This is the original BOMAG factory service manual for the BF 800 P road finisher, document number 008 921 54, written for machines in the serial ranges 821 837 65 1001, 821 837 67 1001, 821 837 70 1001 and 821 837 74 1001. At 1,110 pages in English, it is the workshop-level book, not the operator's booklet: the volume a mechanic opens when the machine needs testing, adjustment or repair rather than a walk-around check.
On a paver, a guessed pressure setting or a made-up adjustment value is how one stopped machine becomes a stopped paving train. This manual exists so you do not have to guess. The PDF download carries over 15,000 bookmarks for jumping straight to the system in front of you, and it prints cleanly, so the pages you need can go to the bench and get dirty while the rest stays on the laptop.
What's Inside This Bomag BF 800 P Manual
| System | Pages | Key Topics |
|---|---|---|
| Front Matter and Machine Identification | 1-6 | Cover, Road Finisher Designation, Four Serial-Number Ranges From 821 837 65 1001, Catalogue Number 008 921 54, 03/2013 |
| General | 7-28 | Fuel Hoses, Radial Seals, Feather Keys, Ball Bearings, Roller Bearings, Screws, Nuts, Starter Motor |
| Technical Data | 29-38 | Full Spec Table: Deutz TCD 2012 L06 at 135 kW, 20000 Kg Operating Weight, Hopper, Screed, Speeds, Tyres and Noise Figures |
| Maintenance | 39-48 | Engine, Fuel System, Cooling System, Hydraulic System, Gearbox, Transfer Case, Tires |
| Engine | 49-96 | Checking the Engine Oil Level; Changing Engine Oil and Oil Filter Cartridge; Replacing the Fuel Pre-Filter Cartridge, Bleed the Fuel System; Replace the Fuel Filter; Check, Clean the Water Separator; Check the Coolant Level |
| Engine Electrics | 97-220 | EMR3 System Components; Engine Control Unit; Deutz EMR 3 - Engine Connections; Pin Assignment of Engine Control EDC16 / EMR3; Rotary Speed Sensor for Camshaft; Speed Sensor, B114 |
| Electrics | 221-282 | Service the Battery, Check the Main Battery Switch; Starting the Engine with Jump Leads; Component Overview - Electrics; View of Control Panel; Danger of Cauterisation ! Danger of Explosion!; Checking the Main Battery Switch |
| Error Codes -- General Information | 283-286 | Travel System, Steering System, Screed Control, Material Control, Diesel Engine, Hydraulic System, CAN Buses |
| Input Codes | 287-328 | Proportional Valves, Front Wheel Drive, Screed Extensions, Tamper Pump, Vibration Pump, Hydraulic Front Gate |
| Replacement of Components and Material Hopper, Description | 329-340 | Material Hopper, Scraper Belts, Augers, Proportional Valves, Auger Pump, Scraper Belt Pump, Tamper Pump, Vibration Pump |
| Vibrating Screed, Description | 341-346 | Basic Screed, Mobile Sections, Drawing Arms, Tamper Units, Levelling Plates, Vibration Units, Exit Flaps |
| Basic Settings on the Screed | 347-352 | Screed, Levelling Plate, Tamper Bars, Straight Crossfalls, Mobile Sections, Pulling Points |
| Assembling the Screed Extensions | 353-368 | Screed Extensions, Attachment Parts, Auger, Tunnel Plate, Dosing Plate, Transverse Struts, Side Door Holder |
| Electric Screed Heating, Repair | 369-378 | Generator, Heating Elements, Temperature Controller, Electrics Box, Door Contact Switch, Insulation Monitor, Tamper Bar |
| Hydraulics | 379-414 | Component Overview -- Hydraulics; Variable Displacement Pumps, A4VG28EP to A4VG180EP; Travel Pump - Viewed on the Machine; Variable Displacement Pumps, A10VG28/45/56 EP; Side Plates - Viewed on the Machine; Axial Piston Pumps, A10VO/VSO 18 to 100 DFR1 |
| Hydraulics - Travel Circuit | 415-420 | Travel Pumps, Travel Motors, Charge Pump, Pressure Filter, Multi-Disc Parking Brakes, 3/2-Way Solenoid Valve, Hand Pump |
| Hydraulics - Material Transport | 421-426 | Scraper Belt Drive, Auger Drive, Tamper Pump, Vibration Pump, Hydraulic Oil Tank, Scraper Belt Motors, Auger Motors |
| Hydraulics - Service | 427-432 | Fan Circuit, Fan Motor, Valve Block, Service Pump, LCS-valve Block, Hydraulic Cylinders, Cooler, Distributor |
| Tests and Adjustments | 433-478 | Vibration Drive, Tamper Motors, Scraper Belts, Hydraulic Test Case, Pressure Relief Valve, Propshaft |
| Suppliers Documentation | 479-660 | Travel Pump; Travel Motor; Service Pump and Fan Pump; Pump Scraper Chains, Augers, Tamper, Vibration |
| Circuit Diagrams - Hydraulic Diagram | 661-684 | Complete Hydraulic Circuit Set, Drawing 83780125: Travel and Vibration Circuits, Screed Levelling, Hopper Wings, Auger Rise/Lower, Service Circuits with Valve Designations Y2xx |
| Circuit Diagrams - Electric Circuit Diagrams | 685-1110 | Complete Wiring Set, 92 Sheets: Driving and Screed Controllers, Terminal-Strip and Connector Views, Fuse and Relay Layouts, Sensor and Solenoid Circuits |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine | Deutz TCD 2012 L06, water-cooled, 6 cylinders | p. 30 |
| Rated power (ISO 3046) | 135 kW at 2000 rpm | p. 30 |
| Operating weight (CECE) | 20000 kg | p. 30 |
| Weight of basic screed | 3900 kg | p. 30 |
| Working speed (1/2) | 0 - 20 / 0 - 40 m/min | p. 30 |
| Max. perm. inclination (ramp) | 15° | p. 30 |
| Hopper capacity | 7.2 m³ | p. 30 |
| Hopper width (wings open) | 3320 mm | p. 30 |
| Front wheels (diameter x width) | 500 x 280 mm | p. 30 |
| Rear tyres / pressure | 445/80 R25 at 4.5 bar | p. 30 |
| Overall length / width / height | 6800 / 2550 / 3865 mm | p. 30 |
| Screed types covered | S500 and S600 | p. 348 |
| Electric starter, assembly torque | 60 Nm | p. 220 |
| Fault code ranges | four-digit, grouped 0000-0999 … 9000-9999 | p. 283 |
| Fault reactions 1 and 2 | warning messages only, NOT stored in the error log | p. 285 |
Bomag BF 800 P Common Problems This Manual Covers
Bomag BF 800 P creeps or loses travel power under load
Start at the travel circuit chapter on page 415 and work the tests and adjustments block that begins on page 433, rather than swapping pumps. Check the machine against its rated working speeds of 0-20 and 0-40 m/min listed on page 30 before condemning the hydrostatic drive.
Manual Section: Hydraulics - travel circuit p. 415Uneven material feed to the screed, segregation or a starved edge in the mat
The material transport hydraulics start on page 421 and the hopper description on page 329. Trace conveyor and auger flow through that circuit; the hopper holds 7.2 cubic metres and opens to 3320 mm with the wings out (page 30), so a starved edge at full width is a feed fault, not a capacity limit.
Manual Section: Hydraulics - material transport p. 421Ripples or tearing in the mat behind the Bomag BF 800 P
Set the screed by the procedure, not by feel: basic settings begin on page 347 and cover the S500 and S600 screeds (page 348). Extension assembly follows on page 353. Confirm the basic setting before touching anything downstream.
Manual Section: Basic settings on the screed p. 347Tamper and vibration no longer pre-compacting behind the screed
The vibrating screed description runs from page 341 and the electric screed heating repair from page 369. Check the compacting system there before blaming the roller behind you.
Manual Section: Vibrating screed, description p. 341Engine hard to start or lying down under load
The engine chapter starts on page 49 and engine electrics on page 97. The machine carries a Deutz TCD 2012 L06, water cooled, six cylinders, rated 135 kW at 2000 rpm (page 30). If the starter has been off, its assembly torque is 60 Nm per page 220.
Manual Section: Engine p. 49Work function dead or an intermittent control fault mid-shift
Error code general information is on page 283 and the input codes follow from page 287. Note that fault reactions 1 and 2 are warning messages only and are NOT written to the error log (page 285), so an empty log does not mean the fault never happened. Electric circuit diagrams start on page 685.
Manual Section: Error codes -- general information p. 283Frequently Asked Questions
Which machines does this manual cover?
It covers the BOMAG BF 800 P road finisher for serial number ranges 821 837 65 1001, 821 837 67 1001, 821 837 70 1001 and 821 837 74 1001. Check the serial plate on your machine against these ranges before buying.
Is this a service manual or just an operator's book?
This is the factory Service Manual, BOMAG document 008 921 54. It is the workshop-level repair book at 1,110 pages, written for testing, adjustment and repair work, not the short operating booklet that ships with the machine.
Does it help with hydraulic and travel drive repairs?
Yes. As the full workshop-level service book for the BF 800 P, it is the reference for repair work across the machine, including the hydrostatic travel drive. On a paver, working from the factory procedures instead of guessed pressure values is what keeps one failure from causing a second.
What engine is fitted to the Bomag BF 800 P, and how much power does it make?
The BF 800 P runs a Deutz TCD 2012 L06, a water-cooled six-cylinder, rated at 135 kW at 2000 rpm per ISO 3046. Those figures come straight from the technical data table on page 30 of the manual, so they match the machine as built, not a generic Deutz spec sheet.
What tyres and tyre pressure does the Bomag BF 800 P need on the rear axle?
Page 30 lists 445/80 R25 tyres at 4.5 bar for the rear axle. Running the wrong pressure on a paver this heavy changes ride height and can throw off screed alignment, so it is worth checking against the manual rather than a tyre shop guess.
What is the assembly torque for the electric starter on the Bomag BF 800 P?
The manual calls for 60 Nm when fitting the electric starter, per the electrics section on page 220. That is a torque wrench spec, not a tighten-and-feel job, since an under-torqued starter mount works loose under vibration.
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