checking the fuel level 5.9 Check the water separator 5.10 Checking the coolant level 5.11 Check the air intake hose 5.12 Changing engine oil and oil filter 5.13 Checking, tensioning, replacing the V-belt 5.14 Clean the cooling fins on engine and hydraulic oil cooler 5.15 Change the oil in the vibrator shaft housing 5.16 Checking the central screw of the drive hub BMP 8500 BOMAG 7 13 23 26 26 31 32 32 33 34 36 39 39 41 42 43 47 49 50 50 51 52 53 53 55 56 57 60 61 62 65 65 66 66 67 69 69 71 72 73 75 5 Table of Contents Trouble shooting 5.17 Draining the fuel tank sludge 5.18 Changing the fuel pre-cleaner, bleeding the fuel system 5.19 Battery service, checking the main battery switch 5.20 Check the rubber buffers 5.21 Checking, adjusting the valve clearance 5.22 Safety field measurement of the Boss safety system 5.23 Change hydraulic oil and filter 5.24 Change the coolant 5.25 Change the fuel lines 5.26 Checking the injection pressure 5.27 Checking the fuel injection pump 5.28 Checking the fuel injection timing 5.29 Check, clean, replace the combustion air filter 5.30 Adjust the scrapers 5.31 Tightening torques for screws with metric unified thread 5.32 Engine conservation 6.1 General notes 6.2 Engine problems 6.3 Problems with remote control Hetronic with spiral cable 6.4 Problems with radio remote control Hetronic in radio operation 6.5 Faults in BOSS safety system 6.6 Fault indicator 6.7 Fault code 6.8 Input codes for BLM control 77 77 79 80 81 82 83 84 86 86 87 87 89 92 92 93 95 96 97 99 102 104 105 106 119 6 BOMAG BMP 8500 1 Technical Data BMP 8500 BOMAG 7 Technical Data Dimensions in mm (inches) BMP 8500 A D H 1000

(39.4) 520

(20.5) 1275

(50.2) K 222

(8.7) L 1897

(74.7) S 25

(1.0) W 850

(33.5) W1 610

(24.2)

*

Weights Operating weight (CECE) Basic weight Mean axle load (CECE) Travel characteristics Travel speed (1) forward/reverse Travel speed (2) forward/reverse Max. gradability without/with vibration (soil dependent) Drive Engine manufacturer Type Cooling Number of cylinders Rated power ISO 9249 Rated speed Drive system Driven drums Brakes Service brake Parking brake 8 BOMAG kg (lbs) kg kg km/h (mph) km/h (mph)

%

kW (hp) rpm BMP 8500 1595 (3516) 1585 (3494) 775 (1709) 1,3 (0.8) 2,5 (1.6) 55/45 Kubota D 1005 Water 3 14,5 (19.4) 2600 hydrostatic front + rear hydrostatic mechanical BMP 8500

*

Steering Type of steering Steering operation Vibration system Vibrating drum Drive system Frequency Amplitude 1/2 Centrifugal force 1/2 Filling capacities Fuel (diesel) Hydraulic oil Engine oil Coolant Vibration housing Safety field system Performance level Reach of the safety field infront of/behind the machine Safety field control Voltage Current consumption at 12 V Protection class Safety field frequency Operating temperature Storage temperature Transponder in remote control Voltage (cable operation) Voltage (battery operation) Transmitting frequency range Operating temperature Storage temperature Safety field antenna Protection class Operating temperature Storage temperature Radio remote control Manufacturer Transmitter Frequency band BMP 8500 BOMAG Technical Data BMP 8500 Articulated joint hydrostatic front + rear hydrostatic 42 1,12/0,56 (0.04/0.02) 72/36 (16186/8093) 24 (6.3) 17 (4.5) 4,7 (1.24) 4,5 (1.19) 2x 1,7 (2x 0.45) PL c

> 1,20 (> 3,94) 8 ... 30 1.5 IP 55 125

-20 ... +80 (-4 ... +176)

-40 ... +85 (-40 ... +185) Hz mm (in) kN (lbf) l (gal us) l (gal us) l (gal us) l (gal us) l (gal us) m (ft) V A kHz C (F) C (F) V V MHz C (F) C (F) 9 ... 30 3.6 868/916

-20 ... +80 (-4 ... +176)

-40 ... +85 (-40 ... +185) C (F) C (F) IP 55

-20 ... +80 (-4 ... +176)

-40 ... +85 (-40 ... +185) HETRONIC F-band 9 Technical Data

*

Transmitting frequency range Number of channels Reach, depending on environment Current draw Weight Receiver Receiver frequency range Current draw Transmitter power pack Voltage Capacity Battery charger Operating voltage

*

The right for technical modifications remains reserved MHz m (ft) mA kg (lbs) MHz mA V Ah V (AC) V (DC) BMP 8500 868 / 916 1 approx. 30 (98.4) approx. 10 approx. 1.6 (3.5) 868 / 916 approx. 10 3.6 1.2 110/230 12 - 24 10 BOMAG BMP 8500 Technical Data The following noise and vibration data acc. to

- EC Machine Regulation edition 2006/42/EC

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

- Vibration Protection Regulation 2002/44/EC were determined during conditions typical for this type of equipment and by application of harmo-

nized standards. During operation these values may vary because of the existing operating conditions. Noise value Sound pressure level on the place of the operator:

LpA = 85 dB(A), determined acc. to ISO 11204 and EN 500 Guaranteed sound power level:

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

! Danger Wear your personal noise protection means (ear defenders) before starting operation. BMP 8500 BOMAG 11 Technical Data 12 BOMAG BMP 8500 2 Safety regulations BMP 8500 BOMAG 13 Safety regulations General This BOMAG machine has been built in com-

pliance 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 l l l it is used for purposes other than the ones it is intended for, it is operated by untrained personnel, it is changed or converted in an unprofessional way, the safety instructions are not observed. Each person involved in the operation, mainte-

nance and repair of the machine must there-

fore read and comply with these safety regulations. If necessary, this must be con-

firmed by obtaining the signature of the cus-

tomer. Furthermore, the following obviously also applies:

l l l applicable accident prevention instructions, generally accepted safety and road traffic reg-

ulations, country specific safety regulations. It is the duty of the operator to be acquainted with these instructions and to apply these accord-

ingly. This applies also for local regulations concerning different types of handling work. Should the recommendations in these instruc-

tions be different from the regulations valid in your country, you must comply with the safety regulations valid in your country. Intended use This machine must only be used for:

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 driving on unstable subbases or insufficient grip or too small contact area (danger of tip-

ping over) using the machine on for towing operating the machine without visual contact l l l The transport of persons is prohibited. Starting and operation of the machine in explosive environments and in underground mining is pro-

hibited. Remaining dangers, remaining risks Despite careful work and compliance with stand-

ards and regulations it cannot be ruled out that fur-

ther dangers may arise when working with and handling the machine. Both the machine as well as all other system com-

ponents comply with the currently valid safety reg-

ulations. Nevertheless, remaining risks cannot be ruled out completely, even when using the ma-

14 BOMAG BMP 8500 chine for the purpose it is intended for and follow-

ing all information given in the operating instructions. A remaining risk can also not be excluded beyond the actual danger zone of the machine. Persons remaining in this area must pay particular attention to the machine, so that they can react immediately in case of a possible malfunction, an incident or failure etc. All persons remaining ion the area of the machine must be informed about the dangers that arise from the operation of the machine. Regular safety inspections Have the machine inspected by an expert (capa-

ble person) as required for the conditiosn the ma-

chine is working under, but at least once every year. Who is allowed to operate the ma-

chine?

Only trained, instructed and authorized persons of at least 18 years of age are permitted to drive and operate this machine. For operation of the ma-

chine the responsibilities must be clearly specified and complied with. Persons under the influence of alcohol, medicine or drugs are not allowed to operate, service or re-

pair the machine. Maintenance and repair work requires specific knowledge and must therefore only be performed by trained specialists. Conversions and alterations to the ma-

chine Unauthorized conversions to the machine are pro-

hibited for safety reasons. Original parts and accessories have been special-

ly designed for this machine. We wish to make ex-

pressly clear that we have not tested or authorized any original parts or special equipment not sup-

plied by us. The installation and/or use of such products can impair the active and/or passive driv-

ing safety. The manufacturer expressly excludes any liability for damage resulting from the use of non-original parts or accessories. Safety regulations Damage, deficiencies, misuse of safety installations Machines which are not safe to operate or in traffic must be immediately taken out of service and shall not be used, until these deficiencies have been properly rectified. Safety installations and switches must neither be removed nor must they be made ineffective. Safety notes in the operating and main-

tenance instructions:

! Danger Sections marked like this point out possible dangers for persons.

! Caution Sections marked like this point out possible dangers for the machine or for parts of the ma-

chine. i Note Sections marked like this provide technical infor-

mation concerning the optimal economical use of the machine. Environment Sections marked like this highlight activities for the safe and environmental disposal of fu-

els and lubricants as well as replaced parts. Observe all environment protection regula-

tions. Loading the machine 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 load-

ing, 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. BMP 8500 BOMAG 15 Safety regulations 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 lift-

ed. 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 be-

fore 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.

! Danger 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 posi-

tion'. Do not use any starting aids like start pilot or ether. After starting check all gauges and control lights. Starting with jump wires Connect positive with positive and negative with negative (ground cable) always connect the ground strap last and disconnect it first! A wrong connection will cause severe damage in the elec-

tric system. Do not start the engine by shorting the electric ter-

minals on the starter motor, because the machine may start to drive immediately. Do not use any starting aids like start pilot or ether. Starting and operation of the machine is closed rooms and trenches Exhaust gases are highly dangerous! Always en-

sure an adequate supply of fresh air when starting and operating in closed rooms and trenches!

Starting the machine Driving the machine Before starting When operating several machines with radio re-

mote controls the system numbers of the individu-

al control units must be checked. Use only machines which are serviced at regular intervals. Become acquainted with the equipment, the con-

trol elements, the working principle of the machine and the working area. Wear your personal protective outfit (hard hat, safety boots, etc.). Before starting the machine check whether:

l l l l l persons or obstructions are near the machine the machine shows any obvious faults all guards and safety elements are in place brakes, control elements and horn are working engine hood is closed and locked Do not start the machine with defective gauges, control lights or control elements. Persons in the danger area Before taking up work, also after breaks, you should always convince yourself that the danger zone is free of persons or obstructions, especially when driving in reverse. Give warning signals, if necessary. Stop work im-

mediately if persons remain in the danger zone, despite the warning. Driving Do not use the machine to transport persons. In case of unusual noises and development of smoke perform trouble shooting and have the fault corrected. Always keep a sufficient distance to excavation walls and embankments and do not use working methods that could impair the stability of the ma-

chine. Do not work with vibration on hard concrete, cured bitumen layers or extremely frozen ground. 16 BOMAG BMP 8500 Driving on inclinations and slopes Fig. 5 Do not drive on gradients exceeding the maximum gradability of the machine. On slopes drive extremely careful and always di-

rectly up or down the slope. Change to a lower gear before starting to drive. Wet and loose soils considerably reduce the ground adhesion of the machine on inclinations and slopes. Higher risk of accident!

Inclination Fig. 6 The tipping angle was measured in static condition on level, hard ground with the machine stopped, no steering and without vibration. With loose soil, acceleration/deceleration, running vibration, steering or attached accessoriies the tip-

ping angle may be considerably lower. Driving across slopes should therefore be strictly avoided, because of the high risk of tipping over and the related risk of severe or even fatal acci-

dents. Safety regulations You should therefore always drive straight up or down a slope. Behaviour in traffic Match the speed to the working conditions. Always give way to loaded transport vehicles. Keep away from edges and embankments. Checking the effect of vibration When compacting with vibration you must check the effect on nearby buildings and underground supply lines (gas, water, sewage, electric power), if necessary stop compaction work with vibration. Do not activate the vibration on hard (frozen, con-

crete) ground. Danger of bearing damage!

Parking the machine Park the machine on horizontal, level, firm ground. Before leaving the machine:

l l shut the engine down, pull the ignition key off secure the machine against unintended use. l Pull off the main battery switch. Mark machines, which could be in the way, with a clearly visible sign. Refuelling Do not inhale any fuel fumes. Refuel only with the engine shut down. Do not refuel in closed rooms. No open fire, do not smoke. Monitor the entire refuelling process. Do not spill any fuel. Catch running out fuel, do not let it seep into the ground. Wipe off spilled fuel. Keep dirt and water away from the fuel. A leaking fuel tank can cause an explosion. En-

sure tight fit of the fuel tank cover, if necessary re-

place immediately. Fire protection measures Familiarise yourself with the location and the oper-

ation of fire fighting equipment. Observe all fire re-

porting and fire fighting possibilities. BMP 8500 BOMAG 17 Safety regulations Maintenance work Comply with the maintenance work described in the operating and maintenance instructions, in-

cluding the information concerning the replace-

ment of parts. Maintenance work must only be performed by qualified and authorized persons. Keep unauthorized persons away from the ma-

chine. Do not perform maintenance work while the ma-

chine is driving or the engine is running. Park the machine on horizontal, level, firm ground. Pull off the ignition key and switch off the main bat-

tery switch. Work on hydraulic lines Relieve hydraulic pressures before working on hy-

draulic lines. Hydraulic oil escaping under pres-

sure can penetrate the skin and cause severe injury. When being injured by hydraulic oil consult a medical doctor immediately, as otherwise this may cause severe infections. Do not step in front of or behind the drums when performing adjustment work in the hydraulic sys-

tem. Do not change the setting of pressure relief valves. Drain the hydraulic oil at operating temperature danger of scalding!

Catch running out hydraulic oil and dispose of en-

vironmentally. Always catch and dispose of hydraulic oils sepa-

rately. Do not start the engine after draining the hydraulic oil. Once all work is completed (with the system still depressurized!) check all connections and fittings for leaks. Changing hydraulic hoses Hydraulic hoses must be visually inspected at reg-

ular intervals. Hydraulic hoses must be immediately replaced if:

the outer layer is damaged down to the inlay

(e.g. chafing, cuts, cracks) the outer layer is brittle (formation of cracks in the hose material) l l l l l l l l l l the hose shows deformations in pressurized and depressurized condition, which do not comply with the genuine shape of the hydrau-

lic hose the hose shows deformations in bends, e.g. squeezing, buckling, layer separation, forma-

tion of blisters parts of the hose are leaking. hoses are not correctly installed. the hydraulic hose has separated from the fit-

ting the fitting shows corrosion that impairs both function and strength. hoses are mixed up by mistake. fittings are damaged or deformed, whereby the function and strength of the hose/hose connection is impaired. Only genuine BOMAG replacement hydraulic hos-

es ensure that the correct hose type (pressure range) is used at the right location. Working on the engine Shut the engine down before opening the engine hood. Drain the engine oil at operating temperature danger of scalding!

Wipe off spilled oil, catch running out oil and dis-

pose of environmentally. Store used filters and other oil contaminated ma-

terials in a separate, specially marked container and dispose of environmentally. Do not leave any tools or other objects, that could cause damage, in the engine compartment. Working on electric parts of the machine

! Caution Disconnect the minus pole first and the plus pole after. Connect the battery in reverse order. Connect the plus pole first and the minus pole after. Before starting to work on electric parts of the ma-

chine disconnect the battery and cover it with insu-

lating material. Do not use fuses with higher ampere ratings and do not repair fuses with a piece of wire. Fire haz-

ard!

18 BOMAG BMP 8500 Working on the battery When working on the battery do not smoke, do not use open fire!

Do not let acid come in contact with hands or clothes! When injured by acid flush off with clear water and seek medical advice. Metal objects (e.g. tools, rings, watch straps) must not come in contact with the battery poles dan-

ger of short circuit and burning!

When recharging non-serviceable batteries re-

move all plugs, to avoid the accumulation of explo-

sive gases. Observe the applicable instructions when starting with an auxiliary battery. Dispose of old batteries according to regulations. Switch off the charging current before removing the charging clamps. Ensure sufficient ventilation, especially if the bat-

tery is to be charged in a closed room. Working on the fuel system Do not inhale any fuel fumes. Avoid open fire, do not smoke, do not spill any fuel. Catch running out fuel, do not let it seep into the ground and dispose off environmentally. Cleaning work Do not perform cleaning work while the motor is running. Do not use gasoline or other easily inflammable substances for cleaning. When cleaning with steam cleaning equipment do not subject electrical parts and insulation material to the direct jet of water, or cover it beforehand. 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 ma-

chine, all electrical components must be discon-

nected from the power supply. Safety regulations Repair work must only be performed by qualified and authorized persons. Use our repair instruc-

tions for this work. Exhaust gases are highly dangerous! Always en-

sure an adequate supply of fresh air when starting in closed rooms!

Test The safety of compaction equipment must be checked by a specialist as required in dependence on the application and the operating conditions, however at least once every year. Radio remote control The machine must only be operated within the field of vision of the operator. The radio remote control must only be used by trained and authorized persons. The safety features incorporated in the radio re-

mote control must be checked at regular intervals. A defective radio remote control must no longer be used. In case of radio interferences watch the fault code display and switch to cable remote control, if nec-

essary The machine will stop when the reach of the radio remote control is exceeded. In case of defects the radio remote control must be immediately taken out of service. The transmitter must be switched off via the emergency stop func-

tion. The connecting cable must be 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 sys-

tem or with repair work must only be performed by qualified personnel. The person performing the work is fully liable for professional execution of repair and maintenance work in compliance with the regulations of the manufacturer. Warranty on spare parts can only be granted if these parts were installed in compliance with our regulations and instructions and by personnel au-

BMP 8500 BOMAG 19 Safety regulations thorized by us. We will not assume liability for changes and modifications not performed by us. Information and safety stickers/decals on the machine Keep safety stickers in good and legible condition

(see parts manual) and comply with their meaning. Replace damaged and illegible stickers/decals. 20 BOMAG BMP 8500 Safety regulations Fig. 7 Stickers and decals 1 Warning sticker: Hand injuries and hot sur-

10 Information sticker "Guaranteed sound capac-

face, read operating instructions Information sticker "Engine start"

2 3 Warning sticker "Danger of crushing"

4 Warning sticker "Hot surface"

5 6 7 Information sticker "Lifting point"

Information sticker "Diesel"

Information sticker "Battery disconnecting switch"

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 8 Brief operating instructions 9 Instruction sticker: "Wear ear defenders"

BMP 8500 BOMAG 21 Safety regulations Fig. 8 Information sticker "Bio Hydraulic Oil"*

Fig. 9 Information sticker "Panolin 46"**

* Optional equipment

** Optional equipment 22 BOMAG BMP 8500 3 Indicators and Controls BMP 8500 BOMAG 23 Indicators and Controls Fig. 10 24 BOMAG 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 BMP 8500 BOMAG 25 Indicators and Controls 3.1 General notes If you are not yet familiar with the control and dis-

play elements on this machine you should read this section thoroughly before starting any opera-

tion on the machine. Here all functions are de-

scribed in detail. Section 4 "Operation" contains only brief descrip-

tions of the individual control steps. 3.2 Description of indicators and control elements a b c j i h d e h g F 1 f F 2 720151 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 en-

gine 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. The machine will stop, vibration is shut down. Restart the machine and move it carefully out of the danger area. e

= Preheating control Preheating for starting at low temper-

atures. 26 BOMAG BMP 8500 Indicators and Controls 720164 Fig. 13 No. 3 = Toggle switch for cable remote con-

trol/radio remote control Position left Position right

= Cable remote control

= Radio remote control*

f g h i j

= Function key F2 To enter code numbers in connection with function key F1

= Function key F1 To enter code numbers in connection with function key F2

= Operating hour meter Counts the operating hours while the engine is running. All maintenance work must be per-

formed according to the indicated op-

erating hours. Display of machine type code, re-

mote control code and fault codes.

= Display of safety field system Lights when the operator is within the safety field. The machine stops. Move the travel lever accordingly to free the machine from the obstruc-

tion.

= not used Fig. 14 No. 4 = Main battery switch Disconnects the ground contact in the electric cir-

cuit of the machine. i Note If the power pack of the radio remote control is to be charged, the main battery switch must remain switched on when the engine is shut down. Fig. 12 No. 2 = Fuse box F119 F103 F14 F54 F67 F48

= (20A) Fuse for starter motor

= (10A) Fuse potential 15

= (25A) Fuse for engine solenoid

= (5A) Fuse for cable remote control

= (25A) Fuse control (potential 30)

= (30A) Preheating BMP 8500 BOMAG 27

* Optional equipment Indicators and Controls AUTOMATIC MAX MIN Vibration switches off automat-

ically when the travel lever is returned to position "0"

720158 Fig. 15 No. 5 = Steering lever Middle position = Straight ahead Position left Position right

= Driving to the left

= Driving to the right Fig. 16 No. 6 = Toggle switch, vibration automatic/

manual 720141 Position Manu-

al

= Vibration comes on when switching on the toggle switch for vibration in high/low ampli-

tude. i Note Machine switches automatically to speed range 1 AUTOMATIC po-

sition

= Vibration comes on automati-

cally when moving the travel lever, after the toggle switch for vibration with high/low am-

plitude has been actuated to any desired position. Fig. 17 No. 7 = Toggle switch, travel ranges Position "turtle" = 1. Travel speed range: 0 ... 1.3 km/h Position "rab-

bit"

= 2nd travel speed range: 0 ... 2.7 km/h, driving with vibration not possible Fig. 18 No. 8 = Toggle switch, engine speed Position "MIN" = idle speed of engine Position "MAX" = maximum engine speed 28 BOMAG BMP 8500 AUTOMATIC MAX MIN 720159 Fig. 19 No. 9 = Travel lever Middle position = Stop position Position front Position rear

= Forward travel

= Reverse travel Fig. 20 No. 10 = Toggle switch for vibration high/low amplitude Position "front" = high amplitude Position "mid-

dle"

Position "rear" =

low amplitude

= vibration switched off Indicators and Controls 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. BMP 8500 BOMAG 29 Indicators and Controls Fig. 23 No. 13 = Ignition switch Position 0

= Ignition/engine off, key can be Fig. 25 No. 15 = Horn button to signalize a danger situation. Position I pulled out

= Ignition on, charge control and oil pressure warning lights are on. Fig. 26 No. 16 = Main fuse for battery 80A

= (F00) Fig. 24 No. 14 = Start button To start the engine in ignition switch position "I".

! Caution 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, per-

form trouble shooting and rectify the cause. 30 BOMAG BMP 8500 4 Operation BMP 8500 BOMAG 31 Operation 4.1 General 4.2 Tests before taking into op-

If you are not yet acquainted with the controls and indicating elements on this machine you should thoroughly read chapter 3 Indicators and control elements before starting work. All indicators and control elements are de-

scribed in detail in this chapter. eration Before the everyday use or before a longer work-

ing period the following tests and inspections must be performed.

! Danger Danger of injury!

Please observe strictly the safety regulations in chapter 2 of these operating and mainte-

nance 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 l l fuel tank and fuel lines for leaks engine, radiator and hydraulic system for leaks screw joints for tight fit l machine for condition, cleanliness, damage l Function of remote control and emergency stop. presence of the appropriate operating and maintenance instructions proper maintenance of the machine l l i Note 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 32 BOMAG BMP 8500 Operation 4.3 BOSS safety system

! Danger Danger of squashing!

Function Only operators carrying the associated remote control are protected. There is no protection for persons laying on the ground. Fig. 27 The machine is surrounded by 2 spherical electro-

magnetic safety fields (Fig. 27). If the machine op-

erator with the remote control enters into the field, which stretches in travel direction, the machine will stop immediately. l Shift the travel lever to neutral position and exit the field, which corresponds with the travel di-

rection. l Operate the machine to the opposite direction

(picture), so that the operator is no longer in the safety field of the machine.

! Caution The operator must become acquainted with the size of the safety field before he starts op-

eration. If an operator is between 2 machines in both safety fields, both corresponding travel direc-

tions of the associated machines will be stopped. The operator must leave the safety field to be able to move the machine again. The minimum distance between operator and machine must be 2 m. When falling short of a distance of 1.2 m, the corresponding travel di-

rection will be stopped. BMP 8500 BOMAG 33 Operation 4.4 Starting the engine

! Danger Wear your personal noise protection means

(ear defenders) before starting operation.

! Danger Exhaust gases are highly dangerous!

Always ensure an adequate supply of fresh air when starting and operating in closed rooms and trenches!

! Caution In this chapter it is assumed that the operator is fully acquainted with the function of the dif-

ferent control elements on the machine. 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. 29 l For cable operation of the machine switch the toggle switch (Fig. 29) to the left. 720162 Fig. 30 l For radio operation of the machine switch the toggle switch (Fig. 30) to the right. 720165 Fig. 31 l If necessary unlock the emergency stop switch

(Fig. 31). 34 BOMAG BMP 8500 Operation The control emits two short buzzer signals. This in-

dicates that the control is ready for operation. i Note If the buzzer does not sound, there must be a fault in the control or the power pack of the control is empty. 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 en-

gine cannot be started. START Fig. 34 l Press the start button to start the engine(Fig. 720155 34).

! Caution 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. 0 Fig. 32 l Set the vibration toggle switch (Fig. 32) to po-

sition "0". 720153 10s 720154 Fig. 33 l Switch on the ignition (Fig. 33). l Under cold outside temperatures preheat for approx. 10 seconds before starting.

! Caution Do not use any starting aid spray . i Note With the ignition switch in position "I" the machine type code will appear in the display module for ap-

prox. 3 seconds. The machine will emit a short horn signal. This in-

dicates that the machine is ready for operation. i Note If the horn does not sound, there must be fault on the machine. BMP 8500 BOMAG 35 Operation Fig. 35 l Switch on the main battery switch (Fig. 35). Fig. 36

! Caution 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. 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. 4.5 Driving the machine (cable remote control)

! Danger Danger of accident!

Before starting to drive make sure that the drive range is absolutely safe. Wet and loose soils considerably reduce the ground adhesion of the machine on inclina-

tions and slopes. Do not drive up and down inclinations exceed-

ing the maximum gradability of the machine

(see technical data). Slowly return the travel lever towards neutral when driving down slopes. Before starting to drive check the function of the remote control. During operation of the machine with remote control the operator must always stay behind or beside the machine. Specified directions ap-

ply only if the operator is standing behind the machine. If the operator is standing in front of the machine all machine movements will be opposite to the movement of the control lever. The machine must only be operated with re-

mote control strapped to the body. The machine must only be operated within the field of vision of the operator. The minimum distance between operator and machine must be 2 m. l Do not overstretch the spiral cable. 36 BOMAG BMP 8500 Operation 720162 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. MAX Fig. 39 l Switch the toggle switch for travel speed rang-

es (Fig. 39) to the desired speed range. MIN 720156 Fig. 38 l Turn the rotary switch for engine speed (Fig. 38) to position MAX. i Note If the machine is not operated over a period of 10 seconds, the engine will be switched to "Eco-

mode" (low idle speed). The engine will return to high idle as soon as either the steering or travel lever is actuated. Fig. 40 l Actuate the travel lever (Fig. 40). The machines drives with a speed which corre-

sponds 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 BMP 8500 BOMAG 37 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. Operation Stopping the machine Fig. 41 l Travel lever (Fig. 41) in middle position. The machine will brake. Steering the machine Fig. 42 l Actuate the travel levers (Fig. 42) accordingly. Straight ahead = Steering lever in middle posi-

tion To drive to the right To drive to the left

= Move the travel lever to the right

= Move the travel lever to the left Cleaning after use

! Caution Keep the cable remote control clean. 38 BOMAG BMP 8500 Operation 4.6 Safety inspection for the ca-

4.7 Switching the vibration on ble remote control and off This safety inspection must be performed regularly once every week, especially after longer breaks.

! Danger Danger of injury!

Make sure that there are no persons within the danger zone.

! Caution Rests of mortar or concrete may restrict the movement of the travel control levers. Check from time to time (with the sender switched off!) whether both travel control levers return reliably to their neutral position when being re-

leased.

! Danger Risk of damage!

When compacting with vibration you must check the effect of nearby buildings and un-

derground supply lines (gas, water, sewage, electric power), if necessary stop compaction with vibration. Do not activate the vibration on hard (frozen, concrete) ground. Danger of bearing damage!

Automatic Fig. 44 l Set the vibration switch (Fig. 44) to "Automat-

ic". 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. 45 l Choose the amplitude (Fig. 45). BMP 8500 BOMAG 39 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. 48 l Choose the amplitude (Fig. 48). Vibration switches on. Fig. 47 l Set the vibration switch (Fig. 47) to position Manual. 40 BOMAG BMP 8500 4.8 Shut down the engine l Switch the vibration off, if necessary. Operation Fig. 51 l Pull off the ignition key (Fig. 51) and store it in a safe place. Fig. 49 l Change to idle speed (Fig. 49) and let the en-

gine run for another few minutes for cooling. Fig. 52 l Switch off and pull out the main battery switch

(Fig. 52). l Plug the safety cap on the lock. Fig. 50 l Turn the ignition switch (Fig. 50) to position

"0".

! Danger Danger of accident!

Secure the machine against unauthorized use. BMP 8500 BOMAG 41 Operation 4.9 Shutting down the engine manually

! Caution If the engine is not automatically shut down when turning the ignition switch to position

"0", you may switch it off manually.

! Danger 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 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 42 BOMAG BMP 8500 4.10 Starting operation of the ra-

dio remote control

! Danger The minimum distance between operator and machine must be 2 m.

! Caution Use the transmitter only if the type approval has been granted. Fig. 57 l Set the toggle switch (Fig. 57) to remote con-

trol position. Inserting the replacement power pack

! Caution Change the power pack only when the sender is switched off. Operation Fig. 58 l Turn the ignition switch to position "0" (Fig. 58) and pull it off. Fig. 59 l Insert the replacement power pack into the re-

ceptacle (Fig. 59) and let it click into place. i Note Make sure the power pack clicks into place. Duty time with a fully charged power pack:

approx. 100 hours Switching on the transmitter

! Danger Life hazard!

In order to avoid unauthorized operation of the machine do not leave the activated transmitter unattended. Operate the transmitter only if the machine is in your field of vision. BMP 8500 BOMAG 43 Operation 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 en-

gine cannot be started. l Strap the transmitter to your body, adjust the belts accordingly. The radio remote control is equipped with a re-

start 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. 60 l If necessary unlock the emergency stop switch

(Fig. 60). Fig. 61 l Set the vibration toggle switch (Fig. 61) to po-

sition "0". Starting the engine i Note 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). i Note Run the engine warm for a short while before start-

ing work. 44 BOMAG BMP 8500 Long distance shut-down Operation Fig. 64 If the distance (Fig. 64) between and transmitter and receiver exceeds 30 m, the machine will stop. i Note To continue travelling reduce the distance and re-

start the machine. Work function

! Danger Life hazard!

Move the machine only when it is directly in sight. The functions of operating elements and con-

trols are identical with the ones for the cable remote control (see previous description). Fig. 65 i Note 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 Drive the machine to a safe place as soon as pos-

sible, so that it will not stop all of a sudden. If necessary switch over to operation with cable re-

mote control and plug the spiral cable into the re-

mote control. During cable operation of the machine the power pack is automatically charged. Replace or recharge the power pack. Switching off the transmitter (engine)

! Caution Do not shut the engine down all of a sudden from full load, but let it idle for a while in posi-

tion "Min" for temperature equalization. If the radio remote control is not going to be used for a longer period of time we strictly rec-

ommend to take the batteries out of the trans-

mitter and to recharge them approx. every four weeks. This avoids complete discharging and prolongs the lifetime of the power packs. BMP 8500 BOMAG 45 Operation 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 trans-

mitter 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. i Note If the power pack of the remote control is to be re-

charged via the remote control cable, the main battery switch (Fig. 67) must be switched on. Cleaning after use

! Caution 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. 46 BOMAG BMP 8500 Operation Charging the power pack in the ma-

chine Fig. 69 l Switch off the transmitter (Fig. 69) with the ig-

nition key. l Plug the spiral cable into the transmitter Fig. 70 l The main battery switch (Fig. 70) must be switched on. i Note The power pack recharging time is approx. 6 hours. 4.11 Replacing, recharging the radio remote control power pack i Note As standard the power pack is recharged in the machine through the spiral cable. A separate bat-

tery charger is available as an option. The re-

charging time is approx. 6 hours.

! Danger Operate the battery charger only in dry rooms at temperatures of min. 0 C to max. 40 C!

A charged power pack is a concentrated ener-

gy source! Do not store charged power packs in a tool box or similar, because metal parts may cause a short circuit. Short circuits may also be caused by keys etc. in a trouser pock-

et.

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

tery charger. Strictly follow the operating instructions for the battery charger. i Note 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. i Note As the charging of the power pack succeeds, the charging current drops, so that overcharging of the power pack is almost impossible. However, if the control is switched off for a couple of days (holi-

days, bad weather) you should also disconnect the charging unit from the mains supply or switch off the main battery switch. BMP 8500 BOMAG 47 Operation Charging the power pack with the ex-

ternal 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) up-

ward 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. i Note The type of plug to be chosen depends on the country. Observe local conditions and regulations. 48 BOMAG BMP 8500 Operation 4.12 Safety inspection for the ra-

dio remote control This safety inspection must be performed regularly once every week, especially after longer breaks.

! Danger Danger of injury!

Make sure that there are no persons within the danger zone.

! Caution Rests of mortar or concrete may restrict the movement of the travel control levers. Check from time to time (with the sender switched off!) whether both travel control levers return reliably to their neutral position when being re-

leased. Fig. 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. Fig. 75 l Insert the power pack into the battery charger

(Fig. 75). 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. i Note The power pack recharging time is approx. 6 hours. When charging is completed the green LED on the charger will start to flash. BMP 8500 BOMAG 49 Operation 4.13 Switching off of the radio re-

4.14 Switching ECO-mode on mote control in case of ra-

dio interferences and off The radio remote control is automatically switched off whenever the radio connection to the receiver is interrupted or disturbed for more than 2 sec-

onds. Resetting the control after switching off by radio interference l Step into the radio transmission range of the machine. Input of code numbers

! Caution 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. F1 h F2 720163 Fig. 80 l Keep both function keys F1 und F2 (Fig. 80) in the display module depressed for two sec-

onds. The display shows "0000", whereby the first digit is flashing. l The value of the flashing digit can be in-

creased by pressing the function key F1. 50 BOMAG BMP 8500 l If the value "9" is displayed and the function key F1 is pressed again, the display will jump back to the value "0". l When pressing the function key F2 the flashing l digit will move one digit to the right. If the fourth digit in the display is flashing func-

tion key F2 is pressed again to confirm the en-

try. The desired function is now executed or the de-

sired value is displayed. l To cancel the display function you must either enter code number "0000" or switch off the ig-

nition. 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. i Note Input code "5059" is used to display the status of ECO-mode. Fig. 81 l Switch off the ignition (Fig. 81). Operation 4.15 Entering the machine type code

! Caution 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 as-

sured. The code can only be entered when the engine is shut down. i Note 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 "Adjust-

ing machine type. The display module now per-

manently shows code "7010". l Enter "7104". The display module now permanently shows code

"7104". l Enter "7011" to finish the procedure. This code number confirms the entered machine type. After having confirmed the machine type the con-

trol switches off, restarts automatically after 3 sec-

onds and is then ready for starting. i Note Whenever switching the ignition on the machine type will appear in the display module for 3 sec-

onds. BMP 8500 BOMAG 51 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 l l l switch off the main battery switch, replace defective components, switch on the main battery switch, plug the spiral cable into the remote control. Fig. 82 l Turn the tumbler switch for the cable remote control to position "Left", cable operation (Fig. 82). 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. The machine is now ready for operation. 52 BOMAG BMP 8500 4.17 Assembling/removing the 4.18 Loading and transport Operation

! Danger 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 ma-

chine. 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 pur-

pose. Check lifting eye for damage before use. Do not use a damaged or in any other way im-

paired lifting eye. The machine must not swing about when be-

ing lifted. Do not step or stand under suspended loads. Lash the machine down, so that it is secured against rolling, sliding and turning over. 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.

! Caution In order to protect the threads turn the fasten-

ing screws into the drums, even after removing the drum extensions.

! Danger Danger of turning over!

When using drums with a working width of 610 mm the second speed range must not be switched on. 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. BMP 8500 BOMAG 53

! Danger Danger of accident!

The machine cannot be steered if the articula-

tion lock is applied. l After transport release the articulation lock again and store it in the receptacle. Operation Fig. 86 Use the central lifting facility (Fig. 86) to lift the ma-

chine. 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). 54 BOMAG BMP 8500 5 Maintenance BMP 8500 BOMAG 55 Maintenance 5.1 General notes on mainte-

nance When performing maintenance work always com-

ply with the appropriate safety regulations. Thorough maintenance of the machine guaran-

tees far longer safe functioning of the machine and prolongs the lifetime of important components. The effort needed for this work is only little com-

pared with the problems that may arise when not observing this rule. The terms right/left correspond with travel direc-

tion forward. 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). Environment During maintenance work catch all oils and fu-

els and do not let them seep into the ground or into the sewage system. Dispose of oils and fu-

els environmentally. Keep used filters in a separate waste container and dispose of environmentally. Catch biodegradable oils separately. Notes on the fuel system The lifetime of the diesel engine depends to a great extent on the cleanliness of the fuel. 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 en-

vironment. 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 pur-

poses. Notes on the performance of the en-

gine On diesel engines both combustion air and fuel in-

jection quantities are thoroughly adapted to each other and determine power, temperature level and exhaust gas quality of the engine. If your engine has to work permanently in "thin air"

(at higher altitudes) and under full load, you should consult the customer service of BOMAG or the customer service of the engine manufacturer. Notes on the cooling system Prepare and check coolant with highest care, since otherwise the engine may be damaged by corrosion, cavitation and freezing. The coolant is prepared by mixing a cooling sys-

tem protection agent (ethylene glycol) into the coolant. Mixing with cooling system protection agent is necessary in all climatic zones. It prevents corro-

sion, lowers the freezing point and raises the boil-

ing point of the coolant. Notes on the hydraulic system During maintenance work on the hydraulic system cleanliness is of major importance. Make sure that no dirt or other contaminating substances can en-

ter into the system. Small particles can produce flutes in valves, cause pumps to seize, clog noz-

zles and pilot bores, thereby making expensive re-

pairs inevitable. 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. 56 BOMAG BMP 8500 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 fil-

ter and protects the hydraulic system. l Clean fittings, filler covers and the area around such parts before disassembly to avoid enter-

ing of dirt. l Do not leave the tank opening unnecessarily open, but cover it so that nothing can fall in. Maintenance 5.2 Fuels and lubricants Engine oil Quality Lubrication oils are classified according to their performance and quality class. Oils according to other comparable specifications may be used. If low sulphur fuel (< 0.05%) is used, you must only use engine oils of API*-classification CF, CF-4, CG-4, CH-4 and CI-4. For operation of an engine with high sulphur fuels it is recommended to use an engine oil of classifi-

cation CF or higher with a total base number of at least 10.

! Caution Engine oils of classification CJ-4 must not be used!

Oil viscosity Since lubrication oil changes its viscosity with the temperature, the ambient temperature at the oper-

ating location of the engine is of utmost impor-

tance when choosing the viscosity class (SAE-

class) . Optimal operating conditions can be achieved by using the following oil viscosity chart as a refer-

ence. Ambient temperature Viscosity over 25 C!

0C to 25C below 0 C SAE 30 SAE10W-30 SAE 15W-40 SAE 20 SAE10W-30 SAE 15W-40 SAE 10 SAE10W-30 SAE 15W-40

*

American Petroleum Institute BMP 8500 BOMAG 57 Maintenance Oil change intervals The longest permissible time a lubrication oil should remain in an engine is 1 year. If the follow-

ing oil change intervals are not reached over a pe-

riod of 1 year, the oil change 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 per-

centage (ppm) of sulphur the fuel used in the en-

gine must comply with all relevant exhaust emission regulations in the are of use of the en-

gine. It is highly recommended to use a fuel with a sul-

phur content of less than 0,10 % (1000 ppm). When using a diesel fuel with a high sulphur con-

tent of 0.50 % (5000 ppm) to 1.0 % (10.000 ppm), the engine oil change intervals must behalved.

! Caution Do not use any fuels with a sulphur content of more than 1,0 % (10000 ppm). It is recommended to use diesel fuel that complies with the specifications EN590 or ASTM D975. Diesel fuel with the designation no. 2-D is a destil-

late fuel with low volatility, which is especially suit-

able for industrial engines and heavy-duty commercial vehicles (SAE J313 JUN87). Since KUBOTA diesel engines with a rated power of less than 56 kW (75 HP) comply with the ex-

haust emission standard of EPA*-stage 4, the use of low or ultra-low sulphur fuel is mandatory for these engines, if the engines are operated within the validity area of the EPA standard. As an alter-

native to no. 2-D you may also use diesel fuel no. 2-D S500 or S15; with ambient temperatures be-

* United States Environmental Protection Agency low -10 C the diesel fuel no. 1-D S500 or S15 should be used fir no. 1-D. The fuel level should always be topped up in due time so that the fuel tank is never run dry, as oth-

erwise filter and injection lines need to be bled. Winter fuel

! Danger Fire hazard!

Diesel fuels must never be mixed with gaso-

line. For winter operation use only winter diesel fuel, to avoid clogging because of paraffin separation. At very low temperatures disturbing paraffin separa-

tion can also be expected when using winter diesel fuel. Coolant Always use a mixture of anti-freeze agent and clean, dehardened water with a mixing ratio of 1:1. Under particularly extreme temperature conditions you should consult the service representation of the engine manufacturer with respect to the anti-

freeze agent to be used. There are various types of anti-freeze agents available. For this engine you should use ethylene glycol. Before filling in the coolant mixed with anti-freeze agent the radiator must be flushed with clean wa-

ter. This procedure should be repeated two to three times to clean the inside of radiator and en-

gine block. Mixing the anti-freeze agent: Prepare a mixture of 50 % anti-freeze agent and 50 % low mineral, clean water. Stirr well before filling it into the radi-

ator. The method for mixing water and anti-freeze agent depends on the brand of the anti-freeze agent. In this respect see standard SAE J1034 and also the standard SAE J814c. Add anti-freeze agent: If the coolant level drops because of evaporation,only clean water is to be used for topping up. In case of leakages you must always fill in anti-freeze agents of the same brand and the same mixing ratio. 58 BOMAG BMP 8500 Maintenance Replace the hydraulic oil filter element every 500 operating hours.

! Caution Do not mix different coolants and additives of any other kind. Do not use any radiator cleaning agent after the anti-freeze agent has been mixed in. The anti-

freeze agent also contains a corrosion protection agent. If this mixes with cleaning agent it may cause the development of sludge, which could damage the cooling system. Anti-freeze concentration 50%

= -37 C Environment Coolant must be disposed of environmentally. Mineral oil based hydraulic oil The hydraulic system is operated with hydraulic oil HV 46 (ISO) with a kinematic Viskositt von 46 mm2/s bei 40 C und 8 mm2/s bei 100 C betrie-

ben. 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 ac-

cording to ISO 6743/3. The viscosity index (VI) should be at least 150 (observe information of manufacturer). Bio-degradable hydraulic oil The hydraulic system can also be operated with a 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.

! Caution Check the filter more frequently after this change. Perform regular oil analyses for content of wa-

ter and mineral oil. BMP 8500 BOMAG 59 Maintenance 5.3 Table of fuels and lubri-

cants Assembly Fuel or lubricant Quantity Summer Winter Attention Observe the level marks Engine

- Engine oil

- Fuel

- Coolant 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) Diesel Winter diesel fuel (down approx. 24 litres to -12C) Mixture of water and anti-freeze agent approx. 4.0 litres

(BOMAG PN 009 940 08; 20 l) Hydraulic system Hydraulic oil (ISO), HLP 46 approx. 17 litres

(BOMAG PN 009 930 09; 20 l) ester based biodegradable hydraulic oil or Vibration housing Engine oil SAE 15W/40 2 x 1.7 l 60 BOMAG BMP 8500 Maintenance 5.4 Running-in instructions i Note The maintenance plan inside the engine hood of the machine assists you when servicing the ma-

chine!

The following maintenance work must be per-

formed when running in new machines or overhauled engines:

! Caution 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 BMP 8500 BOMAG 61 d e r i u q e r s a Maintenance 5.5 Maintenance table No. Maintenance work Comment y l i a d

, s r u o h g n i t a r e p o 0 1 s r u o h

. r e p o 0 5 2 s r u o h

. r e p o 0 0 5 s r u o h

. r e p o 0 0 0 1 s r u o h

. r e p o 0 0 0 2 s r u o h

. r e p o 0 0 0 3 y r e v e y r e v e y r e v e y r e v e y r e v e y r e v e X X X X X X X X X X X 5.6 5.7 5.8 5.9 Check the engine oil level Dipstick mark Check the hydraulic oil level Inspection glass Check the fuel level Check the water separator 5.10 Check the coolant level 5.11 Check the air intake hose 5.12 Change engine oil and oil filter*

5.13 Check, tension, replace the V-belt 5.14 Clean radiator cooling fins 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 5.18 Change the fuel pre-cleaner, bleed the fuel system at least 1x per year see foot note min. 1x per year see foot note 5.19 Service the battery, check the battery pole grease main switch 5.20 Check the rubber buffers 5.21 Check, adjust the valve clearance 5.22 Check the safety field in front of/be-

hind the machine 0.145 ... 0.185 mm 5.23 Change hydraulic oil and filter***

at least every 2 years X X X X X X X 62 BOMAG BMP 8500 s r u o h s r u o h

. r e p o 0 5 2 y r e v e

. r e p o 0 0 5 y r e v e y l i a d

, s r u o h g n i t a r e p o 0 1 y r e v e No. Maintenance work Comment 5.24 Change the coolant 5.25 Changing the fuel lines 5.26 Check the injection pressure 5.27 Check the fuel injection pump 5.28 Check the fuel injection timing 5.29 Check, clean, change the combustion air filter 5.30 Adjust the scrapers 5.31 Tightening torques 5.32 Engine conservation min. 1x per year Maintenance s r u o h s r u o h s r u o h

. r e p o 0 0 0 1 y r e v e

. r e p o 0 0 0 2 y r e v e

. r e p o 0 0 0 3 y r e v e X X X X X d e r i u q e r s a X X X 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. BMP 8500 BOMAG 63 Maintenance 64 BOMAG BMP 8500 Every 10 operating hou rs 5.6 Check the engine oil level 5.7 Checking the hydraulic oil Every 10 operating hours

! Caution 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 imme-

diately. For quality of oil refer to the "table of fuels and lubricants". level

! Caution If, during the daily inspection of the oil level the hydraulic oil level is found to have dropped, check all lines, hoses and compo-

nents for leaks. 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 bot-

toms. l Pull the dipstick back out. The oil level must always be between the "MIN"-

and "MAX"-marks. l l If the oil level is too low top up oil immediately. 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) . If necessary remove the cover from the filter. l Fill up hydraulic oil up to the MAX mark in the l inspection glass. l Screw the cover back on. BMP 8500 BOMAG 65 Every 10 operating hours 5.8 Checking the fuel level 5.9 Check the water separator

! Danger 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.

! Caution For quality and quantity of fuel refer to the "ta-

ble of fuels and lubricants". Environment Catch running out fuel, do not let it seep into the ground. i Note The service intervals for the water separator de-

pend on the water content in the fuel and can therefore not be determined precisely. After taking the engine into operation you should therefore check the water separator every day for signs of water. Environment Any fuel must be caught and disposed of in an environmentally friendly manner. 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. Fig. 91 l Clean the area around the filler cover, unscrew the filler cover (Fig. 91).

! Caution 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. 66 BOMAG BMP 8500 Every 10 operating hours 5.10 Checking the coolant level

! Danger Danger of scalding!

Open the cap on the coolant compensation tank only when the engine is cold.

! Caution If, during the daily inspection the coolant level is found to have dropped, check all lines, hos-

es and engine for leaks. For quality of coolant refer to "fuels and lubri-

cants". 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. BMP 8500 BOMAG 67 Every 10 operating hours 68 BOMAG BMP 8500 Every 250 operating hours 5.11 Check the air intake hose 5.12 Changing engine oil and oil Every 250 operating hours 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. filter

! Danger Danger of scalding!

When draining off hot oil. By hot oil when unscrewing the engine oil fil-

ter.

! Caution The oil change at 250 operating hours refers to the use of fuels with a sulphur content of less than 0.5%. When using fuels with a sulphur content higher than 0.5% the oil change inter-

vals must be halved. Drain the engine oil only when the engine is warm. For quality and quantity of oil refer to the "table of fuels and lubricants". Environment Catch running out oil and dispose of environ-

mentally 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. BMP 8500 BOMAG 69 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. 98 l Fill in new engine oil (Fig. 98). l Tighten the oil filler cap properly. 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. l Tighten the filter element for another half turn. 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). 70 BOMAG BMP 8500 5.13 Checking, tensioning, re-

placing the V-belt

! Danger Danger of accident!

Perform this work only with the engine shut down. Checking the V-belt 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 be-

tween the V-belt pulleys, retighten if neces-

sary. Every 250 operating hours 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. 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. BMP 8500 BOMAG 71 Every 250 operating hours

! Caution 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 Danger of injury!

Perform cleaning work only after the engine has cooled down and with the engine stopped.

! Caution Do not damage any cooling fins on the cooler core when cleaning. i Note Dirt on fan blades and radiator reduce the cooling effect. Dirt deposits in these areas are substantial-

ly supported by oil and fuel on these surfaces. For this reason you should always seal any oil or fuel leaks in the vicinity of the cooling fan or the radia-

tor and clean the cooling surfaces after. Cleaning with compressed air i Note 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. 72 BOMAG BMP 8500 Cleaning with cold cleansing agent

! Caution 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 wa-

ter jet. l Run the engine warm for a while to avoid cor-

rosion. Every 250 operating hours 5.15 Change the oil in the vibra-

tor shaft housing

! Caution Change the oil at operating temperature. For this purpose run the machine approx. half an hour with vibration. Environment Catch running out oil and dispose of environ-

mentally.

! Danger Danger of injury!

Do not step under suspended loads. Fig. 104 l Lift the machine up and support it safely (Fig. 104). BMP 8500 BOMAG 73 Every 250 operating hours For quality and quantity of oil refer to the table of fuels and lubricants. l Screw the drain and ventilation plugs back in. Fig. 105 l Unscrew the drain and filling plug on the front drum (Fig. 105). l Drain and catch all oil. Fig. 108 l Unscrew the drain and ventilation plugs (Fig. 105) from the upper drum. l Drain and catch all oil. Fig. 106 l Jack up the opposite side of the machine and secure it adequately (Fig. 106). 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. 74 BOMAG BMP 8500 Every 250 operating hours 5.16 Checking the central screw of the drive hub

! Caution 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). Fig. 110 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. BMP 8500 BOMAG 75 Every 250 operating hours 76 BOMAG BMP 8500 Every 500 operating hours 5.17 Draining the fuel tank sludge

! Danger Fire hazard!

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

! Danger Health hazard!

Do not inhale any fuel fumes. Environment Catch running out fuel, do not let it seep into the ground. i Note 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 Every 500 operating hours 5.18 Changing the fuel pre-

cleaner, bleeding the fuel system

! Danger Fire hazard!

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

! Danger Health hazard!

Do not inhale any fuel fumes. Environment 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. BMP 8500 BOMAG 77 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 hand-

tight. Bleed the fuel system 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. Fig. 115 l Open the bleeding screw on the fuel filter (Fig. 115) and crank the engine with the starter, un-

til fuel runs out without air bubbles. l Retighten the bleeding screw. 78 BOMAG BMP 8500 Every 500 operating hours not forget to perform regular open-circuit volt-

age measurements.

! Caution Exhausted batteries (batteries with formation of sulphate on the plates) are not covered un-

der warranty!

l Open the maintenance flap and remove the battery cover. 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 dis-

tilled 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. 5.19 Battery service, checking the main battery switch

! Danger Danger of cauterisation ! Danger of explosion!

When working on the battery do not use open fire, do not smoke!

The battery contains acid. Do not let acid come in contact with skin or clothes!

Wear protective clothing!

Do not lay any tools on the battery!

For recharging remove the plugs from the bat-

tery to avoid the accumulation of highly explo-

sive gases. Environment Dispose of the old batteries environmentally. i Note Maintenance free batteries also need care. Main-

tenance free only means that the fluid level does not need to be checked. Each battery suffers un-

der self-discharge, which may, in not checked oc-

casionally, even cause damage to the battery 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 ap-

prox. 10 hours after the last charging process or one hour after the last discharge. l After each charging process allow the battery to rest for one hour before taking it into service. l For resting periods of more than one month you should always disconnect the battery. Do BMP 8500 BOMAG 79 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. 80 BOMAG BMP 8500 Every 1000 operating hours 5.21 Checking, adjusting the valve clearance

! Caution We recommend to have this work carried out by trained personnel or our after sales service. Check and adjust only when the engine is cold. Cylinder 1 is on the flywheel side. l Disassemble cylinder head cover and glow plug. Fig. 119 Crankshaft position 1 IN EX l Crank the engine until both valves on cylinder

=

= Exhaust valve Intake valve 1 are overlapping. l Perform the adjustment of the valve by follow-

ing the adjustment diagram 1"(Fig. 119), black mark. 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. 121 Crankshaft position 2 IN EX l Turn the crankshaft one revolution (360 ) fur-

=

= Exhaust valve Intake valve 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. i Note After a short test run check the engine for leaks. BMP 8500 BOMAG 81 Every 1000 operating hours 5.22 Safety field measurement of the Boss safety system

! Danger Danger of injury!

The safety field of the machine must be meas-

ured at a height fo one meter, also after main-

tenance/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 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. 82 BOMAG BMP 8500 Every 2000 operating hours 5.23 Change hydraulic oil and fil-

ter i Note See also the notes on the hydraulic system in the chapter "General notes on maintenance".

! Danger Danger of scalding!

When draining off hot hydraulic oil!

! Caution The hydraulic oil must also be changed after major repairs in the hydraulic system. Perform the oil change when the hydraulic oil is warm. Replace the hydraulic oil filter element with every hydraulic oil change. Clean the area round hydraulic oil tank, filler opening and breather filter. Do not start the engine after draining the hy-

draulic oil. Do not use any detergents to clean the system. For quality and quantity of oil refer to the "table of fuels and lubricants". When changing from mineral oil based hydrau-

lic oil to an ester based biologically degradable oil, you should consult the lubrication oil serv-

ice of the oil manufacturer for details. Environment Catch running out oil and dispose of environ-

mentally. l Drive the machine, until the hydraulic oil has reached operating temperature. l Shut down the engine. Every 2000 operating hours 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. i Note We recommend to use the BOMAG filling and fil-

tering unit with fine filter to fill the system. This en-

sures finest filtration of the hydraulic oil, prolongs the lifetime of the hydraulic oil filter and protects the hydraulic system. 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. BMP 8500 BOMAG 83 Every 2000 operating hours Fig. 125 l Check the oil level in the inspection glass (Fig. 125). 5.24 Change the coolant

! Danger Danger of scalding!

Change the coolant only when the engine is cold. Do not remove the radiator cap when the en-

gine is still hot. Always wear gloves when handling anti-freeze agent.

! Caution Always screw the radiator cap tightly back on

(second detent). Always fill the engine cooling system with an anti-freeze mixture (corrosion protection). Do not use more than 50% anti-freeze. Do not mix different coolants and additives of any other kind. If necessary flush the cooling system 2-3 times with clear water. For quality and quantity of coolant refer to the

"table of fuels and lubricants". Environment Catch running out coolant and dispose of envi-

ronmentally. Fig. 126 l Remove the radiator cap (Fig. 126). 84 BOMAG 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. 129 l Fill in coolant until the level reaches the bottom edge of the radiator filler socket (Fig. 129). 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. 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-

l erating temperature. Let the engine cool down and check the cool-

ant level again, if necessary top up in the com-

pensation tank. BMP 8500 BOMAG 85 Every 2000 operating hours 5.25 Change the fuel lines 5.26 Checking the injection pres-

sure i Note This work must only be performed by authorized service personnel. i Note 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.

! Danger Fire hazard!

When working on the fuel system do not use open fire, do not smoke and do not spill any fu-

el. Do not inhale any fuel fumes. Environment Catch running out fuel, do not let it seep into the ground. Fig. 131 084 l Replace all fuel hoses (Fig. 131) including their hose clips. 86 BOMAG BMP 8500 Every 3000 operating hours Every 3000 operating hours 5.27 Checking the fuel injection 5.28 Checking the fuel injection pump timing i Note This work must only be performed by authorized service personnel. i Note This work must only be performed by authorized service personnel. BMP 8500 BOMAG 87 Every 3000 operating hours 88 BOMAG BMP 8500 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. 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). As required 5.29 Check, clean, replace the combustion air filter

! Caution Do not use gasoline or hot fluids to clean the filter cartridge. After cleaning the filter cartridge must be in-

spected with a torch for damage. Dry air filter cartridges with damaged filter ele-

ment or seal must be replaced in any case. The dry air filter element must be replaced af-

ter 3 times cleaning, but at the latest after one year, irrespective of the operating hours. Each cleaning interval must be marked with a cross on the cover of the filter element. Cleaning does not make sense if the cartridge is covered with a sooty deposit. Use a new fil-

ter cartridge. Incorrectly handled filter elements may be-

come ineffective because of damage (e.g.:

cracks) and cause engine damage. When working in dusty environments the filter service may become due considerably earlier. This my be noticed by a drop in engine power and black exhaust fumes. Fig. 132 Servicing of the dry air filter is necessary when the yellow piston (Fig. 132) has reached the inscrip-

tion "Service", but at the latest after one year. After completion of the filter service reset the indi-

cator back to "Zero" by pressing the button. BMP 8500 BOMAG 89 As required Fig. 135 l Pull the filter element (Fig. 135) carefully out of Fig. 137 l Thoroughly clean the inside of the outlet tube the housing.

! Caution Avoid contact between filter element and housing. Fig. 136 l Clean the sealing face on the outlet tube (Fig. 136). Dust on the outer diameter of the outlet tube can impair effective sealing.

(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 prob-

lem 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 incor-

rect handling. Especially on the inside of the open end (sealing area). Do not install a damaged filter element. Fig. 138 l Insert the filter element (Fig. 138). 90 BOMAG BMP 8500 As required

! Caution Do not continue to use a damaged filter ele-

ment. If in doubt use a new filter element. The radial sealing area is located at the inside of the open filter edge. This critical sealing area must be under slight tension after the filter has been in-

stalled. In order to achieve a tight seal apply pres-

sure to the outer edge of the filter and not to the moveable centre. l Reinstall the filter hood with the dust discharge valve.

! Caution The dust discharge valve must point vertically downwards. Dry cleaning of the filter cartridge

! Danger Eye injury!

Wear protective clothing (goggles, gloves). Fig. 139 i Note 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. BMP 8500 BOMAG 91 As required 5.30 Adjust the scrapers 5.31 Tightening torques for i Note If the scrapers (2 per drum) are worn, they must be adjusted or replaced. screws with metric unified thread 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. Fig. 141

* Strength classes for screws with untreated, non-

lubricated surface. Screw quality designations are stamped on the screw heads. 8.8 = 8G 10.9 = 10K 12.9 = 12K l Drum extension - drum The values result in a 90% utilization of the screws yield point at a coefficient of friction total =

0,14.Compliance with the specified tightening tor-

ques is checked with torque wrenches. When us-

ing MoS2 lubricants the specified tightening torques do not apply.

= 652 Nm i Note Self-locking nuts must always be replaced once they have been unscrewed. 92 BOMAG BMP 8500 As required Anti-corrosion oils are those that comply with the specification MIL-L-21260 B or TL 9150-037/2 or Nato Code C 640/642.

! Caution Mark a machine with a conserved engine by at-

taching a clearly visible warning tag. 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 fol-

lowing 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. In-

stead of mixing anti-corrosion oil with the fuel it is also possible to fill the tank with injection pump testing oil with anti-corrosive properties

(e.g. Calibration Fluid B). l Run the engine for 10 minutes until all lines, fil-

ter, pump and nozzles are filled with the con-

serving mixture and the new engine oil is distributed to all parts. 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. i Note Depending on weather conditions, these conserv-

ing 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". BMP 8500 BOMAG 93 As required 94 BOMAG BMP 8500 6 Trouble shooting BMP 8500 BOMAG 95 Trouble shooting 6.1 General notes The following work must only be carried out by qualified and trained personnel or by the BOMAG sales service. Please observe strictly the safety regulations in chapter 2 of these operating and mainte-

nance instructions. Malfunctions are frequently caused by incorrect operation of the machine or insufficient mainte-

nance. Whenever a fault occurs you should there-

fore thoroughly read these instruction on correct operation and maintenance. If you cannot locate the cause of a fault or rectify it yourself by following the trouble shooting chart, you should contact the service departments at our branch offices or deal-

ers. On the following pages you will find a selection of fault remedies. It goes without saying that not all possible reasons for faults could be listed.

! Danger Danger of injury!

Do not touch rotating parts of the engine. 96 BOMAG BMP 8500 Trouble shooting Remedy Fill fuel tank 6.2 Engine problems Fault Possible cause Fuel tank empty Engine does not start Poor starting of engine or en-

gine works irreg-

ularly with poor power Fuel filter clogged, in winter due to paraf-

fin separation Change the filter, use winter fuel Fuel lines leaking Battery not charged or not connected Check all line connections for leaks and tighten the fittings Charge the battery, check the pole clamps Operating error see section Starting the engine Incorrect valve clearance Adjust the valve clearance Inclination switch has switched off Reduce the inclination Battery power too low Have battery checked Battery pole clamps loose or oxidized, causing the starter to turn too slow Clean the pole clamps, tighten and cover them with acid-free grease Especially in winter: use of too viscous en-

gine oil Use an engine oil complying with the am-

bient temperatures Fuel supply too low, fuel system clogged by paraffin separation during winter Change the fuel filter. Check the line con-

nections for leaks and tighten the fittings. Use winter fuel under cold conditions The specified valve clearance is not cor-

rect Adjust the valve clearance Injection valve or injection pump defective Have examined by a specialist Engine looses power and speed, exces-

sive exhaust smoke 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 bro-

ken piston rings or incorrect valve clear-

ance Have piston rings and pistons examined by a specialist, adjust the valve clearance Injection valve defective Have examined by a specialist BMP 8500 BOMAG 97 Trouble shooting Fault Possible cause Remedy Engine over-

heating, engine must be shut down immedi-

ately!

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

Lack of cooling air Leaks in the lubrication system, oil level too low Remove any clogging from the cooling air 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 Engine oil with wrong SAE viscosity class Change the engine oil Charge control light lights up during operation The generator does not charge the bat-

tery, because of defect on generator or regular Have examined by a specialist 98 BOMAG BMP 8500 Trouble shooting 6.3 Problems with remote con-

trol Hetronic with spiral ca-

ble Fault Possible cause Remedy Engine stops without any reason Engine oil pressure too low or en-

gine oil pressure switch defective

(does the oil pressure controol lamp light up while the engine is running?) Battery Emergency stop push button Check engine oil level or oil pressure switch Check battery terminals for tight fit (inter-

mittent contact?) Check the main battery switch Replace the battery Switch operated? Display off, pull button out Switch defective? replace Fuses F 54, F 67, F 103 defective Replace the fuses (may be damaged by Toggle switch cable/radio S101 Relay K 11 Spiral cables All wiring looms vibration) Check plug connections, bridge switch for testing Replace the relay Check the plug connections in the relay base Check the continuity of the individual ca-

bles Check the cables for short circuit to the housing Replace the cables 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 BMP 8500 BOMAG 99 Trouble shooting Fault Possible cause Inclination sensor Regulator A 70 module (BLM) Main wiring loom Remedy Check the sensor signal, input code 1405 Bridge connections 5 and 6 on the plug for the inclination sensor If necessary replace the sensor Pull off the four-pin plug above the regula-

tor, if OK, replace the regulator Replace the module Replace the main wiring loom Engine wiring harness Replace the engine wiring loom Ignition on, display mod-

ule on, but starting not possible Travel lever not in "0"-position Fuse F 119 Battery Inclination sensor Relay K 39 Actuate the travel lever and return it to "0"-

position Check with input code 2500 and 2501 Replace the fuses (may be damaged by vibration) A clicking sound on module A 70 indicates that the battery is empty, if necessary re-

place the battery Check the sensor signal, (input code 1405) Bridge connections 5 and 6 on the plug for the inclination sensor If necessary replace the sensor Check the relay control with code 5070

(start repetition lock!) Replace the relay Check the plug connections in the relay base Transmitter Replace the transmitter A 70 module (BLM) Replace the module All wiring looms Check all wiring looms for intermittent contact, to do so wobble all cables, espe-

cially close to the plug connections, while the engine is running Check also the plug connections on the regulator and the ground cable between engine and frame. After starting still no function Not waited for horn signal before starting Press the horn button or wait fro the horn signal before starting 100 BOMAG BMP 8500 Trouble shooting Fault Possible cause Remedy Emergency stop push button Transmitter Spiral cables Switch operated? Display off, pull button out Switch defective? Replace Replace the transmitter Check the continuity of the individual ca-

bles Check the cables for short circuit to the housing Replace the cables A 70 module (BLM) Replace the module Display module shows CTO when ignition is on Main wiring loom Spiral cables Main wiring loom Replace the main wiring loom Check the continuity of the individual ca-

bles Check the cables for short circuit to the housing Replace the cables Check whether plug X3:30 or X3:31 is loose Check for short circuit between X24:6 and 7, or CAN+ und CAN- or 8 and 3 on the display module A 70 module (BLM) Replace the module Engine not running at max. speed, otherwise OK Toggle switch for speed S 134 Fuse F 14 Toggle switch in position "Max ?

Check with input code 2505 If necessary replace the toggle switch Replace the fuses (may be damaged by vibration) Engine solenoid Y 46 (adjustment) Adjust the engine solenoid if the fuse Relay K 114 keeps blowing Check the relay control with code 5050 Replace the relay Check the plug connections in the relay base A 70 module (BLM) Main wiring loom Replace the module Replace the main wiring loom Engine wiring harness Replace the engine wiring loom BMP 8500 BOMAG 101 Trouble shooting 6.4 Problems with radio remote control Hetronic in radio op-

eration i Note Assumed that the function is correct when using the spiral cable. Steel ropes or metal attachments on the frame can disturb the radio connection. Fault Possible cause Remedy Machine does not re-

spond Incorrect or defective aerial Replace the aerial (observe the frequency of the aerial) Check the plug connection between aerial and receiver Ignition on, display mod-

ule on, but starting not possible Engine stops without any reason The receiver is electrically not or not correctly connected Check the plug connection between re-

ceiver and machine Receiver and tansmitter have dif-

ferent system numbers Installation of transmitter and receiver with identical system-no. Power pack empty or defective Charge or replace the power pack Distance between machine and transmitter more than 30 m Toggle switch radio/cable (S101) Move closer to the machine Check the plug connection Bridge switch for testing Transmitter or receiver defective Replace transmitter or receiver Power pack empty or defective Charge or replace the power pack Transmitter or receiver defective Replace transmitter or receiver Power pack empty or defective Charge or replace the power pack Disturbance caused by other radio systems Incorrect or defective aerial Distance between machine and transmitter more than 30 m Toggle switch radio/cable (S101) Check whether the problem arises when other radio signals are transmitted nearby

(airport, construction crane, etc.) If necessary contine in cable operation Replace the aerial (observe the frequency of the aerial) Check the plug connection between aerial and receiver Move closer to the machine Check the plug connection Bridge switch for testing 102 BOMAG BMP 8500 Trouble shooting Fault Possible cause Remedy Emergency stop push button Switch operated? Display off, pull button out Switch defective? replace Transmitter or receiver defective Replace transmitter or receiver Main wiring loom Replace the main wiring loom BMP 8500 BOMAG 103 Trouble shooting 6.5 Faults in BOSS safety sys-

tem Fault Possible cause Remedy no travel move-

ments, steering is still possible The operator is inside the safety field Leave the safety field Transponder (in transmitter) has not been taught see chapter Safety equipment, teaching the BOSS safety system transponder Safety antenna front / rear defective or not plugged in Replace the antenna, check plug connec-

tion Distance between machine and transmit-

ter more than 30 m Move closer to the machine Safety field control defective or not plugged in Replace the safety field control or check the plug connection Transmitter defective Replace the transmitter Wiring loom for safety field antennas Replace the wiring loom for safety field antennas

! Danger Danger of injury!

After maintenance and/or repair work on the safety system the safety field length must be checked again, see corresponding chapter. 104 BOMAG BMP 8500 6.6 Fault indicator Trouble shooting Fig. 142 Faults are displayed in the display module h (Fig. 142) in form of flashing fault codes. If several faults occur at the same time, these will be indicated by flashing codes, one after the other. BMP 8500 BOMAG 105 Trouble shooting 6.7 Fault code Overview Fault code Function group 1000 - 1999 Travel system 2000 - 2499 Steering 2500 - 2999 Remote controls 5000 - 5499 Diesel engine 7000 - 7499 Input codes for machine parameterization 7500 - 7999 Operating hour meter, load spectrum (input codes) 8000 - 8999 Severe software error 9000 - 9998 External IO nodes, joysticks, data collectors (CAN communication and hardware de-

fects ) 9999 Unknown fault, displayed value higher than +/- 10000, automatic output by the BMFSA Fault codes of travel functions Code Fault reaction Description of fault Possible cause 1030 Output is switched off, function no longer possible 1031 Output is switched off, function no long-

er possible 1032 Output is switched off, function no long-

er possible Output valve travel-

ling forward, Y 16 Too high current flow out of this output Out-

put was switched off!

Output valve travel-

ling forward, Y 16 Short-circuit current flow out of this output Output was switched off!

Output valve travel-

ling forward, Y 16 No or too low current flow out of this output Excessive current flow in current path, probably because of a defective coil or a short circuit to ground Short circuit to ground in the current path Lines rubbed through Valve defective Wire breakage in cur-

rent path Current path con-

nected to +12V Terminal on BLM X3:22 X3:22 X3:22 Input code for diag-

nose

-

-

1030 1031 1032 106 BOMAG BMP 8500 Trouble shooting Code Fault reaction Description of fault Possible cause Terminal on BLM 1033 Engine is shut down 1040 Output is switched off, function no long-

er possible 1041 Output is switched off, function no long-

er possible 1042 Output is switched off, function no long-

er possible 1043 Engine is shut down 1050 Output is switched off, function no long-

er possible 1051 Output is switched off, function no long-

er possible Output valve travel-

ling forward, Y 16 Although the output is switched off, voltage is present Output valve travel-

ling reverse, Y 17 Too high current flow out of this output Out-

put was switched off!

Output valve travel-

ling reverse, Y 17 Short-circuit current flow out of this output Output was switched off!

Output valve travel-

ling reverse, Y 17 No or too low current flow out of this output Output valve travel-

ling reverse, Y 17 Although the output is switched off, voltage is present Output valve 2. gear, Y 03 Too high current flow out of this output Out-

put was switched off!

Output valve 2. gear, Y 03 Short-circuit current flow out of this output Output was switched off!

Current path con-

nected to +12V X3:22 X3:24 X3:24 X3:24 Excessive current flow in current path, probably because of a defective coil or a short circuit to ground Short circuit to ground in the current path Lines rubbed through Valve defective Wire breakage in cur-

rent path Current path con-

nected to +12V Current path con-

nected to +12V X3:24 X3:11 X3:11 Excessive current flow in current path, probably because of a defective coil or a short circuit to ground Short circuit to ground in the current path Lines rubbed through Valve defective Input code for diag-

nose 1030 1031 1032

-

-

1040 1041 1042 1040 1041 1042

-

-

BMP 8500 BOMAG 107 1052 1053 1062 1063 Trouble shooting Code Fault reaction Description of fault Possible cause Output is switched off, function no long-

er possible Output valve 2. gear, Y 03 No or too low current flow out of this output Wire breakage in cur-

rent path Current path con-

nected to +12V Output is switched off, engine runs only with idle speed Current path con-

nected to +12V X3:11 Terminal on BLM X3:11 Input code for diag-

nose 1050 1051 1052 1050 1051 1052 Output valve 2. gear, Y 03 Although the output is switched off, voltage is present Output brake valve, Y 04 Too high current flow out of this output Out-

put was switched off!

Output brake valve, Y 04 Short-circuit current flow out of this output Output was switched off!

Output brake valve, Y 04 Although the output is switched off, voltage is present Output valve vibra-

tion low ampl., Y 56 Too high current flow out of this output Out-

put was switched off!

1060 Output is switched off, function no long-

er possible 1061 Output is switched off, function no long-

er possible X3:40 X3:40

-

-

Excessive current flow in current path, probably because of a defective coil or a short circuit to ground Short circuit to ground in the current path Lines rubbed through Valve defective Output is switched off, function no long-

er possible Output brake valve, Y 04 No or too low current flow out of this output Wire breakage in cur-

rent path Current path con-

nected to +12V X3:40 Output is switched off, engine runs only with idle speed Current path con-

nected to +12V X3:40 1060 1061 1062 1060 1061 1062 1305 Output is switched off, function no long-

er possible X3:12

-

Excessive current flow in current path, probably because of a defective coil or a short circuit to ground 108 BOMAG BMP 8500 Trouble shooting Terminal on BLM Input code for diag-

nose X3:12

-

Code Fault reaction Description of fault Possible cause 1306 Output is switched off, function no long-

er possible 1307 1308 Output is switched off, function no long-

er possible Output is switched off, engine runs only with idle speed 2nd gear is inhibited 1310 Output is switched off, function no long-

er possible 1311 Output is switched off, function no long-

er possible 1312 1313 Output is switched off, function no long-

er possible Output is switched off, engine runs only with idle speed 2nd gear is inhibited Output valve vibra-

tion low ampl., Y 56 Short-circuit current flow out of this output Output was switched off!

Output valve vibra-

tion low ampl., Y 56 No or too low current flow out of this output Output valve vibra-

tion low ampl., Y 56 Although the output is switched off, voltage is present Output valve vibra-

tion high ampl., Y 57 Too high current flow out of this output Out-

put was switched off!

Output valve vibra-

tion high ampl., Y 57 Short-circuit current flow out of this output Output was switched off!

Output valve vibra-

tion high ampl., Y 57 No or too low current flow out of this output Output valve vibra-

tion high ampl., Y 57 Although the output is switched off, voltage is present Short circuit to ground in the current path Lines rubbed through Valve defective X3:12 Wire breakage in cur-

rent path Current path con-

nected to +12V Current path con-

nected to +12V X3:12 X3:13 X3:13 X3:13 Excessive current flow in current path, probably because of a defective coil or a short circuit to ground Short circuit to ground in the current path Lines rubbed through Valve defective Wire breakage in cur-

rent path Current path con-

nected to +12V Current path con-

nected to +12V X3:13 1305 1306 1307 1305 1306 1307

-

-

1310 1311 1312 1310 1311 1312 BMP 8500 BOMAG 109 Trouble shooting Fault codes steering Code Fault reaction Description of fault Possible cause 2010 Output is switched off, function no long-

er possible 2011 Output is switched off, function no long-

er possible Output valve steer-

ing right, Y 237 Too high current flow out of this output Out-

put was switched off!

Output valve steer-

ing right, Y 237 Short-circuit current flow out of this output Output was switched off!

Excessive current flow in current path, probably because of a defective coil or a short circuit to ground Short circuit to ground in the current path Lines rubbed through Valve defective Terminal on BLM Input code for diag-

nose X3:19 1010 X3:19

-

2012 Output is switched off, function no long-

er possible Output valve steer-

ing right, Y 237 No or too low current flow out of this output Wire breakage in cur-

rent path Current path con-

nected to +12V X3:19 2013 Engine is shut down 2020 Output is switched off, function no long-

er possible 2021 Output is switched off, function no long-

er possible 2022 Output is switched off, function no long-

er possible Output valve steer-

ing right, Y 237 Although the output is switched off, voltage is present Output valve steer-

ing left, Y 238 Too high current flow out of this output Out-

put was switched off!

Output valve steer-

ing left, Y 238 Short-circuit current flow out of this output Output was switched off!

Output valve steer-

ing left, Y 238 No or too low current flow out of this output Current path con-

nected to +12V X3:19 X3:21 X3:21 X3:21 Excessive current flow in current path, probably because of a defective coil or a short circuit to ground Short circuit to ground in the current path Lines rubbed through Valve defective Wire breakage in cur-

rent path Current path con-

nected to +12V 1010 1011 1012 1010 1011 1012

-

-

1020 1021 1022 110 BOMAG BMP 8500 Trouble shooting Code Fault reaction Description of fault Possible cause Terminal on BLM 2023 Engine is shut down Current path con-

nected to +12V X3:21 Output valve steer-

ing left, Y 238 Although the output is switched off, voltage is present Fault codes of remote control Input code for diag-

nose 1020 1021 1022 Code 2500 2600 2601 2605*

Fault reaction Description of fault Possible cause Engine is stopped, all func-

tions are locked, horn sounds Operation of two remote control system at the same time A remote control with cable and a wireless remote con-

trol are operated at the same time. Engine stopped, emergency stop relay in the control is switched off, all outputs on control are switched off Engine stopped, emergency stop relay in the control is switched off, all outputs on control are switched off Engine stopped, emergency stop relay in the control is switched off, all outputs on control are switched off Remote control emergen-

cy stop Emergency stop on remote control operated Fault in data transfer be-

tween remote control sender and receiver Receive signal too weak Battery empty Radio signal transmission is disturbed Distance between sender an machine too big Radio signal transmission is disturbed Distance between sender an machine too big 2611 Engine is shut down. 2612 Engine is shut down. 2613 Engine is shut down CANopen fault in bus communication CANopen fault in bus communication CANopen fault in bus communication

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

BMP 8500 BOMAG 111 Terminal on BLM X3:20 Input code for diagnose not possible 0561 X3:03 5020 Trouble shooting General fault codes diesel engine, ma-

chine Code Fault reaction Description of fault Possible cause Only warning, horn sounds, display module is dark, Potential 15 miss-

ing Control has switched relay K11, no voltage 5015 5016 Output is switched off, function no longer possible 5020 Only warning, horn sounds Battery voltage too low Battery voltage al-

ready below 11 Volt when switching on Input engine oil pressure, B 06 Oil pressure switch delivers the signal

"no engine oil pres-

sure"

Fuse F 103 defective Relay K11 defective Cable breakage in wiring loom Battery acid level too low Battery defective Battery discharged The oil pressure switch has measured a too low oil pres-

sure. The engine may be shut down. Should this message be displayed even though the engine is not running, the fol-

lowing faults should be examined:

Current path has short circuit to ground Engine oil level not correct Engine oil pump de-

fective Pressure relief valve after engine oil filter soiled Oil pressure switch defective 5021 Engine shut down by too low oil pressure Input engine oil pressure, B 06 Fault 5 0 2 0 present longer than 8 sec-

onds Engine is shut down see fault code 5 0 2 0 X3:03 5020 112 BOMAG BMP 8500 Code Fault reaction Description of fault Possible cause Trouble shooting Terminal on BLM Input code for diagnose X3:41

-

X3:10 X3:10

-

-

Generator regulator defective Line between regula-

tor and control inter-

rupted Lack of fuel Engine stopped even though the BLM con-

trol did not submit a corresponding com-

mand Excessive current flow in current path, probably because of a defective coil or a short circuit to ground Short circuit to ground in the current path Lines rubbed through Valve defective Wire breakage in current path Current path con-

nected to +12V X3:10 Current path con-

nected to +12V X3:10 5040 5041 5042 5040 5041 5042 5025 Engine running 5031 Machine standing 5040 Output is switched off, engine stops 5041 Output is switched off, engine stops 5042 Output is switched off, engine stops 5043 Output is switched off, engine stops No rotary speed signal from the generator regulator Only warning Engine stops, en-

gine stalled Output HW-shut-

down solenoid, Y 13 Too high current flow out of this output Output was switched off!

Output HW-shut-

down solenoid, Y 13 Short-circuit current flow out of this output Output was switched off!

Output HW-shut-

down solenoid, Y 13 No or too low current flow out of this output Output HW-shut-

down solenoid, Y 13 Although the output is switched off, volt-

age is present BMP 8500 BOMAG 113 Trouble shooting Code Fault reaction Description of fault Possible cause Terminal on BLM Input code for diagnose 5050 Output is switched off, engine runs only with idle speed 5051 Output is switched off, engine runs only with idle speed 5052 5053 5054 5060 Output is switched off, engine runs only with idle speed Output is switched off, engine runs only with idle speed Output switched off, no potential 15 on machine, control is working, engine is stopped or cannot be started Output relay K 114, engine speed sole-

noid Too high current flow out of this output Output was switched off!

Output relay K 114, engine speed sole-

noid Short-circuit current flow out of this output Output was switched off!

Output HW-shut-

down solenoid, Y 13 No or too low current flow out of this output Output relay K 114, engine speed sole-

noid Although the output is switched off, volt-

age is present Input AUX signal engine solenoid Y 13 Output relay K 11, changeover of po-

tential 15 Too high current flow out of this output Output was switched off!

X3:09 Excessive current flow in current path, probably because of a defective coil or a short circuit to ground X3:09 Short circuit to ground in the current path Lines rubbed through Wire breakage in current path Current path con-

nected to +12V X3:09 Current path con-

nected to +12V X3:09

-

-

5050 5051 5052 5050 5051 5052 X3:04 X3:07

-

-

Wire breakage in current path Excessive current flow in current path, probably because of a defective coil or a short circuit to ground 114 BOMAG BMP 8500 Trouble shooting Terminal on BLM Input code for diagnose X3:07

-

Code Fault reaction Description of fault Possible cause 5061 5062 5063 5070 Output switched off, no potential 15 on machine, control is working, engine is stopped or cannot be started Output switched off, no potential 15 on machine, control is working, engine is stopped or cannot be started Output switched off, no potential 15 on machine, control is working, engine is stopped or cannot be started Output switched off, engine cannot be started 5071 Output switched off, engine cannot be started 5072 5073 Output switched off, engine cannot be started All outputs switched off, engine stopped, safety relay switched off Output relay K 11, changeover of po-

tential 15 Short-circuit current flow out of this output Output was switched off!

Output relay K 11, changeover of po-

tential 15 No or too low current flow out of this output Output relay K 11, changeover of po-

tential 15 Although the output is switched off, volt-

age is present Output relay K 39, starter Too high current flow out of this output Output was switched off!

Output relay K 39, starter Short-circuit current flow out of this output Output was switched off!

Output relay K 39, starter No or too low current flow out of this output Output relay K 39, starter Although the output is switched off, volt-

age is present Short circuit to ground in the current path Lines rubbed through Wire breakage in current path Current path con-

nected to +12V X3:07 Current path con-

nected to +12V X3:07 Excessive current flow in current path, probably because of a defective coil or a short circuit to ground Wire breakage in current path Current path con-

nected to +12V Lines rubbed through Wire breakage in current path Current path con-

nected to +12V X3:06 X3:06 X3:06 Current path con-

nected to +12V X3:06 5060 5061 5062 5060 5061 5062

-

-

5070 5071 5072 5070 5071 5072 BMP 8500 BOMAG 115 Trouble shooting Code Fault reaction Description of fault Possible cause Terminal on BLM Input code for diagnose 5080 5085 Output switched off, horn cannot sound 5081 5086 Output switched off, horn cannot sound 5082 5087 5083 5088 5090 Output switched off, horn cannot sound Horn may sound continuously Machine does not start 5091 Shut down of diesel engine X3:08 X3:36 X3:08 X3:36 X3:08 X3:36 X3:08 X3:36

-

-

5080 5081 5082 5080 5081 5082 X3:23 1405 X3:23 1405 Output horn, H 07 Too high current flow out of this output Output was switched off!

Output horn, H 07 Short-circuit current flow out of this output Output was switched off!

Output horn, H 07 No or too low current flow out of this output Output horn, H 07 Although the output is switched off, volt-

age is present Input inclination switch B56 The machine cannot be started, because the input does not re-

ceive a signal from the inclination switch Input inclination switch B56 The diesel engine is shut down because the input on the con-

trol does not receive a signal from the in-

clination sensor Excessive current flow in current path, probably because of a defective coil or a short circuit to ground Short circuit to ground in the current path Lines rubbed through Horn defective Wire breakage in current path Current path con-

nected to +12V Current path con-

nected to +12V Wire breakage in current path Switch defective The switch is in actu-

ated state (incorrect installation position) Wire breakage in current path Switch defective The switch is in actu-

ated state (machine has turned over) The machine must first be shut down after it has been placed in correct position. 116 BOMAG BMP 8500 Trouble shooting Terminal on BLM Input code for diagnose X3:23 1405 Code Fault reaction Description of fault Possible cause 5092 Shut down of diesel engine 5100 Warning horn sounds, only warn-

ing!

5101 Vibration and 2. gear switched off Input inclination switch B56 The diesel engine is shut down because the input on the con-

trol does not receive a signal from the in-

clination sensor

+ Start lock activated Input coolant tem-

perature sensor, B53 Coolant temperature too high Input coolant tem-

perature sensor, B53 Coolant temperature too high over a long-

er period of time The switch is in actu-

ated state (machine has turned over)

+ Start lock activated Wire breakage in current path Switch defective Lack of coolant Radiator defective Sensor defective X3:05 5100 Lack of coolant Radiator defective Sensor defective X3:05 5100 Fault in BOSS safety system Code Fault reaction Description of fault Possible cause 6001 6010 6011 6012 6013 6014 Machine travels for 15min. without activated BOSS safe-

ty system. Attention: Only for servicing purposes!

Warning that service mode is active Service mode activated via in-

put code Travel movement not possi-

ble, only steering Fault of front safety field an-

tenna (W12) Travel movement not possi-

ble, only steering Fault of rear safety field an-

tenna (W13) Travel movement not possi-

ble, only steering Transponder fault (no feed-

back) Travel movement not possi-

ble, only steering Transponder fault Travel movement not possi-

ble, only steering Fault in safety field control

(A115) Wire breakage in current path, front safety field anten-

na defective Wire breakage in current path, rear safety field antenna defective Fault in radio link of safety system, transponder of re-

mote control defective Internal fault in transponder of remote control Internal fault in safety field control BMP 8500 BOMAG 117 Trouble shooting Code Fault reaction Description of fault Possible cause Wire breakage in current path Travel movement not possi-

ble, only steering 6015 6016 Fault in bus communication between safety field control and transponder Reception quality safety field control Faults in parameterization Code Fault reaction Description of fault Possible cause 7010 Machine cannot be started, module is not completely initial-

ized No machine type set Module is new, pa-

rameters were deleted Terminal on BLM Input code for diagnose 0725 118 BOMAG BMP 8500 Trouble shooting 6.8 Input codes for BLM control Outputs for travel functions Input code Description of display function Display values 1010 1011 1012 Output valve steering right, Y 237 Voltage at output Output valve steering right, Y 237 Current at output Output valve steering right, Y 237 Logic level of control 1015 Valve control, steering Output valve steering left, Y 238 Voltage at output Output valve steering left, Y 238 Current at output Output valve steering left, Y 238 Logic level of control Output valve travelling forward, Y 16 Voltage at output Output valve travelling forward, Y 16 Current at output 1020 1021 1022 1030 1031 1032 1040 1041 1042 Display value = output voltage in Volt Display value = output current in Amper 0000 = Output not triggered 0001 = Output triggered 0100 = steering to the left 0010 = Valve not triggered 0011 = steering to the right Display value = output voltage in Volt Display value = output current in Amper 0000 = Output not triggered 0001 = Output triggered Display value = output voltage in Volt Display value = output current in Amper 0100 = Driving forward 0010 = Drum stopped 0011 = Driving reverse Display value = output voltage in Volt Display value = output current in Amper Output valve travelling forward, Y 16 Logic level of control 0000 = Output not triggered 0001 = Output triggered 1035 Valve control, travel system Output valve travelling reverse, Y 17 Voltage at output Output valve travelling reverse, Y 17 Current at output Output valve travelling reverse, Y 17 Logic level of control 0000 = Output not triggered 0001 = Output triggered BMP 8500 BOMAG 119 Trouble shooting Input code Description of display function Display values 1050 1051 1052 1060 1061 1062 Output valve 2. gear, Y 03 Voltage at output Output valve 2. gear, Y 03 Current at output Output valve 2. gear, Y 03 Logic level of control Output brake valve, Y 04 Voltage at output Output brake valve, Y 04 Current at output Output brake valve, Y 04 Logic level of control Display value = output voltage in Volt Display value = output current in Amper 0000 = Output not triggered 0001 = Output triggered Display value = output voltage in Volt Display value = output current in Amper 0000 = Output not triggered 0001 = Output triggered Outputs for work functions Input code Description of display function Display values 1305 1306 1307 1310 1311 1312 Output valve vibration low amplitude, Y 56 Voltage at output Output valve vibration low amplitude, Y 56 Current at output Display value = output voltage in Volt Display value = output current in Amper Output valve vibration low amplitude, Y 56 Logic level of control 0000 = Output not triggered 0001 = Output triggered Output valve vibration high amplitude, Y 57 Voltage at output Output valve vibration high amplitude, Y 57 Current at output Output valve vibration high amplitude, Y 57 Logic level of control Display value = output voltage in Volt Display value = output current in Amper 0000 = Output not triggered 0001 = Output triggered 120 BOMAG BMP 8500 Trouble shooting Inputs logic and power module Input code Description of display function Display values 1400 Input signal L from generator regulator 1401 Input oil pressure switch, B 06 12 V > Generator stopped Ground, 0 V > Generator running 12 V > No oil pressure Ground, 0 V > Oil pressure 1402 Input limit switch engine speed solenoid, Aux 12 V > Solenoid retracted 0V Ground > Solenoid not in end position 1405 Input inclination sensor, B 56 12 V > Inclination less than 45 0V Ground > Inclination higher than 45 1409 1410 Activation input, cable remote control, S 101 12 V > Operating mode cable remote con-

trol Activation input, radio remote control, S 101 12 V > Operating mode wireless Diesel engine, machine electrics Input code Description of display function Display values 5010 5020 5030 5040 5041 5042 5050 Engine speed Display value = 1/min Engine oil pressure, B 06 Shows status of input engine oil pressure 0000 = No engine oil pressure 0001 = Engine oil pressure OK Inclination sensor, B 56 Shows the switching state of the inclination switch Output bia winding of shut-down solenoid, Y 13 Voltage at output Output bia winding of shut-down solenoid, Y 13 Current at output Output bia winding of shut-down solenoid, Y 13 Logic level of control Output relay K 114, engine speed solenoid Voltage at output 0000 = No signal, machine inclined more than 45, or switch defective 0001 = OK, inclination of machine less than 45 Display value = output voltage in Volt Display value = output current in Amper 0000 = Output not triggered 0001 = Output triggered Display value = output voltage in Volt BMP 8500 BOMAG 121 Trouble shooting Input code Description of display function Display values 5051 5052 5055 5056 5057 5058 5059 5060 5061 5062 5070 5071 5072 5080 5081 5082 5085 5086 Output relay K 114, engine speed solenoid Current at output Display value = output current in Amper Output relay K 114, engine speed solenoid Logic level of control 0000 = Output not triggered 0001 = Output triggered Enable parameter change ECO-mode Confirm parameter change ECO-mode Subsequently switch off the ignition!

ECO-mode off ECO-mode on Display of ECO-mode setting Output relay K 11, potential changeover Voltage at output Output relay K 11, potential changeover Current at output Enter code number 5055 first!

Enter code number 5055 first!

0 = ECO-mode off 1 = ECO-mode off Display value = output voltage in Volt Display value = output current in Amper Output relay K 11, potential changeover Logic level of control 0000 = Output not triggered 0001 = Output triggered Output relay K 39, starter Voltage at output Output relay K 39, starter Current at output Output relay K 39, starter Logic level of control Output horn, H 07 Voltage at output Output horn, H 07 Current at output Output horn, H 07 Logic level of control Output 2 horn, H 07 Voltage at output Output 2 horn, H 07 Current at output Display value = output voltage in Volt Display value = output current in Amper 0000 = Output not triggered 0001 = Output triggered Display value = output voltage in Volt Display value = output current in Amper 0000 = Output not triggered 0001 = Output triggered Display value = output voltage in Volt Display value = output current in Amper 122 BOMAG BMP 8500 Trouble shooting Input code Description of display function Display values 5087 Output 2 horn, H 07 Logic level of control 5100 Coolant temperature sensor, B 53 0000 = Output not triggered 0001 = Output triggered 0000 = Temperature too high, excessive temperature 0001 = Temperature OK Checking the function of the remote controls Input code Description of display function Display values 2500 2501 Actuation of travel lever on remote control, S 138 Actuation of steering joystick on remote control, S 137 2502 Position of switch for vibration, S 36 2503 Position of switch for type of vibration, S 132 2504 Position of switch for fast speed, S 133 2505 Position of switch for engine speed, S 134 2506 Position of button for horn, S 03 0100 = Travel lever shifted forward 0010 = Travel lever not moved 0001 = Travel lever shifted backward 0100 = Joystick actuated to the left 0010 = Joystick not moved 0001 = Joystick actuated to the right 0100 = Switch operated to forward, vibra-

tion high amplitude 0010 = Switch not operated 0001 = Switch operated to reversed, vibra-

tion low amplitude 0100 = Switch operated to forward, auto-

matic operation 0010 = Switch not operated, manual oper-

ation 0100 = Switch operated to forward, fast speed selected 0010 = Switch not operated, fast speed disabled 0100 = Switch operated to forward, high engine speed 0010 = Switch not operated, idle speed 0000 = Button not operated 0001 = Button operated i Note With the input codes listed above it is possible to check the transfer of the individual switching sig-

nals from the remote controls to the central control unit. For this purpose start the machine and subse-

quently press the horn button to bring the remote BMP 8500 BOMAG 123 Trouble shooting control sender in operating mode for this function test. For testing the spiral cable switch the operating mode switch to cable operation, connect the spiral cable to the sender and start the machine. If the engine starts, the spiral cable is OK. System information Input code Description of display function Display values 0555 0561 Software Version Shows the software version number. Supply voltage Shows the voltage value Setting the remote control type 3-digit version number Display value = voltage in V Input code Description of display function Display values Switches on function "Set remote control type"

See adjustment instructions confirms the entered remote control type See adjustment instructions Preselect radio remote control, default set-

ting See adjustment instructions 0660 0661 0662 Fault log Input code Description of display function Display values 0700 0701 0710 Switch on function Show stored faults See adjustment instructions Switch off function "Show stored faults"

See adjustment instructions Delete all stored faults See adjustment instructions BOSS safety system Input code Description of display function Display values 6000 6001 Enable service mode 6000 Service mode active, machine travels for 15min. without activated BOSS safety sys-

tem. Attention: Only for servicing purposes!

6001 = service mode active 6002 Service mode inactive 124 BOMAG BMP 8500 Trouble shooting Reading out the operating hour meter Input code Description of display function Display values 7500 7501 Display of hours, operating hour meter The full hours are displayed Display of minutes, operating hour meter The minute digits of the operating hour me-

ter are displayed Setting the machine type Input code Description of display function Display values 7010 7011 7103 7104 Switches on function "Set machine type"

See adjustment instructions Confirms entered machine type See adjustment instructions Preselect machine type BMP 8500 with protection bow See adjustment instructions Preselect machine type BMP 8500 without protection bow See adjustment instructions BMP 8500 BOMAG 125 Trouble shooting 126 BOMAG BMP 8500

 

 

 

 

 

 

 

 

 

 

Fiir TeraTron-Komponenten (BSS-R) TeraTron Model: BSS0134R FCC ID: QLXBSS0134R, IC: 4430A- BSS0134R

 

 

TeraTron Agent Authorization Company: TeraTron Address: Martin-Siebert-Str. 5 Product Name: Schutzfeld-Steuerung / Reader (BSS-R) Model Number(s): BSS0134R Product Description: Schutzfeld-Steuerung / Reader (BSS-R) We authorize MiCOM Labs Inc., 575 Boulder Court, Pleasanton, California 94566, USA, to act on our behalf on all matters concerning the certification of above named equipment. We declare that MiCOM Labs Inc. is allowed to forward all information related to the approval and certification of equipment to the regulatory agencies as required and to discuss any issues concerning the approval application. Any and all acts carried out by MiCOM Labs on our behalf shall have the same effect as acts of our own. ag Siguane [?- e Date: 2018-09-03 Name: Rainer Helberg Title: .e- Ay Company: TeraTron

 

 

Teratron TeraTron GmbH, Martin-Siebert-Str. 5 , 51647 Gummersbach Office of Engineering Technology Federal Communications Commission 7435 Oakland Mills Road Columbia, MD 21046 USA Date: 2018-09-03 Subject; Request for Confidentiality FCC ID: QLXBSS0134R To Whom It May Concern, Pursuant to the provisions of the Commissions rules Title 47 Sections 0.457 and 0.459, we are requesting the Commission to withhold the following attachment(s) as confidential documents from public disclosure indefinitely. These documents contain detailed system and equipment descriptions and are considered as proprietary information in operation of the equipment. The public disclosure of these documents might be harmful to our company and would give competitors an unfair advantage in the market. Schematic Diagram X] Block Diagram

[_] Parts List

[X] Operational Description

[_] Tune-up Procedure In additional to above mentioned documents, in order to comply with the marketing regulations in Title 47 CFR 2.803 and the importation rules in Title 47 CFR 2.1204, while ensuring that business sensitive information remains confidential until the actual marketing of newly authorized devices, we request Short Term Confidentiality of the following attachment(s);

xX] External Photos

[x] Test Setup Photos Internal Photos X] User Manual _] For 45 days, pursuant to Public Notice DA 04-1705. OR

[x] For 180 days pursuant to KDB 726920 DO1. It is our understanding that all measurement test reports, FCC ID label format and correspondence during the certification review process cannot be granted as confidential documents and this information will be available for public review once the grant of equipment authorization is issued. ry a, Hie He Name: Rainer Helberg j