Operating instructions

Maintenance instructions

BPH 80/65
S/N 101 700 00 ....

Vibratory plate compactor

Catalogue number
008 147 41 09/2005
 Foreword

The BOMAG machines are products from the For your own safety you should only use gen-
F oreword

wide range of BOMAG compaction equipment. uine BOMAG spare parts.

Decades of experience in designing machines
of this type as well state of the art production We reserve the right for technical modifica-
and testing methods, such as lifetime tests of tions without prior notification.
all important components and highest quality These operating and maintenance instructions
demands, guarantee maximum reliability of are also available in other languages.
your machine. Spare parts catalogue and repair instructions are
available from your BOMAG dealer against the se-
Using these instructions will
rial number of your machine.
l help youto get to know the machine.
You can also obtain detailed information on the
l avoidmalfunctions caused by unprofessional correct use of your machine for earth work and as-
operation. phalt applications from your BOMAG dealer.
The above points do not constitute an extension
Compliance with the maintenance instructions will
of the warranty of the warranty and liability condi-
l increasethe reliability of your machine on site, tions specified in the general terms of business of
l prolongthe lifetime of the machine, BOMAG.
We wish you much success with the BOMAG ma-
l reducerepair costs and downtime.
chine.
BOMAG will not assume liability for the functioning BOMAG GmbH
of the machine
Printed in Germany
l if it is handled in a way which does not comply Copyright by BOMAG
with the usual modes of use,
l if it is used for purposes other than those men-
tioned in these instructions.

No warranty claims can be lodged for damage re-

sulting from
l operating errors,
l insufficient maintenance and
l wrong fuels and lubricants.

Please note!
This manual was written to be used by operators
and maintenance personnel on the site.
You should only operate the machine if you have
been properly instructed in the operation of it and
by observing the contents of this manual.
Please observe strictly all applicable safety regu-
lations.
Please observe also the guidelines of the Civil En-
gineering Liability Association "Safety Rules for
the Operation of Road Rollers and Soil Compac-
tors" and the applicable accident prevention regu-
lations.

BPH 80/65 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 ma-
chine.
Upon receipt of the machine our organization will
instruct you about correct operation and mainte-
nance.
Please observe strictly all safety regulations and
notes on potential dangers!

Fig. 2

Fig. 3

4 BOMAG BPH 80/65

 Table of Contents

Technical Data 7
Safety regulations 11
Operation 17
3.1 General notes 18
3.2 Before starting work 18
3.3 Folding the steering rod down 19
3.4 Control elements 19
3.5 Starting the engine 20
3.6 Starting with jump leads 21
3.7 Work/operation 22
3.8 Back- up protection 25
3.9 Stop-function, switching the vibration off 25
3.10 Stopping the vibratory plate, shutting the engine down 26
3.11 Loading 27
Maintenance 29
4.1 General notes on maintenance 30
4.2 Fuels and lubricants 31
4.3 Table of fuels and lubricants 33
4.4 Running-in instructions 34
4.5 Maintenance chart 35
4.6 Checking the fuel level 36
4.7 Checking the engine oil level 36
4.8 Checking the hydraulic oil level 37
4.9 Checking the air filter service indicator 37
4.10 Checking the water separator 38
4.11 Checking the condition of the battery, greasing the poles 39
4.12 Checking the air filter, cleaning if necessary 40
4.13 Changing the engine oil 42
4.14 Changing the engine oil filter 43
4.15 Checking, adjusting the valve clearance 43
4.16 Clean cooling fins and cooling air intake opening 44
4.17 Check the oil level in the vibrator housing 45
4.18 Changing the dry air filter 46
4.19 Changing the fuel filter 48
4.20 Changing the oil in the vibrator housing 49
4.21 Changing hydraulic oil and filter 50
4.22 Checking the rubber buffers 51
4.23 Retightening the bolted connections 52
Trouble shooting 53
5.1 General notes 54
5.2 Engine faults 55

BPH 80/65 BOMAG 5

Table of Contents

6 BOMAG BPH 80/65

 1 Technical Data

BPH 80/65 BOMAG 7

 Technical Data

Fig. 4

*
BPH 80/65

Dimensions
(L) Overall length mm 2330
(L1) Length of base plate mm 1080
(W) Overall width mm 650
(W1) Width with extension mm 800
plates
(W2) Width with extension mm 950
plates
(H) Lowest passing height mm 785
(H1) Max. height with ex- mm 1630
treme position of steering
rod

Weights
Basic weight kg 775
Operating weight (CECE) kg 780
with wear plates
Operating weight (CECE) kg 799
with extension plates

8 BOMAG BPH 80/65

 Technical Data

* BPH 80/65
Drive
Engine manufacturer Hatz
Type 1D 90 W
Cooling air
Working cycles 4
Number of cylinders 1
Rated power ISO 9249 kW (PS) 11,5 (15,6)
Rated speed rpm 3000
Starting gear electric starter
Fuel diesel
Fuel tank capacity l 10
Drive hydro-mech.(2 shafts)
Working speed max. m/min 28
max. gradability % 30

Vibration system
Frequency Hz 55
Amplitude mm 2,5
* Technical modifications reserved

BPH 80/65 BOMAG 9

Technical Data

The following noise and vibration data acc. to

- EC Machine Regulation edition 98/37/EC and

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

- Vibration Protection Regulation 2002/44/EC

were determined during conditions typical for this type of equipment and by application of harmo-
nized standards.

During operation these values may vary because of the existing operating conditions.

Noise value
sound pressure level on the operator’s stand:
LpA = 91.8 dB(A), determined acc. to ISO 11204 and EN 500

Garanteed sound capacity level:

LWA = 109 dB(A), determined acc. to ISO 3744 and EN 500

! Danger
Loss of hearing!
Wear your personal noise protection means (ear defenders) before starting operation.

Vibration value
Hand-arm vibration:
Vector total of the weighted effective acceleration in three orthogonal directions:

Weighted total vibration value

ahw = 7.0 m/sec2 on crushed rock determined acc. to ISO 5349 and EN 500

! Caution
Observe the daily vibration load (Industrial safety acc. to 2002/44/EC).

10 BOMAG BPH 80/65

 2 Safety regulations

BPH 80/65 BOMAG 11

Safety regulations

General Who is allowed to work with the ma-

chine?
This BOMAG machine is built in accordance
with the latest technical standard and the valid The machine must only be operated by trained
technical rules and regulations. However, dan- and authorized persons who are at least 18 years
gers for persons and property may arise from of age. The responsibilities for the operation of the
the machine if it is: machine must be clearly specified and complied
with.
l put to unintended use,
Persons under the influence of alcohol, medica-
l operated by untrained personnel, tion or drugs must not operate, service or repair
l modified or altered in an unprofessional way, the machine.
l the applicable safety regulations are not ob- Maintenance and repair tasks require specific
served. knowledge and must therefore only be carried out
by trained and qualified personnel.
Each person involved in operation, mainte-
nance and repair of the machine must there-
Conversions and alterations to the ma-
fore read and apply these safety regulations. If
necessary this should be confirmed by obtain- chine
ing the signature of the customer. Unauthorized conversions to the machine are pro-
Furthermore the following regulations and instruc- hibited for safety reasons.
tions are obviously also valid: Original parts and accessories have been de-
signed especially for the machine. We wish to
l all applicable instructions for the prevention of
make expressly clear, that we have not tested or
accidents,
authorized any original parts or special equipment
l generally acknowledged safety and road traffic not supplied by us. The installation and/or use of
regulations, such products can also impair the active and/or
l country specific regulations. passive driving safety. The manufacturer express-
ly excludes any liability for damage resulting from
the use of non-original parts and accessories.
Intended use
This machine must only be used for: Safety notes in the operating and main-
l compaction of all types of soil, tenance instructions:
l repair work on all types of soil,
l reinforcement of pedestrian walkways, ! Danger
l work in trenches, Paragraphs marked like this highlight possible
dangers for persons.
l filling and compaction of hard shoulders.
l The machine should be checked by an expert !Caution
once every year.
Paragraphs marked this way highlight possi-
ble dangers for machines or parts of the ma-
Unintended use chines.
Dangers may, however, arise from the machine if
it is used by untrained personnel in an unprofes-
sional way or if it is used for purposes other than
i Note
those mentioned in these instructions. Sections marked like this provide technical infor-
mation concerning the optimal economical use of
the machine.

12 BOMAG BPH 80/65

 Safety regulations

Environment Starting in closed rooms

Sections marked like this highlight activities Exhaust fumes are life threatening! Always ensure
for the safe and environmental disposal of fu- an adequate supply of fresh air when starting in
els and lubricants as well as replaced parts. closed rooms!

Safety stickers on the machine Operation

Keep safety stickers in good condition and legible Guide the machine in such a way, that your hands
and follow their meaning. stay clear of any solid obstructions, risk of injury.
Replace damaged and illegible safety stickers. Watch out for unusual noises and development of
smoke. Detect the cause and have the fault cor-
rected.
Loading the machine
Operate the vibratory plate only with full throttle, as
Secure the machine against turning over or slip- otherwise the centrifugal clutch may be damaged.
ping off.
Never let the machine run unattended.
Persons are highly endangered if they
l step under loads being lifted or Parking the machine
l stand under loads being lifted If possible, park the machine on level ground.
Secure the machine on the transport vehicle Before leaving the machine:
against rolling off, slipping and turning over.
l Park the machine so, that it cannot turn over.

Starting the machine l Shut the engine down and pull the ignition key
out.
Before starting Always secure parked machines, which could be
Become acquainted with the equipment, the con- in the way, with appropriate measures.
trol elements, the working mode of the machine
and the area you will be working in. Filling the fuel tank
Use your personal protective outfit (hard hat, safe- Refuel only with the engine shut down.
ty boots etc.). Wear ear defenders.
Do not refuel in closed rooms.
Check before starting, whether:
No open fire, do not smoke.
l the machine shows any obvious defects
Do not spill any fuel. Catch running out fuel, do not
l all protective devices are properly secured in let it seep into the ground.
their place
l the control elements are fully functional Maintenance
l the machine is free of any oily and combustible Maintenance work must only be carried out by
material qualified and authorized personnel.
l all handles are free of grease, oils, fuels, dirt, Keep unauthorized persons away from the ma-
snow and ice. chine.
Use only machines which have been serviced at Do not perform service work while the engine is
regular intervals. running.
Do not use any starting aids such as Startpilot or If possible, park the machine on level and firm
ether. ground.
The vibration must always be shut off before start-
ing the engine. Working on hydraulic lines
For starting remove your feet from the danger Vor jeder Arbeit an Hydraulikleitungen diese
zone of the base plate. drucklos machen. Unter Druck austretendes Hy-
drauliköl kann die Haut durchdringen und schwere

BPH 80/65 BOMAG 13

Safety regulations

Verletzungen verursachen. Bei Verletzungen du- Only genuine BOMAG hydraulic hoses ensure
rch Hydrauliköl sofort einen Arzt aufsuchen, da that the correct type of hose (pressure range) is
sonst schwere Infektionen entstehen können. used at the right place.
When performing adjustment work in the hydraulic Working on the engine
system do not step or stand in front of or behind
the drum. Drain the engine oil at operating temperature -
danger of scalding!
Do not change the setting of high pressure relief
valves. Wipe off spilled oil, catch running out oil and dis-
pose of environmentally.
Drain hydraulic oil at operating temperature - dan-
ger of scalding! Store used filters and other oil containing materials
in a specially marked container and dispose of en-
Catch running out hydraulic oil and dispose of sep- vironmentally.
arately.
Always catch and dispose of biological hydraulic Working on electric components
oils separately. Before starting to work on electric components dis-
Do not start the engine after draining off the hy- connect the battery and cover it with insulating ma-
draulic oil. terial.

Nach allen Arbeiten (bei noch druckloser Anlage!) Working on the battery
die Dichtheit aller Anschlüsse und Verschraubun- When working on the battery do not smoke, do not
gen prüfen. use open fire.
Wear your protective outfit! Do not let skin and clothes come in contact with
acid.
Changing hydraulic hoses In case of injuries caused by acid flush the respec-
All hydraulic hoses must be inspected visually at tive parts with clear water and consult a doctor for
regular intervals. medical advice.
Hydraulic hoses must be immediately replaced in Do not place any tools on the battery, danger of
case of: short circuit.
l the outer layer is worn down to the metal lining When recharging the battery remove all plugs to
(e.g. chafing, cuts, cracks) avoid an accumulation of explosive gases.
l embrittlement of the outer layer (development Dispose of old batteries environmentally.
of cracks in the hose material)
Working on the fuel system
l deformation under pressurized and deoressu-
No open fire, do not smoke, do not spill any fuel.
rized condition, which are not in accordance
with the normal shape of the hydraulic hose Catch running out fuel, do not let it seep into the
ground and dispose of environmentally.
l deformation in bends, e.g, squeezes, kinks,
layer separation, formation of blisters Cleaning
l leakages. Do not clean the machine while the engine is run-
ning.
l incorrect installation.
Do not use gasoline or other combustible sub-
l separation of the hydraulic hose from the fit-
stances for cleaning purposes.
ting
When using steam cleaning equipment do not
l corrosion of the crimped fittings, which will im- subject electric parts to the direct water jet or cover
pair the function and reduce the strength. it beforehand.
l Do not mix up hoses by mistake. Do not guide the water jet directly into the air filter
l damage or deformation of the fitting, which im- and into the air intake opening.
pairs the function and strength of the hose/
hose connection.

14 BOMAG BPH 80/65

 Safety regulations

After maintenance work

Reinstall all protective devices after completing
the maintenance work.

Repair
Repairs must only be performed by qualified and
authorized personnel. Use our repair instructions
for this purpose.
Exhaust gases are a threat to life! Always ensure
an adequate supply of fresh air when starting in
closed rooms!
If the machine is defective, attach a warning tag on
the steering handle.

Test
Depending on the type of applicational and the op-
erating conditions vibratory equipment has to be
examined by a specialist whenever required, but
at least once every year.

BPH 80/65 BOMAG 15

Safety regulations

16 BOMAG BPH 80/65

 3 Operation

BPH 80/65 BOMAG 17

Operation

3.1 General notes 3.2 Before starting work

Please read section 3 Indicators and Control Ele- Please observe strictly the safety regulations
ments thoroughly before operating the machine if in chapter 2 of these operating and mainte-
you are not yet fully familiar with the indicators and nance instructions.
control elements of the machine.
Refer also to the detailed description in the
All indicators and control elements are described
chapter "Maintenance".
in detail in this chapter.
Top up missing lubricants in compliance with the
maintenance instructions.
l Stand the machine on ground as level as pos-
sible.
l Check fuel tank and lines for leakages.
l Check the engine oil level, if necessary top up
to the top level mark.
l Check the hydraulic oil level, top up if neces-
sary.
l Check the fuel level, top up if necessary.
l Check the dry air filter service indicator.
l Check the condition of the whole machine and
the screw connections for tight fit.

Danger
!

Loss of hearing!
Always wear your personal noise protection
means (ear defenders) before starting opera-
tion.

18 BOMAG BPH 80/65

 Operation

3.3 Folding the steering rod 3.4 Control elements

down

! Danger
Danger of accident!
Drive the machine only with the steering rod
folded down.
Guide the machine only by the steering rod.
The steering rod is resiliently mounted in oper-
ating position.

Fig. 6
No. 1 = throttle lever
No. 2 = ignition key
No. 3 = push button vibration ON/OFF
No. 4 = Travel lever (toggle switch)
No. 5 = Back-up protection

Fig. 5

l Pull the locking lever (Fig. 5) up and fold the

steering rod down, so that it can swing freely.

BPH 80/65 BOMAG 19

 Operation

The vibration is now switched for starting the

3.5 Starting the engine engine.

! Danger
Danger of explosion!
Never use any starting aid sprays or other in-
flammable fluids to assist starting.

! Danger
Danger of injury!
Before starting make sure that no persons are
inside the danger zone of engine or machine
and that all guards and safety installations are
properly fastened. Fig. 8

For starting remove your feet from the danger l Set the throttle lever (Fig. 8) to position "MIN."
area of the base plate. (idle speed).
The vibration must always be switched off be-
fore starting the engine.

Fig. 9

l Turn the ignition key to position "I" (Fig. 9) , the

Fig. 7 warning buzzer sounds.
l Press the push button vibration "ON/OFF" l Then turn the ignition key further to position
(Fig. 7) . "II", the engine starts.
l As soon as the engine has started turn the ig-
nition key back to position "I".
The warning buzzer stops.

20 BOMAG BPH 80/65

 Operation

3.6 Starting with jump leads

i Note
Choose this starting method if the starter battery is
discharged.
l Remove the cover from the battery.

Caution
!

Wrong connections will cause tremendous

damage in the electric system.
Fig. 10
The auxiliary battery must have the same volt-
age as the normal starter battery.
! Caution
Run the engine warm for a short while before
starting work (Fig. 10) .
l Once the engine has run warm for a short
while the vibratory plate is ready for operation.

! Caution
When the engine is running keep the ignition
key in position "I".
If the starting procedure takes longer than 10
seconds, wait for at least 15 seconds before
trying again.
Too long operation of the starter motor will dis- Fig. 11
charge the battery.
l Open the front covering hood (Fig. 11) .

Fig. 12

l Connect the plus poles on auxiliary battery

and starter battery with the jump wire (Fig. 12)
.

BPH 80/65 BOMAG 21

Operation

l Use the second jump wire to connect the mi-

nus poles on auxiliary battery and starter bat- 3.7 Work/operation
tery.
l Perform the starting process as described be-
fore. i Note
As soon as the engine responds to short throttle
l Once the engine is running disconnect the mi-
commands you may start to operate the vibratory
nus poles first and the plus poles after.
plate.

i Note
Danger
!

This method rules out a short circuit caused by the

Danger of accident!
contact of plus and minus cables.
Only operate the vibratory plate with the steer-
l Reattach the battery cover.
ing rod folded down.
Guide the vibratory plate only by the steering
rod.
Use your personal noise insulation means (ear
defenders).

Fig. 13

l Pull the locking lever (Fig. 13) up and fold the

steering rod down.

22 BOMAG BPH 80/65

 Operation

Switching the vibration on

Fig. 14

l Adjust the steering rod to the required height

Fig. 16
using the height adjustment (Fig. 14) .

! Danger
Danger of accident!
The vibratory plate will immediately vibrate for-
ward or reverse at a speed that corresponds
with the travel lever position (toggle switch).
l Turn the vibration push button (Fig. 16) clock-
wise and unlock it.

Vibration is switched on.

l Adjust the desired travel direction forward or
reverse with the travel lever (toggle switch).

Fig. 15
Driving forward
l Set the throttle lever (Fig. 15) to position
"MAX.".
i Note
Vibration must be switched on.
Caution
!

Operate the vibratory plate only with full en-

gine speed.

i Note
For short breaks always return the throttle lever to
idle speed position.

BPH 80/65 BOMAG 23

Operation

i Note
Vibration must be switched on.
l Press the bottom part of the travel lever (tog-
gle switch) (Fig. 18) , until the vibratory plate
has reached the desired reverse speed.

i Note
The travel lever (toggle switch) returns to middle
position. The chosen reverse travel speed re-
mains unchanged.

Fig. 17 If the vibratory plate gets stuck

l Keep the top part of the travel lever (toggle
switch) pressed (Fig. 17) , until the vibratory
plate has reached the desired forward speed.

i Note
The travel lever (toggle switch) returns to middle
position. The chosen forward speed remains un-
changed.

Driving in reverse

Fig. 19

l Set the throttle lever (Fig. 19) to position "Min".

l Guide the vibratory plate by the steering rod in
compliance with the travel lever position, until
it comes free.

Fig. 18

! Danger
Danger of accident!
As a measure to avoid injuries when driving re-
verse the vibratory plate should only be guided
by the hand from the side.

24 BOMAG BPH 80/65

 Operation

3.8 Back- up protection 3.9 Stop-function, switching

the vibration off
! Danger
Danger of accident! ! Danger
As a measure to avoid injuries during reverse Danger of accident!
travel the vibratory plate should only be guid-
If the vibration is switched off while the vibra-
ed by the handle from the side.
tory plate is still driving, the vibratory plate will
immediately come to a halt.
When switching the vibration on the vibratory
plate will immediately resume driving.

Fig. 20

l When actuating the back-up protection (Fig.

20) the travel lever (toggle switch) is reversed
from reverse travel to forward travel. Fig. 21

l Press the push button vibration "ON/OFF"

(Fig. 21) .

Vibration is switched off and the vibratory

plate comes immediately to a halt.

BPH 80/65 BOMAG 25

Operation

Caution
3.10 Stopping the vibratory !

Do not shut the engine down all of a sudden

plate, shutting the engine from full load, but let it idle for a while for tem-
down perature equalization.

Danger
!

Danger of accident!
Stop the vibratory plate with the travel lever
(toggle switch) first, before switching the vi-
bration off.

Fig. 24

l Shift the throttle lever to position "Min" (Fig.

24) and let the engine run with idle speed for a
short while.

Fig. 22

l Actuate the travel lever (toggle switch) until the

vibratory plate vibrates on the spot (Fig. 22) .

Fig. 25

l To shut the engine down turn the ignition key

to position "0" (Fig. 25) and pull it out. The
warning buzzer stops.

Fig. 23

l Press the push button vibration "ON/OFF"

(Fig. 23) .
Vibration is switched off.

26 BOMAG BPH 80/65

 Operation

3.11 Loading

! Danger
Danger of accident!
Make sure that no persons are endangered by
the machine tipping or sliding off.
Lash the machine down, so that it is properly
secured against slipping off, sliding about and
turning over.
When loading the machine attach the lifting
gear only to the lifting hook. Fig. 27

The machine must not swing about when be- l Fold the lifting hook up (Fig. 27) .
ing lifted.
Use only safe lifting gear of sufficient load
bearing capacity.
Do not step or stand under loads being lifted.

Fig. 28

l To load the vibratory plate (Fig. 28) attach the

lifting tackle (rope) to the lifting hook.

Fig. 26 Danger
!

l Adjust the steering rod (Fig. 26) upright and Danger of accident!
lock it in the last locking position. Lash the vibratory plate to the transport vehi-
cle so that it properly secured against sliding
about and tipping off!

BPH 80/65 BOMAG 27

Operation

28 BOMAG BPH 80/65

 4 Maintenance

BPH 80/65 BOMAG 29

Maintenance

l Do not draw off fuel from near the bottom of

4.1 General notes on mainte- the fuel drum.
nance l Fuel left in the fuel drum is not suitable for the
engine and should only be used for cleaning
purposes.
When performing maintenance work strictly ob-
serve the respective safety regulations and partic- Notes on the engine performance
ularly the safety regulations mentioned in chapter Combustion air and fuel injection rates of the die-
2 of these operating and maintenance instruc- sel engine have been carefully adjusted and deter-
tions. mine the engine's performance and temperature
Thorough maintenance of the machine ensures level as well as the quality of the exhaust gas.
maximum reliability and prolongs the lifetime of im- If your machine has to operate permanently in
portant components. The necessary effort can by "thin air" (at high altitudes) and with full power, you
no means be compared with the faults which may should consult the after sales service of BOMAG
occur when not observing these instructions. or the service department of the engine manufac-
l Clean machine and engine thoroughly before turer.
starting maintenance work.
l For maintenance work park the machine on Opening the front and rear hoods.
level ground.
l Maintenance work must generally be carried
out with the engine shut down.
l During maintenance work catch all oils and fu-
els and do not let them seep into the ground.
Dispose of oils and fuel environmentally.

Notes on the fuel system

The lifetime of the diesel engine is decisively de-
pending on the cleanliness of the fuel.
l Keep the engine free of dirt and water as this
could damage the injection elements of the en-
gine. Fig. 29

l Zinc lined drums are not suitable for storing fu- No. 1 = front hood
el. No. 2 = lifting eye
l The fuel drum should rest for a longer period No. 3 = rear hood
of time before drawing off fuel.
l Under no circumstances must the drum be
rolled to the tapping pint just before drawing off
fuel.
l When choosing the storage location for fuel
make sure that spilled fuel will not harm the en-
vironment.
l Do not let the suction hose disturb the sludge
on the bottom of the drum.

30 BOMAG BPH 80/65

 Maintenance

4.2 Fuels and lubricants

Engine oil
Use winter grade engine oil for winter operation!
In order to assure perfect cold starting it is import
to chose the viscosity (SAE-class) of the engine oil
according to the ambient temperature.
For winter operation below -10°C the oil change in-
tervals must be shortened.
Fig. 30

l Open the lock on the rear hood.

l Fold the rear hood back.

Fig. 31
Fig. 32
l Fold the lifting eye towards the rear hood. Lubrication oil with a too high viscosity index caus-
l Fold the front hood back. es starting difficulties. The temperature when
starting the engine is therefore of highest impor-
tance when choosing the viscosity of engine oil for
winter operation.

Oil viscosity
Since lubrication oil changes its viscosity with the
temperature, the ambient temperature at the oper-
ating location of the engine is of utmost impor-
tance when choosing the viscosity class (SAE-
class) (see diagram).
Occasional falling short of the temperature limit
(e.g. use of SAE 15W/40 down to -15°C) may ef-
fect the cold starting ability of the engine, but will
not cause any engine damage.
Temperature related lubrication oil changes can
be avoided by using multi-purpose oils. The follow-

BPH 80/65 BOMAG 31

Maintenance

ing oil change intervals apply also when using mul- Fuels
ti-purpose oils.
Quality
Regular lubrication oil changes You should only use commercially available brand
diesel fuel with a sulphur content below 0.5% and
The longest permissible time a lubrication oil
ensure strict cleanliness when filling in. A higher
should remain in an engine is 1 year.
sulphur content has a negative effect on the oil
change intervals. Use only winter-grade diesel fuel
Oil quality under low ambient temperatures. The fuel provi-
You should preferably use oils of API-quality class sion should always be topped up in due time, so
CD-CE-CF-CG, or CCMC-D4/D5/PD2 (SHPD) that the tank will not run dry.
oils. When using oils with a lower quality standard The following fuel specifications are permitted:
the oil change intervals must be reduced.
EN 590 DIN 51601; Nato Codes F-54, F-75, F-76;
Lubrication oil change intervals BS 2869: A1 and A2; ASTM D 975-78:
Oil change intervals with oil quality 1-D and 2-D; VV-F-800 a: DF-A, DF-1 and DF-2.
API: CD- Winter fuel
CE-CF-
For winter operation use only winter diesel fuel, to
CG =
avoid clogging because of paraffin separation.
CCMC-D4/
At very low temperatures disturbing paraffin sepa-
D5/PD2
ration can also be expected when using winter die-
(SHPD) = 6 months
sel fuel.
In most cases a sufficient cold resistance can also
!Caution be achieved by adding flow enhancing fuel addi-
These intervals apply only when using a diesel tives. Consult the engine manufacturer.
fuel with maximum 0,5 % sulphur by weight
and for ambient temperatures higher than -10 Mineral oil based hydraulic oil
¯C (14°F).
The hydraulic system is operated with hydraulic oil
l When using fuels with a sulphur content of HV 32 (ISO) with a kinematic viscosity of 32 mm2/
more than 0,5% to 1% or under ambient tem- s at 40°C. For topping up or for oil changes use
peratures below -10 ¯C (-10°C) the oil change only high-quality hydraulic oil, type HVLP accord-
intervals specified in the table must be halved. ing to DIN 51524, part 3, or hydraulic oils type HV
When using fuels with a sulphur content higher according to ISO 6743/3. The viscosity index (VI)
than 1% to 1.5% the engine oil must have a must be at least 150. (Observe the information of
TBN of approx. 12 x the S-content in % by the manufacturer).
weight when halving the oil change intervals.

Lubrication oil quality classes

The API-classification is used to classify the oil
quality.
The oil manufacturer is solely responsible for as-
signing a product to a certain quality class.

i Note
When changing to a higher alloyed oil quality after
a longer period of operation, it is recommended to
perform the first oil change of the higher quality oil
already after 25 operating hours.

32 BOMAG BPH 80/65

 Maintenance

4.3 Table of fuels and lubri-

cants

Assemblies Fuels, Lubricants Approx. quantity

Summer Winter Attention

Observe level marks

Engine Engine oil API: CD-CE-CF-CG approx. 2,0 l

SAE 15W/40

(-10°C to +40°C)

(+14°F to +104°F)

SAE 30 SAE 10W

(+5°C to +30°C) (-5°C to -30°C)

(+41°F to +86°F) (+23°F to -22°F)

- Fuel Diesel Winter diesel fuel 10 l

(-12°C) (+10.4°F)*

Vibrator shaft same as engine oil 0,8 l

housing

Hydraulic oil same as Panolin SHF Synth. 32 28,0 l

*For lower temperatures refer to the mixing table

in chapter 4.2

BPH 80/65 BOMAG 33

Maintenance

4.4 Running-in instructions

For the start-up of new machines of over-

hauled engines the following maintenance
work must be performed:

! Caution
During the running-in period up to approx. 200
operating hours check the engine oil level two
times every day.
Depending on the engine load the oil con-
sumption will drop to its normal level after a
running time of approx. 100 to 200 operating
hours.

After 25 operating hours

l Change the engine oil.
l Check engine and machine for leaks.
l Check the valve clearance, adjust if neces-
sary.
l Check the oil level in the vibrator shaft hous-
ing.
l Check the hydraulic oil level.
l Retighten the fastening screws for air filter, ex-
haust silencer, fuel tank and other attach-
ments.
l Tighten the screw connections on the ma-
chine.

34 BOMAG BPH 80/65

 Maintenance

4.5 Maintenance chart

With all maintenance intervals perform also

the work for preceeding shorter intervals.

Pos. Description Note

Maintenance every day

4.6 Check the fuel level
4.7 Check the engine oil level
4.8 Check the hydraulic oil level
4.9 Check the air filter service indicator
4.10 Check the water separator
Maintenance every month
4.11 Check the condition of the battery, grease the poles
4.12 Clean the dry air filter
Maintenance every 6 months
4.13 Change the engine oil
4.14 Change the engine oil filter
4.15 Check, adjust the valve clearance
4.16 Clean cooling fins and cooling air intake opening
4.17 Check the oil level in the vibrator housing
4.18 Change the dry air filter
Dim. mm (inch)
4.19 Change the fuel filter
4.20 Change the oil in the vibrator housing
4.21 Change the hydraulic oil filter
4.22 Check the rubber buffers
As required
4.23 Retighten the bolted connections Check the machine
visually

BPH 80/65 BOMAG 35

 Maintenance every day

Maintenance every day

4.6 Checking the fuel level 4.7 Checking the engine oil lev-
el
! Danger l Place the machine on level ground, so that the
When working on the fuel system do not use engine is in horizontal position.
open fire, do not smoke, fire hazard!
Do not refuel in closed rooms.
Refuel only with the engine shut down.

Fig. 34

l Shut the engine down.

l Pull the oil dipstick (Fig. 34) out, clean it with a
Fig. 33 clean cloth and reinsert it until it bottoms.
l Clean the area around the filler neck cover, re- l Pull the dipstick back out and read the oil level.
move the filler neck cover (Fig. 33) .
Nominal value:
The oil level should reach the top mark. If the oil
Caution
!
level is too low top up oil immediately.
Dirty fuel can cause malfunction or damage to
the engine. For quality and quantity of oil refer to the table
of fuels and lubricants.
l Fill in fuel through a funnel with screen.
l Check the seal on the dipstick, if necessary
l Close the tank tightly.
use a new one.
For quality of fuel refer to the table of fuels and l Push the dipstick in until it bottoms.
lubricants.

36 BOMAG BPH 80/65

 Maintenance every day

4.8 Checking the hydraulic oil 4.9 Checking the air filter serv-
level ice indicator

Fig. 35 Fig. 36

l Check the oil level in the inspection glass on l Accelerate the engine for a short moment to
the hydraulic oil tank. full speed. If the rubber bellows contracts and
covers the green section during this process,
l Maximum level middle of inspection glass.
the air filter system needs to be serviced. Un-
l At least 1/3 of inspection glass. der very dusty conditions check the rubber bel-
lows several times per day.
!Caution
Hydraulic oil is not consumed like engine oil. If
during the daily oil check the oil level is found
to have dropped, check all lines, hoses and
components for leakages.
l Screw the filler cap off.
l Fill in hydraulic oil to the middle of the inspec-
tion glass.
l Screw the filler cap back on. For quality and
quantity of oil refer to the table of fuels and lu-
bricants.

BPH 80/65 BOMAG 37

Maintenance every day

4.10 Checking the water separa-

tor

Fig. 37

i Note
The inspection interval for the water separator de-
pends solely on the water content in the fuel and
the care you take during refuelling. The separator
should be inspected at least once every week.
l Slacken the hexagon screw for approx. 2-3
turns.
l Catch the emerging drops in a transparent
container.

i Note
Since water is specifically heavier than diesel fuel,
water will run out first, followed by fuel. This can be
noticed by a clear separating line.
l Tighten the hexagon screw again as soon as
only fuel runs out.

38 BOMAG BPH 80/65

 Maintenance every month

Non-maintenance free batteries

Maintenance every m onth

4.11 Checking the condition of

the battery*, greasing the Caution
!

poles Top up missing fluid with distilled water.

l Open the plugs and check the acid level, if
necessary top up with distilled water.
Danger
!

Danger of injury! With control inserts:

The acid level must reach the bottom of the control
When working on the battery do not smoke, do
inserts.
not use open fire.
Do not let skin and clothes come in contact Without control inserts
with acid. Acid level 10 to 15 mm above the upper edge of
Wear protective goggles. the lead plate, measure with a clean wooden stick.
Do not place any tools on the battery. With transparent battery housing:
Acid level up to the mark on the housing.

Maintenance free batteries

Perform only the following points:
l Check the battery for cleanliness.
l Clean the poles.
l Tighten the terminal clamps.

! Caution
Dispose of old batteries environmentally.

Fig. 38
Danger
!

l Open the rear hood. Development of gas!

l Take the vibration insulation mats off.
If possible remove the plugs when recharging
l Take the battery (Fig. 38) out and clean the the battery, to avoid an accumulation of highly
battery compartment. explosive gases.
l Clean the outside of the battery.
l Clean the battery poles and pole clamps and
cover them with acid free grease (vaseline).
l Check the fastening of the battery.
l Check the condition of the vibration insulation
mats, replace if necessary.
l Close the front hood again tightly after having
serviced the battery.

* Option

BPH 80/65 BOMAG 39

Maintenance every month

4.12 Checking the air filter,

cleaning if necessary

! Caution
Do not use gasoline or hot fluids to clean the
filter cartridge.
Dry air filters with damaged filter element or
seal ring must be replaced in any case. It is
therefore recommended to keep at least one
filter cartridge in stock.
Replace the air filter cartridge after five-times Fig. 40
cleaning, but at the latest after 1/2 year. l Taking the air filter cartridge off (Fig. 40) .
Each cleaning interval should be marked on
the filter cartridge. Caution
!

In case of sooty deposit on the filter cartridge No dirt or foreign particles must enter the
cleaning is useless. Use a new filter cartridge. clean air side.
Incorrectly handled filter cartridges may be- Do not blow the filter housing out with com-
come ineffective because of damage (e.g. pressed air.
cracks) and lead to engine damage.
l Clean the inside of the filter housing only with
In case of wet or oily contamination replace the a clean cloth.
filter cartridge.
l Clean the cover thoroughly.
Do not run the engine without air filter.

! Danger
Eye injury!
Wear protective goggles.

Fig. 39

l Remove the air filter cover (Fig. 39) .

Fig. 41

l Blow the filter cartridge (Fig. 41) out with dry

compressed air (max. 5 bar) from inside to out-
side.
l Check the filter cartridge for damage, replace
if necessary.

40 BOMAG BPH 80/65

 Maintenance every month

Fig. 42

l Insert the filter cartridge (Fig. 42) into the

housing.
l Assemble the filter cover, ensure correct fit of
cover and seal ring.

BPH 80/65 BOMAG 41

 Maintenance every 6 months

Maintenance every 6 months

4.13 Changing the engine oil

! Danger
Danger of scalding! When draining off hot en-
gine oil.

Environment
Catch running out fuel, do not let it seep into
the ground and dispose of environmentally.

Fig. 44
Caution
!

Drain the engine oil at operating temperature. l Unscrew the oil drain plug and catch running
out oil (Fig. 44) .
Stand the machine on level ground.
l Clean the plug and screw it back in with a new
Change the engine oil filter with every oil seal ring.
change.
l Open the front hood.
! Caution
Clean the engine oil filter before filling in new
oil, refer to the next section.

Fig. 43

l Pull the dipstick (Fig. 43) out.

Fig. 45

l Unscrew the oil filler neck cap.

l Fill in new engine oil (Fig. 45) .

For quality and quantity of oil refer to the table

of fuels and lubricants.
l Insert the oil dipstick and check the oil level.
l Unscrew the oil filler neck cap.
l After a short test run check drain plug and oil
filter for leaks.
l Close the rear hood.

42 BOMAG BPH 80/65

 Maintenance every 6 months

4.14 Changing the engine oil fil- 4.15 Checking, adjusting the
ter valve clearance

! Caution i Note
Disassemble the engine oil filter after draining Check and adjust only when the engine is cold (20
the engine oil. +/- 10 °C).
The gasket for the cylinder head cover must be
generally renewed.

Checking the valve clearance

l Clean the area around the cylinder head.

Fig. 46
No.1 = oil filter
No.2 = O-ring
No.3 = plug
l Unscrew the plug and pull the engine oil filter
out of the housing (Fig. 46) . Fig. 47

l Wipe the plug clean and blow it out with com- l Unscrew the cylinder head cover and take it off
pressed air. with the gasket (Fig. 47) .

l Insert the new filter cartridge with the recess l Turn the engine crankshaft in sense of rotation
pointing downwards. until compression resistance can be felt.

l Check the O-ring, replace if necessary.

l Apply some oil to the thread and the O-ring of
the plug.
l Push the engine oil filter into the housing and
tighten the plug.
l After filling in engine oil perform a short test
run and check for leaks, if necessary retighten
the fastening screw.

BPH 80/65 BOMAG 43

Maintenance every 6 months

Adjusting the valve clearance

4.16 Clean cooling fins and cool-
ing air intake opening

i Note
Dirty operating conditions, especially lubrication
oil and fuel deposits on the cooling fins of the cyl-
inder and in the cooling air intake reduce the cool-
ing power. You should therefore immediately seal
any leaks in the area of the fuel tank, the cylinder
or the cooling air intake and clean the cooling fins
after.

Fig. 48 Caution
!

l Check the valve clearance on both valves with For cleaning the engine must be stopped and
a feeler gauge (Fig. 48) . cooled down.
l Loosen the hexagon nut.
Dry dirt
l Adjust the adjustment screw with a screwdriv-
er so that the feeler gauge fits through the gap
between rocker arm and valve shaft with just
noticeable resistance after retightening the
hexagon nut.
l Attach the cylinder head cover with a new gas-
ket and tighten the screws evenly.
l Check the cylinder head cover for leaks after a
short test run.

Fig. 49

l Open the rear hood and clean the intake open-

ing for the cooling air area (Fig. 49) .

44 BOMAG BPH 80/65

 Maintenance every 6 months

4.17 Check the oil level in the vi-

brator housing

i Note
Park the machine on level ground.

Fig. 50

l Dry clean the entire cooling air area like cylin-

der head, cylinder flywheel blower and blow it
out with compressed air (Fig. 50) .

Wet or oily dirt

Danger
!
Fig. 51
Fire hazard!
l Unscrew bleeding screw 1 (Fig. 51).
Do not use any inflammable solvents.

Caution
!

Do not spray directly on electric assemblies

and plug connectors or dry them with com-
pressed air immediately after.
Find the cause of oily dirt and have leaks
sealed by the after sales service of BOMAG.
Do not hold the water jet directly into the air fil-
ter, the exhaust and the electric system (if
present).

l Disconnect the battery*.

Fig. 52
l Spray the entire cooling air area with cleaning
solution (e.g. cold cleansing agent), let it soak l Unscrew oil level inspection plug 2 (Fig. 52)
in for a while and clean off with a sharp water and check the oil level.
jet.
l Run the engine warm for a short while to avoid i Note
corrosion. Some oil should run out of the oil level inspection
bore (1).
l If necessary top up oil. For this purpose un-
screw filler plug (3) and fill in oil.
l Screw in filler plug (3) back in.

* Option

BPH 80/65 BOMAG 45

Maintenance every 6 months

For quality and quantity of oil refer to the table

of fuels and lubricants. 4.18 Changing the dry air filter
l Turn in level inspection plug (2) with a new
seal ring.

Fig. 54

l Remove the air filter cover (Fig. 54) .

Fig. 53
Turn in bleeding screw 1 (Fig. 53).

Fig. 55

l Taking the air filter cartridge off (Fig. 55) .

! Caution
No dirt or foreign particles must enter the
clean air side.
Do not blow the filter housing out with com-
pressed air.
l Clean the inside of the filter housing only with
a clean cloth.
l Clean the cover thoroughly.

46 BOMAG BPH 80/65

 Maintenance every 6 months

Fig. 56

l Insert the filter cartridge (Fig. 56) into the

housing.
l Assemble the filter cover, ensure correct fit of
cover and seal ring.

BPH 80/65 BOMAG 47

 Maintenance every year

Maintenance every year

4.19 Changing the fuel filter

! Danger
When working on the fuel system do not use
open fire, do not smoke, fire hazard! Do not
spill any fuel, do not inhale any fuel fumes.

! Caution
The change interval of the fuel filter depends
on the cleanliness of the fuel. If necessary the
maintenance must be performed every six Fig. 59
months.
l Pull the fuel lines off both sides of the fuel filter
and install a new filter (Fig. 59) .

Environment
Dispose of the used filter environmentally.

! Caution
Ensure strict cleanliness, so that no dirt can
fall into the fuel hose.
l The fuel filter must be generally renewed.
l Mind the flow direction - arrows.
l Open the fuel supply, if necessary prime with
Fig. 57 the fuel pump.
l Open the filler cap on the tank (Fig. 57) . l Close the filler cap on the tank again.
l Check fuel filter and lines for leaks after a short
test run.

i Note
The fuel system is automatically bled.

Fig. 58

l Place a suitable container under the filter to

catch running out fuel (Fig. 58) .
l Close the fuel supply line.

48 BOMAG BPH 80/65

 Maintenance every year

For quality and quantity of oil refer to the table

4.20 Changing the oil in the vi- of fuels and lubricants.
brator housing l Stand the machine horizontally.

Environment
Catch running out old oil, do not let it seep into
the ground and dispose off environmentally.
l Tilt the machine towards the drain side and
support it securely.

Fig. 62

l Fill in oil, until oil starts to run out through in-

spection bore 1 (Fig. 62).
l Clean inspection and drain plug (2) and screw
it back in with a new seal ring.
l Screw in filler plug (3).

Fig. 60

l Unscrew bleeding screw 1 (Fig. 60).

Fig. 63

l Turn in bleeding screw 1 (Fig. 63).

Fig. 61

l Unscrew filler plug 1 (Fig. 61) as well as level

i Note
and drain plug (2). If the seal ring on the bleeding screw is worn use
a new bleeding screw with seal ring.
l Drain off and catch old oil.

i Note
Leave the machine in this position until all oil has
run out of the drain bore.

BPH 80/65 BOMAG 49

Maintenance every year

l Take the hydraulic oil filter out and wipe the fil-
4.21 Changing hydraulic oil and ter chamber out with a lint-free clean cloth.
filter l Install the new hydraulic oil filter.
l Attach the cover and fasten it with the screws.
l Fill in hydraulic oil to the middle of the inspec-
tion glass.

For quality and quantity of oil refer to the table

of fuels and lubricants.
l Screw the filler socket on.
l After filling the hydraulic oil tank and a short
test run check for leaks, if necessary tighten
the fastening screws.

Fig. 64

l Screw the filler socket on (Fig. 64) .

l Draw the hydraulic oil out with a pump.

Environment
Catch running out oil, do not let it seep into the
ground and dispose of environmentally.

Caution
!

Draw the hydraulic oil out at operating temper-

ature.
Stand the machine on level ground.
Change the hydraulic oil filter with every oil
change.

Fig. 65

l Unscrew the fitting and take the cover off (Fig.

65) .

50 BOMAG BPH 80/65

 Maintenance every year

4.22 Checking the rubber buffers

Fig. 66

l Check all rubber buffers (Fig. 66) for cracks

and broken out bits and replace if damaged.
l Check the rubber buffers for tight fit.

BPH 80/65 BOMAG 51

 As required

As requir ed

4.23 Retightening the bolted

connections
l Check all bolted connections for tight fit,
retighten if necessary.

i Note
Do not re-tighten the cylinder head fastening
screws!
l Check the machine for damage and leaks,
have repaired if necessary.

52 BOMAG BPH 80/65

 5 Trouble shooting

BPH 80/65 BOMAG 53

Trouble shooting

5.1 General notes

The following work must only be carried out by

qualified and trained personnel or by the
BOMAG sales service.

Please observe strictly the safety regulations

in chapter 2 of these operating and mainte-
nance instructions.
Faults occur frequently due to the fact, that the
machine has not been properly operated or serv-
iced. Therefore, whenever a fault occurs, read
through these instructions on correct operation
and maintenance. If you cannot locate the cause
of the fault or eliminate it yourself by following the
trouble shooting charts, you should contact our
customer service departments at our branch office
or dealers.
On the following pages you will find a selection of
fault remedies. It is quite obvious that we were not
able to list all possible causes for faults.

54 BOMAG BPH 80/65

 Trouble shooting

5.2 Engine faults

Faults Possible cause Remedy

The engine Throttle lever in stop or idle speed posi- Set the lever to starting position.
does not start or tion. Shut-down lever in stop position.
not immediately.
But can be No fuel at the injection pump Check the complete fuel system system-
cranked with the atically. If no result: Check the fuel line to
starter. the engine fuel filter, the function of the
fuel lift pump.

Incorrect valve clearance Check the valve clearance, adjust it if nec-

essary.

No oil pressure Check the oil level. Activate the mechani-

cal oil pressure monitoring system.

Fuel filter clogged (can be noticed if no Change the fuel filter Fill in fuel
fuel runs after pulling the fuel line off).

Charge level of battery too low Charge the battery

Engine hard to Oil of too high viscosity Drain the oil and fill in oil with lower vis-
crank cosity

Engine has no no valve clearance Check and adjust the valve clearance
compression

Under very low Too high fuel viscosity die to insufficient Fill in a temperature resistant fuel mixture
temperatures cold resistance

Starting speed too low (viscosity of oil too Change the lubrication oil and fill in oil of
high) correct viscosity class

Black exhaust Too much oil in the vibrator housing. Check the hydraulic oil level.
fumes The en-
gine power may Air filter clogged Clean the air filter
also be low Valve clearance not correct Adjust the valve clearance
(speed drops)
This is not Injection nozzle defective Change the injection nozzle
caused by the
injection pump Too much oil in the crankcase Drain the oil off to the "Max"-mark on the
dipstick

Poor engine The throttle lever does not stay in the cho- Block the throttle control.
power (engine sen position.
speed drops)

No exhaust Air in the injection system Check the function of the bleeding valve
fumes
Fuel filter dirty Change the fuel filter

BPH 80/65 BOMAG 55

Trouble shooting

Faults Possible cause Remedy

Engine over- Cooling air flow restricted Clean the cooling air inlet Clean the cool-
heating ing fins

Injection system not working correctly Have the injection system examined

Too much oil in the crankcase Drain the lubrication oil down to the
"Max"-mark on the dipstick.

Engine stalls Fuel supply not correct

Fuel tank empty Fill in fuel

Fuel filter clogged (can be noticed if no Change the fuel filter Check the function
fuel runs after pulling the fuel line off). of the bleeding valve

Vacuum in the fuel tank Clear the ventilation bore in the tank filler
cap.

The throttle lever returns by itself to Block the throttle control.

"Stop"-position

The mechanical oil pressure monitoring Check the oil pressure, activate the oil
system shuts the engine down because of pressure monitoring system
too low oil pressure

Lack of oil Have the engine repaired, stop work im-

mediately (risk of total engine damage!)

56 BOMAG BPH 80/65