Instruktsiya Bomag BPH 80 65 S

Operating Instruction
Maintenance Instruction
Original Operating Instructions
BPH 80/65 S
S/N 101 700 15 1001>
Reversible vibratory plate
008 122 61 © 10/2016

2
Table of contents
Table of contents
1 Introduction........................................................................................................................................... 5
1.1 Foreword........................................................................................................................................ 6
1.2 Machine type plate and engine type plate.................................................................................. 8
2 Technical data........................................................................................................................................ 9
2.1 Noise data.................................................................................................................................... 11
3 Safety regulations............................................................................................................................... 13
4 Indicators and Controls...................................................................................................................... 25
4.1 General notes.............................................................................................................................. 27
4.2 Description of indicators and control elements ...................................................................... 28
5 Operation............................................................................................................................................. 33
5.1 General......................................................................................................................................... 34
5.2 Tests before taking into operation............................................................................................ 35
5.3 Preparing the cable remote control for operation................................................................... 36
5.4 Operating the low oil level safety device.................................................................................. 38
5.5 Starting the engine ..................................................................................................................... 39
5.6 Taking the radio remote control into service........................................................................... 41
5.7 Inserting the replacement power pack...................................................................................... 43
5.8 Replacing, recharging the radio remote control power pack................................................. 44
5.9 Switching on the transmitter, starting the engine.................................................................... 48
5.10 Safety inspection for the radio remote control...................................................................... 52
5.11 Work/operation.......................................................................................................................... 54
5.12 Stopping the machine............................................................................................................... 58
5.13 Shutting the engine down........................................................................................................ 59
5.14 Cleaning after use..................................................................................................................... 61
5.15 Changing the BLM-control....................................................................................................... 62
5.16 Entering the machine type code into the display module..................................................... 63
5.17 Loading/transport..................................................................................................................... 65
6 Maintenance........................................................................................................................................ 67
6.1 General notes on maintenance.................................................................................................. 68
6.2 Fuels and lubricants................................................................................................................... 71
6.2.1 Engine oil................................................................................................................................... 71
6.2.2 Fuel............................................................................................................................................ 71
6.2.3 Hydraulic oil................................................................................................................................ 72
6.3 List of fuels and lubricants........................................................................................................ 74
6.4 Running-in instructions.............................................................................................................. 75
6.4.1 General...................................................................................................................................... 75
6.4.2 After 25 operating hours............................................................................................................. 75
6.5 Maintenance Table...................................................................................................................... 76
6.6 Daily maintenance....................................................................................................................... 77
6.6.1 Check the engine oil level.......................................................................................................... 77
6.6.2 Checking the fuel level............................................................................................................... 77
6.6.3 Checking the hydraulic oil level.................................................................................................. 78
6.6.4 Check the air filter service indicator........................................................................................... 79
BPH 80/65 S 3
Table of contents
6.6.5 Check the water separator......................................................................................................... 79

6.6.6 Check the rubber buffers ........................................................................................................... 80
6.7 Maintenance every month.......................................................................................................... 81
6.7.1 Checking the condition of the battery......................................................................................... 81
6.8 Half-annual maintenance............................................................................................................ 83
6.8.1 Check, adjust the valve clearance............................................................................................. 83
6.8.2 Clean the cooling fins and the cooling air intake openings........................................................ 84
6.8.3 Check the oil level in the vibrator housing.................................................................................. 85
6.8.4 Replace the air filter................................................................................................................... 87
6.9 Annual maintenance................................................................................................................... 88
6.9.1 Changing engine oil and oil filter................................................................................................ 88
6.9.2 Replacing the fuel filter............................................................................................................... 89
6.9.3 Change the oil in the exciter shaft housing................................................................................ 91
6.9.4 Changing hydraulic oil and filter................................................................................................. 92
6.10 As required................................................................................................................................ 97
6.10.1 Check the air filter, replace if necessary................................................................................... 97
6.10.2 Tightening the screws.............................................................................................................. 98
6.10.3 Engine conservation................................................................................................................. 99
7 Trouble shooting............................................................................................................................... 101
7.1 General notes............................................................................................................................ 102
7.2 Starting with jump wires........................................................................................................... 103
7.3 Engine problems....................................................................................................................... 105
7.4 Faults in radio remote control................................................................................................. 107
7.5 Fault indicator........................................................................................................................... 108
7.6 Fault code.................................................................................................................................. 109
7.7 Fuse assignment....................................................................................................................... 111
8 Disposal............................................................................................................................................. 113
8.1 Final shut-down of machine..................................................................................................... 114
4 BPH 80/65 S
Introduction
1 Introduction
BPH 80/65 S 5
Introduction – Foreword
1.1 Foreword
BOMAG manufactures machines for earth, asphalt and refuse
compaction, stabilizers/recyclers as well as planers and
pavers.
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 guar-
antee maximum reliability of your machine.
These operating and maintenance instructions are part of your
machine.
They provide necessary information to operate your machine
safely and properly.
They also contain information on required operating, maintenance
and repair measures.
Carefully read the operating and maintenance instructions before
taking your machine into operation.
Please observe the safety regulations strictly and follow all instruc-
tions to ensure safe operation.
If you are not yet acquainted with the controls and indicating ele-
ments on this machine, you should thoroughly read the corre-
sponding chapter.
The description of the individual operating steps including the
notes on safety to be followed can be found in chapter “Operation”.
Before every start up, carry out all required visual inspections and
function tests.
Ensure the compliance with the specified operating, maintenance
and repair measures to maintain the functional safety of your
machine.
A description of all necessary maintenance work, maintenance
intervals as well as information on fuels and lubricants can be
found in the chapter “Maintenance”.
Do not service or repair your machine by yourself to avoid harming
persons or damaging material or environment.
The machine must only be serviced and repaired by qualified and
authorized personnel.
Contact our Customer Service to carry out the required mainte-
nance work or necessary repairs.
In case of operating errors, inadequate maintenance or the use of
unapproved fuels and lubricants all warranty claims will become
null and void.
For your own personal safety you should only use original parts
from BOMAG.
For your machine we offer service kits to make maintenance
easier.
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.
6 BPH 80/65 S
Introduction – Foreword
Apart from that, you can also order the spare parts catalogue
against the serial number of your machine.
The above notes do not constitute an extension of the warranty
and liability conditions specified in the general sales and delivery
conditions of BOMAG GmbH.
We wish you successful work with your BOMAG machine.
BPH 80/65 S 7
Introduction – Machine type plate and engine type plate
1.2 Machine type plate and engine type plate

Please enter here:
Machine type (1):
Serial number (2):
Fig. 1: Machine type plate (example)
Please enter here:

Engine type (1):
Engine number (2):
Fig. 2: Engine type plate (example)
8 BPH 80/65 S
Technical data
2 Technical data
BPH 80/65 S 9
Technical data
Dimensions
Fig. 3
H L L1 W W1
785 1118 1088 650 800
(30.9) (44.0) (42.8) (25.6) (31.5)
Dimensions in millimetres
(Dimensions in inch)
Weights
Operating weight (CECE) (W) 707 kg
(1543) (lbs)
Operating weight (CECE) (W1) 750 kg
(1653) (lbs)
Basic weight 745 kg
(1642) (lbs)
Travel characteristics
Max. working speed 28 m/min
(92) (ft/min)
Max. gradability (depending on soil) 30 %
Drive
Engine manufacturer Hatz
Type 1D 90 W
10 BPH 80/65 S
Technical data – Noise data
Drive
Cooling Air
Number of cylinders 1
Rated power ISO 3046 10.9 kW
(14.2) (hp)
Rated speed 3000 min-1
Drive system hydraulic
Exciter system
Frequency 55 Hz
(3300) (vpm)
Amplitude 1.80 mm
(0,071) (in)
Centrifugal force 80 kN
(17985) (lbf)
Filling capacities
Fuel (diesel) 10.0 l
(2.6) (gal us)
2.1 Noise data

The following noise and vibration data were determined in accord-
ance with the following guidelines under equipment specific condi-
tions and by using harmonized standards:
n EU Machine Directive edition 2006/42/EU
n Noise Emission Directive 2000/14/EU, Noise Protection Direc-
tive 2003/10/EU
During operation these values may vary because of the prevailing
operating conditions.
Sound pressure level at the opera- LpA = 90 dB(A), determined acc. to ISO 11204 and EN 500.
tor's place
WARNING!
Loss of hearing caused by too high noise bur-
dens!
– Wear your personal protective equipment (ear
protection).
BPH 80/65 S 11
Technical data – Noise data
Guaranteed sound power level LWA = 109 dB(A), determined acc. to ISO 3744 and EN 500
12 BPH 80/65 S
Safety regulations
3 Safety regulations
BPH 80/65 S 13
Safety regulations
General This BOMAG machine has been built in compliance with the
latest technical standard and complies with the applicable
regulations and technical rules. However, dangers for persons
and property may arise from this machine, if:
n it is used for purposes other than the ones it is intended for,
n it is operated by untrained personnel,
n it is changed or converted in an unprofessional way,
n the safety instructions are not observed.
Each person involved in the operation, maintenance and
repair of the machine must therefore read and comply with
these safety regulations. If necessary, this must be confirmed
by obtaining the signature of the customer.
Furthermore, the following obviously also applies:
n applicable accident prevention instructions,
n generally accepted safety and road traffic regulations,
n country specific safety regulations. It is the duty of the operator
to be acquainted with these instructions and to apply these
accordingly. This applies also for local regulations concerning
different types of handling work. Should the recommendations
in these instructions be different from the regulations valid in
your country, you must comply with the safety regulations valid
in your country.
Intended use This machine must only be used for:

n Compaction of all types of soils
n Repair work on all types of soil
n Paving of walkways
n Work in trenches
n Underfilling and compaction of hard shoulders
Improper use Dangers may arise from the machine when it is used for purposes
other than the one it is intended for.
Any danger caused by improper use is the sole responsibility of the
operating company or driver/operator, the manufacturer cannot be
made liable.
Examples for improper use are:
n dragging the machine along as a measure of transportation
n throwing the machine off the transport vehicle
n attaching an additional weight to the machine
n using the machine for towing
n operating the machine without visual contact
It is not permitted to stand on the machine while working.
Any transport ropes fastened to the machine must be removed
before operation.
Starting and operating the machine in explosive environments and
in underground mining is prohibited.
14 BPH 80/65 S
Safety regulations
Remaining dangers, remaining Despite careful work and compliance with standards and regula-
risks tions it cannot be ruled out that further dangers may arise when
working with and handling the machine.
Both the machine as well as all other system components comply
with the currently valid safety regulations. Nevertheless, remaining
risks cannot be ruled out completely, even when using the machine
for the purpose it is intended for and following all information given
in the operating instructions.
A remaining risk can also not be excluded beyond the actual
danger zone of the machine. Persons remaining in this area must
pay particular attention to the machine, so that they can react
immediately in case of a possible malfunction, an incident or failure
etc.
All persons remaining ion the area of the machine must be
informed about the dangers that arise from the operation of the
machine.
Regular safety inspections Have the machine inspected by an expert (capable person) as
required for the conditiosn the machine is working under, but at
least once every year.
Who is allowed to operate the Only trained, instructed and authorized persons of at least 18 years
machine? of age are permitted to drive and operate this machine. For opera-
tion of the machine the responsibilities must be clearly specified
and complied with.
Persons under the influence of alcohol, medicine or drugs are not
allowed to operate, service or repair the machine.
Maintenance and repair work requires specific knowledge and
must therefore only be performed by trained specialists.
Changes and conversions to the Unauthorized changes to the machine are prohibited for safety rea-
machine sons.
Original parts and accessories have been specially designed for
this machine.
We wish to make explicitly clear that we have not tested or
approved any parts or accessories not supplied by us.
The installation and/or use of such products may have an adverse
effect on the active and/or passive safety.
The manufacturer explicitly excludes any liability for damage
caused by the use of non-original parts or accessories.
Damage, deficiencies, misuse of Machines which are not safe to operate must be immediately taken
safety installations out of service and shall not be used, until these deficiencies have
been properly rectified.
Safety installations and switches must neither be removed nor
must they be made ineffective.
BPH 80/65 S 15
Safety regulations
Notes on safety in the operating

and maintenance instructions WARNING!
Paragraphs marked like this highlight possible dan-
gers for persons.
NOTICE!
Paragraphs marked like this highlight possible dan-
gers for machines or parts of the machine.
Paragraphs marked like this contain technical infor-

mation for the optimal economical use of the
machine.
ENVIRONMENT!
Paragraphs marked like this point out practices for
safe and environmental disposal of fuels and lubri-
cants as well as replacement parts.
Observe the regulations for the protection of the
environment.
Loading/transporting the machine Make sure that persons are not endangered by the machine tipping
or sliding off.
Use only safe lifting gear of sufficient load bearing capacity Min-
imum lifting capacity of lifting gear: see operating weight in chapter
"Technical Data".
Loads must only be attached and hoisted by an expert (capable
person).
Fasten the lifting gear only at the specified lifting points.
Check lifting eye for damage before use. Do not use a damaged or
in any other way impaired lifting eye.
Do not lift or lower the machine jerkily.
The tension must always be effective in vertical direction.
The machine must not swing about when being lifted.
Do not step or stand under suspended loads.
Always use suitable lashing gear on the lifting points to lash down
the machine.
Lash the machine down, so that it is secured against rolling, sliding
and turning over.
Recovering/towing the machine The machine can be recovered by lifting it out of the danger area.
16 BPH 80/65 S
Safety regulations
Use only safe lifting gear of sufficient load bearing capacity Min-
imum lifting capacity of lifting gear: see operating weight in chapter
"Technical Data".
Loads must only be attached and hoisted by an expert (capable
person).
Fasten the lifting gear only at the specified lifting points.
Check lifting eye for damage before use. Do not use a damaged or
in any other way impaired lifting eye.
The tension must always be effective in vertical direction.
The machine must not swing about when being lifted.
Starting the machine Before starting

When operating several machines with radio remote controls the
system numbers of the individual control units must be checked.
Become acquainted with the equipment, the control elements, the
working principle of the machine and the working area.
Wear your personal protective outfit (hard hat, safety boots, etc.).
Wear ear defenders.
Before starting the machine check whether:
n the machine shows any obvious faults
n all guards and safety elements are in place
n the controls are fully functional
n the machine is free of oily and combustible material
n all grips are free of grease, oils, fuel, dirt, snow and ice.
Use only machines which are serviced at regular intervals.
Do not start the machine with defective gauges, control lights or
control elements.
Do not take any loose objects with you or fasten them to the
machine.
Do not use any starting aids like start pilot or ether.
Starting with jump wires
Connect plus to plus and minus to minus (ground cable) – always
connect the ground strap last and disconnect it first! A wrong con-
nection 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.
Starting and operation of the machine is closed rooms and
trenches
Exhaust gases are extremely dangerous! Always ensure an ade-
quate supply of fresh air when starting and operating in closed
rooms and trenches!
BPH 80/65 S 17
Safety regulations
Operation of the machine Persons in the danger area

Before taking up work, also after breaks, you should always con-
vince yourself that the danger zone is free of persons or obstruc-
tions.
Give warning signals, if necessary. Stop work immediately if per-
sons remain in the danger zone, despite the warning.
Operation
In case of unusual noises and development of smoke perform
trouble shooting and have the fault corrected.
Do not let the machine run unattended.
Do not use the machine to transport persons.
Always keep a sufficient distance to excavation walls and embank-
ments and do not use working methods that could impair the sta-
bility of the machine.
Checking the effect of vibration
When compacting with vibration you must check the effect on
nearby buildings and underground supply lines (gas, water,
sewage, electric power), if necessary stop compaction work with
vibration.
Do not activate the vibration on hard (frozen, concrete) ground.
Danger of bearing damage!
Parking the machine Park the machine on horizontal, level, firm ground.
Before leaving the machine:
n shut the engine down, pull the ignition key off
n secure the machine against unintended use.
n Pull off the main battery switch.
Mark machines, which could be in the way, with a clearly visible
sign.
Filling in fuel Do not inhale any fuel fumes.

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.
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.
Fire protection measures
Familiarise yourself with the location and the operation of fire
fighting equipment. Observe all fire reporting and fire fighting possi-
bilities.
18 BPH 80/65 S
Safety regulations
Maintenance work Comply with the maintenance work described in the operating and
maintenance instructions, including the information concerning the
replacement of parts.
Maintenance work must only be performed by qualified and author-
ized persons.
Keep unauthorized persons away from the machine.
Do not touch hot engine parts.
Do not perform maintenance work while the motor is running.
Park the machine on level, firm ground.
Remove the key from the ignition switch.
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.
Do not change the setting of pressure relief valves.
Drain the hydraulic oil at operating temperature – danger of
scalding!
Any hydraulic oil must be caught and disposed of in an environ-
mentally friendly manner.
Always catch and dispose of hydraulic oils separately.
Do not start the engine after draining the hydraulic oil.
Once all work is completed (with the system still depressurized!)
check all connections and fittings for leaks.
Changing hydraulic hoses
Hydraulic hoses must be visually inspected at regular intervals.
Hydraulic hoses must be immediately replaced if:
n the outer layer is damaged down to the inlay (e.g. chafing,
cuts, cracks).
n the outer layer is brittle (formation of cracks in the hose mate-
rial).
n the hose shows deformations in pressurized and depressurized
condition, which do not comply with the genuine shape of the
hydraulic hose.
n the hose shows deformations in bends, e.g. squeezing, buck-
ling, layer separation, formation of blisters,
n parts of the hose are leaking.
n hoses are not correctly installed
n the hydraulic hose has separated from the fitting
n the fitting shows corrosion that impairs both function and
strength.
n fittings are damaged or deformed, whereby the function and
strength of the hose - hose connection is impaired.
hoses are mixed up by mistake.
Only genuine BOMAG replacement hydraulic hoses ensure that
the correct hose type (pressure range) is used at the right location.
BPH 80/65 S 19
Safety regulations
Working on the engine

Drain the engine oil at operating temperature – danger of scalding!
Wipe off spilled oil, catch running out oil and dispose of environ-
mentally.
Store used filters and other oil contaminated materials in a sepa-
rate, specially marked container and dispose of environmentally.
Working on electric parts of the machine
Before starting to work on electric parts of the machine disconnect
the battery and cover it with insulating material.
Do not use fuses with higher ampere ratings and do not bridge
fuses - fire hazard!
Working on the battery
When working on the battery do not smoke, do not use open fire!
Do not let acid come in contact with hands or clothes! When
injured by acid flush off with clear water and seek medical advice.
Metal objects (e.g. tools, rings, watch straps) must not come in
contact with the battery poles – danger of short circuit and burning!
For recharging remove the plugs from the battery to avoid the
accumulation of highly explosive gases.
Observe the applicable instructions when starting with an auxiliary
battery.
Switch off the charging current before removing the charging
clamps.
Ensure sufficient ventilation, especially if the battery is to be
charged in a closed room.
Dispose of old batteries according to regulations.
Working on the fuel system
Do not inhale any fuel fumes.
Avoid open fire, do not smoke, do not spill any fuel.
Catch running out fuel, do not let it seep into the ground and dis-
pose off environmentally.
Cleaning work
Do not perform cleaning work while the motor is running.
Do not use gasoline or other easily inflammable substances for
cleaning.
When using a steam cleaner for cleaning do not subject electrical
parts and insulation material to the direct jet or cover these items
beforehand.
Do not guide the water jet directly into air filter and air intake or
exhaust muffler.
After maintenance work
After all maintenance work is completed reinstall all guards and
safety installations.
20 BPH 80/65 S
Safety regulations
Repair Mark a defective machine by attaching a warning tag to the dash-

board.
Repair work must only be performed by qualified and authorized
persons. Use our repair instructions for this work.
Exhaust gases are highly dangerous! Always ensure an adequate
supply of fresh air when starting in closed rooms!
Welding
Before starting welding work on the machine disconnect the battery
and cover the fuel tank with insulating material.
Radio remote control 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 author-
ized persons.
The safety features incorporated in the radio remote control must
be checked at regular intervals.
A defective radio remote control must no longer be used.
In case of radio interferences watch the fault code display and
switch to cable remote control, if necessary
The machine will stop when the reach of the radio remote control is
exceeded.
In case of defects the radio 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 discon-
nected from the machine related socket on the receiver. The radio
remote control must only be repaired by the manufacturer or spe-
cialists 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 exe-
cution of repair and maintenance work in compliance with the regu-
lations 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.
Safety stickers on the machine Keep safety stickers in good condition and legible and follow their
meaning.
Replace damaged and illegible safety stickers.
BPH 80/65 S 21
Safety regulations
Fig. 4
1 Information sticker - Diesel
2 Information sticker - Ultra-low sulphur fuel
3 Information sticker - Lifting point
4 Information sticker - Hydraulic oil
5 Information sticker - Main battery switch
6 Brief operating instructions
7 Information sticker - Warning lamps
8 Information sticker - Guaranteed sound capacity level
9 Instruction sticker - Wear ear protection
10 Information sticker - Lashing point
22 BPH 80/65 S
Safety regulations
Fig. 5
11 Information sticker - Solenoid valves
12 Information sticker - cable/radio remote control
13 Information sticker - Allocation of fuses
14 Prohibition sticker - High pressure cleaning
15 Information sticker - Starter switch
16 Maintenance sticker
BPH 80/65 S 23
Safety regulations
Information sticker - Tighten by handOptional equipment
Fig. 6
24 BPH 80/65 S
Indicators and Controls
4 Indicators and Controls
BPH 80/65 S 25
Indicators and Controls
Fig. 7
1 Toggle switch for cable remote control/radio remote control

2 Display module
3 Fuse box
4 Dummy socket, spiral cable
5 Sight glass for hydraulic oil level
6 Main battery switch
7 BLM control
8 Charge control light, battery
9 Oil pressure control light
10 Start button
26 BPH 80/65 S
Indicators and Controls – General notes
11 Ignition switch
12 Travel lever, right
13 Toggle switch, engine speed
14 Emergency stop switch
15 Control light data transfer/power pack radio remote control
16 Vibration toggle switch
17 Travel lever, left
18 Horn button
4.1 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.
The section "Operation" contains only brief descriptions of the indi-
vidual control steps.
BPH 80/65 S 27
Indicators and Controls – Description of indicators and control elements
4.2 Description of indicators and control elements

n Toggle switch for cable remote control/radio remote control
Position "Left" Cable remote control

Position "Right" Radio remote control
Fig. 8
n Display module
To show operating hours as well as display and input of machine
type code, remote control code and fault codes.
Fig. 9
n Fuse box
Fuse assignment see chapter “Trouble shooting”.
n Dummy socket, spiral cable

Socket to connect the plug of the spiral cable for operation with
radio or infrared remote control
n Sight glass for hydraulic oil level

The oil level in the hydraulic oil tank can be checked in this sight
glass. For inspection park the machine on level ground.
28 BPH 80/65 S
n Main battery switch

Disconnects the ground contact in the electric circuit of the
machine.
If the power pack of the radio remote control is to

be charged, the main battery switch must remain
switched on when the engine is shut down.
Fig. 10
n BLM control
The BLM control processes the signals received from the remote
control and manages the machine specific codes.
n Battery charge control light
lights yellow when switching the ignition on

in case of a charge fault during opera-
tion, perform trouble shooting
goes out after starting the engine.
Fig. 11
n Oil pressure control light
lights red when switching the ignition on

goes out after starting the engine.
NOTICE!
If the oil pressure drops during operation shut
down the engine immediately.
Fig. 12
The warning buzzer sounds. The engine shuts

down after 8 seconds.
BPH 80/65 S 29
n Start button
to start the engine.
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.
Fig. 13
n 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. 14
n Travel lever, right
Position 0 Neutral position to start engine /

machine drives forward to the right
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.
Fig. 15
Position "rear" Reversing to the right
30 BPH 80/65 S
n Toggle switch, engine speed
Position "MIN" idle speed of engine

Position "MAX" maximum engine speed
The engine speed can only be reduced when the

vibration is switched on.
Fig. 16
n Emergency stop push button
actuated transmitter and diesel engine will be

switched off.
unlocked switches on the transmitter.
Fig. 17
n Control light data transfer/power pack radio remote control

Flashes green when the transmitter is switched on.
Lights red when the accumulator voltage drops too low.
Fig. 18
n Vibration toggle switch
Position "Vibration" Vibration is switched on.
Position "0" Vibration is switched off.
Fig. 19
BPH 80/65 S 31
n Travel lever, left
Position 0 Neutral position to start engine /

machine drives forward to the left
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.
Fig. 20
Position "rear" Reversing to the left
n Horn button
to signalize a danger situation.
Fig. 21
32 BPH 80/65 S
Operation
5 Operation
BPH 80/65 S 33
Operation – General
5.1 General
If you are not yet acquainted with the controls and indicating
elements on this machine you should thoroughly read chapter
"Indicators and control elements" before starting work.
All indicators and control elements are described in detail in
this chapter.
34 BPH 80/65 S
Operation – Tests before taking into operation
5.2 Tests before taking into operation

The following inspections must be carried out before each working
day or before a longer working period.
WARNING!
Danger of accident!
Please observe strictly the safety regulations in the
corresponding section of this instruction manual!
Park the machine on ground as level as possible.

Clean the machine.
Check Engine and machine for condition, and damage

Fuel tank and fuel lines for condition and leaks
Hydraulic oil tank and lines for condition and leaks
Screw joints for tight fit
Function of travel lever
Function of emergency stop
Function of remote control
For a description of the following tasks refer to the

chapter "Daily maintenance".
Fuel level, top up if necessary

Engine oil level, top up if necessary
Hydraulic oil level, top up if necessary
Air filter service indicator
Water separator
Rubber buffer
BPH 80/65 S 35
Operation – Preparing the cable remote control for operation
5.3 Preparing the cable remote control for operation

Press lock (1) Ä Fig. 22 of the rear covering hood in, pull
lock (2) up and fold covering hood (3) to the front.
Fig. 22
Take the remote control out of the control box Ä Fig. 23.
Fig. 23
Strap the remote control to your body.

Plug the spiral cable into the remote control.
Make sure that the cable of the cable remote con-

trol is freely moveable inside the cable opening
provided for this purpose.
Switch on the main battery switch Ä Fig. 24.
Fig. 24
36 BPH 80/65 S
Operation – Preparing the cable remote control for operation
Switch the toggle switch Ä Fig. 25 to the "left" (cable opera-

tion).
Fig. 25
If necessary unlock the emergency stop switch Ä Fig. 26 on

the remote control.
Fig. 26
Set the vibration toggle switch to position "0" Ä Fig. 27.

Close and lock the rear covering hood.
Fig. 27
BPH 80/65 S 37
Operation – Operating the low oil level safety device
5.4 Operating the low oil level safety device
NOTICE!
The low oil level safety device does not release the
operator from his duty to check the oil level every
day.
The engine is equipped with a low oil level safety device, which
interrupts the fuel flow to the injection pump. The engine will stop.
If the low oil level safety device has responded or if the fuel tank
has been driven empty, the fuel shut-off valve must be opened
manually.
Always perform the following work if:
n after the low oil level safety device has responded and engine
oil has been filled up.
n if the fuel tank was driven empty.
n if the fuel in the supply line has been used up when cranking
the engine free during cold starting or by starting faults
Fill in fuel
Fig. 28
Press the hand lever Ä Fig. 28 for approx. five seconds

against the spring.
The engine is ready for starting.
38 BPH 80/65 S
Operation – Starting the engine
5.5 Starting the engine
WARNING!
Danger of explosion!
Do not use starting aid sprays or other inflammable
fluids for starting.
WARNING!
Exhaust gases are extremely dangerous!
Always ensure an adequate supply of fresh air
when starting and operating in closed rooms and
trenches!
WARNING!
Danger of accident!
Before starting make sure that there are no per-
sons in the danger area of engine or machine and
that all safety installations are in place.
Always keep an eye on a running machine.
WARNING!
Loss of hearing!
Wear your personal noise protection means (ear
defenders) before starting operation.
Switch on the ignition Ä Fig. 29 on the remote control. The

warning buzzer on the control sounds.
The machine will emit a short horn signal. This indicates that
the machine is ready for operation.
Fig. 29
BPH 80/65 S 39
Operation – Starting the engine
Charge and oil pressure control lights Ä Fig. 30 light up.
With the ignition switch in position "I" the machine

type code will appear in the display module for a
few seconds.
If the horn does not sound, there must be a fault

on the remote control. If the horn does not sound,
there must be fault on the machine.
Fig. 30
Press the start button to start the engine Ä Fig. 31.
Fig. 31
Once the engine is running both charge and oil pressure control
light must go out Ä Fig. 32.
If no oil pressure is present after 8 seconds (lack of

oil), the warning buzzer will sound and the engine
will shut down.
NOTICE!
Fig. 32 Run the engine warm with low speed for a short
while before starting work.
When the engine is running leave the ignition key
in position "I".
If the starting attempt takes longer than 10 sec-
onds wait at least 15 seconds before trying again.
Excessive running of the starter will discharge the
battery.
40 BPH 80/65 S
Operation – Taking the radio remote control into service
5.6 Taking the radio remote control into service

Fig. 33
Take the remote control out of the control box Ä Fig. 34,
plug the spiral cable into the dummy socket.
Fig. 34
Strap the remote control to your body.
In order to operate the machine in radio mode the

spiral cable must be plugged into the dummy
socket on the machine provided for this purpose.
The radio remote control works only if trans-
mitter and receiver have identical serial num-
bers.
Fig. 35
BPH 80/65 S 41
Operation – Taking the radio remote control into service
Switch the toggle switch Ä Fig. 36 to the "right" (radio opera-

tion).
Fig. 36
If necessary unlock the emergency stop switch Ä Fig. 37 on

the remote control.
Fig. 37
Set the vibration toggle switch to position "0" Ä Fig. 38.

Close and lock the rear covering hood.
Fig. 38
42 BPH 80/65 S
Operation – Inserting the replacement power pack
5.7 Inserting the replacement power pack
NOTICE!
Change the power pack only when the sender is
switched off.
Turn the ignition switch to position "0" Ä Fig. 39 and pull it

off.
Fig. 39
Insert the replacement power pack into the receptacle

Ä Fig. 40 and let it click into place.
Make sure the power pack clicks into place.
Duty time with a fully charged power pack:

approx. 100 hours
Fig. 40
BPH 80/65 S 43
Operation – Replacing, recharging the radio remote control power pack
5.8 Replacing, recharging the radio remote control power pack
As standard the power pack is recharged in the

machine through the spiral cable. A separate bat-
tery charger is available as an option. The
recharging time is approx. 6 hours.
WARNING!
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 trouser pocket.
NOTICE!
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 bat-
tery charger.
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.
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 (holi-
days, bad weather) you should also disconnect the
charging unit from the mains supply or switch off
the main battery switch.
44 BPH 80/65 S
Charging the power pack in the

machine
Switch off the transmitter Ä Fig. 41 with the ignition key.
Plug the spiral cable into the transmitter
Fig. 41
The main battery switch Ä Fig. 42 must be switched on.
The power pack recharging time is approx. 6

hours.
The power pack can also be recharged when
leaving the spiral cable plugged in the transmitter
during operation.
Fig. 42
Charging the power pack with the

external battery charger
Switch off the transmitter Ä Fig. 43 with the ignition key.
Fig. 43
BPH 80/65 S 45
Press the power pack forward and lift it out of the housing
Ä Fig. 44.
Fig. 44
Push lock 1 Ä Fig. 45 on the mains unit of the battery

charger forward and pull plug (2) upward out of the mains
unit.
Fig. 45
Plug the corresponding plug Ä Fig. 46 onto the mains unit of

the battery charger.
The type of plug to be chosen depends on the

country. Observe local conditions and regulations.
Fig. 46
Insert the power pack into the battery charger Ä Fig. 47.
Fig. 47
46 BPH 80/65 S
Connect the battery charger to a power source Ä Fig. 48.
The two light emitting diodes on battery charger and mains unit
must light up.
The power pack recharging time is approx. 6

hours.
When charging is completed the green LED on the
charger will start to flash.
Fig. 48
BPH 80/65 S 47
Operation – Switching on the transmitter, starting the engine
5.9 Switching on the transmitter, starting the engine
WARNING!
Life hazard
Do not leave the activated transmitter unattended
or with the key inserted to avoid unauthorized
operation of the machine.
Operate the transmitter only if the machine is in
your field of vision.
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.
Strap the transmitter to your body, adjust the belt accordingly.
If necessary unlock the emergency stop switch Ä Fig. 49.
Fig. 49
Switching on the transmitter

Set the vibration toggle switch Ä Fig. 50 to position "0".
Fig. 50
48 BPH 80/65 S
Starting the engine

To start the engine the travel levers must be in rest
position (neutral) and the vibration toggle switch in
position "0".
The remote control is equipped with a re-start lock.
Switch on the ignition Ä Fig. 51.
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.
The machine is now ready for operation.
WARNING!
Fig. 51
Danger of accident!
With toggle switch in position "VIBRATION" the
vibratory plate will move immediately after starting.
Press the start button to start the engine Ä Fig. 52.
Before starting work run the engine warm with low

speed.
Fig. 52
If the distance Ä Fig. 53 between and transmitter and receiver

exceeds 50 m, the machine will stop.
To continue travelling reduce the distance, shift the

control levers for a moment to neutral position and
then to the desired travel direction.
Fig. 53
BPH 80/65 S 49
Work function
WARNING!
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).
If the battery voltage drops down to a too low level

during operation (power pack discharged), the red
warning light on the control will light up approx. 10
minutes before the engine is shut down. The
warning buzzer starts to sound approx. 1 minute
before the shut down
Drive the machine to a safe place as soon as pos-
sible, so that it will not stop all of a sudden.
If necessary switch over to operation with cable
Fig. 54 remote control and plug the spiral cable into the
remote control. During cable operation of the
machine the power pack is automatically charged.
Replace or recharge the power pack.
Switching off the transmitter

(engine) NOTICE!
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 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 life-
time of the power pack.
Turn the ignition key Ä Fig. 55 to position "0".
Transmitter and engine will be switched off after two seconds, the
green control light on the transmitter goes out.
Fig. 55
50 BPH 80/65 S
Switch off and pull out the main battery switch Ä Fig. 56.
Plug the safety cap on the lock.
Fig. 56
Pull off the ignition key Ä Fig. 57 and store it in a safe place.
If the power pack of the remote control is to be

recharged via the spiral cable, the main battery
switch must remain switched on.
Fig. 57
Cleaning after use

NOTICE!
Keep the 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.
After work clean the transmitter with a clean cloth or brush.

Check the state of bellows and sealing caps at regular inter-
vals, have replaced by an expert, if necessary.
BPH 80/65 S 51
Operation – Safety inspection for the radio remote control
5.10 Safety inspection for the radio remote control

This safety inspection must be performed regularly once every
week, especially after longer breaks.
WARNING!
Danger of injury!
Make sure that there are no persons within the
danger zone.
NOTICE!
Rests of mortar or concrete may restrict the move-
ment 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.
With the transmitter switched off actuate and hold one of the
travel levers 1 or 2 Ä Fig. 58.
Switch on the transmitter and try to start the diesel engine.
The diesel engine must not start.
Fig. 58
Return the travel lever to neutral position (rest position).

Start the engine and actuate the travel lever again.
The functions must now work as usual.

Operate the emergency stop switch (3).
The machine must stop and the engine must be shut down.
With the transmitter switched off switch on the toggle switch
"Vibration".
Switch on the transmitter and try to start the diesel engine.
The diesel engine must not start.

Set the toggle switch "Vibration" to position "0".
Start the engine and actuate the toggle switch again.
The functions must now work as usual.
52 BPH 80/65 S
Operation – Safety inspection for the radio remote control
BPH 80/65 S 53
Operation – Work/operation
5.11 Work/operation
Operation of the vibratory plate can be started as

soon as the engine responds to short throttle com-
mands.
Always shift the throttle lever to position "MIN" for
short work breaks.
WARNING!
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 tech-
nical data).
Slowly return the travel lever towards neutral when
driving down slopes.
Before starting to drive check the function of the
remote control.
During operation of the machine with remote con-
trol 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 move-
ment 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.
Wear your personal noise protection (ear
defenders).
NOTICE!
If the machine is operated with cable remote con-
trol avoid excessive stretching of the spiral cable.
54 BPH 80/65 S
Shift the throttle lever Ä Fig. 59 to position "MAX.", until

maximum speed is reached.
Fig. 59
Forward travel
Set vibration toggle switch Ä Fig. 60 to "VIBRATION".
WARNING!
Danger of accident!
The vibratory plate moves immediately forward.
Fig. 60
Steering forward
Push the right hand travel lever Ä Fig. 61 for a short time
backward.
The machine steers slightly to the right.
Fig. 61
Push the left hand travel lever Ä Fig. 62 for a short time
backward.
The machine steers slightly to the left.
Fig. 62
BPH 80/65 S 55
Backwards travel
WARNING!
Danger of accident!
In order to avoid accidents and injury operate the
machine only from the side.
Operate both travel levers Ä Fig. 63 together to reverse

travel position and hold them in this position.
The machine drives straight ahead in reverse.
Fig. 63
Steering in reverse
Release the left hand travel lever for a moment, hold the right
hand travel lever in reversing position Ä Fig. 64.
The machine steers slightly to the left.
Fig. 64
Release the right hand travel lever for a moment, hold the left
hand travel lever in reversing position Ä Fig. 65.
The machine steers slightly to the right.
Fig. 65
56 BPH 80/65 S
If the vibratory plate got stuck

Set the throttle lever Ä Fig. 66 to position "MIN".
Guide the vibratory plate in accordance with the travel lever
position, until it comes free.
Fig. 66
BPH 80/65 S 57
Operation – Stopping the machine
5.12 Stopping the machine

Set the toggle switch for vibration Ä Fig. 67 to position "0".
As soon as the toggle switch for vibration is in

position "0" the machine will come to a halt.
Fig. 67
58 BPH 80/65 S
Operation – Shutting the engine down
5.13 Shutting the engine down
NOTICE!
Do not shut the engine down all of the sudden from
full speed, but let it idle for a while for temperature
equalization.
Set the throttle lever to position "MIN" Ä Fig. 68.
Fig. 68
Set the toggle switch for vibration Ä Fig. 69 to position "0".
The engine speed can only be reduced when the

vibration is switched on.
Fig. 69
Turn the ignition key Ä Fig. 70 to position "0".
Fig. 70
BPH 80/65 S 59
Operation – Shutting the engine down
Pull off the ignition key Ä Fig. 71 and store it in a safe place.
Fig. 71
Switch off and pull out the main battery switch Ä Fig. 72.
Plug the safety cap on the lock.
WARNING!
Danger of accident!
Secure the machine against unauthorized use.
Fig. 72
60 BPH 80/65 S
Operation – Cleaning after use
5.14 Cleaning after use
NOTICE!
Keep the radio remote control clean. Rests of con-
crete, clay or mortar may damage the bellows on
travel levers and sealing caps on push buttons and
switches, so that water can enter. Do not use a
water jet or a high pressure or steam cleaner for
cleaning.
After work clean the transmitter with a clean cloth or brush.

Check the condition of bellows and sealing caps at regular
intervals, replace if necessary.
BPH 80/65 S 61
Operation – Changing the BLM-control
5.15 Changing the BLM-control
NOTICE!
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.
Pull lock 1 Ä Fig. 73 in direction of arrow and pull plug (2)

out downwards.
Unscrew four hexagon screws (3) and take off the BLM-con-
trol.
Fig. 73
Fasten the new BLM-control with four hexagon screws 3

Ä Fig. 74.
Insert plug (2) and push in lock (1) in direction of arrow.
NOTICE!
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.
Fig. 74
62 BPH 80/65 S
Operation – Entering the machine type code into the display module
5.16 Entering the machine type code into the display module
NOTICE!
When retrofitting a radio remote control, the
machine code must be set in the display module.
The machine type code for the BPH 80/65 S is
"7102"
The machine must not be operated with a wrong
type settings, as otherwise the correct function of
the control can no longer be assured.
The code can only be entered when the engine is
shut down.
Fig. 75
Switch on the ignition Ä Fig. 76.
Input on the display module
Fig. 76
Enter machine type code "7102" on the display

module Ä Fig. 77.
Fig. 77
BPH 80/65 S 63
Operation – Entering the machine type code into the display module
Keep both keys (F1 and F2) depressed for two seconds. The
display shows „0000“, whereby the first digit is flashing.
The value of the flashing digit can be increased by 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".
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 dis-

played.
To cancel the display function you must either enter code
number "0000" or switch off the ignition.
Entering the machine type code

Enter code number "7010".
This code number activates the function "Adjusting machine type“.

The display module now permanently shows code "7010".
Enter code "7102".
The display module now permanently shows the entered code.

Enter code number "7011".
This code number confirms the entered machine type.

After the confirmation of the machine type the control switches off.
The control automatically switches on again is now ready for
starting. The display module shows the machine type for 3 sec-
onds.
Whenever switching the ignition on the machine type will appear in
the display module for 3 seconds.
The machine type code can be checked by

entering the code "7010".
64 BPH 80/65 S
Operation – Loading/transport
5.17 Loading/transport
WARNING!
Danger of accident! Life hazard!
Make sure that persons are not endangered by the
machine tipping or sliding off.
Use only safe lifting gear of sufficient load bearing
capacity Minimum lifting capacity of lifting gear:
see operating weight in chapter "Technical Data".
Loads must only be attached and hoisted by an
expert (capable person).
For lifting the machine attach the lifting gear only to
the lifting eye provided for this purpose.
Check lifting eye for damage before use. Do not
use a damaged or in any other way impaired lifting
eye.
The tension must always be effective in vertical
direction.
The machine must not swing about when being
lifted.
Always use suitable lashing gear on the lifting
points to lash down the machine.
Lash the machine down, so that it is secured
against rolling, sliding and turning over.
Fold the lifting hook Ä Fig. 78 up.
Fig. 78
BPH 80/65 S 65
Operation – Loading/transport
Always attach the lifting tackle to the lifting eye to load the
vibratory plate Ä Fig. 79 on a transport vehicle.
Lash the vibratory plate down to the transport vehicle, so that
it is secured against rolling, sliding and turning over. Fasten
the lashing tackle at the marked lashing points.
Fig. 79
66 BPH 80/65 S
Maintenance
6 Maintenance
BPH 80/65 S 67
Maintenance – General notes on maintenance
6.1 General notes on maintenance

When performing maintenance work ensure strict compliance with
the respective safety instructions and particularly the safety regula-
tions mentioned in the corresponding section of these operating
and maintenance instructions.
Thorough maintenance of the machine guarantees far longer safe
functioning of the machine and prolongs the lifetime of important
components. The effort needed for this work is only little compared
with the problems that may arise when not observing this rule.
Always clean machine and engine thoroughly before starting
maintenance work.
For maintenance work stand the machine on level ground.
Do not touch hot engine parts.
Perform maintenance work only with the engine shut down.
Always remove the main battery switch for all maintenance
work.
Relieve hydraulic pressures before working on hydraulic
lines.
Before working on electric parts of the machine disconnect
the battery and cover it with insulation material.
The terms right/left correspond with travel direction forward.
ENVIRONMENT!
During maintenance work catch all oils and fuels
and do not let them seep into the ground or into
the sewage system. Dispose of oils and fuels envi-
ronmentally.
Keep used filters in a separate waste container
and dispose of environmentally.
Catch and dispose of biodegradable oils sepa-
rately.
Notes on the fuel system The lifetime of the diesel engine depends to a great extent on the
cleanliness of the fuel.
Keep fuel free of contaminants and water, since this will
damage the injection elements of the engine.
Drums with inside zinc lining are not suitable to store fuel.
The fuel drum must rest for a longer period of time before
drawing off fuel.
Under no circumstances must the drum be rolled to the tap-
ping point just before drawing out fuel.
When choosing the storage place for fuel make sure that
spilled fuel will not harm the environment.
68 BPH 80/65 S
Do not let the hose stir up the slurry at the bottom of the
drum.
Do not draw off fuel from near the bottom of the drum.
Fuel residues in the drum are not suitable for the engine.
Notes on the performance of the On diesel engines both combustion air and fuel injection quantities
engine are thoroughly adapted to each other and determine power, tem-
perature level and exhaust gas quality of the engine.
If your engine has to work permanently in "thin air" (at higher alti-
tudes) and under full load, you should consult our customer service
or the customer service of the engine manufacturer.
Notes on the hydraulic system During maintenance work on the hydraulic system cleanliness is of
major importance. Make sure that no dirt or other contaminating
substances can enter into the system. Small particles can produce
flutes in valves, cause pumps to seize, clog nozzles and pilot
bores, thereby making expensive repairs inevitable.
If, during the daily inspection of the oil level the hydraulic oil
level is found to have dropped, check all lines, hoses and
components for leaks.
Seal leaks immediately. If necessary inform the responsible
customer service.
Do not store drums with hydraulic oil outdoors, or at least
under a cover. Water can be drawn in through the bunghole
when the weather changes.
We recommend to use our filling and filtering unit with fine
filter to fill the system. This ensures finest filtration of the
hydraulic oil, prolongs the lifetime of the hydraulic oil filter
and protects the hydraulic system.
Clean fittings, filler covers and the area around such parts
before disassembly to avoid entering of dirt.
Do not leave the tank opening unnecessarily open, but cover
it so that nothing can fall in.
Frequent causes of faults

Operating errors
Incorrect, inadequate maintenance
If you cannot locate the cause of a fault or rectify it yourself by fol-

lowing the trouble shooting chart, you should contact our customer
service department.
BPH 80/65 S 69
Opening the front and rear cov-

ering hood.
1 Front covering hood

2 Lifting eye
3 Rear covering hood
Fig. 80
Open lock (2) Ä Fig. 81 of rear covering hood (3).

Fold the rear covering hood open.
Fig. 81
Fold lifting eye (1) Ä Fig. 82 towards the rear covering hood.
Fold the front covering hood (2) up.
Fig. 82
70 BPH 80/65 S
Maintenance – Fuels and lubricants
6.2 Fuels and lubricants

6.2.1 Engine oil
6.2.1.1 Oil quality
The following engine oil specifications are permitted:
n API CD/CE/CF/CF-4/CG-4 or higher quality
n ACEA B2/E2 or higher quality
Avoid mixing engine oils.
6.2.1.2 Oil viscosity

Since engine oil changes its viscosity with the temperature, the
ambient temperature at the operating location of the engine is of
utmost importance when choosing the viscosity class (SAE-class).
The temperature data of the SAE-class always refers to fresh oils.
The engine oil ages during travel operation because of soot and
fuel residues. This adversely affects the properties of the engine
oil, especially at low ambient temperatures.
Optimal operating conditions can be achieved by using the oil vis-
cosity chart as a reference.
Fig. 83: Oil viscosity diagram
6.2.1.3 Oil change intervals

Annually or every 250 operating hours.
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.
6.2.2 Fuel
6.2.2.1 Fuel quality
The following fuel specifications are permitted:
n EN 590
n ASTM D975 Grade-No. 1-D and 2-D
n BS 2869 A1/A2
In order to fulfil national emission regulations one must strictly use
the legally required fuels (e.g. sulphur content).
BPH 80/65 S 71
6.2.2.2 Winter fuel

For winter operation use only winter diesel fuel, to avoid clogging
because of paraffin separation.
At very low temperatures disturbing paraffin separation can also be
expected when using winter diesel fuel.
Diesel fuels suitable for temperatures down to -44 °C (-47 °F) are
available for Arctic climates.
NOTICE!
Danger of engine damage!
– The admixture of petroleum and the addition of
“flow enhancing additives” (fuel additives) is
not permitted.
6.2.2.3 Storage
Even traces of zinc, lead and copper can cause deposits in the
injection nozzles, especially in modern Common-Rail injection sys-
tems.
Zinc and lead coatings in refuelling systems and fuel lines are not
permitted.
Copper containing materials (copper lines, brass items) should be
avoided, because they can cause catalytic reactions in the fuel with
subsequent depositing in the injection system.
6.2.3 Hydraulic oil

6.2.3.1 Mineral oil based hydraulic oil
The hydraulic system is operated with hydraulic oil HV 32 (ISO)
with a kinematic viscosity of 32 mm2/s at 40 °C (104 °F).
For topping up or for oil changes use only high-quality hydraulic oil,
type HVLP according to DIN 51524, part 3, or hydraulic oils type
HV according to ISO 6743/3.
The viscosity index (VI) should be at least 150 (observe informa-
tion of manufacturer).
6.2.3.2 Bio-degradable hydraulic oil

The hydraulic system can also be operated with a synthetic ester
based biodegradable hydraulic oil.
The biologically quickly degradable hydraulic oil Panolin HLP
Synth.46 meets all demands of a mineral oil based hydraulic oil
according to DIN 51524.
In hydraulic systems filled with Panolin HLP Synth.46 always use
the same oil to top up.
72 BPH 80/65 S
When changing from mineral oil based hydraulic oil to an ester

based biologically degradable hydraulic oil, you should consult the
lubrication oil service of the oil manufacturer, or our customer
service for details.
NOTICE!
Risk of damage!
– Check the filter more frequently after this
change.
– Perform regular oil analyses for content of
water and mineral oil.
– Replace the hydraulic oil filter element every
500 operating hours.
BPH 80/65 S 73
Maintenance – List of fuels and lubricants
6.3 List of fuels and lubricants

Assembly group Fuel or lubricant Filling quantity
Summer Winter Observe the level
mark!
Engine oil SAE 10W-40 1.6 l
Specification: Ä Chapter 6.2.1 „Engine oil“ on page 71 (0.4 gal us)
SAE 15W-40
SAE 10W-30
SAE 30 SAE 10W
Fuel Diesel Winter diesel fuel 10.0 l
Specification: Ä Chapter 6.2.2 „Fuel“ on page 71 (2.6 gal us)
Exciter shaft housing as engine oil 0.8 l

(0.2 gal us)
Hydraulic system Hydraulic oil (ISO), HV 32 25 l
Specification: Ä Chapter 6.2.3.1 „Mineral oil based (6.6 gal us)
hydraulic oil“ on page 72
or ester based biodegradable hydraulic oil
Specification: Ä Chapter 6.2.3.2 „Bio-degradable
hydraulic oil“ on page 72
74 BPH 80/65 S
Maintenance – Running-in instructions
6.4 Running-in instructions

6.4.1 General
The following maintenance work must be performed when running
in new machines or overhauled engines.
6.4.2 After 25 operating hours

Change the engine oil.
Check the valve clearance, adjust if necessary.
Check engine and machine for leaks.
Retighten the fastening screws on air filter, exhaust and other
attachments.
Retighten the bolted connections on the machine.
Check the oil level in the vibrator housing.
BPH 80/65 S 75
Maintenance – Maintenance Table
6.5 Maintenance Table

No. Maintenance works Page
Daily maintenance
6.6.1 Check the engine oil level 77
6.6.2 Checking the fuel level 77
6.6.3 Checking the hydraulic oil level 78
6.6.4 Check the air filter service indicator 79
6.6.5 Check the water separator 79
6.6.6 Check the rubber buffers 80
Maintenance every month
6.7.1 Checking the condition of the battery 81
Half-annual maintenance
6.8.1 Check, adjust the valve clearance 83
6.8.2 Clean the cooling fins and the cooling air intake openings 84
6.8.3 Check the oil level in the vibrator housing 85
6.8.4 Replace the air filter 87
Annual maintenance
6.9.1 Changing engine oil and oil filter 88
6.9.2 Replacing the fuel filter 89
6.9.3 Change the oil in the exciter shaft housing 91
6.9.4 Changing hydraulic oil and filter 92
As required
6.10.1 Check the air filter, replace if necessary. 97
6.10.2 Tightening the screws 98
6.10.3 Engine conservation 99
76 BPH 80/65 S
Maintenance – Daily maintenance
6.6 Daily maintenance

6.6.1 Check the engine oil level
NOTICE!
Park the machine on level ground so that the
engine is in horizontal position.
For quality and quantity of oil refer to the "table of
fuels and lubricants".
Shut down the engine.

Pull the dipstick Ä Fig. 84 out, wipe it off with a lint-free,
clean cloth and reinsert it until it bottoms.
Pull out the oil dipstick again and read the oil level.
The oil level should reach the upper mark on the dipstick. If
the oil level is too low top up oil immediately.
Check the seal on the dipstick, replace if necessary.
Push the dipstick in again until it bottoms.
Fig. 84
6.6.2 Checking the fuel level
WARNING!
Fire hazard!
When working on the fuel system do not use open
fire, do not smoke, do not spill any fuel.
Do not refuel in closed rooms.
WARNING!
Health hazard!
NOTICE!
For quality and quantity of fuel refer to the "table of
ENVIRONMENT!
Catch running out fuel, do not let it seep into the
ground.
BPH 80/65 S 77
Clean the area around the filler cover, unscrew the filler cover
Ä Fig. 85.
NOTICE!
Contaminated fuel can cause malfunction or even
damage of the engine.
Fig. 85
Fill in fuel, if necessary through a funnel with screen.

Close the tank again.
6.6.3 Checking the hydraulic oil level
NOTICE!
If, during the daily inspection of the oil level the
hydraulic oil level is found to have dropped, check
all lines, hoses and components for leaks.
Check the hydraulic oil level in the inspection glass

Ä Fig. 86.
At room temperature of approx. 20¯C the hydraulic

oil level should reach approx. the middle of the
inspection glass.
Minimum level 1/3 of inspection glass.
Fig. 86
If necessary fill up hydraulic oil, unscrew the filler cap to do

so.
Fill in hydraulic oil, until it reaches the middle of the inspec-
tion glass.
Reassemble the filler cap.
78 BPH 80/65 S
6.6.4 Check the air filter service indicator
NOTICE!
Under very dusty conditions check the rubber bel-
lows several times every day.
Accelerate the engine for a short while to full speed.
If the rubber bellows Ä Fig. 87 contracts and covers the

green field, the air filter must be cleaned or, if necessary,
replaced (see chapter "Checking, cleaning or replacing the
air filter").
Fig. 87
6.6.5 Check the water separator
WARNING!
Fire hazard!
WARNING!
Health hazard!
ENVIRONMENT!
Any fuel must be caught and disposed of in an
environmentally friendly manner.
The inspection interval for the water separator

depends on the water proportion in the fuel and the
care that is exercised when refuelling, it shoulod
be carried out at least once per week.
BPH 80/65 S 79
Place the transparent container Ä Fig. 88 under the drain

plug.
Loosen the screw for approx. 2 to 3 turns and collect running
out water/fuel.
Since water is heavier than diesel fuel, water will

run out before the fuel. This can be noticed by a
clearly visible parting line.
Fig. 88
When only fuel comes running out, tighten the drain plug
again.
6.6.6 Check the rubber buffers

Check all rubber buffers Ä Fig. 89 for tight fit, cracks and
damage and replace immediately if damaged.
Fig. 89
80 BPH 80/65 S
Maintenance – Maintenance every month
6.7 Maintenance every month

6.7.1 Checking the condition of the battery
WARNING!
Danger of cauterisation !
When working on the battery do not use open fire,
do not smoke.
Do not let acid come in contact with skin or clothes.
Wear safety goggles.
Do not lay any tools on the battery.
Open the rear covering hood.

Remove the vibration insulation mat.
Remove the battery Ä Fig. 90 and clean the battery com-
partment.
Clean the outside of the battery.
Clean battery poles and terminals clamps and spray with
Tectyl.
Check the fastening of the battery.
Check the condition of the vibration insulation mat, replace if
Fig. 90
necessary.
Close the front covering hood again tightly after servicing the
battery.
Non-maintenance free batteries

NOTICE!
Top up missing fluid with distilled water.
Unscrew the plugs and check the acid level, if necessary top
up with distilled water
With control inserts:

Acid level up the bottom of the control inserts.
Without control inserts
Measure the acid level with a clean wooden stick 10 to 15 mm
above the upper edge of the lead plate.
With transparent battery housing
The acid level must reach the level mark on the housing.
Maintenance free batteries Perform only the following points:
BPH 80/65 S 81
Maintenance – Maintenance every month
Check the battery for cleanliness.

Clean the poles
Tighten the terminal clamps.
NOTICE!
Dispose of the old batteries environmentally.
WARNING!
Development of gas!
For recharging remove the plugs from the battery
to avoid the accumulation of highly explosive
gases.
82 BPH 80/65 S
Maintenance – Half-annual maintenance
6.8 Half-annual maintenance

6.8.1 Check, adjust the valve clearance
NOTICE!
We recommend to have this work carried out by
trained personnel or our after sales service.
Check and adjust only when the engine is cold.
The gasket for the cylinder head cover must be
generally renewed.
Check the valve clearance

Clean the area around the cylinder head.
Unscrew the cylinder cover and take it off with the seal ring
Ä Fig. 91.
Turn the engine in correct direction, until compression resist-
ance can be felt.
Fig. 91
Check the valve clearance with a feeler gauge on both valves

Ä Fig. 92.
Nominal value:
Intake and exhaust valve: 0.30 mm (0.012 in)
Fig. 92
BPH 80/65 S 83
Adjust the valve clearance

Slightly slacken the counter nut (2) Ä Fig. 93.
Adjust setscrew (1) with a screwdriver, until the feeler gauge
can be inserted and pulled out with little resistance after
retightening the counter nut.
Retighten the counter nut.
Install the cylinder head cover with a new gasket.
After a short test run check the valve cover for leaks.
Fig. 93
6.8.2 Clean the cooling fins and the cooling air intake openings
NOTICE!
Dirty operating conditions, particularly lubrication
oil and fuel deposits on the cooling fins of the
engine and the cooling air intake opening have an
adverse effect on the cooling of the engine.
You should therefore immediately seal any oil or
fuel leaks near fuel tank, cylinder or cooling air
intake.
NOTICE!
For cleaning the engine must be shut down and
cooled down.
Dry dirt
Open the front covering hood and clean the intake opening of
the cooling air section Ä Fig. 94.
WARNING!
Danger of injury!
Always wear protective clothes (goggles, gloves)
when working with compressed air.
Fig. 94
84 BPH 80/65 S
Dry clean the entire cooling air area on cylinder head, cyl-
inder and flywheel blades and blow them off with com-
pressed air Ä Fig. 95.
Fig. 95
Wet or oily contamination

WARNING!
Fire hazard!
Do not use any inflammable solvents.
NOTICE!
Do not subject electric assemblies and plug con-
nections to the direct water jet, or at least dry them
immediately after with compressed air.
Do not guide the water jet directly into air filter,
exhaust pipe and electrical components.
Look for the cause of oily contamination and have
any leaks sealed by our customer service.
Disconnect the battery.

Spray the entire cooling air area with cleaning solution (e.g.
cold cleansing agent), let it soak in for a while and wash off
with a powerful water jet.
Run the engine warm for a while to avoid corrosion.
6.8.3 Check the oil level in the vibrator housing
Park the machine on level ground.
BPH 80/65 S 85
Unscrew bleeding screw 1 Ä Fig. 96.
Fig. 96
Unscrew oil level inspection plug 2 Ä Fig. 97 and check the

oil level.
Some oil should run out of the oil level inspection

bore (1).
Fig. 97
If necessary top up oil. For this purpose unscrew filler plug

(3) and fill in oil.
Screw in filler plug (3) back in.
For quality and quantity of oil refer to the table of fuels and
lubricants.
Turn in level inspection plug (2) with a new seal ring.
Turn in bleeding screw 1 Ä Fig. 98.
Fig. 98
86 BPH 80/65 S
6.8.4 Replace the air filter
NOTICE!
Do not run the engine without air filter.
Remove the filter cover Ä Fig. 99.
Fig. 99
Take off the air filter Ä Fig. 100.
NOTICE!
The clean air side must be kept clean of dirt and
foreign particles.
Do not blow the inside of the filter housing out with
compressed air.
Fig. 100
Wipe the inside of the filter housing only with a clean cloth.
Clean the cover thoroughly.
Insert the new air filter Ä Fig. 101 into the housing.
Install the filter cover, ensure correct fit of cover and seal.
Fig. 101
BPH 80/65 S 87
Maintenance – Annual maintenance
6.9 Annual maintenance

6.9.1 Changing engine oil and oil filter
Perform this maintenance work at the latest after

250 operating hours
WARNING!
Danger of scalding!
When draining off hot oil.
By hot oil when unscrewing the engine oil filter.
NOTICE!
Drain the engine oil only when the engine is warm.
Tilt the machine slightly backward to drain off the
oil.
For quality and quantity of oil refer to the "table
of fuels and lubricants".
ENVIRONMENT!
Catch running out oil and dispose of environmen-
tally together with the oil filter.
Open the front cover.
Pull out the oil dipstick Ä Fig. 102.
Fig. 102
88 BPH 80/65 S
Unscrew the oil drain plug and catch running out old oil
Ä Fig. 103.
Clean the oil drain plug and screw it back in with a new seal
ring.
Park the machine on level ground.
Fig. 103
Unscrew the oil filter cover (3) Ä Fig. 104 and pull the oil
filter (1) out of the housing.
Clean the screen insert carefully to avoid bending of the wire
mesh.
Wipe out the oil filter cover and blow it clean with com-
pressed air.
Insert the new filter cartridge with the recess pointing down
(watch the "TOP" mark).
Check the O-ring (2), replace if necessary.
Fig. 104 Slightly oil the thread and the O-ring on the oil filter cover.
Tighten the oil filter cover.
Fill in new engine oil .
Insert the oil dipstick and check the oil level, correct if neces-
sary.
Perform a test run, inspect drain plug and oil filter for leaks.
Close the rear covering hood.
6.9.2 Replacing the fuel filter
WARNING!
Fire hazard!
WARNING!
Health hazard!
BPH 80/65 S 89
NOTICE!
The service interval to change the fuel filter
depends on the cleanliness of the fuel used. If nec-
essary this service must be performed every six
months.
Ensure strict cleanliness to keep dirt out of the fuel
lines.
ENVIRONMENT!
Dispose of the used fuel filter environmentally.
Clean the area around the filler cover, unscrew the filler cover
Ä Fig. 105.
Fig. 105
Place a suitable container under the fuel filter to catch run-

ning out fuel Ä Fig. 106.
Shut off the fuel supply line.
Fig. 106
Pull the fuel supply lines off both sides of the fuel supply and
install a new fuel filter Ä Fig. 107.
Fig. 107
90 BPH 80/65 S
Fuel filters must generally be replaced.

Mind the flow direction (arrow)
Open the fuel supply, if necessary prime fuel with the fuel
pump.
Close the tank again.
After a short test run check fuel filter and lines for leaks.
The fuel system is self bleeding.
6.9.3 Change the oil in the exciter shaft housing
ENVIRONMENT!
Catch running out old oil, do not let it seep into the
ground and dispose off environmentally.
For quality and quantity of oil refer to the ”table of
fuels and lubricants”.
Tilt the machine towards the drain side and support it

securely.
Unscrew bleeding screw (1) Ä Fig. 108.
Fig. 108
BPH 80/65 S 91
Unscrew filler plug (1) Ä Fig. 109 as well as level inspection

and drain plug (2).
Drain off and catch old oil.
Leave the machine in this position until all oil has

run out of the drain bore.
Fig. 109
Stand the machine horizontally.
Fill fresh oil in through the filler opening, until oil starts to run
out through inspection bore (1) Ä Fig. 110.
Screw in the inspection and drain plug (2) with a new seal
ring.
Screw in filler plug (3) back in.
Fig. 110
Turn in bleeding screw (1) Ä Fig. 111.
If the seal ring on the bleeding screw is worn use a

new bleeding screw with seal ring.
Fig. 111
6.9.4 Changing hydraulic oil and filter
Perform this maintenance work at the latest after

500 operating hours
92 BPH 80/65 S
WARNING!
Danger of scalding!
When draining off hot hydraulic oil.
Danger of scalding with hot oil when unscrewing
the hydraulic oil filter.
NOTICE!
Perform the oil change when the hydraulic oil is
warm.
The hydraulic oil must also be changed after major
repairs in the hydraulic system.
Do not use any detergents to clean the system.
Do not start the engine after draining the hydraulic
oil. Do not run the pumps without oil.
Replace the hydraulic oil filter with every hydraulic
oil change.
When changing from mineral oil based hydraulic oil
to an ester based biologically degradable oil, you
should consult the lubrication oil service of the oil
manufacturer for details.
ENVIRONMENT!
Catch running out oil and dispose of environmen-
tally together with the hydraulic oil filters.
Drive the machine, until the hydraulic oil has reached oper-
ating temperature.
Clean the area around the filler opening.
BPH 80/65 S 93
Unscrew the filler cap from the hydraulic oil tank Ä Fig. 112.
Fig. 112
Unscrew the leak oil connection Ä Fig. 113, let the hydraulic
oil run out and catch it.
Screw all nozzles back on.
Fig. 113
Unscrew the screws and take off the cover Ä Fig. 114.
Fig. 114
Unscrew the hydraulic oil filter Ä Fig. 115.

Attach the new hydraulic oil filter and screw it on.
Attach the lid Ä Fig. 114 with a new seal ring and fasten it.
Fig. 115
94 BPH 80/65 S
Unscrew and take off the filter housing (4) Ä Fig. 116.
Take out the filter element (1).
Clean the filter housing with a clean, lint-free cloth.
Renew O-ring (2) and backing ring (3).
Insert the new filter element.
Attach and tighten the filter housing.
Fig. 116
Fill in hydraulic oil until it reaches the middle of the inspection

glass.
We recommend to use our filling and filtering unit

with fine filter to fill the system. This ensures finest
filtration of the hydraulic oil, prolongs the lifetime of
the hydraulic oil filter and protects the hydraulic
system.
Loosen the fastening screws of the filler neck and remove the
complete screen element Ä Fig. 117.
Clean the screen.
Reinsert the filler neck and tighten the fastening screws.
Fig. 117
Unscrew the filler cap from the hydraulic oil tank Ä Fig. 118.
Fig. 118
BPH 80/65 S 95
After a short test run check the engine oil level

Ä Fig. 119and also check for leaks.
Fig. 119
96 BPH 80/65 S
Maintenance – As required
6.10 As required
6.10.1 Check the air filter, replace if necessary.
NOTICE!
Do not use gasoline or hot fluids to clean the filter.
Air filters with damaged filter element or seal ring
must be replaced in any case. It is therefore rec-
ommended to keep at least one air filter in stock.
Replace the air filter cartridge after five times
cleaning, but at the latest after half a year.
Each cleaning interval must be marked with a
cross on the cover of the air filter.
Cleaning does not make sense if the air filter ele-
ment is covered with a sooty deposit. Use a new
air filter.
Incorrectly handled air filters may become ineffec-
tive because of damage (e.g. cracks) and cause
damage to the engine.
In case of wet or oily dirt replace the filter element.
Do not run the engine without air filter.
Remove the filter cover Ä Fig. 120.
Fig. 120
Take off the air filter Ä Fig. 121.
NOTICE!
The clean air side must be kept clean of dirt and
foreign particles.
Do not blow the inside of the filter housing out with
compressed air.
Fig. 121
Wipe the inside of the filter housing only with a clean cloth.
Clean the cover thoroughly.
BPH 80/65 S 97
WARNING!
Danger of injury!
Always wear protective clothes (goggles, gloves)
when working with compressed air.
Blow the air filter Ä Fig. 122 out from inside to outside with
dry compressed air (max. 5 bar (72 psi)).
Hold the air filter under an angle to the light or examine it with
a lamp for cracks or other signs of damage, replace if neces-
sary.
NOTICE!
The air filter must be replaced if the slightest
Fig. 122 damage on filter paper or seal lips is found.
Insert the air filter Ä Fig. 123 into the housing.

Install the filter cover, ensure correct fit of cover and seal.
Fig. 123
6.10.2 Tightening the screws
Self locking nuts must always be replaced by new

ones after they have been unscrewed.
*Strength classes for screws with untreated, non-lubricated sur-

faces. The quality designations are stamped on the screw heads.
8.8 = 8 G
10.9 = 10 K
12.9 = 12 K
The values result in a 90% utilization of the screw's yielding point
at a coefficient of friction of μ total = 0.14.
The compliance with the tightening torques is to be checked with
torque wrenches.
Fig. 124 The tightening torques are not applicable when using MoS2 lubri-
cants.
98 BPH 80/65 S
6.10.3 Engine conservation

If the engine is to be shut down for a longer period of time (e.g.
over winter), we recommend the following measures to avoid cor-
rosion:
Clean engine and cooling system: With cold cleansing agent
and water jet or, even better, with steam cleaning equipment.
Run the engine warm and shut it down.
Drain the still warm engine oil and fill in anti-corrosion engine
oil.
Drain and catch the fuel from the fuel tank, mix it well with
10% anti-corrosion oil and fill it back in. Instead of mixing the
fuel with anti-corrosion oil you may also fill the tank with
injection pump testing oil with anti-corrosive properties (e.g.
Calibration fluid B).
Then run the engine for 10 minutes, so that lines, filter, pump
and nozzles are filled with the conserving mixture and the
new engine oil is distributed to all parts.
Take the cylinder head cover off, spray the rocker chamber
with a mixture of diesel fuel and 10% anti-corrosion oil. Then
fasten the cover again.
Crank the engine several times to spray the combustion
chamber (throttle lever in stop position).
Take the V-belt off and spray the grooves of the V-belt pulleys
with anti-corrosion oil. Remove the anti-corrosion oil before
taking the machine back into service.
Close air intake on air filter and exhaust opening tightly.
Depending on weather conditions these con-

serving 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 service.
Anti-corrosion oils are those that comply with the
MIL-L-21260 or TL 9150-037/2 resp. Nato Code C
640/642.
NOTICE!
A machine with conserved engine must be clearly
marked by attaching a clear warning tag.
BPH 80/65 S 99
100 BPH 80/65 S

Trouble shooting
7 Trouble shooting
BPH 80/65 S 101

Trouble shooting – General notes
7.1 General notes

Please observe strictly the safety regulations in the corre-
sponding section of these operating and maintenance instruc-
tions.
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 oper-
ation and maintenance.
If you cannot locate the cause of a fault or rectify it yourself by fol-
lowing the trouble shooting chart, you should contact our customer
service department.
102 BPH 80/65 S

Trouble shooting – Starting with jump wires
7.2 Starting with jump wires
Use this stating procedure if the starter battery is

discharged.
Fig. 125
Take the remote control out of the control box Ä Fig. 126.
Fig. 126
NOTICE!
A wrong connection will cause severe damage in
the electric system.
The auxiliary battery must have the same voltage
as the starter battery (12V).
Fig. 127
BPH 80/65 S 103

Trouble shooting – Starting with jump wires
Fold the protective cover of the battery up Ä Fig. 128.
Fig. 128
Join the plus poles on external battery and starter battery

with the jump wire Ä Fig. 129.
Use the second jump start cable to connect the negative
poles (ground) on external battery and starter battery.
Perform starting as described in the chapter "Stzarting the
engine".
When the engine is running remove the jump start cable from
the two negative poles first and from the positive poles after.
Fig. 129
This work sequence is necessary to avoid short cir-
cuit caused by contact between positive and nega-
tive cables.
Fold the battery cover down again.

Close and lock the covering hood.
Starting under low temperatures
NOTICE!
Do not use any starting aid spray Ä Fig. 130.
Fig. 130
104 BPH 80/65 S

Trouble shooting – Engine problems
7.3 Engine problems

Fault description Cause Remedy
No or poor starting of engine. But can Throttle lever in stop or idle Set the lever to Start position.
be cranked with the starter. speed position. Stop lever in
Stop position.
No fuel at the injection pump. Check the entire fuel system sys-
tematically.
Incorrect valve clearance Check, adjust the valve clearance.
No oil pressure Check the oil level.
(warning buzzer sounds, Check the oil level.
engine is shut down)
Fuel filter clogged Replace the fuel filter, fill in fuel
(can be detected if no fuel Replace the fuel filter, fill in fuel
runs out when pulling the fuel
line off)
Insufficiently charged battery Charge battery
Engine difficult to crank Oil with too high viscosity Drain the oil off and fill in oil with
lower viscosity
Engine has no compression no valve clearance Check, adjust the valve clearance
With low temperatures Fuel slurry caused by insuffi- Fill with a temperature resistant
cient low temperature resist- fuel mix
ance
Starter speed too low Drain off oil and fill in oil of correct
viscosity
(oil with too high viscosity) Drain off oil and fill in oil of correct
viscosity
Black exhaust smoke, engine may Air filter clogged Clean the air filter
have insufficient power (speed
drops), this is not caused by the Incorrect valve clearance Adjust the valve clearance
injection pump Injection nozzle defective Have examined by a specialist
Too much oil in crankcase Drain the oil down to the MAX-
mark on the dipstick
Insufficient engine power (speed Throttle lever does not stay in Block the throttle control.
drops) selected position
No exhaust smoke Air in injection system Have examined by a specialist
Fuel filter soiled Replace the fuel filter
Engine overheating Lack of cooling air Clean cooling air inlet and cooling
fins
Function of injection system Have examined by a specialist
not correct
Too much oil in crankcase Drain the oil down to the Max-mark
on the dipstick
BPH 80/65 S 105

Trouble shooting – Engine problems

Engine stops Fuel supply not correct
Fuel tank empty Fill in fuel
Fuel filter clogged Replace the fuel filter, check func-
tion of breather valve
(can be detected if no fuel Replace the fuel filter, check func-
runs out when pulling the fuel tion of breather valve
line off)
Vacuum in the fuel tank Clear the ventilation bore in the
filler cap
Throttle lever returns to stop Block the throttle control
position by itself
Lack of oil Return engine for repair, do not
continue to work (risk of total
damage)
106 BPH 80/65 S

Trouble shooting – Faults in radio remote control
7.4 Faults in radio remote control

Transmitter
Transmitter switched Power pack extremely Replace and recharge the power pack.
on, control lamp does discharged
not light
Rapid flashing of Power pack empty Replace and recharge the power pack.
warning lamp
Warning lamp flashing Neutral position warning Return the travel levers to rest position "0".
Other symptoms The fault detection in the Switch the transmitter off and on again, if the fault
transmitter has occurs again inform the customer service depart-
responded ment.
Receiver
Transmitter switched Selector switch for cable Set the selector switch to the correct position. Check
on, machine does not remote control/radio cable and plug connection, in case of damage inform
drive remote control incorrectly the customer service department.
adjusted. Power supply
for receiver faulty.
The control fails during Interference caused by Watch whether the interference occurs when e.g.
operation other radio systems operation of a radio system is started on an adjacent
construction (up to 800 m as the crow flies) or a con-
struction vehicle with radio remote control is used in
the vicinity. Change of frequency.
Battery charger
Insert power pack, con- Power failure Check the mains socket, insert another power pack;
trol lamp does not light if the fault is thereby rectified replace the first power
pack, if the fault is not rectified the battery charger is
defective.
BPH 80/65 S 107

Trouble shooting – Fault indicator
7.5 Fault indicator

The display module Ä Fig. 131 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.
Fig. 131
108 BPH 80/65 S

Trouble shooting – Fault code
7.6 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 1-5
BMFSA
Description of ”effects”
1 Warning, fault code is displayed,

audible signal in 5 second intervals.
2 Impairment of function, the faulty func-

tion 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 moni-
toring board in 5 second intervals.
BPH 80/65 S 109

Trouble shooting – Fault code
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.
5 Fatal fault. The function of the control

is no longer assured. The control will
be switched off. Fault code is dis-
played, signal lamp in monitoring
board lights permanently.
110 BPH 80/65 S

Trouble shooting – Fuse assignment
7.7 Fuse assignment
WARNING!
Fire hazard!
Do not use fuses with higher ampere ratings and
do not bridge fuses.
Fuse box
Fig. 132
Fuse Amperage Designation

F67 25A Fuse, BLM control
F54 5A Fuse cable remote control
F103 10A Fuses potential 15
F119 20A Fuse engine
BPH 80/65 S 111

Trouble shooting – Fuse assignment
112 BPH 80/65 S

Disposal
8 Disposal
BPH 80/65 S 113

Disposal – Final shut-down of machine
8.1 Final shut-down of machine

If the machine can no longer be used and needs to be finally shut
down you must carry out the following work and have the machine
disassembled by an officially recognized specialist workshop.
WARNING!
Danger of cauterisation ! Danger of explosion!
When working on the battery do not use open fire,
do not smoke!
The battery contains acid. Do not let acid come in
contact with skin or clothes!
Wear protective clothing!
Remove the batteries and dispose of in compliance with legal

regulations.
ENVIRONMENT!
Collect all fuels and lubricants, do not let them
seep into the ground and dispose of in compliance
with legal regulations.
Empty the fuel tank.

Drain lubrication oil from engine and exciter housing.
Drain off hydraulic oil.
WARNING!
Danger of explosion!
Parts that previously contained combustible fluids
must not be cut with a cutting torch.
114 BPH 80/65 S

Instruktsiya Bomag BPH 80 65 S

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Operating Instruction

S/N 101 700 15 1001>

Reversible vibratory plate

008 122 61 © 10/2016

6.6.5 Check the water separator......................................................................................................... 79

1.2 Machine type plate and engine type plate

Fig. 1: Machine type plate (example)

Please enter here:

Fig. 2: Engine type plate (example)

2.1 Noise data

Intended use This machine must only be used for:

Notes on safety in the operating

Paragraphs marked like this contain technical infor-

Starting the machine Before starting

Operation of the machine Persons in the danger area

Filling in fuel Do not inhale any fuel fumes.

Working on the engine

Repair Mark a defective machine by attaching a warning tag to the dash-

Information sticker - Tighten by handOptional equipment

4 Indicators and Controls

1 Toggle switch for cable remote control/radio remote control

4.1 General notes

4.2 Description of indicators and control elements

Position "Left" Cable remote control

n Dummy socket, spiral cable

n Sight glass for hydraulic oil level

n Main battery switch

If the power pack of the radio remote control is to

n Battery charge control light

lights yellow when switching the ignition on

n Oil pressure control light

lights red when switching the ignition on

The warning buzzer sounds. The engine shuts

Perform the starting process for maximum 15 to 20

Position 0 Insert or pull out key, ignition/engine

n Travel lever, right

Position 0 Neutral position to start engine /

The position of the two travel levers to each other

Position "rear" Reversing to the right

n Toggle switch, engine speed

Position "MIN" idle speed of engine

The engine speed can only be reduced when the

n Emergency stop push button

actuated transmitter and diesel engine will be

n Control light data transfer/power pack radio remote control

n Vibration toggle switch

Position "Vibration" Vibration is switched on.

Position "0" Vibration is switched off.

n Travel lever, left

Position 0 Neutral position to start engine /

The position of the two travel levers to each other

Position "rear" Reversing to the left

5.2 Tests before taking into operation

Park the machine on ground as level as possible.

Check Engine and machine for condition, and damage

For a description of the following tasks refer to the

Fuel level, top up if necessary

5.3 Preparing the cable remote control for operation

Strap the remote control to your body.

Make sure that the cable of the cable remote con-

Switch on the main battery switch Ä Fig. 24.

Switch the toggle switch Ä Fig. 25 to the "left" (cable opera-

If necessary unlock the emergency stop switch Ä Fig. 26 on