Bomag BMP 8500 Service Training Revised

BMP 8500
Service Training
BMP 8500 Overview
Simple servicing due to excellent accessibility.
© BOMAG GmbH Slide 2

BMP 8500 Overview
Technical Data
A 1000 mm/39.37 in L 1897 mm/74.69 in

D 520 mm/20.47 in S 25 mm/.984249 in
H 1275 mm/50.20 in W 850 mm/33.47 in
K 222 mm/8.74 in W1 222 mm/24.02 in
Weight
Operating weight (CECE) kg/lbs 1595/3516.4
Basic weight kg/lbs 1585/3494.3
Mean axle load (CECE) kg/lbs 775/1708.6
BMP 8500 Overview
Technical Data
Travel Characteristics
Travel speed (1) forward/reverse mph/kmh 0 to.8/0 to 1.3
Travel speed (2) forward/reverse mph/kmh 0 to 1.5/0 to 2.5
Maximum gradability without/with vibration (soil dependent) % 55/45
BMP 8500 Overview
Technical Data
Engine
Engine manufacturer Kubota
Type D 1005
Cooling Water
Number of cylinders 3
Rated power ISO 9249 kW 14.5/HP 19.45 Rated
speed rpm 2600
Combustion principle 4-stroke diesel
Low idle speed rpm 850 ±50
High idle speed rpm 2750 ±50
Valve clearance intake mm 0.145 to 0.185
Valve clearance exhaust mm 0.145 to 0.185

BMP 8500 Overview
Technical Data
Drive System
Drive system hydrostatic
Driven drums front + rear
Brake
Service brake hydrostatic
Parking brake mechanical

BMP 8500 Overview
Technical Data
Steering
Type of steering Articulated joint
Steering operation hydrostatic
Vibration system
Vibrating drum front + rear
Drive system hydrostatic
Frequency Hz/VPM 42/2520
Amplitude mm/in1.12-0.56/0.04-0.02
Centrifugal force kN/lbf 72-36/16186.24-
8093.122
Dual direction-vibration exciter system:

2 forces / 2 amplitudes

BMP 8500 Overview
Machine Type Serial Number Location
Machine type and serial number plate
Machine serial number also stamped into frame

BMP 8500 Overview
Engine Type Engine Number Location
Engine type and engine number

BMP 8500 Overview
Technical Data
Filling capacities
Fuel (diesel) l/g 24/6.34
Hydraulic oil l/g 17/4.49
Engine oil l/g 4.7/1.24
Coolant l/g 4.5/1.19
Vibration housing l/g 2x 1,7/.31

BMP 8500 Overview
Technical Data
1 Steering pump 7 Fuel tank

2 Travel pump 8 Central electrics
3 Vibration pump 9 Battery
4 Exhaust system 10 Hydraulic control valve block
5 Diesel engine 11 Hydraulic oil tank
6 Cooler 12 Air filter
BMP 8500 Overview
Technical Data
13 Single point lifting facility 16 Coolant compensation container

14 Air filter service indicator 17 Engine oil filter
15 Fuel filter 18 Hydraulic oil filter

BMP 8500 Overview
Travel System
1 Travel motor 4 Gear

2 Cylinder roller bearing 5 Cylinder roller bearing
3 Drive shaft 6 Pinion travel motor

BMP 8500 Overview
Travel System
Travel motors
Type 2000 Series
Quantity 2
System Eaton Geroller hydraulic motor
Displacement (stage 1) cm3/rev. 306.6

BMP 8500 Overview
Travel System
Travel pump
Type AZPFFB-12-8+5,5+4R
System Triple gear pump
Max. displacement cm3/rev. 5.5
High pressure limitation bar 250 psi 3626

BMP 8500 Overview
Travel System
Engine
The travel pump is a directly driven gear pump, which is connected with the vibration pump
via a coupling. The travel pumps deliver the hydraulic oil from the tank through the control
valve block to the travel motors and back to the tank.

BMP 8500 Overview
Vibration System
1 Gear 4 Change over weight

2 Cylinder roller bearing 5 Eccentric
3 Coupling vibration motor

BMP 8500 Overview
Vibration System
6 Vibration motor
7 Exciter unit

BMP 8500 Overview
Vibration System
By reversing the vibration motor or the sense of rotation, we can change the amplitude.
High amplitude: The exciter shaft rotates clockwise. Both eccentrics add up and generate a
higher resultant centrifugal force.

BMP 8500 Overview
Vibration System
Low amplitude: The exciter shafts rotate counter-clockwise. The eccentric weight (2) swings
over. The centrifugal force generated by the two eccentrics are subtracted from one another
resulting in a lower resultant centrifugal force.

BMP 8500 Overview
Vibration System
The leak oil port in the pump housing allows the motor to be reversed. This allows an in series
connection. Due to the connection between radial seal and the low pressure side standard
motors and pumps can be loaded with pressure of up to approximately 3 bar 43.5 psi. When
the gear motor is supplied with pressure oil, a torque can be taken off the protruding output
shaft. A differentiation is there by made between motors for one direction of rotation and
allows the motor to be reversed.
BMP 8500 Overview
Vibration System
Vibration Control
The vibration control elements are integrated in the same valve block as the control elements
for the travel system. The vibration control is linked with the travel system control as follows:
If the machine is driven with high travel speed, a 4/2-way solenoid valve will cut off the oil flow
to the vibration motor and directs it additionally to the travel circuit.
When the vibration is switched on, the oil flow from the vibration pump must first start rotation
of the resting exciter shaft. The pressure (starting pressure) caused by this high starting
resistance of the resting exciter shaft is limited to max. 250 bar 3626 psi by a pressure relief
valve inside the control valve block. Once the final speed of the exciter shafts is reached, the
resistance of the exciter shafts becomes lower and the pressure drops down to a value
(operating pressure) which is influenced by external effects (degree of compaction, soil
condition, etc.).
The sense of rotation of the vibration motors can be reversed by actuation of a 4/3-way valve.
This way the amplitude adjustment is realized.

BMP 8500 Overview
Control Valve Block

BMP 8500 Overview
Control Valve Block
1.2 Travel direction valve (4/3-way solenoid valve)

2.3 Vibration valve (4/3-way solenoid valve)
3.3 3/2-way solenoid valve for brake
3.5 4/3-way solenoid valve for steering

BMP 8500 Overview
Control Valve Block
1.1 Pressure relief valve for travel circuit 2.2 Valve 2nd gear (4/3-way solenoid valve)
(250 bar 3626 psi) 2.4 Pre-loaded check valve
1.3.1 Load lowering valve rear 3.1 Pressure relief for steering
1.3.2 Load lowering valve front 3.2 Pressure relief for brake
2.1 Pressure relief valve for vibration circuit

BMP 8500 Overview
Control Valve Block
A1 To rear travel motor port A B3 To steering cylinder port B

A2 To rear vibration motor port A BR To port on brake cylinder
A3 To steering cylinder port A L1 Leak oil travel control
B1 To front travel motor port B L2 Leak oil vibration
B2 to front vibration motor port B

BMP 8500 Overview
Control Valve Block
P1 Connection travel pump

P2 Connection vibration pump
P3 Connection steering pump
T1 Return flow to tank via oil cooler
T2 Return flow to tank, direct

BMP 8500 Overview
Hydraulic Line Connections to Control Valve Block
1 P1 Connection travel pump to control block

2 P2 Connection vibration pump to control block
3 P3 Connection steering pump to control block
BMP 8500 Overview
3 T1 Return flow to tank via oil cooler

4 & 5 through tee 1 T2 Return flow to tank, direct
BMP 8500 Overview
1 A3 To steering cylinder port A

2 B3 To steering cylinder port B
BMP 8500 Overview
1 A1 Block to rear travel motor port A

2 A2 Block to rear vibration motor port A
3 A1 to B1 Front travel motor port B
4 A4 to B2 Front vibration motor port B
5 A5 to L1 Leak oil travel control
6 A5 to L2 Leak oil vibration
7 A6 to BR To port on brake cylinder

BMP 8500 Overview
Hydraulic Line Connections
3 & 5 Jumper hoses travel and vibration

front to rear

BMP 8500 Overview
1 A1 To rear travel motor port A

2 A3 To rear travel motor port B
3 A2 To rear vibration motor port A
4 A4 to rear vibration motor port B
5 A5 to leak oil rear travel control
6 Leak oil rear vibratory motor

BMP 8500 Overview
1 A6 To brake cylinder

BMP 8500 Overview
Hydraulic Line Connections Center Frame
In order to be able to work without routing hydraulic hoses through the endangered area
between the drums, the hydraulic oil is directed through deep drilled holes in the center
frame. Inside the center frame hydraulic hoses connect the deep drilled holes with the
Travel motors, the vibration motors, and the brake cylinder.
BMP 8500 Overview
Overview of Drum
1 Travel motor
2 Middle frame
3 Drum
4 Cover/flange
5 Cylinder roller bearing
6 Vibration motor
7 Vibrator shaft
8 Gear exciter shaft
9 Drive shaft
10 Cylinder roller bearing
11 Gear drive shaft
12 Pinion travel motor

BMP 8500 Overview
Electrical Overview (Understanding circuit diagrams) New format

BMP 8500 Overview
The table of contents list the individual functions and identifies the corresponding sheets in the wiring diagram.
BMP 8500 Overview
Sheets with representations of functions

The main reading direction is sheet by sheet, from top to bottom and from right to left. All sheets are
successively numbered.

BMP 8500 Overview
BOMAG used the resolved type of representation, in this case parts and components with different
functions, which belonged to the same components (e.g. relay coil and relay contact), can be represented
on different sheets. Cross-references, which refer to sheet and current path, serve as linkage between
these partial components.
BMP 8500 Overview
15_54~
+SEAT/16.1
Current paths are successively numbered from 0 to 9.

Potential cross references serve purpose of tracking signals, which are transferred from on representation
of a function to another. Potential cross-references additionally may have structuring symbols assigned to
Them. Example: potential > 15_54 - + SEAT/16.1 (on sheet 4, current path 8) continues to the right on
sheet 16, current path 1, +SEAT is the structuring symbol.
BMP 8500 Overview
87
30/4.4
87a
Relay cross-references
Relay cross-references serve the tracking of signals, which need to be tracked for components with out
going contacts. A mimic diagram with information about the contact.types of relay and there positions in
The wiring diagram is additionally attached to the bottom of each contact coil.
BMP 8500 Overview

-K61
4.2
Example: The relay cross-reference (K61/4.2) (on sheet 4, current path 4) indicates that the relay coil on
sheet 4 is found in current path 2.
BMP 8500 Overview
List of components: The list of components is the first evaluation list that follows the representation of
function. This list contains all components used in the wiring diagram, except terminal strips and plugs.
BMP 8500 Overview

List of components: Components are always listed in an alphanumeric format. The alphanumeric
identification follows standard DIN. This alphanumeric identification always identifies the same
component, e.g. : “S04 “ is always a brake switch regardless of what BOMAG you might be working on.
The component identifications are listed in alphanumeric order in the list of components. Each
component has the corresponding cross-reference assigned, identifying where it can be found in the
wiring diagram, which installation location it is assigned, and to which part of the system it belongs to.
The functions and technical characteristics are also described.

BMP 8500 Overview
Overview of terminal strips: The overview of terminal strips contains all terminal strips used in the
circuit diagram. Each terminal strip starts on a new page and can be localized via the cross-reference in
the wiring diagram.
BMP 8500 Overview
Overview of plugs: The overview of plugs contains all plugs used in the circuit diagram. The following
information is listed for each plug. Contact numbering, structuring symbols, function text, and use in
wiring diagram.

BMP 8500 Overview
Overview of pins: The overview of pins informs about the different types inputs and outputs of the
electronic controls (E-BOX) used in the machine as well as signals and potentials.

BMP 8500 Overview

Circuit symbols (International Electrical Commission IEC) standard
1 Current source 7 Voltmeter

2 Conductor 8 Ampere meter
3 Switch 9 Resistance
4 Ground 10 Backup
5 Filament lamp 11 Line connected (fixed)
6 Filament lamp with two luminous elements 12 Line connected (separable)

BMP 8500 Overview

Representation of electric devices: Electronic devices and components are increasingly used in
construction industry. Controls with software, control elements (e.g. joysticks man/machine
interface (e.g. screens, LCD displays) are frequently used to represent and control machines
functions. The internal construction of such components in most cases are protected or just too
complex to be illustrated in the wiring diagram with in the context of actual machine function. There
are two different ways to simplify the representation of such devices in the diagram.
Black-Box representation: The Black-Box representation shows the device as a Box with the
connections required for the machine function. Connections which are not needed do not need to
be represented.
The Black-Box representation is mainly used when no differentiated information (e.g. signals on
pins) is available.

BMP 8500 Overview

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

BMP 8500 Overview

PLC representation: The PLC-Box representation of connecting pins uses a table with associated
connecting plugs, which are used in connection with the machine functions. The table symbols can be
arranged in a line, if necessary. Connections which are not needed do not need to be represented.
The PLC-Box representation enables the representation of further reaching functional descriptions to
the individual component connections.
The PLC-Box representation is mainly used for controls with BOMAG software, or for electronic
devices which were specified accordingly, and where information on the assignment of signals is
available.
Identification of similar, adjacent switching symbols: In wiring diagrams you will frequently find the
BMP 8500 Overview

situation that symbols of the same type appear in a line or are arranged just next to each other. In
such cases it is common practice to reduce the identification on the subsequent symbol to the criteria,
which are different to the previous symbol to the left.
Example: -X0 36 and -X0 37: In the example illustrated here the component identification "-X0" for the
left plug symbol is also valid for the right plug symbol.

BMP 8500 Overview
Designation of components in the wiring diagram: The designation of components in the wiring
diagram groups several electrical parts of the machine in one group. The components can be
identified by the following table.

BMP 8500 Overview

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

BMP 8500 Overview

a consumer or switch used in a motor vehicle has a terminal designation.In Germany the designation
of the individual connection terminals is determined by the standard DIN 72552. The following table
shows some examples from this DIN standard.

BMP 8500 Overview

a consumer or switch used in a motor vehicle has a terminal designation.In Germany the designation
of the individual connection terminals is determined by the standard DIN 72552. The following table
shows some examples from this DIN standard.

BMP 8500 Overview
Controls
1. A67 Electronic immobilizer1
2. P17 Display module
3. F05 - F119 Fuse box
4. S101 Toggle switch for cable remote
control/radio remote control
5. XS Socket
6. S30 Main battery switch
7. S137 Steering control lever
8. S132 Toggle switch, vibration
automatic/manual
9. S133 Toggle switch, travel ranges
10. S134 Toggle switch, engine speed
11. S138 Travel direction control lever
12. S36 Toggle switch for vibration high/low
amplitude
13. S102 Emergency stop switch
14. H77 Control light data transfer/power
pack radio remote control
15. S181 Key switch
16. S131 Start engine
17. S03 Horn button

BMP 8500 Overview
Fuses
No 3 Fuse Box
F119= (20A) Fuse for starter motor
F103=(10A) Fuse potential 15
F14=(25A) Fuse for engine solenoid
F54=(5A) Fuse for cable remote control
F05=(10A) Fuse for utility socket
F67=(25A) Fuse control (potential 30)
F48=(30A) Preheating
F68=(5A) Immobilizer

BMP 8500 Overview
Boss safety system
Function
The machine is surrounded by 2 spherical
electromagnetic safety fields. If the
machine operator with the remote control
enters into the field, which stretches in
travel direction, the machine will stop
immediately.
The minimum distance between operator

and machine must be 2 m/6.56 ft. When
falling short of a distance of 1.2 m/3.94 ft,
the corresponding travel direction will be
stopped.
Only operators carrying the associated

remote control are protected.

BMP 8500 Overview
Boss safety system
The BOMAG protection field control BOSS

prevents the operator - and only the operator -
from becoming trapped between machine and
wall. As the machine approaches the operator
it will stop once the distance between operator
and machine becomes less than 1.2 m/3.94 ft.
This is irrespective of whether the operator is
in front of or behind the machine.
The engine keeps running and the steering is

operable, but travelling towards the operator is
no longer possible. Travelling in the opposite
direction (away from the operator) is still
possible. To be able to continue travelling
towards the operator the distance to the
machine must be increased and the travel
lever must first be returned to neutral, before
travel operation is resumed.

BMP 8500 Overview
Boss safety system

The remote control of the machine is equipped
with a transponder (small PCB) which sends
a permanent control signal to the protection
field control in the machine.
Once the transponder enters into the

protection field, it transmits an alarm to the
protection field control. The control then
interrupts the electric power supply to the
corresponding travel control valve and sends a
stop command to the machine control (BLM),
causing the machine to stop.
If the control signal emitted by the transponder

is incorrect or does not exist, the machine will
also be stopped.
Parallel to this the protection field logic of the

protection field control is permanently
monitored by a testing facility. In case of a
fault in the protection field logic, the testing
facility will switch off the travel control valves.

BMP 8500 Overview
Boss safety system

Communication of protection field system
Communication between transponder and

protection field control either takes place via
the spiral cable, or via radio.
For the signal transmission via radio both the

transponder and the protection field control
are equipped with their own transmitter,
receiver and antenna.
This means that in radio mode the system

works with two radio signals. One signal from
transponder to protection field control and one
signal from the radio transmitter to the receiver
in the machine control.
Both systems must work with the same

frequency (868 MHz for Europe - 916 MHz
for USA). Please bear this in mind when
ordering spare parts!

BMP 8500 Overview
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):
1. Shut down the engine,

2. Switch off the main battery switch,
3. Replace defective components,
4. Switch on the main battery switch,
5. Plug the spiral cable into the remote control.
Turn the tumbler switch for the cable remote

control to position "Left", cable operation.

BMP 8500 Overview
Teaching the BOSS safety system transponder
Turn the ignition switch to position I charge

control lamp and oil pressure control lamp come
on.
Move the remote control out of the safety field.
The safety field control lamp goes out at the

latest after 2 seconds.
The machine is now ready for operation.

BMP 8500 Overview
Safety field measurement of the Boss safety system
The safety field of the machine must be

measured at a height of one meter/3.3 ft, also
after maintenance/repair work on the safety
system. A safety field length less than 1.20
m/3.94 ft is not permitted.
Step behind the machine with the remote

control and allow the machine to move towards
you, until it stops.
Measure the distance between machine and

remote control housing.
Nominal value: Less than 1.20 m/3.94 ft
Repeat this inspection in front of the machine.

BMP 8500 Overview
Fault display readout
Faults are displayed in the display module h 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.
h

BMP 8500 Overview
Checking the oil in the vibrator shaft housing
You must lift up the machine on one side and

put it on a block of wood or something else
suitable that is 145 mm high.
Open both plugs on the side you have elevated.

The oil must stay on the lower edge of the lower
hole.
Repeat this procedure on the opposite side of

the compactor.

BMP 8500 Overview
Display module input functions
161 of service manual for safety bar version

193 of service manual for safety field version

BMP 8500 Overview
Manuals you will need Operating Instructions/Maintenance Instructions Service-Manual

All manuals and schematics are available online at
www.BOMAG.com/Americas

BMP 8500 Overview

Bomag BMP 8500 Service Training Revised

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BMP 8500

Simple servicing due to excellent accessibility.

© BOMAG GmbH Slide 2

A 1000 mm/39.37 in L 1897 mm/74.69 in

© BOMAG GmbH Slide 5

© BOMAG GmbH Slide 6

Dual direction-vibration exciter system:

© BOMAG GmbH Slide 7

Machine Type Serial Number Location

Machine type and serial number plate

Machine serial number also stamped into frame

© BOMAG GmbH Slide 8

Engine Type Engine Number Location

Engine type and engine number

© BOMAG GmbH Slide 9

© BOMAG GmbH Slide 10

1 Steering pump 7 Fuel tank

13 Single point lifting facility 16 Coolant compensation container

© BOMAG GmbH Slide 12

1 Travel motor 4 Gear

© BOMAG GmbH Slide 13

© BOMAG GmbH Slide 14

© BOMAG GmbH Slide 15

© BOMAG GmbH Slide 16

1 Gear 4 Change over weight

© BOMAG GmbH Slide 17

© BOMAG GmbH Slide 18

© BOMAG GmbH Slide 19

© BOMAG GmbH Slide 20

© BOMAG GmbH Slide 22

Control Valve Block

© BOMAG GmbH Slide 23

Control Valve Block

1.2 Travel direction valve (4/3-way solenoid valve)

© BOMAG GmbH Slide 24

Control Valve Block

© BOMAG GmbH Slide 25

Control Valve Block

A1 To rear travel motor port A B3 To steering cylinder port B

© BOMAG GmbH Slide 26

Control Valve Block

P1 Connection travel pump

© BOMAG GmbH Slide 27

Hydraulic Line Connections to Control Valve Block

1 P1 Connection travel pump to control block

Hydraulic Line Connections to Control Valve Block

3 T1 Return flow to tank via oil cooler

Hydraulic Line Connections to Control Valve Block

1 A3 To steering cylinder port A

Hydraulic Line Connections to Control Valve Block

1 A1 Block to rear travel motor port A

© BOMAG GmbH Slide 31

Hydraulic Line Connections

3 & 5 Jumper hoses travel and vibration

© BOMAG GmbH Slide 32

Hydraulic Line Connections

1 A1 To rear travel motor port A

© BOMAG GmbH Slide 33

Hydraulic Line Connections

© BOMAG GmbH Slide 34

Hydraulic Line Connections Center Frame

© BOMAG GmbH Slide 36

Electrical Overview (Understanding circuit diagrams) New format