From travel pump to Boss safety system, this 71-page Bomag BMP 8500 Service Training PDF walks the multi-purpose compactor's drive, vibration, hydraulic and electrical circuits end to end. The electrical section runs pages 37 to 57 and teaches how BOMAG builds its circuit diagrams: resolved representation, potential and relay cross references, terminal strip, plug and pin overviews, and the DIN component codes that stay the same on every BOMAG. The machine's own diagram sheets are not in this book; they ship with the separate wiring documentation, and this section is what makes them readable. Exciter unit coverage splits high and low amplitude operation, and the control valve block section identifies every port, relief valve and hydraulic line connection down to the jumper hoses. When you teach a new Boss transponder, verify the safety field reaches its full 1.20 m length, and load the machine knowing its 1595 kg CECE operating weight. One dropped safety field and the whole trench stands still. Buy it once and this bookmarked, text-searchable PDF stays yours for the life of the machine.
What's Inside This Bomag BMP 8500 Manual
| System | Pages | Key Topics |
|---|---|---|
| BMP 8500 Overview | 2-12 | Technical Data, Machine and Engine Identification, Filling Capacities, Component Overview |
| Travel System | 13-16 | Travel Motor Components, Travel Motors, Travel Pump, Travel Pump Operation |
| Vibration System | 17-22 | Vibration System Components, Vibration Motor, Exciter Unit, High Amplitude, Low Amplitude, Leak Oil Port, Vibration Control |
| Control Valve Block | 23-27 | Valve Identification, Pressure Relief Valves, Port Identification, Connection Identification |
| Hydraulic Line Connections | 28-35 | Hydraulic Line Connections to Control Valve Block, Return Flow Connections, Steering Cylinder Connections, Travel and Vibration Motor Connections, Jumper Hoses |
| Overview of Drum | 36 | Drum Components, Drive Components, Bearing Components |
| Electrical Overview | 37-57 | Reading Direction, Resolved Representation, Potential Cross References, Relay Cross References, List of Components, Overview of Terminal Strips |
| Controls | 58 | Electronic Immobilizer, Display Module, Fuse Box, Remote Control Switches, Main Battery Switch, Steering Control Lever, Travel Direction Control Lever, Emergency Stop Switch |
| Fuses | 59 | Fuse Box Layout, Fuse Specifications, Fuse Functions |
| Boss Safety System | 60-66 | Communication of Protection Field System, Teaching the Boss Safety System Transponder, Safety Field Measurement of the Boss Safety System |
| Fault Display Readout | 67 | Display Module, Flashing Fault Codes, Multiple Fault Indication |
| Maintenance Procedures | 68-69 | Checking the Oil in the Vibrator Shaft Housing, Lifting the Machine, Opening Plugs, Checking Oil Level, Display Module Input Functions, Safety Bar Version, Safety Field Version |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Safety field length | 1.20 m/3.94 ft | p. 66 |
| Operating weight (CECE) | 1595 kg | p. 3 |
| Basic weight | 1585 kg | p. 3 |
| Mean axle load (CECE) | 775 kg | p. 3 |
| Engine rated power | 14.5 kW | p. 5 |
| Low idle speed | 850 rpm | p. 5 |
| High idle speed | 2750 rpm | p. 5 |
| Fuel tank capacity | 24 L | p. 10 |
| Hydraulic oil capacity | 17 L | p. 10 |
| Engine oil capacity | 4.7 L | p. 10 |
| Coolant capacity | 4.5 L | p. 10 |
| Travel pump high pressure limitation | 250 bar | p. 15 |
| Vibration system frequency | 42 Hz | p. 7 |
Bomag BMP 8500 Common Problems This Manual Covers
Bomag BMP 8500 engine won't start after cold night, cranks but never fires
Drain the fuel precleaner and check for paraffin separation in winter fuel; waxed diesel plugs the filter overnight. Replace the fuel filter cartridge and bleed air from the supply line. Confirm the tank actually has fuel; capacity is 24 L per the filling chart on page 10, and a near-empty tank pulls air on grades.
Manual Section: BMP 8500 Overview p. 10Machine stops moving mid-pass, engine runs fine but drum will not turn
Check the hydraulic oil level first; the system holds 17 L, and a low tank starves the closed-loop travel pump. Test circuit pressure at the pump ports against the 250 bar high pressure limitation on page 15. If pressure collapses under load, inspect the travel pump and travel motors using the component breakdown starting on page 13.
Manual Section: Travel System p. 13Engine overheats during long compaction passes, temperature warning comes on mid-shift
Clean the cooling fins and cooling-air ducts with compressed air; trench dust chokes airflow faster than any other cause on this machine. Check the coolant level after cooldown and fill toward the 4.5 L system capacity listed on page 10. Inspect the V-belt while the shrouds are off and replace it if glazed or cracked.
Manual Section: BMP 8500 Overview p. 10Drum vibration weak or will not switch between high and low amplitude
Verify the engine reaches its 2750 rpm high idle at full throttle; low speed alone kills amplitude before anything hydraulic does. Check that the exciter runs at the rated 42 Hz frequency shown on page 7, then inspect the vibration motor, leak oil port and amplitude adjustment using the exciter unit section starting on page 17.
Manual Section: Vibration System p. 17Remote control dead, display module flashing fault codes and machine refuses all commands
Check the flashing sequence on the display module using the readout procedure on page 67; multiple stored faults flash one after another. Measure the safety field and calibrate it to the 1.20 m (3.94 ft) specification on page 66 if the BOSS system tripped. After swapping a remote unit, teach the transponder per page 64 before restarting the pass.
Manual Section: Fault Display Readout p. 67Vibrator shaft housing oil level unknown after a seal weep or before a long compaction job
Lift the machine on one side and set it on a block 145 mm high, then open both plugs on the elevated side. The oil must stay on the lower edge of the lower hole; top up through the upper hole if it sits below. The full procedure is on page 68 of the Maintenance Procedures section.
Manual Section: Maintenance Procedures p. 68Frequently Asked Questions
How do I pair or replace the remote control on a Bomag BMP 8500?
When replacing a defective remote control, ensure you use a unit with a completely black housing. Follow the procedure: shut down the engine, switch off the main battery switch, replace the components, switch the battery back on, and plug the spiral cable into the remote control. Finally, turn the tumbler switch for the cable remote control to the 'Left' position for cable operation. p. 64
What do BMP 8500 fault codes mean?
Faults are indicated on the display module 'h' in the form of flashing fault codes. If multiple faults occur simultaneously, they will be displayed sequentially as flashing codes. p. 67
What are the fuel and hydraulic oil filling capacities on the Bomag BMP 8500?
The fuel (diesel) tank capacity is 24 liters (6.34 gallons), and the hydraulic oil tank capacity is 17 liters (4.49 gallons). p. 10
What are the valve clearance specifications for the Bomag BMP 8500 engine?
The valve clearance for both the intake and exhaust valves on the Kubota D 1005 engine is 0.145 mm to 0.185 mm. p. 5
What is the rated engine speed and power for the BMP 8500?
The Kubota D 1005 engine has a rated power of 14.5 kW (19.45 HP) at a rated speed of 2600 rpm. p. 5
What is the procedure for checking the oil in the vibrator shaft housing?
Lift the machine on one side and place it on a block that is 145 mm high. Open both plugs on the elevated side; the oil must stay on the lower edge of the lower hole. p. 68
How quickly can I access this Bomag BMP 8500 manual after buying?
A single searchable PDF file of 71 pages, downloadable right after payment. Nothing ships, nothing waits in the mail.
Can I print just the pages I need from this Bomag BMP 8500 manual?
Yes. The PDF has no DRM restrictions, so print any page or section you need for your shop. Works with any standard printer.
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