Operators Manual 00811141.e05 4z53r

Operating instructions Maintenance instructions

BMP 851 S/N 101 720 04 .... 101 720 05 ....

Multi-purpose compactor

Catalogue number

008 111 41

05/2005

Foreword BOMAG machines are products from the wide range of BOMAG compaction equipment. F oreword

BOMAG’s vast experience in connection with state-of-the-art production and testing methods, such as lifetime tests of all important components and highest quality demands guarantee maximum reliability of your machine.

You should only operate the machine after you have been instructed and in compliance with these instructions. Strictly observe the safety regulations. Please observe also the guidelines of the Civil Engineering Liability Association ”Safety Rules for the Operation of Road Rollers and Soil Compactors” and all relevant accident prevention regulations.

This manual comprises: l

Safety regulations

l

Operating instructions

l

Maintenance instructions

l

Trouble shooting

For your own personal safety you should only use original spare parts from BOMAG. In the course of technical development we reserve the right for technical modifications without prior notification. These operating and maintenance instructions are also available in other languages.

Using these instructions will l

help you to become familiar with the machine.

l

avoid malfunctions caused by unprofessional operation.

Compliance with the maintenance instructions will l

enhance the reliability of the machine on construction sites,

l

prolong the lifetime of the machine,

l

reduce repair costs and downtimes.

Furthermore, the spare parts catalogue is available from your BOMAG dealer against the serial number of your machine. Your BOMAG dealer will also supply you with information about the correct use of our machines in soil and asphalt construction. The above notes do not constitute an extension of the warranty and liability conditions specified in the general of business of BOMAG GmbH. We wish you successful work with your BOMAG machine.

BOMAG GmbH will not assume liability for the function of the machine

BOMAG GmbH

l

if it is handled in a way that does not comply with the usual modes of use,

l

if it is used for purposes other than the ones it is intended for (see safety regulations).

Printed in Copyright by BOMAG

No warranty claims can be lodged in case of damage resulting from l

operating errors,

l

insufficient maintenance and

l

wrong fuels and lubricants.

Please note! This manual was written for operators and maintenance personnel on construction sites. Always keep this manual close at hand, e.g. in the tool compartment of the machine or in a specially provided container. These operating and maintenance instructions are part of the machine.

BMP 851

BOMAG

3

Foreword Please fill in ............................ Machine type (Fig. 1) ............................ Serial No. (Fig. 1 and 2) ............................ Engine type (Fig. 3) ............................ Engine No. (Fig. 3)

i

Note

Fig. 1

Fill in the above listed data when receiving the machine. Upon receipt of the machine our organization will instruct you about correct operation and maintenance. Please observe strictly all safety regulations and notes on potential dangers!

Fig. 2

Fig. 3

4

BOMAG

BMP 851

Table of Contents

Technical Data Safety regulations Indicators and Controls

7 13 21

Operation

31

Maintenance

BMP 851

3.1 General notes 3.2 Description of indicators and control elements

24 24

4.1 General 4.2 Tests before taking into operation 4.3 Opening / closing the service hood 4.4 Starting the engine 4.5 Driving the machine (cable remote control) 4.6 Safety inspection for the cable remote control 4.7 Backup protection bow for backward travel 4.8 Switching the vibration on and off 4.9 Shutting the engine down 4.10 Shutting down the engine manually 4.11 Starting operation of the radio remote control 4.12 Replacing, recharging the radio remote control power pack 4.13 Safety inspection for the radio remote control 4.14 Switching off of the radio remote control in case of radio interferences 4.15 Starting operation of the infrared remote control 4.16 Replacing, recharging the infrared remote control power pack 4.17 Safety inspection of infrared remote control 4.18 Changing the BLM-control 4.19 Entering the machine type code into the display module 4.20 Entering the remote control code into the display module 4.21 Open the engine hood 4.22 Opening the rear frame 4.23 Assembling/removing the drum extension 4.24 Loading and transport

32 32 33 33 38 41 42 42 44 45 46 51 53 54 55 59 62 63 64 65 67 67 68 68

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 chart 5.6 Checking the engine oil level 5.7 Checking the hydraulic oil level 5.8 Checking the fuel level 5.9 Fuel filter, draining off water 5.10 Checking the air intake hose

72 73 75 76 77 78 78 79 79 80

BOMAG

71

5

Table of Contents

Trouble shooting

6

5.11 5.12 5.13 5.14 5.15 5.16 5.17 5.18 5.19 5.20 5.21 5.22 5.23 5.24 5.25 6.1 6.2 6.3 6.4 6.5 6.6

Cleaning cooling fins/cooling air blower Changing engine oil and oil filter Checking, adjusting the valve clearance Checking the oil level in the vibration bearing housings Checking, cleaning, changing the combustion air filter Servicing the battery Drain the sludge from the fuel tank Check the pretension of the engine hood Replacing the fuel filter Changing the oil for the vibrator bearings Changing hydraulic oil, hydraulic oil filter and breather filter Adjusting the scrapers Bleeding the fuel system Tightening torques for screws with metric unified thread Engine conservation

80 81 83 84 85 87 88 88 90 91 92 94 94 95 95

General notes Engine Problems with remote control Hetronic with spiral cable Problems with radio remote control Hetronic in radio operation Fault indicator Fault code

98 99 101 106 108 109

BOMAG

97

BMP 851

1 Technical Data

BMP 851

BOMAG

7

Technical Data

Fig. 4

Dimensions in mm

A

D

H

K

L

S

W

BMP 851

550

500

1200

240

1500

10

850

*

BMP 851

Weights Basic weight Operating weight (CECE) mean axle load Travel characteristics (soil dependent) Travel speed 1 Travel speed 2 Max. gradability without/with vibration

8

BOMAG

kg kg kg

1540 1548 774

km/h km/h

0 to 1,2 0 to 2,7

%

55/45

BMP 851

Technical Data *

BMP 851

Drive Engine manufacturer Type Cooling Number of cylinders Rated power ISO 9249 Rated speed Battery Drive system Driven drums

kW rpm V/AH

Hatz 2G40 Air 2 13,8 2800 12/55 hydrostatic front + rear

Brakes Service brake Parking brake

hydrostatic hydrostatic

Steering Type of steering Steering operation

Lever hydrostatic

Vibration system Frequency Amplitude Centrifugal force

Hz mm kN

32 2,10 80

Filling capacities Fuel (diesel) Hydraulic oil Engine oil

l l l

19 38 2,5

Infrared remote congtrol Manufacturer

Co. HETRONIC D-84085 Langquaid

Radio remote control Manufacturer

Co. HETRONIC D-84085 Langquaid

Transmitter Frequency band Transmitting frequency range Number of channels HF-transmitting pwoer Reach, depending on environment Current draw Weight

BMP 851

MHz

F-band 868 / 916 / 315 / 429 1 mW FM 50 m approx. 10 mA approx. 1,6 kg

BOMAG

9

Technical Data *

BMP 851

Receiver Receiver frequency range Current draw

MHz

Transmitter power pack Voltage Capacity

3,6 V 1,2 Ah

Battery charger Operating voltage *

10

868 / 916 / 315 / 429 approx. 10 mA

110 / 230 V AC / 12 - 24 V DC

The right for technical modifications remains reserved

BOMAG

BMP 851

Technical Data The following noise and vibration values according to the EC-directive for machines, edition (91/368/ EEC) were measured at nominal engine speed and with the vibration switched on. The machine was standing on an elastic base. During operation these values may vary because of the existing operating conditions.

Noise value The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is sound pressure level on the operator’s stand: LpA = 86 dB(A) sound capacity level: LWA =105 dB(A) These sound values were determined according to ISO 6081 for the sound pressure level (LpA) and ISO 3744, DIN 45635 for the sound capacity level (LwA).

BMP 851

BOMAG

11

Technical Data

12

BOMAG

BMP 851

2 Safety regulations

BMP 851

BOMAG

13

Safety regulations General

chine movements, which are not in compliance with the movement of the control elements.

This BOMAG machine is built in accordance with the latest technical standard and the valid technical rules and regulations. There is, however, a risk of danger for persons and property if: l

the machine is used for purposes other than those it is intended for

l

the machine is operated by untrained personnel

l

the machine is modified or converted in an unprofessional way

l

the applicable safety regulations are not observed.

Unintended use Dangers may, however, arise from the machine if it is used by untrained personnel in an unprofessional way or if it is used for purposes other than those mentioned in these instructions. Do not work with vibration on hard concrete, on a cured concrete layer or heavily frozen ground. Starting and operation of the machine in an explosive environment is prohibited.

Who is allowed to work with the machine?

Each person involved in operation, maintenance and repair of the machine must therefore read and apply these safety regulations. This should be confirmed by obtaining the signatures of the customer, if necessary.

The machine must only be operated by trained and authorized persons which are at least 18 years of age. The responsibilities for the operation of the machine must be clearly specified and complied with.

Furthermore the following regulations and instructions are obviously also valid:

Persons under the influence of alcohol, medication or drugs must not operate, service or repair the machine.

l

applicable accident prevention instructions

l

generally acknowledged safety and road traffic regulations

l

country specific safety regulations. It is the duty of the operator to know and observe these regulations. This applies also for local regulations and the regulations for various types of manual work. If the recommendations in this manual differ from the regulations valid in your country, you must strictly observe the regulations in your country.

Intended use This machine must only be used for: l

Earth work in trench and sewer construction.

l

You should only operate the machine with fully functional safety equipment.

l

Have the machine inspected by an expert once every year.

l

The place of the operator is behind the machine.

When operating the machine from the opposite side, actuation of travel controls will cause ma-

14

Maintenance and repair tasks require specific knowledge and must therefore only be carried out by trained and qualified personnel.

Conversions and alterations to the machine Unauthorized conversions to the machine are prohibited for safety reasons. Original parts and accessories have been specially designed for this machine. We wish to make expressly clear that we have not tested or authorized any original parts or special equipment not supplied by us. The installation and/or use of such products can impair the active and/or ive driving safety. The manufacturer expressly excludes any liability for damage resulting from the use of non-original parts or accessories.

Safety notes in the operating and maintenance instructions: !

Danger

Sections marked like this point out possible dangers for persons.

BOMAG

BMP 851

Safety regulations Caution Sections marked like this point out possible dangers for the machine or for parts of the machine. !

i

Note

Starting the machine Before starting When operating several machines with infrared or radio remote controls the addresses of the controls must be checked. Clean transmitting and receiving elements before starting operation.

Sections marked like this provide technical information concerning the optimal economical use of the machine.

Use only machines which are serviced at regular intervals.

Environment Sections marked like this highlight activities for the safe and environmental disposal of fuels and lubricants as well as replaced parts.

Wear your personal protective outfit (hard hat, safety boots, etc.).

Become acquainted with the equipment, the control elements, the working principle of the machine and the working area.

Before mounting the machine check whether:

Observe all environment protection regulations.

Information and safety stickers/decals on the machine Keep stickers/decals complete (see spare parts catalogue) and fully legible and observe their meaning.

l

persons or obstructions are beside or under the machine

l

the machine is free of oily and combustible material

l

all grips, steps and platforms are free of grease, oils, fuel, dirt, snow and ice

l

engine hood is closed and locked

Before starting the machine check whether:

Replace damaged or illegible stickers/decals immediately.

Loading the machine Use only strong and stable loading ramps. The ramp inclination must be lower than the gradability of the machine.

l

the machine shows any obvious faults

l

all guards and safety elements are in place

l

brakes, control elements and horn are working

Do not start the machine with defective gauges, control lights or control elements.

Secure the machine against turning over or slipping off.

Do not take any loose objects with you or fasten them to the machine.

Secure the machine on the transport vehicle against rolling off, slipping and turning over.

Starting For starting set all control levers to 'neutral position'.

Persons are highly endangered if l

they step or stand under loads being lifted

Do not use any starting aids like start pilot or ether.

l

they remain in the drive range of the machine during a demonstration or during loading.

After starting check all gauges and control lights.

The machine must not swing about when lifted off the ground. Use only safe lifting gear of sufficient load bearing capacity. Attach the lifting gear only to the specified lifting points.

BMP 851

Starting with jump wires Connect positive with positive and negative with negative (ground cable) – always connect the ground strap last and disconnect it first! A wrong connection will cause severe damage in the electric system. Do not start the engine by shorting the electric terminals on the starter motor, because the machine may start to drive immediately.

BOMAG

15

Safety regulations Do not use the vibration on hard (frozen, concrete) ground. Risk of bearing damage!

Starting in closed rooms Exhaust gases are highly dangerous! Always ensure an adequate supply of fresh air when starting in closed rooms!

Parking the machine Park the machine on level and firm ground.

Driving the machine

Before leaving the machine:

Persons in the endangered area

l

Before starting or resuming work, and especially when reversing, check that there are no persons or obstructions in the endangered area.

shut the engine down and pull the ignition key out,

l

secure the machine against unauthorized use.

If necessary, give warning signals. Stop work immediately if persons remain in the danger area despite the warning.

Always secure parked machines, which could be in the way, with appropriate measures.

Filling in fuel

Driving

Do not inhale any fuel fumes.

Do not use the machine to transport persons.

Refuel only with the engine shut down.

Stop the machine if you notice unusual noises or the development of smoke. Investigate the cause and have the fault corrected.

Do not refuel in closed rooms. No open fire, do not smoke.

Keep a sufficient distance to excavations and embankments and make sure that your work does not impair the stability of the machine. Do not work with vibration on hard concrete, on a cured concrete layer or deeply frozen ground.

Do not spill any fuel. Catch running out fuel, do not let it seep into the ground. Wipe off spilled fuel. Keep dirt and water away from the fuel. A leaking fuel tank can cause an explosion. Ensure tight fit of the fuel tank cover, if necessary replace immediately.

Driving on slopes and gradients Do not drive up and down gradients, which exceed the max. gradability of the machine.

Fire protection measures Familiarise yourself with the location and the operation of fire fighting equipment. Observe all fire reporting and fire fighting possibilities.

When driving on slopes, drive carefully straight up or down the slope. Change to the lower speed range before approaching the slope. Wet and loose ground reduces the ground adhesion of the machine on inclinations and slopes. Higher risk of accident!

Maintenance work Comply with the maintenance work described in the operating and maintenance instructions, including the information concerning the replacement of parts.

Behaviour in traffic Match the speed of the machine to the working conditions.

Maintenance work must only be performed by qualified and authorized persons.

Always allow loaded transport vehicles to . Keep clear of edges and embankments. Check the effect of vibration When compacting with vibration check the effect of the vibration on nearby buildings and underground supply lines (gas, water, sewage, electric power supply), stop vibratory compaction if necessary.

For overhead maintenance and assembly work use the access steps and working platforms provided or other secure means. Do not use machine parts as access steps. Keep unauthorized persons away from the machine. Do not perform maintenance work while the machine is driving or the engine is running. Park the machine on horizontal, level, firm ground.

16

BOMAG

BMP 851

Safety regulations Pull off the ignition key and switch off the main battery switch.

l

hoses are mixed up by mistake.

l

fittings are damaged or deformed, whereby the function and strength of the hose/hose connection is impaired.

Work on hydraulic lines Relieve hydraulic pressures before working on hydraulic lines. Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury. When being injured by hydraulic oil consult a medical doctor immediately, as otherwise this may cause severe infections.

Only genuine BOMAG replacement hydraulic hoses ensure that the correct hose type (pressure range) is used at the right location. Working on the engine Shut the engine down before opening the engine hood.

Do not step in front of or behind the drums when performing adjustment work in the hydraulic system. Do not change the setting of pressure relief valves.

Drain the engine oil at operating temperature – danger of scalding! Wipe off spilled oil, catch running out oil and dispose of environmentally.

Drain the hydraulic oil at operating temperature – danger of scalding! Catch running out hydraulic oil and dispose of environmentally. Always catch and dispose of hydraulic oils separately.

Store used filters and other oil contaminated materials in a separate, specially marked container and dispose of environmentally. Do not leave and tools or other objects, that could cause damage, in the engine compartment.

Do not start the engine after draining the hydraulic oil.

Working on electric parts of the machine

Once all work is completed (with the system still depressurized!) check all connections and fittings for leaks.

Before starting to work on electric parts of the machine disconnect the battery and cover it with insulating material.

Changing hydraulic hoses Hydraulic hoses must be visually inspected at regular intervals. Hydraulic hoses must be immediately replaced if:

Do not use fuses with higher ampere ratings and do not repair fuses with a piece of wire. Fire hazard! Working on the battery When working on the battery do not smoke, do not use open fire!

l

the outer layer is damaged down to the inlay (e.g. chafing, cuts, cracks)

l

the outer layer is brittle (formation of cracks in the hose material)

Do not let acid come in with hands or clothes! When injured by acid flush off with clear water and seek medical advice.

l

the hose shows deformations in pressurized and depressurized condition, which do not comply with the genuine shape of the hydraulic hose

Metal objects (e.g. tools, rings, watch straps) must not come in with the battery poles – danger of short circuit and burning!

l

the hose shows deformations in bends, e.g. squeezing, buckling, layer separation, formation of blisters

l

parts of the hose are leaking.

Observe the applicable instructions when starting with an auxiliary battery.

l

hoses are not correctly installed.

Dispose of old batteries according to regulations.

l

the hydraulic hose has separated from the fitting

Switch off the charging current before removing the charging clamps.

l

the fitting shows corrosion that impairs both function and strength.

Ensure sufficient ventilation, especially if the battery is to be charged in a closed room.

BMP 851

When recharging serviceable batteries remove all plugs, to avoid the accumulation of explosive gases.

BOMAG

17

Safety regulations A defective infrared remote control must no longer be used.

Working on the fuel system Do not inhale any fuel fumes.

In case of malfunctions of the infrared remote control watch the fault code display and switch to cable remote control, if necessary

No 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.

The machine with infrared remote control will be shut down if

Cleaning work Do not perform cleaning work while the engine is running.

l

Always clean the transmitting and receiving diodes before using the infrared remote control.

Do not use gasoline or other easily inflammable substances for cleaning.

In case of defects the infrared remote control must be immediately taken out of service. The transmitter must be switched off via the emergency stop function. The connecting cable must be disconnected from the machine related socket on the receiver. Repairs on the infrared remote control must only be performed by the manufacturer or by specialists authorized by the manufacturer.

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

the machine moves out of the reach.

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.

When working on plug connections the machine battery must be disconnected or the connecting cable of the receiver pulled off.

Repair

All work related with the initial installation of a system or with repair work must only be performed by qualified personnel.

Mark a defective machine by attaching a warning tag to the dashboard.

The person performing the work is fully liable for professional execution of repair and maintenance work in compliance with the regulations of the manufacturer.

Before starting electric welding work on the machine, battery and receiver must be disconnected from the power supply. Repair work must only be performed by qualified and authorized persons. Use our repair instructions for this work.

Warranty on spare parts can only be granted if these parts were installed in compliance with our regulations and instructions and by personnel authorized by us. We will not assume liability for changes and modifications not performed by us.

Exhaust gases are highly dangerous! Always ensure an adequate supply of fresh air when starting in closed rooms!

Radio remote control

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.

The machine must only be operated within the field of vision of the operator. The radio remote control must only be used by trained and authorized persons. The safety features incorporated in the radio remote control must be checked at regular intervals.

Infrared remote control The machine must only be operated within the field of vision of the operator.

A defective radio remote control must no longer be used.

The infrared remote control must only be used by trained and authorized persons. The safety features incorporated in the infrared remote control must be checked at regular intervals.

18

In case of radio interferences watch the fault code display and switch to cable remote control, if necessary

BOMAG

BMP 851

Safety regulations The machine with radio remote control will be shut down if l

the machine moves out of the reach.

In case of defects the radio remote control must be immediately taken out of service. The sender must be switched off via the emergency stop function. The connecting cable must be disconnected from the machine related socket on the receiver. The radio remote control must only be repaired by the manufacturer or specialists authorized by the manufacturer. When working on plug connections the machine battery must be disconnected or the connecting cable of the receiver pulled off. All work related with the initial installation of a system or with repair work must only be performed by qualified personnel. The person performing the work is fully liable for professional execution of repair and maintenance work in compliance with the regulations of the manufacturer. Warranty on spare parts can only be granted if these parts were installed in compliance with our regulations and instructions and by personnel authorized by us. We will not assume liability for changes and modifications not performed by us.

BMP 851

BOMAG

19

Safety regulations

20

BOMAG

BMP 851

3 Indicators and Controls

BMP 851

BOMAG

21

Indicators and Controls

Fig. 5

22

BOMAG

BMP 851

Indicators and Controls 1

Unlocking of engine hood

12 Locking clamp for service flap

2

Central lifting device

13 Travel lever for left hand drums

3

Receiver for radio remote control/infrared evaluator

14 Toggle switch, vibration automatic / manual

4

Display module

16 Toggle switch, engine speed

5

Fuse box

17 Travel lever for right hand drums

6

Toggle switch for cable remote control/radio remote control/infrared remote control

18 Toggle switch for vibration forward/reverse

7

Main battery switch

8

Battery charge control light

20 Control light data transfer/power pack radio remote control/infrared remote control

9

Engine oil pressure warning light

21 Start button

15 Toggle switch, travel ranges

19 Emergency stop switch

10 Control unit

22 Ignition switch

11 Dummy socket, spiral cable

23 Horn button

BMP 851

BOMAG

23

Indicators and Controls 3.1

General notes

If you are not yet familiar with the control and display elements on this machine you should read this section thoroughly before starting any operation on the machine. Here all functions are described in detail. Section 4 "Operation" contains only brief descriptions of the individual control steps.

3.2

Description of indicators and control elements

No. 1 = Unlocking of engine hood Lock to fasten the engine hood. No. 2 = Central lifting device Lifting hook to attach lifting tackle No. 3 = Receiver for radio remote control*/infrared evaluator* Receives the control signals from the transmitter and converts these to hydraulic control movements.

Fig. 6

No. 4 = Display module To show operating hours as well as display and input of machine type code, remote control code and fault codes.

*

24

BOMAG

Optional equipment

BMP 851


Fig. 9

No. 7 = Main battery switch Disconnects the ground in the electric circuit of the machine.

Fig. 7

No. 5 = Fuse box

i

(1), 20A = (F119) Fuse for starter motor (2), 10A = (F103) Fuse potential 15 (3), 20A = (F14) Fuse for engine solenoid (4), 5A

= (F54) Fuse for cable remote control

Note

If the power pack of the radio or infrared remote control is to be charged, the main battery switch must remain switched on when the engine is shut down.

(5), 25A = (F67) Fuse control (potential 30)

Fig. 10 Fig. 8

No. 8 = Battery charge control light

No. 6 = Toggle switch cable remote control / radio or infrared remote control

lights yellow

Position left

= Cable remote control

Position right

= Radio*-/infrared remote control*

BMP 851

= when switching the ignition on = in case of a charge fault during operation, perform trouble shooting

goes out

BOMAG

= after starting the engine.

25


Fig. 11

Fig. 13

No. 9 = Oil pressure control light

No. 13 = Travel lever for left hand drums

lights red

= when switching the ignition on

Position 0

goes out

= after starting the engine.

Caution If the oil pressure drops during operation shut down the engine immediately.

i

!

i

Note

The warning buzzer sounds. The engine shuts down after 8 seconds.

= Neutral position to start the engine

Note

The position of the two travel levers to each other is decisive for driving straight ahead, left or right hand cornering and turning on the spot. When turning the machine on the spot the machine will automatically switch to low speed range. Position "front" = Forward travel Position "rear" = Backwards travel

Fig. 12

No. 10 = Control unit

Fig. 14

Control unit to control the machine.

No. 14 = Toggle switch, vibration automatic / manual

No. 11 = Dummy socket, spiral cable Socket to connect the plug of the spiral cable for operation with radio or infrared remote control No. 12 = Locking clamp for service flap Lock to fasten the service flap.

26

Position "Manual" = Vibration switches on when shifting the control lever (17) for vibration forward or reverse.

BOMAG

BMP 851

Indicators and Controls i

Note

Machine switches automatically to speed range 1 Position "Automatic" = Vibration is switched on: when moving both travel levers to forward/reverse after both control levers (17) for vibration have been actuated to any desired position. = Vibration is switched off: with travel levers in position "0", or when turning on the spot. = The sense of exciter shaft rotation changes with the travel direction.

Fig. 16

No. 16 = Toggle switch, engine speed min/max Position min.

= idle speed of engine

Position max.

= maximum engine speed

Fig. 15

No. 15 = Toggle switch travel ranges I and II

Fig. 17

Position "turtle" = 1. Travel range 0 ... 1.3 km/h

No. 17 = Travel lever for right hand drums

Position "rabbit"

Position 0 = 2. Travel range 0 ... 2.7 km/h, driving with vibration not possible

i

= Neutral position to start the engine

Note

The position of the two travel levers to each other is decisive for driving straight ahead, left or right hand cornering and turning on the spot. When turning the machine on the spot the machine will automatically switch to low speed range. Position "front" = Forward travel Position "rear" = Backwards travel

BMP 851

BOMAG

27


Fig. 18

Fig. 20

No. 18 = Toggle switch for vibration forward/ reverse

No. 20 = Control light data transfer/power pack radio remote control/infrared remote control

i

Note

The vibration toggle switch must also be actuated if toggle switch "Vibration Automatic / Manual" is in position "Automatic", so that vibration is automatically switched on when actuating the travel levers.

Flashes green when the transmitter is switched on. Lights red when the accumulator voltage drops too low.

Position "front" = Exciter shaft rotates forward ("Manual" mode) Position "middle" = Vibration switched off Position "rear" = Exciter shaft rotates backwards ("Manual" mode)

Fig. 21

No. 21 = Start button to start the engine.

i Fig. 19

No. 19 = Emergency stop push button actuated

= transmitter and diesel engine will be switched off.

unlocked

= switches on the transmitter.

28

Note

Perform the starting process for maximum 15 to 20 seconds without interruption and pause for about 1 minute between starting attempts. Should the engine not start in this time, perform trouble shooting and rectify the cause.

BOMAG

BMP 851


Fig. 22

No. 22 = Ignition switch Position 0

= Insert or pull out key, ignition/ engine off

Position I

= Ignition on, charge and oil pressure control lamps light up

Fig. 23

No. 23 = Horn button to signalize a danger situation.

BMP 851

BOMAG

29


30

BOMAG

BMP 851

4 Operation

BMP 851

BOMAG

31

Operation 4.1

General

4.2

If you are not yet familiar with the operating and control elements on this machine you should thoroughly read chapter 3 “Indicators and control elements” before starting work.

Tests before taking into operation

Before the everyday use or before a longer working period the following tests and inspections must be performed.

All indicators and control elements are described in detail in this chapter. !

Danger

Danger of injury! Please observe strictly the safety regulations in chapter 2 of these operating and maintenance instructions. Park the machine on ground as level as possible.

l

Check: l

Screw connections

l

Function of travel levers

l

Damage on the machine

l

Function of the remote control

i

Note

The following inspection work is described in chapter "Maintenance every 10 Operating Hours".

32

l

Engine oil level

l

Hydraulic oil level

l

Fuel level

BOMAG

BMP 851

Operation 4.3

Opening / closing the service hood

4.4

Starting the engine

Fig. 25 Fig. 24 l

Open quick lock 1 (Fig. 24).

l

Fold the service hood up to the right.

l

Loosen clamp lock 1 (Fig. 25) and open the hood by the knob (2).

Danger Danger of squashing! !

For closing hold the flap only by the knob (2).

Fig. 26 l

BMP 851

BOMAG

Switch on the main battery switch (Fig. 26).

33

Operation

Fig. 27

Fig. 29

l

Unfold battery box 1 (Fig. 27) and take off control (2).

l

Strap the control to your body and plug the spiral cable into the remote control, if required.

l

For radio or infrared operation of the machine switch the toggle switch (Fig. 29) to the right.

Fig. 30 l

Fig. 28 l

If necessary unlock the emergency stop switch (Fig. 30).

For cable operation of the machine switch the toggle switch (Fig. 28) to the left.

Fig. 31 l

34

BOMAG

Switch the toggle switch for vibration forward/ reverse (Fig. 31) to position "0".

BMP 851

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 engine cannot be started. Fig. 32

Switch on the ignition (Fig. 32).

l

Fig. 34

Press the start button to start the engine (Fig. 34).

l

Fig. 33

Charge and oil pressure control lights (Fig. 33) light up.

l

i

Note

With the ignition key in position "1" the machine type code will appear in the display module for a few seconds. The machine will emit a short horn signal. This indicates that the machine is ready for operation.

i

Note

If the horn does not sound, there must be fault on the machine.

Fig. 35

Once the engine is running both charge and oil pressure control light must go out (Fig. 35).

l

The control emits two short buzzer signals. This indicates that the control is ready for operation.

i

Note

If no oil pressure is present after 8 seconds (lack of oil), the warning buzzer will sound and the engine will shut down.

BMP 851

BOMAG

35

Operation Run the engine warm for a short while before starting work.

Fig. 37 l

Fig. 36

Loosen clamp lock 1 (Fig. 37) and open the hood by the knob (2).

Fold the control box (Fig. 36) in.

l

i

Note

With the control box folded out the machine will only move in 1st gear. Close the hood

l

!

Danger

Danger of squashing! Hold the hood only by knob 2 (Fig. 25) to close.

Starting with jump wires

Fig. 38 l

Caution A wrong connection will cause severe damage in the electric system.

Unfold battery box 1 (Fig. 38) and take off control (2).

!

Fig. 39 l

36

BOMAG

Switch on the main battery switch (Fig. 39).

BMP 851

Operation Starting under low temperatures

Caution Only use a 12 volt battery for jump starting. !

Fig. 41 Fig. 40

When starting with an external battery connect the plus poles (Fig. 40) first and the minus poles (ground cable) after.

l

l

Switch the vibration off

l

Start the engine as described above

l

After starting disconnect the cable from the minus poles (ground cable) first and from the plus poles last.

l

Fold the control box back in and close the hood.

!

!

Caution

Do not use any starting aid spray (Fig. 41).

Danger

Danger of squashing! Hold the hood only by knob 2 (Fig. 37) to close.

BMP 851

BOMAG

37

Operation 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 inclinations and slopes. Do not drive up and down inclinations exceeding the maximum gradability of the machine (see technical data). Slowly return the travel lever towards neutral when driving down slopes.

Fig. 42 l

Before starting the engine switch the toggle switch (Fig. 42) to the left to position "Cable operation"

l

Start the engine (see chapter "Starting the engine").

Before starting to drive check the function of the remote control. During operation of the machine with remote control the operator must always stay behind or beside the machine. Specified directions apply only if the operator is standing behind the machine. If the operator is standing in front of the machine all machine movements will be opposite to the movement of the control lever. The machine must only be operated with remote control strapped to the body. The machine must only be operated within the field of vision of the operator. l

If necessary remove the cable remote control from the console and strap it to your body.

l

Do not overstretch the spiral cable.

38

Fig. 43 l

BOMAG

Set the toggle switch (Fig. 43) to maximum engine speed.

BMP 851

Operation Stopping the machine

Fig. 44

Set the toggle switch (Fig. 44) to the desired travel stage.

l

Fig. 46 l

i

Note

If the console of the remote control is folded down or the machine is operated with the attached cable remote control, the machine will only drive in low travel speed range (turtle) for safety reasons.

Shift both travel lever (Fig. 46) to position "0". The machine will brake.

Steering the machine (forward travel)

Fig. 47 l

Actuate the travel levers (Fig. 47) accordingly.

Fig. 45

Actuate both travel levers (Fig. 45) together. The machines drives with a speed which corresponds with the displacement of the travel control levers. Standstill

= both travel levers in middle position

Forward travel = shift both travel levers forward Backward travel = pull both travel levers back

BMP 851

BOMAG

39

Operation Steering the machine (backward travel)

When working with automatic vibration the vibration will be switched off.

Fig. 50

Fig. 48

Actuate the travel levers (Fig. 48) accordingly.

l

Turning on the spot to the right

i

push the right hand travel lever (Fig. 50) forward and pull the left hand travel lever back.

l

Cleaning after use

Note

In soft ground the machine may dig in. When working with automatic vibration the vibration will be switched off.

Caution Keep the cable 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 cable remote control with a clean cloth or brush.

l

Check the state of bellows and sealing caps at regular intervals, have replaced by an expert, if necessary.

Fig. 49

pull the right hand travel lever (Fig. 49) back and push the left hand travel lever forward.

l

Turning on the spot to the left

i

Note

In soft ground the machine may dig in.

40

BOMAG

BMP 851

Operation 4.6

Safety inspection for the cable remote control

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

l

With the transmitter switched off switch on the toggle switch "Vibration".

l

Switch on the transmitter and try to start the diesel engine.

The diesel engine must not start. l

Set the toggle switch "Vibration" to position "0".

l

Start the engine and actuate the toggle switch again.

Danger

Danger of injury! Make sure that there are no persons within the danger zone.

The functions must now work as usual.

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 released. !

Fig. 51 l

With the transmitter switched off actuate and hold one of the travel levers 1 or 2 (Fig. 51).

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.

BMP 851

BOMAG

41

Operation 4.7

Backup protection bow for backward travel

4.8

!

Switching the vibration on and off

Danger

Risk of damage! When compacting with vibration you must check the effect of nearby buildings and underground supply lines (gas, water, sewage, electric power), if necessary stop compaction with vibration. Do not activate the vibration on hard (frozen, concrete) ground. Danger of bearing damage!

i Fig. 52

Actuation of the backup protection bow (Fig. 52) stops the machine. l

Push both travel control levers forward to move the machine away from the obstruction.

Note

If the machine starts to jump when working in "Automatic"-mode downhill, change the vibration mode to "Manual" and choose the sense of rotation of the vibrator shaft against the travel direction.

Automatic

Fig. 53 l

42

BOMAG

Set the toggle switch (Fig. 53) to "Automatic".

BMP 851

Operation Manual

Fig. 54

Operate the vibration toggle switch (Fig. 54) forward or backward.

l

Fig. 56

Set the toggle switch (Fig. 56) to position ”Manual”.

l

i

Note

In this case the actuation direction is of no relevance.

Fig. 57

Operate the vibration toggle switch (Fig. 57) forward or backward.

l

Fig. 55

Shift both travel levers 1 and 2 (Fig. 55) to forward or backward.

l

i

Note

The vibration starts with the appropriate sense of rotation, even with the travel levers in "0"-position.

The machine starts to move and the vibration switches on automatically. The sense of rotation of the exciter shaft changes automatically, depending on the travel direction. Neutral position = vibration off.

i

Note

When turning the machine on the spot vibration will switch off automatically. After turning is completed the vibration will automatically be switched on again.

BMP 851

BOMAG

43

Operation 4.9 l

Shutting the engine down

If necessary switch the vibration off and return the travel levers to position "0".

Fig. 60

Pull off the ignition key (Fig. 60) and store it in a safe place.

l

Fig. 58 l

Change to idle speed (Fig. 58) and let the engine run for another few minutes for cooling.

Fig. 61 l

Switch off and pull out the main battery switch (Fig. 61).

l

Plug the safety cap on the lock.

Fig. 59 l

Turn the ignition switch (Fig. 59) to position "0".

!

Danger

Danger of accident! Secure the machine against unauthorized use.

44

BOMAG

BMP 851

Operation 4.10 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. 64 l

Open quick lock 1 (Fig. 64).

l

Fold the service hood up to the right.

Fig. 62 l

Turn the ignition switch (Fig. 62) to position "0".

Fig. 65 l

Pull the lock (Fig. 65) and open the engine hood to the front.

Fig. 63 l


BMP 851

Fig. 66 l

BOMAG

Keep hand lever 1 (Fig. 66) on the engine depressed, until the engine shuts down.

45

Operation 4.11 Starting operation of the radio remote control !

Caution

Use the transmitter only if the type approval has been granted.

Fig. 67 l


l


l

Close engine hood and service flap.

Danger Danger of accident! !

Fig. 68

Secure the machine against unauthorized use.

i

Note

If the spiral cable is not used insert the plug of the spiral cable into the dummy socket 1 (Fig. 68) on the machine provided for this purpose.

Fig. 69

46

l

If necessary store the cable remote control in the machine and fold the control box in.

l

Set the toggle switch (Fig. 69) to remote control position.

l

Close the service flap .

BOMAG

BMP 851

Operation Inserting the replacement power pack

Switching on the transmitter

Caution Change the power pack only when the sender is switched off. !

!

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.

i

Note

All normal work functions can only be operated from a defined neutral position, i.e. the respective control elements must be in rest position when switching the sender on. If this is not true, the engine cannot be started. l

Fig. 70

Strap the transmitter to your body, adjust the belts accordingly.

Turn the ignition switch to position "0" (Fig. 70) and pull it off.

l

Fig. 72 l

Fig. 71


Insert the replacement power pack into the receptacle (Fig. 71) and let it click into place.

l

i

Note

Make sure the power pack clicks into place. Duty time with a fully charged power pack: approx. 100 hours

BMP 851

BOMAG

47

Operation

Fig. 73


l

Starting the engine

i

Fig. 75

Engine oil pressure warning light and battery charge control light (Fig. 75) on the machine light up. The machine is now ready for operation.

Note

Before starting the engine both travel levers and the vibration control lever must be in rest position (neutral). The radio remote control is equipped with a restart lock.

Fig. 76 l


Fig. 74 l


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.

48

BOMAG

BMP 851

Operation Work function !

Danger

Life hazard! Move the machine only when it is directly in sight. The functions of operating elements and controls are identical with the ones for the cable remote control (see previous description).

Fig. 77

Once the engine is running both battery charge control light and oil pressure warning lamp (Fig. 77) must go out.

i

Note

If no oil pressure is present after 8 seconds (lack of oil), the warning buzzer will sound and the engine will shut down. Run the engine warm for a short while before starting work.

Fig. 79

Long distance shut-down

i

Note

If the battery voltage drops to a too low level during operation (power pack discharged), the red warning light on the control (Fig. 79) will light up approx. 10 minutes before the engine is shut down. The warning buzzer will sound approx. 1 minute before the shut down. Drive the machine to a safe place as soon as possible, so that it will not stop all of a sudden. If necessary switch over to operation with cable remote control and plug the spiral cable into the remote control. During cable operation of the machine the power pack is automatically charged. Fig. 78

Replace or recharge the power pack.

If the distance (Fig. 78) between and transmitter and receiver exceeds 50 m, the machine will stop.

Switching off the transmitter (engine)

i

Note

To continue travelling reduce the distance, shift the travel levers for a moment to neutral position and then to the desired travel direction.

BMP 851

Caution Do not shut the engine down all of a sudden from full load, but let it idle for a while in position "Min" for temperature equalization. !

BOMAG

49

Operation If the radio remote control is not going to be used for a longer period of time we strictly recommend to take the batteries out of the transmitter and to recharge them approx. every four weeks. This avoids complete discharging and prolongs the lifetime of the power packs.

Fig. 82


l

i Fig. 80 l

Turn the ignition key (Fig. 80) to position "0".

Transmitter and engine will be switched off after two seconds, the green control light on the transmitter goes out.

Note

If the power pack of the remote control is to be recharged via the remote control cable, the main battery switch (Fig. 81) 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


Fig. 81 l

Switch off and pull out main battery switch 1 (Fig. 81).

l


50

BOMAG

BMP 851

Operation Charging the power pack in the machine

4.12 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 battery charger is available as an option. The recharging time is approx. 6 hours. Danger Operate the battery charger only in dry rooms at temperatures of min. 0 °C to max. 40 °C! !

A charged power pack is a concentrated energy source! Do not store charged power packs in a tool box or similar, because metal parts may cause a short circuit. Short circuits may also be caused by keys etc. in a tro pocket.

Fig. 83 l

Switch off the transmitter (Fig. 83) with the ignition key.

l

Plug the spiral cable into the transmitter

Caution Change the power pack only when the sender is switched off. !

Before connecting the battery charger make sure that the mains voltage is in accordance with the specifications mentioned on the battery charger. Strictly follow the operating instructions for the battery charger. Fig. 84

i

Note

The full discharging capacity is only reached after several charging cycles.

i

The main battery switch (Fig. 84) must be switched on.

l

Ageing of the power pack reduces the discharging capacity and therefore the operating time of the sender.

i

Note

The power pack recharging time is approx. 6 hours.

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 (holidays, bad weather) you should also disconnect the charging unit from the mains supply or switch off the main battery switch.

BMP 851

BOMAG

51

Operation Charging the power pack with the external battery charger

Fig. 87

Push lock 1 (Fig. 87) on the mains unit of the battery charger forward and pull plug (2) upward out of the mains unit.

l

Fig. 85 l


Fig. 88

Plug the corresponding plug (Fig. 88) onto the mains unit of the battery charger.

l

Fig. 86 l

Press the power pack forward and lift it out of the housing (Fig. 86).

i

Note

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

52

BOMAG

BMP 851

Operation 4.13 Safety inspection for the radio 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. Fig. 89

Insert the power pack into the battery charger (Fig. 89).

l

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 released. !

Fig. 90

Connect the battery charger to a power source (Fig. 90).

l

The two light emitting diodes on battery charger and mains unit must light up.

i

Fig. 91 l


l


Note

The power pack recharging time is approx. 6 hours. When charging is completed the green LED on the charger will start to flash.


Return the travel lever to neutral position (rest position).

l

Start the engine and actuate the travel lever again.




BMP 851

BOMAG

53

Operation l


l


4.14 Switching off of the radio remote control in case of radio interferences



l



The radio remote control is automatically switched off whenever the radio connection to the receiver is interrupted or disturbed for more than 2 seconds.

Resetting the control after switching off by radio interference l

Step into the radio transmission range of the machine.

Fig. 92 l

Switch on the ignition (Fig. 92) and restart the machine.

Operation can be resumed.

54

BOMAG

BMP 851

Operation 4.15 Starting operation of the infrared remote control !

Danger

Inserting the replacement power pack Caution Change the power pack only when the sender is switched off. !

Danger of injury! Observe the safety and receiving ranges.

Fig. 95

Turn the ignition switch to position "0" (Fig. 95) and pull it off.

l

Fig. 93

i

Note

If the cable remote control is not used insert the plug of the spiral cable into the dummy socket (Fig. 93) on the machine provided for this purpose.

Fig. 96

Insert the replacement power pack into the receptacle (Fig. 96) and let it click into place.

l

i Fig. 94 l

If necessary store the cable remote control in the machine and fold the control box in.

l

Set the toggle switch (Fig. 94) to remote control position.

l

Close the service flap .

BMP 851

Note

Make sure the power pack clicks into place. Duty time with a fully charged power pack: approx. 100 hours

BOMAG

55

Operation Switching on the transmitter (machine) !

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.

Fig. 99


l

Fig. 97 l

Clean the cover of the pre-amplifier (Fig. 97).

Fig. 100 l


l

Direct the transmitter towards the receiver on the machine.

Starting the engine

i Fig. 98 l

Clean the transmission window (Fig. 98) of the transmitter.

l

Strap the transmitter to your body, adjust the belts accordingly.

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.

i

Note

Before starting the engine both travel levers and the vibration control toggle switch must be in rest position (neutral). The infrared remote control is equipped with a restart lock.

56

BOMAG

BMP 851

Operation

Fig. 101 l

Fig. 103



l

The green control light on the transmitter flashes for a moment, the transmitter is ready for operation. After a period of approx. 5 - 10 seconds the signal horn on the machine starts to sound.

Fig. 104

Once the engine is running both battery charge control light and oil pressure warning lamp (Fig. 104) must go out.

l

Fig. 102

Charge control light and oil pressure warning light on the machine (Fig. 102) light up. The machine is now ready for operation.

i

Note

If no oil pressure is present after 8 seconds (lack of oil), the warning buzzer will sound and the engine will shut down.

Work function Danger Life hazard !

Move the machine only when it is directly in sight. The functions of operating elements and controls are identical with the ones for the cable remote control (see previous description).

BMP 851

BOMAG

57

Operation

Fig. 105

Fig. 106 l

i

Note

Turn the ignition key (Fig. 106) to position "0".

Transmitter and engine will be switched off after two seconds, the green control light on the transmitter goes out.

If the battery voltage drops down to a too low level during operation (power pack discharged), the red warning light on the infrared remote control will light up approx. 10 minutes before the engine is shut down (Fig. 105). The warning buzzer starts to sound approx. 1 minute before the shut down If a discharged power pack (with insufficient charge level) is inserted, the warning light will flash. Drive the machine to a safe place as soon as possible, so that it will not stop all of a sudden. If necessary switch over to cable operation and plug the spiral cable into the dummy socket. During cable operation of the machine the power pack is automatically charged.

Fig. 107

Replace or recharge the power pack.

l


l


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 position "Min" for temperature equalization. !

If the infrared remote control is not going to be used for a longer period of time we strictly recommend to take the batteries out of the transmitter and to recharge them approx. every four weeks. This avoids complete discharging and prolongs the lifetime of the power packs. l

58

Direct the transmitter towards the receiver on the machine.

BOMAG

BMP 851

Operation 4.16 Replacing, recharging the infrared remote control power pack

i

Note

As standard the power pack is recharged in the machine through the spiral cable. A separate battery charger is available as an option. The recharging time is approx. 6 hours. Fig. 108

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


l

i

Note

If the power pack of the remote control is to be recharged via the remote control cable, the main battery switch (Fig. 107) must be switched on.

A charged power pack is a concentrated energy source! Do not store charged power packs in a tool box or similar, because metal parts may cause a short circuit. Short circuits may also be caused by keys etc. in a tro pocket.

Cleaning after use Caution Change the power pack only when the sender is switched off. !

Caution Keep the infrared 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.

Before connecting the battery charger make sure that the mains voltage is in accordance with the specifications mentioned on the battery charger. Strictly follow the operating instructions for the battery charger.

l

After work clean the transmitter with a clean cloth or brush.

l


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 (holidays, bad weather) you should also disconnect the charging unit from the mains supply or switch off the main battery switch.

BMP 851

BOMAG

59

Operation Charging the power pack in the machine

Charging the power pack with the external battery charger

Fig. 109

Fig. 111

l


l

Plug the spiral cable into the transmitter

l


Fig. 112 Fig. 110

l

The main battery switch (Fig. 110) must be switched on.

l

i

Press the power pack forward and lift it out of the housing (Fig. 112).

Note

The power pack recharging time is approx. 6 hours.

60

BOMAG

BMP 851

Operation

Fig. 113

Fig. 115

Push lock 1 (Fig. 113) on the mains unit of the battery charger forward and pull plug (2) upward out of the battery charger.

l

Insert the power pack into the battery charger (Fig. 115).

l

Fig. 116 Fig. 114

i

Connect the battery charger to a power source (Fig. 116).

l

Plug the corresponding plug (Fig. 114) onto the mains unit of the battery charger.

l

The two light emitting diodes on battery charger and mains unit must light up.

Note

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

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 851

BOMAG

61

Operation 4.17 Safety inspection of infrared remote control This safety inspection must be performed regularly once every week, especially after longer breaks. !

l


l




l


Danger

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


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

Fig. 117 l


l



Return the travel levers to rest position.

l

Start the engine and actuate the travel levers again.




62

BOMAG

BMP 851

Operation 4.18 Changing the BLM-control

Caution If a new BLM-control has been installed, the codes for machine type and remote control must be entered via the display module, as described in the following chapters. !

! Caution When changing the BLM-control on the machine, the Customer Service Department of BOMAG must be informed about operating hours and serial number, as otherwise the warranty for this machine will become null and void.

Fig. 118 l

Pull lock 1 (Fig. 118) in direction of arrow and pull plug (2) out downwards.

l

Unscrew four hexagon screws (3) and take off the BLM-control.

Fig. 119 l

Fasten the new BLM-control with four hexagon screws 3 (Fig. 119).

l

Insert plug (2) and push in lock (1) in direction of arrow.

BMP 851

BOMAG

63

Operation 4.19 Entering the machine type code into the display module Caution When retrofitting a radio or infrared remote control, the machine type code must be set in the display module. !

The machine type code for the BMP 851 is "7101" The machine must not be operated with a wrong type settings, as otherwise the correct function of the control can no longer be assured.

Fig. 121

Open the service hood (Fig. 121).

l

Input on the display module

The code can only be entered when the engine is shut down.

Fig. 122

i Fig. 120 l

64


Note

Enter machine type code "7101" on the display module (Fig. 122). l

Keep both keys (F1 and F2) depressed for two seconds. The display shows the reading "000" with the first digit flashing.

l

The value of the flashing digit can be increase dby pressing key (F1). If the value "9" is displayed and the key (F1) is pressed again, the display will jump back to the value "0".

l

Pressing key (F2) moves the flashing digit one digit to the right. If the fourth digit in the display is flashing key (F2) is pressed again for confirmation.

BOMAG

BMP 851

Operation The desired function is now executed or the desired value is displayed. To cancel the display function you must either enter code number "000" or switch off the ignition.

l

4.20 Entering the remote control code into the display module

Entering the machine type code

This code number activates the function "Setting machine type". The display module now permanently shows code "7010". Enter code "7101".

l

For the radio remote control the default remote control code is "0662". When changing to an infrared remote control, the remote control code must be set to "0663".

The display module now permanently shows the entered code.

The machine must not be operated with a wrong remote control code, as otherwise the correct function of the control can no longer be assured.

Enter code number "7011".

l

Caution The code for the remote control is preset in the factory. When retrofitting an infrared remote control, the remote control code must be set in the display module. !


l

This code number confirms the entered machine type. After the confirmation of the machine type the control switches off.

The code can only be entered when the engine is shut down.

The control starts automatically again and is ready for use. The display module shows the machine type for 3 seconds. Whenever switching the ignition on the machine type will appear in the display module for 3 seconds.

i

Note

The machine type code can be checked by entering the code "7010".

Fig. 123 l

BMP 851

BOMAG


65

Operation Entering the remote control code Enter code number "0660".

l

This code number activates the function "Setting remote control type". The display module now permanently shows code "0660". Enter the code according to the type of remote control.

l

i

Note

The code for the radio remote control is "0662" Fig. 124 l

The code for the infrared remote control is "0663"

Open the service hood (Fig. 124).

The display module now permanently shows the entered code.

Input on the display module


l

This code number confirms the entered remote control type. After the confirmation of the remote control type the control switches off. The control starts automatically again and is ready for use.

i

Note

The remote control code can be checked by entering the code "0665". Fig. 125 l

Keep both keys (F1 and F2) (Fig. 125) depressed for two seconds. The display shows the reading "000" with the first digit flashing.

l

The value of the flashing digit can be increase dby pressing key (F1). If the value "9" is displayed and the key (F1) is pressed again, the display will jump back to the value "0".

l

Pressing key (F2) moves the flashing digit one digit to the right. If the fourth digit in the display is flashing key (F2) is pressed again for confirmation.

The desired function is now executed or the desired value is displayed. l

66

To cancel the display function you must either enter code number "000" or switch off the ignition.

BOMAG

BMP 851

Operation 4.21 Open the engine hood l

4.22 Opening the rear frame

Open the service hood (see previous description).

Fig. 127 l

Unscrew the fastening screws (Fig. 127) on both sides of the machine.

l

Swing the rear frame to the side.

Fig. 126 l

Pull the lock (Fig. 126) and open the engine hood to the front.

BMP 851

BOMAG

67

Operation 4.23 Assembling/removing the drum extension

4.24 Loading and transport

Assembly

Danger of accident!

!

Danger

Use only stable loading ramps of sufficient load bearing capacity. Lash the machine down so that no persons are endangered by the machine falling off, sliding about or turning over. Always use shackles on the lifting points for loading, tying or lifting the machine. Do not step or stand under suspended loads. The machine must not swing about when being lifted.

Fig. 128

Attach drum extensions 2 (Fig. 128) to the drums, turn three fastening screws (1) into each drum and tighten.

l

Removal l

Unscrew the fastening screws and take off the drum extensions.

l

Turn the fastening screws back into the drum and fasten. Fig. 129

Caution In order to protect the threads turn the fastening screws into the drums, even after removing the drum extensions. !

Use the central lifting facility (Fig. 129) to lift the machine.

Danger Danger of turning over! !

When using drums with a working width of 650 mm the second speed range must not be switched on.

68

BOMAG

BMP 851

Operation Loading weight see technical data

Fig. 130 l

Drive the machine onto the transport vehicle and lash it down by the two lashing eyes (Fig. 130).

BMP 851

BOMAG

69

Operation

70

BOMAG

BMP 851

5 Maintenance

BMP 851

BOMAG

71

Maintenance 5.1

Notes on the engine performance

General notes on maintenance

Combustion air and fuel injection rates of the diesel engine have been carefully adjusted and determine the engine's performance and temperature level as well as the quality of the exhaust gas.

Pay careful attention to all applicable safety instructions when servicing the machine. Thorough maintenance of the machine ensures maximum reliability and prolongs the lifetime of important components. The effort required for these activities is small when compared with the problems which may arise if these instructions are not observed. l

Clean machine and engine thoroughly before starting maintenance work.

l

Park the machine on level ground for service work.

l

Maintenance work must generally be carried out with the engine shut down.

l

Depressurize hydraulic lines before working on them.

l

Disconnect the battery and cover it with insulation material before starting to work on electrical components.

If your machine has to operate permanently in "thin air" (at high altitudes) and with full power, you should consult BOMAG's after sales service or the service department of the engine manufacturer.

Notes on the hydraulic system Cleanliness is of utmost importance when servicing the hydraulic system. Make sure, that no dirt or other contaminating substances enter into the system. Small particles can flute valves, cause pumps to seize and block restrictors and pilot bores, thereby causing costly repairs. l

If, during the daily oil level check the oil level is found to have dropped, check all lines, hoses and components for leakages.

l

Seal external leakages immediately. If necessary inform the after sales service of BOMAG.

l

Wherever possible use the filling and filtering unit (BOMAG - part-no.: 007 610 01) to fill the hydraulic system.

The left/right are always related to travel direction forward. l

l

Collect oils and fuel environmentally and do not let them seep into the ground or into the sewage system. Dispose of oils and fuel environmentally.

This unit is fitted with a fine filter to clean the hydraulic oil in order to prolong the service life of the filter and the lifetime of important components. l

Clean fittings, filler caps and their immediate surrounding area before removing them, so that no dirt can fall in.

l

Do not leave the tank opening unnecessarily open, cover it so that no dirt can fall in.

Always catch and dispose of biodegradable oils separately.

Frequent causes of failures l

Operating errors

l

Incorrect, inadequate maintenance

If you cannot identify the cause of a fault by following the trouble shooting chart or cannot eliminate a fault yourself, you should one of our service stations at our branch offices or dealers.

Notes on the fuel system The lifetime of the diesel engine is decisively dependent on the cleanliness of the fuel. l

72

Keep the engine free of dirt and water as this could damage the injection elements of the engine.

BOMAG

BMP 851

Maintenance 5.2

lowing oil change intervals also apply for multi-purpose oils.

Fuels and lubricants

Regular lubrication oil changes

Engine oil l

Use winter-grade engine oil for winter operation!

To ensure perfect cold starting it is important to choose the viscosity (SAE grade) of the engine oil with respect to the ambient temperature. The oil change intervals must be shortened when working at temperatures below -10°C.

The longest permissible utilization time for the lubrication oil in the engine is 1 year. If the following oil change intervals are not reached within a year, the oil must be changed at least once every year, irrespective of the operating hours.

Oil quality Lubrication oils are differentiated according to their performance abilities and their quality class. The most common specifications are the ones according to API (American Petroleum Institute) and CCMC (Committee of Common Market Automobile Constructors). Permitted API-oils Aspirating engines = CD, CE, CF4 Permitted CCMC-oils Aspirating engines = D4, D5, PD2, (SHPD)

Lubrication oil change intervals Oil change intervals every 250 operating hours for oil quality API: CD, CE, CF4, CCMC: D4, D5, PD2, (SHPD)

Fig. 131

Lubrication oil with a too high viscosity index will cause starting difficulties. The temperature when starting the engine is therefore decisive for selecting the correct viscosity for winter operation.

Oil viscosity Since the viscosity of the lubrication oil changes with the temperature, the ambient temperature at the engine's operating location determines the viscosity class (SAE-grade) to be chosen (see diagram). Although cold stating abilities may be impaired if the temperature occasionally drops below the limit (e.g. use of SAE 15W/40 down to -15°C), this will not cause any damage to the engine. Temperature related lubrication oil changes can be avoided when using multi-purpose oils. The fol-

BMP 851

Fuels Quality Only use commercially available brand diesel fuel: The following fuel specifications are permitted: DIN 51601- DK; Nato Codes: F-54, F-75, F-76; BS 2869: A1 and A2; ASTM D 975-78: 1-D and 2-D; VV-F-800 a: DF-A, DF-1 and DF-2.

Winter fuel For winter operation only use winter-grade diesel fuel to avoid clogging caused by paraffin separation. Under very low temperatures such separations can be expected even with winter-grade diesel fuel.

BOMAG

73

Maintenance In most cases it is also possible to mix in fuel additives to improve the flow properties. Consult the engine manufacturer for details.

Mineral oil based hydraulic oil The hydraulic system works with hydraulic oil HV 46 (ISO) with a kinematic viscocity of 46 mm2/s at 40°C. For topping up or changing the hydraulic oil use only quality hydraulic oil type HVLP according to DIN 51524, part 3, or hydraulic oil type HV according to ISO 6743/3. The viscosity index (VI) should be at least 150 (observe the information from the manufacturer).

Biodegradable hydraulic oil On request, the hydraulic system can also be filled with ester based biodegradable hydraulic oil, Panolin HLP Synth. 46. This biodegradable hydraulic oil Panolin HLP Synth. 46 meets the demands of a mineral oil based hydraulic oil according to DIN 51524. The same oil must be used for topping up hydraulic systems filled with Panolin HLP Synth. 46. When changing from a mineral oil based hydraulic oil to an ester based biodegradable hydraulic oil consult the lubrication oil service department of the oil manufacturer. Check the filter more frequently after changing to the new oil.

Lubrication grease For lubrication purposes use an EP-high pressure grease, lithium saponified (penetration 2).

74

BOMAG

BMP 851

Maintenance 5.3

Table of fuels and lubricants

Assembly

Fuel or lubricant Summer

Winter

Quantity approx. Attention Observe the level marks

Engine

Engine oil API-CD-CE-CF4 or CCMC-D4-D5-PD2

up to max. dipstick mark 2,5 litres

SAE 30W

SAE 10W

(+5°C to +30°C)

(-5°C to -30°C) SAE 15W/40 (-10°C to + 40°C) Fuel

Diesel Vibrator shaft bearing Hydraulic system

Winter diesel fuel* (down 19 litres to -12 °C) Engine oil SAE 15W/40

Hydraulic oil (ISO), HV46, kinem. viscosity 46 mm2/s at 40 °C

BMP 851

BOMAG

1,3 litres up to dipstick mark approx. 38 litres

75

Maintenance 5.4

i

Running-in instructions

Note

he maintenance plan in the engine hood of the machine makes maintenance work much easier! Maintenance after 25 operating hours The following work must generally be performed on new or overhauled engines: l

Change the engine oil

l

Change the engine oil filter

l

Check the oil for the vibration bearings

l

Check the engine for leakages

l

Check the valve clearance, correct if necessary

l

Check the air filter fastening and other attachments for tight fit.

l

Tighten the fastening screws for the engine mounts.

! Caution Do not tighten the cylinder head fastening screws.

Maintenance up to approx. 200 operating hours

76

l

New engines normally have a higher oil consumption. It is recommended to check the oil level twice every day during the running-in period.

l

After the running-in period, it is enough to check the oil level once every day

l

Check the screw connections on the machine, tighten if necessary.

l

Check for leakages.

BOMAG

BMP 851

Maintenance 5.5

Maintenance chart

With all maintenance intervals perform also the work for shorter preceding service intervals. No.

Designation

Note

Every 10 operating hours 5.6 5.7 5.8 5.9

Check the engine oil level Check the hydraulic oil level Check the fuel level Drain the water separator

Observe the dipstick marks Inspection glass

Every 250 operating hours 5.10 5.11 5.12 5.13 5.14

Check the air intake hose Clean cooling fins/cooling fan Chang engine oil and oil filter cartridge at least 1x per Observe the dipstick marks year) Check, adjust the valve clearance 0.10 mm on cold engine Check the oil level in the vibration bearings Level inspection bore

Every 500 operating hours 5.15 5.16 5.17 5.18

Check, clean, change the combustion air filter Servicing the battery Drain the sludge from the fuel tank Check the pretension of the engine hood

approx. 2mm

Every 1000 operating hours 5.19 5.20

Replace the fuel filter Change the oil in the vibrator shaft housing

Every 2000 operating hours 5.21

Change hydraulic oil, hydraulic oil filter and breather at least every 2 years filter*

As required 5.22 5.23 5.24 5.25 5.26

Adjust the scrapers Bleed the fuel system Tightening torques for screws with metric unified thread Fill the battery Engine conservation

only if the fuel tank has been driven empty

distilled water

*Also in case of repairs in the hydraulic system

BMP 851

BOMAG

77

Every 10 operating hours Every 10 oper ating hours

5.6

i

Checking the engine oil level

Note

!

Park the machine on level ground, so that the engine is in a horizontal position. Caution Fill the oil up to the "MAX"-mark before a longer work period. !

l

5.7

Checking the hydraulic oil level Caution

In hydraulic systems filled with Panolin HLP Synth. 46, the same oil must be used for filling up. In case of any other ester based oil consult the lubrication service department of the respective oil manufacturer.

Open the engine hood.

Fig. 133

Check the oil level in the inspection glass (Fig. 133) on the hydraulic oil tank.

l

Fig. 132 l

Pull the dipstick 2 (Fig. 132) out, wipe it dry with a lint free, clean cloth and reinsert it until it bottoms.

Caution Hydraulic oil is not consumed like engine oil.

l

Pull the oil dipstick out again.

If, during the daily oil level check, the oil level is found to have dropped, check all lines, hoses and components for leakages.

!

The oil level must reach the "MAX"- mark (3). l

Top up oil immediately if the oil level is too low.

l

Unscrew the filler cover (1).

l

l

If necessary, remove the protection guard (1) and unscrew the filler cover (2).

If the oil level is too high detect the cause and drain the oil off.

l

Fill in hydraulic oil until it reaches the middle of the MAX.-inspection glass.

l

Check the sealing ring (4) on the cover, replace it if necessary.

l

Reinstall the filler cover and the protection guard.

l

Screw the filler cover (1) back on.

For quality and quantity of oil refer to the table of fuels and lubricants.

For quality and quantity of oil refer to the table of fuels and lubricants.

78

BOMAG

BMP 851

Every 10 operating hours 5.8 !

Checking the fuel level

5.9

i

Danger

Fuel filter, draining off water

Note

Do not inhale any fuel fumes.

The service intervals for the water separator depend on the water content in the fuel and can therefore not be determined precisely. After taking the engine into operation you should therefore check the filter bowl initially every day for signs of water.

Caution Contaminated fuel can cause malfunction or even damage of the engine.

Environment Catch running out fuel and dispose of environmentally.

Fire hazard! When working on the fuel system do not use open fire, do not smoke. Do not refuel in closed rooms.

!

If necessary, fill in fuel through a funnel with screen filter.

Fig. 135 l

Slacken bleeding screw 1 (Fig. 135) for a few turns.

l

Slacken 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. 134 l

Clean the area around the filler opening, unscrew the cover, check the filling level and fill in fuel as necessary (Fig. 134).

For quality of fuel refer to the table of fuels and lubricants.

BMP 851

BOMAG

79

Every 250 operating hours Every 250 operating h ours

5.10 Checking the air intake hose

5.11 Cleaning cooling fins/cooling air blower

i

Note

Dirty operating conditions, especially deposits of lubrication oil and fuel on the cooling fins of the engine and the cooling air intake opening, reduce the cooling effect. You should therefore seal any leakages near the cooling air blower, the cylinder or the cooling air intake opening immediately and clean the cooling fins after. Danger Eye injury! !

Fig. 136 l

l

Check the fastening of the fastening clamps (Fig. 136), tighten if necessary. Check the condition of the air intake hose, replace if necessary.

Wear your protective outfit (protective goggles, gloves). Cleaning must only be carried out after the engine has been stopped and cooled down. Caution Do not run the engine without air guide plates. !

Dry dirt

Fig. 137

80

l

Remove all air guide plates (Fig. 137).

l

Dry clean all air guide plates as well as cylinder heads, cylinders and flywheel fans and blow the dirt off with compressed air.

BOMAG

BMP 851

Every 250 operating hours Wet and oily dirt Spray the entire cooling area with a cleansing agent (cold cleansing agent), let it soak in for a while, then spray it off with a strong water jet.

l

Caution Do not hold the water or steam jet directly into the intake opening of the dry air filter or into the exhaust. !

Cover all electrical components and the insulation material. l

Run the engine warm for a short while to avoid corrosion.

l

Find the reason for the oil deposit and seal the leak.

l

5.12 Changing engine oil and oil filter !

Danger

Danger of scalding! There is a danger of scalding when draining off hot engine oil. Caution Drain the engine oil only when the engine is warm. !

The machine must be in horizontal position. Change the engine oil at least 1 x per year.

Reinstall the air guide parts. Environment Catch old oil and dispose of oil and filter environmentally.

Fig. 138

BMP 851

l

Unscrew the drain plug (Fig. 138) and catch running out oil.

l

Turn the oil drain plug back in with a new seal ring.

BOMAG

81

Every 250 operating hours

Fig. 139

Fig. 141

Loosen and unscrew the engine oil filter cartridge with a suitable screwdriver 1 (Fig. 139).

l

l

Wipe the sealing face 1 (Fig. 141) on the engine clean.

l

Cover the rubber seal (2) of the new filter cartridge slightly with clean oil.

l

Spin on the new filter cartridge (3) and tighten it hand-tight.

Fig. 140

Lift off the screen plate 1 (Fig. 140) behind with a screwdriver.

l

Caution Do not damage sealing face (2). !

l

Blow out the screen plate (1) from the inside with compressed air.

l

Press the cleaned screen plate back into the oil pressure relief valve.

82

Fig. 142 l

Unscrew cover 1 (Fig. 142).

l

Fill new engine oil in through the oil filler opening, until the "MAX"-mark (3) on the dipstick (2) is reached.

For quality and quantity of oil refer to the table of fuels and lubricants. l

Check the condition of the cover seals (4), replace if necessary.

l

Fasten the cover (1).

l

After a short test run of the engine check drain plug and filter for leak tightness.

l

Check the oil level on the dipstick, top up oil if necessary.

BOMAG

BMP 851

Every 250 operating hours Valve clearance for both valves 0.1 mm.

5.13 Checking, adjusting the valve clearance !

l

Turn the crankshaft another 180 in direction of engine rotation and check the valve clearance on the first cylinder, adjust if necessary.

l

Turn the crankshaft another 180 further and check the valve clearance on the second cylinder, adjust if necessary.

Caution

Adjust the valve clearance only when the engine is cold 10 ... 30 °C.

Adjustment

Clean the area around the valve covers from dirt.

l

l

Check the valve clearance with a feeler gauge (0.10 mm).

The feeler gauge (5) must fit with little resistance. l

If the valve clearance has to be corrected, slacken the counter nut (6) and turn the adjustment screw (7) until the feeler gauge (5) fits with only little resistance after retightening the counter nut.

l

Reassemble the valve covers with new seals and tighten the fastening screws evenly.

l

After the test run check the valve cover for tight fit.

Fig. 143

Unscrew the fastening screws 1 (Fig. 143) and take the covers (3) with the sealing rings (2) and (4) off.

l

Caution Always replace the sealing rings. !

Adjustment method: Cylinder 1 = flywheel side - sense of rotation clockwise Cylinder 2 = power take-off side (not used) - sense of rotation counter-clockwise l

Turn the crankshaft in direction of engine rotation until the valves on the second cylinder are overlapping.

Overlapping means: Exhaust valve not yet closed, inlet valve starts to open.

BMP 851

BOMAG

83

Every 250 operating hours 5.14 Checking the oil level in the vibration bearing housings

i

Note

Check the oil level only at operating temperature after running the vibration for about 1/2 hour.

Fig. 144 l

Unscrew the oil filler and control plug (Fig. 144).

Some oil must drip out of the filler and level bore. l

If necessary top up oil.

For quality of oil refer to the table of fuels and lubricants. l

84

Screw the filler and control plugs back in tightly.

BOMAG

BMP 851

Every 500 operating hours Every 500 oper ating hours

5.15 Checking, cleaning, changing the combustion air filter !

Caution

Do not use gasoline or hot fluids to clean the filter cartridge. After cleaning, the filter cartridge must be examined with a torch for damage. Dry air filter cartridges with damaged filter element or seal must be replaced without fail. The dry air filter cartridge must be replaced after 3 cleaning sessions, but at the latest after 1 year, irrespective of the operating hours. Each cleaning interval should be marked with a cross on the cover of the filter cartridge. Cleaning is useless if the cartridge is covered with a sooty deposit. Use a new cartridge.

Fig. 146 l

Carefully loosen the filter element.

The filter element sits exactly on the output tube, thereby providing a seal on the inside of the filter cover. Carefully remove the filter element, to reduce the free amount of dust. To loosen the seal, pull the filter element carefully up, to the side or turn it (Fig. 146).

Incorrectly handled filter cartridges may be ineffective because of damage (e.g. cracks) and can cause damage to the engine. If the machine is operated in a dusty environment the filter service may be necessary at an earlier date. This may cause a drop in engine power resulting in black exhaust fumes.

Fig. 147 l

Fig. 145 l

Open both clamping bows 1 (Fig. 145).

l

Take the filter hood off.

l

Clean the filter hood and the dust discharge valve (2).

BMP 851

Pull the filter element (Fig. 147) carefully out of the housing.

! Caution Do not bang the filter element against the housing.

BOMAG

85

Every 500 operating hours cially the inner side of the open end (sealing area). Do not install a damaged filter element.

Fig. 148 l

Clean the sealing surface on the outlet tube (Fig. 148).

Fig. 150

Dust on the outside diameter of the outlet tube may cause poor sealing.

Installing the filter element (Fig. 150).

l

The radial sealing area is located on the inside of the open filter rim. This critical sealing area must be slightly tensioned after installing the filter. To ensure proper sealing, apply some pressure to the outer edge of the filter, but not to the moveable centre. Reinstall the filter hood and the dust discharge valve.

l

Caution The dust discharge valve must point vertically downwards. !

Dry cleaning of the filter cartridge

Fig. 149 l

Thoroughly clean the inside of the outlet tube (Fig. 149) and the filter housing.

Danger Eye injury! !

Dirt falling into the outlet tube will ultimately reach the engine and cause excessive wear. l

Wear your protective outfit (protective goggles, gloves).

Check the used filter element.

The old filter element may be used to detect foreign particles on the sealing face, which lead to leakages. A stripe of dust on the clean air side of the filter may be a sign of this. Remove the problem before installing a new filter element. l

Clean or replace the filter element.

l

Examine the filter element thoroughly for damage.

Check the filter element for possible damage caused by shipment, cleaning or handling. Espe-

86

BOMAG

BMP 851

Every 500 operating hours 5.16 Servicing the battery !

Danger

Danger of causticization ! When working on the battery do not use open fire, do not smoke! Do not let acid come in with skin or clothes! Wear protective clothing! Do not lay any tools on the battery!

Fig. 151

i

For recharging remove the plugs (if present) from the battery to avoid the accumulation of highly explosive gases.

Note

To clean the filter, fit a tube to the air gun (Fig. 151), the end of which is bent by approx. 90. It must reach down to the bottom of the cartridge. Blow the cartridge out with dry pressure air (max. 5 bar) by moving the tube up and down the inside of the cartridge until all dust has been blown out.

l

Environment Dispose of the old batteries environmentally. l

Open the maintenance flap and remove the battery cover.

Examine the filter cartridge with a torch for any cracks and holes in the paper.

l

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

Fig. 152

BMP 851

l

Remove the battery (Fig. 152) and clean the battery compartment.

l

Clean the outside of the battery.

l

Clean battery poles and terminals clamps and spray with Tectyl.

l

Check the fastening of the battery.

BOMAG

87

Every 500 operating hours 5.17 Drain the sludge from the fuel tank !

5.18 Check the pretension of the engine hood

Danger

Fire hazard! When working on the fuel system do not use open fire, do not smoke. Do not spill any fuel. Do not inhale any fuel fumes. Environment Catch running out fuel, do not let it seep into the ground. l

Fold out the rear frame

Fig. 154 l

Measure the distance between bottom edge of hood and frame (Fig. 154).

Fig. 153 l

l

88

Unscrew the drain plug (Fig. 153) from underneath the fuel tank and drain off all fuel. Turn the drain plug tightly back in.

Fig. 155 l

BOMAG

Unlock the hood (Fig. 155).

BMP 851

Every 500 operating hours

Fig. 156 l

Repeat the distance measurement (Fig. 156).

Nominal value: Pretension (difference) approx. 2 mm

Fig. 157 l

In order to adjust the pretension loosen the fastening screws (Fig. 157) and adjust the latch receptacle accordingly.

BMP 851

BOMAG

89

Every 1000 operating hours Every 1000 operating hour s

5.19 Replacing the fuel filter !

Danger

Fire hazard! When working on the fuel system do not use open fire, do not smoke. Environment Catch running out fuel. Fig. 159 l

Operate hand lever 1 (Fig. 159) on fuel pump, until you can hear fuel running back through the fuel return line into the fuel tank.

l

Perform a test run and check the fuel system for leak tightness.

Fig. 158 l

Pull the fuel hoses (Fig. 158) off the filter.

l

Unscrew the fuel filter.

l

Assemble the new fuel filter and push the fuel hose sback on.

90

BOMAG

BMP 851

Every 1000 operating hours 5.20 Changing the oil for the vibrator bearings !

Caution

Change the oil at operating temperature. Let the machine run for approx. 30 mins. with vibration, to do this. Environment Catch any oil running out and dispose of environmentally.

Fig. 160 l

Unscrew the drain plug 2 (Fig. 160) and the oil filler and level plug (1), drain the oil off and catch it.

l

Once the oil has run out, clean the drain plug and screw it back in tightly.

Fill in oil until it reaches the lower edge of the filler and level bore. For quality and quantity of oil refer to the table of fuels and lubricants. Screw the filler and control plug (1) tightly back in.

l

!

Caution

Overfilling causes overheating of the vibration bearings!

BMP 851

BOMAG

91

Every 2000 operating hours Every 2000 operating hour s

5.21 Changing hydraulic oil, hydraulic oil filter and breather filter

i

Note

See also "notes on the hydraulic system and notes on the hydraulic oil". Caution Apart from the normal oil change intervals the hydraulic oil must also be changed after major repairs in the hydraulic system. !

Fig. 161 l

Unscrew the fastening screws (Fig. 161) for the service cover and take the cover with the gasket (2) off.

l

Check the condition of the gasket, replace if necessary.

Change the hydraulic oil only at operating temperature. We recommend the use of the filling and filtering unit with fine filter (BOMAG part-no. 007 610 01) to fill the hydraulic system. Do not start the engine after draining the hydraulic oil. This will damage hydraulic components! Do not use any detergents to clean the system. Change the hydraulic oil filter element after each hydraulic oil change (refer to the respective chapter).

!

Danger

Danger of scalding! There is a danger of scalding with hot oil when draining off hydraulic oil!

Fig. 162

Environment Catch any oil running out and dispose of environmentally! l

92

Clean the area around the maintenance cover and the hydraulic oil tank.

Unscrew the leakage hose from the vibration motor (Fig. 162) and catch any hydraulic oil running out.

l

i

Note

The hydraulic oil can also be pumped off and new oil filled in with the filling and filtering unit.

BOMAG

BMP 851

Every 2000 operating hours i

Note

The breather filter for the hydraulic oil tank is integrated in the filler cover and must therefore be replaced with the cover. l

Close the tank with a new filler cover.

l

Reinstall the protective guard (1).

l

Perform a test run and check the system for leaks.

Fig. 163 l

Unscrew the hydraulic oil filter cartridge (Fig. 163) inside the tank.

l

Check the hydraulic oil tank for cleanliness, if necessary clean the inside of the tank thoroughly.

l

Clean the drain plug and screw it back in with a new sealing ring.

l

Tighten the filter cartridge hand tight.

l

Reinstall the cover of the hydraulic oil tank with the gasket.

Fig. 164 l

Remove the protection guard 1 (Fig. 164).

l

Open the filler opening (2).

l

Fill in hydraulic oil through the screen.

Refer to the table of fuels and lubricants for quality and quantity of oil. l

Check the hydraulic oil level in the inspection glass.

BMP 851

BOMAG

93

As required As requir ed

5.22 Adjusting the scrapers

i

5.23 Bleeding the fuel system

i

Note

If the scrapers are worn (2 per drum) they must be adjusted or replaced.

Note

This work only needs to be performed after the fuel tank has been driven empty, when changing the fuel filter or if work has been performed in the fuel system. Danger Fire hazard! !

When working on the fuel system do not use open fire, do not smoke. ! Caution Catch running out fuel.

Fig. 165 l

Slacken the fastening screws (Fig. 165) on both sides of the machine.

l

Adjust the scraper to a gap of approx. 3 to 5 mm from the drum.

l

Retighten the fastening screws.

Fig. 166 l

94

BOMAG

Operate hand lever 1 (Fig. 166) on fuel pump (2), until you can hear fuel running back through the fuel return line into the fuel tank.

BMP 851

As required 5.24 Tightening torques for screws with metric unified thread

5.25 Engine conservation If the engine is to be shut down for a longer period of time (e.g. during winter) we recommend the following conservation measures for the engine to avoid corrosion: l

Clean the engine, including the cooling system with cold cleansing agent and a water jet or, even better, with a steam jet.

l

Run the engine warm and shut it down.

l

Drain the still warm engine oil and fill in anticorrosion engine oil.

l

Drain the fuel from the fuel tank, mix it well with 10% anti-corrosion oil and fill it in again. Instead of mixing anti-corrosion oil with the fuel it is also possible to fill the tank with injection pump testing oil with anti-corrosive properties (e.g. Calibration Fluid B).

l

Run the engine for 10 minutes until all lines, filter, pump and nozzles are filled with the conserving 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 (without 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.

Fig. 167

* Strength classes for screws with untreated, nonlubricated surface. Screw quality designations are stamped on the screw heads. 8.8 = 8G 10.9 = 10K 12.9 = 12K Drum extension - drum

l

= 652 Nm The values result in a 90% utilization of the screw’s yield point at a coefficient of friction total = 0,14.Compliance with the specified tightening torques is checked with torque wrenches. When using MoS2 lubricants the specified tightening torques do not apply.

i

Note

Self-locking nuts must always be replaced once they have been unscrewed.

i

Note

Depending on weather conditions, these conserving measures will provide protection for approx. 6 - 12 months. The conserving oil must be replaced by engine oil according to the API- (MIL) classification before taking the machine into operation. Refer to the section "Fuels and lubricants".

BMP 851

BOMAG

95

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 attaching a clearly visible warning tag.

96

BOMAG

BMP 851

6 Trouble shooting

BMP 851

BOMAG

97

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 maintenance instructions. Malfunctions are frequently caused by incorrect operation of the machine or insufficient maintenance. Whenever a fault occurs you should therefore thoroughly read these instruction on correct operation and maintenance. If you cannot locate the cause of a fault or rectify it yourself by following the trouble shooting chart, you should the service departments at our branch offices or dealers. On the following pages you will find a selection of fault remedies. It goes without saying that not all possible reasons for faults could be listed.

!

Danger

Danger of injury! Do not touch rotating parts of the engine.

98

BOMAG

BMP 851


Engine

Faults

Possible cause

Remedy

The engine does not start

Fuel tank empty

Fill the tank

Fuel filter clogged,in winter due to paraffin separation

Change the filter, use winter diesel fuel

Fuel lines leaking

Check the line connections for leaks and tighten the fittings

Battery discharged or not connected

Charge the battery, check the terminal clamps

Operating errors

See section 'starting the engine'

Incorrect valve clearance

Adjust the valve clearance

Nominal power of battery too low

Have the battery checked

Battery terminals loose or oxidized causing slow rotation of the starter

Clean the terminal clamps, tighten them and cover them with acid-free grease.

Especially during winter: the use of too viscous engine oil

Use engine oil suitable for the ambient temperature

Fuel supply restricted, fuel system clogged due to paraffin separation in winter

Change the fuel filter. Check the line connections for leaks and tighten the fittings. Use winter fuel in the cold season.

Incorrect valve clearance

Adjust the valve clearance

Injection valve or injection pump defective

Have examined by a specialist

Engine oil level too high

Drain the oil to the upper dipstick mark

Air filter dirty

Clean, change if necessary

Poor compression due to burned or broken compression rings or incorrect valve clearance

Have piston rings and pistons examined by a specialist, correct the valve clearance

Injection valve defective


Cooling fins excessively soiled

Clean the cooling fins

Injection valve defective


Engine oil level too high

Drain the oil to the upper dipstick mark

Filling capacity of the injection pump not correctly adjusted

Have adjusted by a specialist

Cooling air flow restricted

Clean the cooling air duct

The engine starts poorly and works irregularly with poor power

Engine power and speed drops, excessive exhaust fumes

Engine overheats, shut down immediately!

BMP 851

BOMAG

99

Trouble shooting Faults

Possible cause

Remedy

Engine oil pressure too low, shut down immediately!

Leakages in the lubrication system, engine oil level too low

Check fittings on oil lines, lubrication oil filter for leaks, tighten the fittings if necessary. Top up engine oil to the mark on the dipstick.

Engine oil of wrong SAE-class

Change the engine oil

The generator does not charge the battery, because either generator or regulator is defective


The charge control light lights up during operation

100

BOMAG

BMP 851


Problems with remote control Hetronic with spiral cable

Fault

Possible cause

Remedy

Engine stops without any reason

Engine oil pressure too low or engine oil pressure switch defective

Check engine oil level or oil pressure switch

Does the red oil pressure warning lamp light up when the engine is running? Battery

Check battery terminals for tight fit (intermittent ?) Check the main battery switch Replace the battery

Emergency stop push button

Switch operated? Display off, pull button out Switch defective? replace

Fuses F 54, F 67, F 103 defective

Replace the fuses (may be damaged by vibration)

Toggle switch cable/radio S101

Check plug connections, bridge switch for testing

Relay K 11

Replace the relay Check the plug connections in the relay base

Spiral cable

Check the continuity of the individual cables Check the cables for short circuit to the housing Replace the cables

All wiring looms

Check all wiring looms for intermittent , to do so wobble all cables, especially close to the plug connections, while the engine is running Check also the plug connections on the regulator and the ground cable between engine and frame.

Transmitter

Replace the transmitter

Inclination sensor

Check the sensor signal, input code 1405 Bridge connections 1 and 2 on plug X8 If necessary replace the sensor

BMP 851

BOMAG

101

Trouble shooting Fault

Possible cause

Remedy

Regulator

Pull off the four-pin plug above the regulator, if OK, replace the regulator

A 70 module (BLM)

Replace the module

Main wiring loom

Replace the main wiring loom

Engine wiring loom

Replace the engine wiring loom

Generator

Pull off the two-pin plug coming from the generator and measure the a.c. voltage between the two cables while the engine is running (approx. 26 V at max. speed) Check both cables for continuity and check the ground connection

Ignition on, display module on, but starting not possible

Toggle switch S 36 vibration not in "0“-position

Toggle switch in "0"-position?

Travel lever not in "0“-position

Actuate the travel lever and return it to "0"position

Check with input code 2502

Check with input code 2500 and 2501 Fuel valve sticking

If the starter turns but the engine goes out, pull off the black plug above the regulator, if OK clean or replace valve.

L-signal (battery voltage) and oil pressure signal not connected to ground (control lights off)

If L- and pressure signals do not switch to ground, starting is not possible

Fuse F 119


Battery

A clicking sound on module A 70 indicates that the battery is empty, if necessary replace the battery

Inclination sensor

Check the sensor signal, (input code 1405)

Pull off the black plug above the regulator, if OK, replace the regulator

Bridge connections 1 and 2 on plug X8 If necessary replace the sensor Relay K 39

Check the relay control with code 5070 (start repetition lock!) Replace the relay Check the plug connections in the relay base

102

BOMAG

BMP 851


Possible cause

Remedy

Ignition switch

Check the switch, the switch connects the two upper cables in the ignition switch for starting

Transmitter


A 70 module (BLM)

Replace the module

All wiring looms

Check all wiring looms for intermittent , to do so wobble all cables, especially close to the plug connections, while the engine is running Check also the plug connections on the regulator and the ground cable between engine and frame.

After starting still no function

Main wiring loom


Engine wiring loom


Not waited for horn signal before starting

Press the horn button or wait fro the horn signal before starting



Transmitter


Spiral cable


All functions fail suddenly, engine continues running

A 70 module (BLM)

Replace the module

Main wiring loom




Spiral cable


BMP 851

Transmitter


A 70 module (BLM)

Replace the module

BOMAG

103


Display module shows CTO when ignition is on

Possible cause

Remedy

Main wiring loom


Spiral cable


Main wiring loom

Check whether plug X3:30 or X3:31 is loose Check for short circuit between X24:6 and 7, X23:11 and 12, or CAN+ und CAN- on the display module

Engine not running at max. speed, otherwise OK

A 70 module (BLM)

Replace the module

Toggle switch for speed S 127

Toggle switch in position "max“ ? Check with input code 2505 If necessary replace the toggle switch

Fuse F 14


Engine solenoid Y 46 (adjustment)

Adjust the engine solenoid if the fuse keeps blowing

Relay K 97

Check the relay control with code 5050 Replace the relay Check the plug connections in the relay base

Engine stops directly after starting

A 70 module (BLM)

Replace the module

Main wiring loom


Engine wiring loom


Fuel valve sticking

Pull off the four-pin black plug above the regulator, if not OK, clean or replace the valve

Regulator

Pull off the four-pin plug above the regulatr, if OK, replace the regulator Check the plug connections on the regulator and the ground cable between engine and frame.

104

BOMAG

BMP 851


Possible cause

Remedy

Generator

Pull off the two-pin plug coming from the generator and measure the a.c. voltage between the two cables while the engine is running (approx. 26 V at max. speed) Check both cables for continuity and check the ground connection

A 70 module (BLM)

BMP 851

Replace the module

BOMAG

105


Problems with radio remote control Hetronic in radio operation

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 respond

Incorrect or defective aerial

Replace the aerial (observe the frequency of the aerial) Check the plug connection between aerial and receiver

The receiver is electrically not or not correctly connected

Check the plug connection between receiver and machine

Receiver and tansmitter have different system numbers

Installation of transmitter and receiver with identical system-no.

Power pack empty or defective

Charge or replace the power pack

Distance between machine and transmitter more than 30 m

Move closer to the machine

Toggle switch radio/cable (S101)

Check the plug connection Bridge switch for testing

Ignition on, display module on, but starting not possible

Engine stops without any reason

Transmitter or receiver defective

Replace transmitter or receiver

Vibration toggle switch (S 36)

Toggle switch in "0"-position? Check with input code 2502







Disturbance caused by other radio systems

Check whether the problem arises when other radio signals are transmitted nearby (airport, construction crane, etc.) If necessary contine in cable operation

Incorrect or defective aerial

Replace the aerial (observe the frequency of the aerial) Check the plug connection between aerial and receiver

Distance between machine and transmitter more than 30 m

106

BOMAG

Move closer to the machine

BMP 851


Possible cause

Remedy

Toggle switch radio/cable (S101)

Check the plug connection Bridge switch for testing



BMP 851



Main wiring loom


BOMAG

107


Fault indicator

Fig. 168

The display module (Fig. 168) for the indication of fault codes is located under the service hood. Faults are indicated by flashing, display values by permanent light. If several faults occur at the same time, these will be indicated by flashing codes, one after the other.

108

BOMAG

BMP 851


Fault code

Fault code

Description of fault

Effect

1000 - 1999

Fault in travel system

1-5

2500 - 2999

Fault in remote controls

1-5

5000 - 5499

Fault on diesel engine

1-5

7000 - 7499

Fault in input code for machine parameterization

1-5

7500 - 7999

Fault operating hour meter, load spectrum (input codes)

1-5

8000 - 8999

Fault, severe software fault

1-5

9000 - 9998

Fault, external IO-node, joystick, data collector

1-5

9999

Unknown fault, displayed value higher than +/- 10000, automatic output by the BMFSA

1-5

5

Description of ”effects” 1

= Warning, fault code is displayed, audible signal in 5 second intervals.

2

= Impairment of function, the faulty function is overridden by an emergency function. Fault code is displayed. Audible signal in 5 second intervals. Signal light in monitoring board flashes at 5 second intervals.

3

= Fault of a partial function, the partial function cannot be overridden by an emergency function. If this fault occurs the machine will stop, after returning the travel lever to ”zero position” the machine can be driven again. The machine can be driven to a limited extent, however, it must be repaired by the service department as quickly as possible. Fault code is displayed. Audible signal and signal light in monitoring board in 5 second intervals.

4

= Fault of a partial function, the partial function cannot be overridden by an emergency function. The machine can no longer be moved, because parts of the travel system are defective (engine will be shut down). Fault code is displayed. Audible signal and signal light in monitoring board in 1 second intervals.

BMP 851

BOMAG

= Fatal fault. The function of the control is no longer assured. The control will be switched off. Fault code is displayed, signal lamp in monitoring board lights permanently.

109

Trouble shooting

110

BOMAG

BMP 851

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