Bomag BPH 80/65 Instructions for use

Operating instructions
Maintenance instructions
Catalogue number
008 147 41 09/2005
BPH 80/65
S/N10170000....
Vibratory plate compactor

Foreword
BOMAG 3 BPH 80/65
F oreword
The BOMAG machines are products from the
wide range of BOMAG compaction equipment.
Decades of experience in designing machines
of this type as well 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.
Using these instructions will
lhelp youto get to know the machine.
lavoidmalfunctions caused by unprofessional
operation.
Compliance with the maintenance instructions will
lincreasethe reliability of your machine on site,
lprolongthe lifetime of the machine,
lreducerepair costs and downtime.
BOMAG will not assume liability for the functioning
of the machine
lif it is handled in a way which does not comply
with the usual modes of use,
lif it is used for purposes other than those men-
tioned in these instructions.
No warranty claims can be lodged for damage re-
sulting from
loperating errors,
linsufficient maintenance and
lwrong 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.
For your own safety you should only use gen-
uine BOMAG spare parts.
We reserve the right for technical modifica-
tions without prior notification.
These operating and maintenance instructions
are also available in other languages.
Spare parts catalogue and repair instructions are
available from your BOMAG dealer against the se-
rial number of your machine.
You can also obtain detailed information on the
correct use of your machine for earth work and as-
phalt applications from your BOMAG dealer.
The above points do not constitute an extension
of the warranty of the warranty and liability condi-
tions specified in the general terms of business of
BOMAG.
We wish you much success with the BOMAG ma-
chine.
BOMAG GmbH
PrintedinGermany
Copyright by BOMAG

Foreword
BOMAG 4 BPH 80/65
Please fill in
............................
Machinetype(Fig.1)
............................
Serial No. (Fig. 1 and 2)
............................
Engine type (Fig. 3)
............................
Engine No. (Fig. 3)
i
Note
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. 1
Fig. 2
Fig. 3

Table of Contents
BOMAG 5 BPH 80/65
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

Table of Contents
BOMAG 6 BPH 80/65

BOMAG 7 BPH 80/65
1 Technical Data

Technical Data
BOMAG 8 BPH 80/65
Fig. 4
*BPH 80/65
Dimensions
(L) Overall length mm 2330
(L1) Length of base plate mm 1080
(W) Overall width mm 650
(W1)Widthwithextension
plates
mm 800
(W2)Widthwithextension
plates
mm 950
(H) Lowest passing height mm 785
(H1) Max. height with ex-
treme position of steering
rod
mm 1630
Weights
Basic weight kg 775
Operating weight (CECE)
with wear plates
kg 780
Operating weight (CECE)
with extension plates
kg 799

Technical Data
BOMAG 9 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

Technical Data
BOMAG 10 BPH 80/65
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 =7.0m/sec
2on crushed rock determined acc. to ISO 5349 and EN 500
!
Caution
Observe the daily vibration load (Industrial safety acc. to 2002/44/EC).

BOMAG 11 BPH 80/65
2 Safety regulations

Safety regulations
BOMAG 12 BPH 80/65
General
This BOMAG machine is built in accordance
with the latest technical standard and the valid
technical rules and regulations. However, dan-
gers for persons and property may arise from
the machine if it is:
lput to unintended use,
loperated by untrained personnel,
lmodified or altered in an unprofessional way,
lthe applicable safety regulations are not ob-
served.
Each person involved in operation, mainte-
nance and repair of the machine must there-
fore read and apply these safety regulations. If
necessary this should be confirmed by obtain-
ing the signature of the customer.
Furthermore the following regulations and instruc-
tions are obviously also valid:
lall applicable instructions for the prevention of
accidents,
lgenerally acknowledged safety and road traffic
regulations,
lcountry specific regulations.
Intended use
This machine must only be used for:
lcompaction of all types of soil,
lrepair work on all types of soil,
lreinforcement of pedestrian walkways,
lwork in trenches,
lfilling and compaction of hard shoulders.
lThe machine should be checked by an expert
once every year.
Unintended use
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
those mentioned in these instructions.
Who is allowed to work with the ma-
chine?
The machine must only be operated by trained
and authorized persons who are at least 18 years
of age. The responsibilities for the operation of the
machine must be clearly specified and complied
with.
Persons under the influence of alcohol, medica-
tion or drugs must not operate, service or repair
the machine.
Maintenance and repair tasks require specific
knowledge and must therefore only be carried out
by trained and qualified personnel.
Conversions and alterations to the ma-
chine
Unauthorized conversions to the machine are pro-
hibited for safety reasons.
Original parts and accessories have been de-
signed especially for the 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 also impair the active and/or
passive driving safety. The manufacturer express-
ly excludes any liability for damage resulting from
the use of non-original parts and accessories.
Safety notes in the operating and main-
tenance instructions:
! Danger
Paragraphs marked like this highlight possible
dangers for persons.
!
Caution
Paragraphs marked this way highlight possi-
ble dangers for machines or parts of the ma-
chines.
i
Note
Sections marked like this provide technical infor-
mation concerning the optimal economical use of
the machine.

Safety regulations
BOMAG 13 BPH 80/65
Environment
Sections marked like this highlight activities
for the safe and environmental disposal of fu-
els and lubricants as well as replaced parts.
Safety stickers on the machine
Keep safety stickers in good condition and legible
and follow their meaning.
Replace damaged and illegible safety stickers.
Loading the machine
Secure the machine against turning over or slip-
ping off.
Persons are highly endangered if they
lstep under loads being lifted or
lstand under loads being lifted
Secure the machine on the transport vehicle
against rolling off, slipping and turning over.
Starting the machine
Before starting
Become acquainted with the equipment, the con-
trol elements, the working mode of the machine
and the area you will be working in.
Use your personal protective outfit (hard hat, safe-
ty boots etc.). Wear ear defenders.
Check before starting, whether:
lthe machine shows any obvious defects
lall protective devices are properly secured in
their place
lthe control elements are fully functional
lthe machine is free of any oily and combustible
material
lall handles are free of grease, oils, fuels, dirt,
snow and ice.
Use only machines which have been serviced at
regular intervals.
DonotuseanystartingaidssuchasStartpilotor
ether.
The vibration must always be shut off before start-
ing the engine.
For starting remove your feet from the danger
zone of the base plate.
Starting in closed rooms
Exhaust fumes are life threatening! Always ensure
an adequate supply of fresh air when starting in
closed rooms!
Operation
Guide the machine in such a way, that your hands
stay clear of any solid obstructions, risk of injury.
Watch out for unusual noises and development of
smoke. Detect the cause and have the fault cor-
rected.
Operate the vibratory plate only with full throttle, as
otherwise the centrifugal clutch may be damaged.
Never let the machine run unattended.
Parking the machine
If possible, park the machine on level ground.
Before leaving the machine:
lPark the machine so, that it cannot turn over.
lShut the engine down and pull the ignition key
out.
Always secure parked machines, which could be
in the way, with appropriate measures.
Filling the fuel tank
Refuel only with the engine shut down.
Do not refuel in closed rooms.
No open fire, do not smoke.
Do not spill any fuel. Catch running out fuel, do not
let it seep into the ground.
Maintenance
Maintenance work must only be carried out by
qualified and authorized personnel.
Keep unauthorized persons away from the ma-
chine.
Do not perform service work while the engine is
running.
If possible, park the machine on level and firm
ground.
Working on hydraulic lines
Vor jeder Arbeit an Hydraulikleitungen diese
drucklos machen. Unter Druck austretendes Hy-
drauliköl kann die Haut durchdringen und schwere

Safety regulations
BOMAG 14 BPH 80/65
Verletzungen verursachen. Bei Verletzungen du-
rch Hydrauliköl sofort einen Arzt aufsuchen, da
sonst schwere Infektionen entstehen können.
When performing adjustment work in the hydraulic
system do not step or stand in front of or behind
the drum.
Do not change the setting of high pressure relief
valves.
Drain hydraulic oil at operating temperature - dan-
ger of scalding!
Catch running out hydraulic oil and dispose of sep-
arately.
Always catch and dispose of biological hydraulic
oils separately.
Do not start the engine after draining off the hy-
draulic oil.
Nach allen Arbeiten (bei noch druckloser Anlage!)
die Dichtheit aller Anschlüsse und Verschraubun-
gen prüfen.
Wear your protective outfit!
Changing hydraulic hoses
All hydraulic hoses must be inspected visually at
regular intervals.
Hydraulic hoses must be immediately replaced in
case of:
lthe outer layer is worn down to the metal lining
(e.g. chafing, cuts, cracks)
lembrittlement of the outer layer (development
of cracks in the hose material)
ldeformation under pressurized and deoressu-
rized condition, which are not in accordance
with the normal shape of the hydraulic hose
ldeformation in bends, e.g, squeezes, kinks,
layer separation, formation of blisters
lleakages.
lincorrect installation.
lseparation of the hydraulic hose from the fit-
ting
lcorrosion of the crimped fittings, which will im-
pair the function and reduce the strength.
lDo not mix up hoses by mistake.
ldamage or deformation of the fitting, which im-
pairs the function and strength of the hose/
hose connection.
Only genuine BOMAG hydraulic hoses ensure
that the correct type of hose (pressure range) is
used at the right place.
Workingontheengine
Drain the engine oil at operating temperature -
danger of scalding!
Wipe off spilled oil, catch running out oil and dis-
pose of environmentally.
Store used filters and other oil containing materials
in a specially marked container and dispose of en-
vironmentally.
Workingonelectriccomponents
Before starting to work on electric components dis-
connect the battery and cover it with insulating ma-
terial.
Workingonthebattery
When working on the battery do not smoke, do not
use open fire.
Do not let skin and clothes come in contact with
acid.
In case of injuries caused by acid flush the respec-
tive parts with clear water and consult a doctor for
medical advice.
Do not place any tools on the battery, danger of
short circuit.
When recharging the battery remove all plugs to
avoid an accumulation of explosive gases.
Dispose of old batteries environmentally.
Working on the fuel system
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 of environmentally.
Cleaning
Do not clean the machine while the engine is run-
ning.
Do not use gasoline or other combustible sub-
stances for cleaning purposes.
When using steam cleaning equipment do not
subject electric parts to the direct water jet or cover
it beforehand.
Do not guide the water jet directly into the air filter
and into the air intake opening.

Safety regulations
BOMAG 15 BPH 80/65
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.

Safety regulations
BOMAG 16 BPH 80/65

BOMAG 17 BPH 80/65
3Operation

Operation
BOMAG 18 BPH 80/65
3.1 General notes
Please read section 3 Indicators and Control Ele-
ments thoroughly before operating the machine if
you are not yet fully familiar with the indicators and
control elements of the machine.
All indicators and control elements are described
in detail in this chapter.
3.2 Before starting work
Please observe strictly the safety regulations
in chapter 2 of these operating and mainte-
nance instructions.
Refer also to the detailed description in the
chapter "Maintenance".
Top up missing lubricants in compliance with the
maintenance instructions.
lStand the machine on ground as level as pos-
sible.
lCheck fuel tank and lines for leakages.
lCheck the engine oil level, if necessary top up
to the top level mark.
lCheck the hydraulic oil level, top up if neces-
sary.
lCheck the fuel level, top up if necessary.
lCheck the dry air filter service indicator.
lCheck 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.

Operation
BOMAG 19 BPH 80/65
3.3 Folding the steering rod
down
!
Danger
Danger of accident!
Drivethemachineonlywiththesteeringrod
folded down.
Guide the machine only by the steering rod.
The steering rod is resiliently mounted in oper-
ating position.
Fig. 5
lPull the locking lever (Fig. 5) up and fold the
steering rod down, so that it can swing freely.
3.4 Control elements
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

Operation
BOMAG 20 BPH 80/65
3.5 Starting the 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.
For starting remove your feet from the danger
area of the base plate.
The vibration must always be switched off be-
fore starting the engine.
Fig. 7
lPress the push button vibration "ON/OFF"
(Fig. 7) .
The vibration is now switched for starting the
engine.
Fig. 8
lSet the throttle lever (Fig. 8) to position "MIN."
(idle speed).
Fig. 9
lTurn the ignition key to position "I" (Fig. 9) , the
warning buzzer sounds.
lThen turn the ignition key further to position
"II", the engine starts.
lAs soon as the engine has started turn the ig-
nition key back to position "I".
The warning buzzer stops.