BPR 100 80d

Machine Translated by Google
Use and maintenance instructions
Original instruction manual
BPR 100/80 D
S/N 101 692 38 1001>
Reversible vibrator plate
Catalog no
008 202 94 SV © 12/2017
Table of Contents
Table of Contents
1 Preface................................................. ................................................ ................................................ 7
1.1 Preface................................................... ................................................... .......................................... 8
1.2 Machine nameplate and engine nameplate............................................ .............................................. 10
2 Technical data................................................... ................................................... ...................................... 11
2.1 Noise and vibration................................................... ................................................ ................. 14
2.1.1 Sound level value................................................ ................................................ ............................. 14 2.1.2 Vibration
values................ ................................................... ................................................... .... 14
3 For your safety................................................... ................................................ ................................... 15
3.1 Basic conditions................................................... ................................................ 16 3.1.1

General............................................... ................................................ ........................................ 16
3.1.2 Explanations for the signal terms used:............................................. .................................... 16 3.1.3 Personal protective
equipment.......... ................................................ ............................................. 17 3.1.4 Intended
use ................................................ ................................................ ................ 18 3.1.5 Intended
use.............................. ................................................... .................................... 18 3.2 Definitions of terms for the responsible
persons........ ................................................ ....... 20 3.2.1 The
operator...................................... ................................................ ............................. 20 3.2.2 Expert/authorized
person.............. ................................................ ......................................... 20 3.2.3 Driver/
operator.. .................. ................................................... ................................................... .. 20 3.3 The basics of safe
operation............................................ ................................................... ........... 22
3.3.1 Remaining dangers and risks............................................. ................................................ ......... 22
3.3.2 Regular safety check............................................. ................................................ ... 22 3.3.3 Modifications and changes
to the machine...................................... ........................................ 22 3.3.4 Damages, defects, misuse of safety
devices................................................... .................... 22 3.4 Handling of substances for
operation............................ ................................................ ....................... 23 3.4.1 Introductory
remarks..................... ................................................ ..................................... 23 3.4.2 Safety and environmental regulations in
the handling of diesel fuel. ................................................ 24 3.4 .3 Safety and environmental regulations in the handling of
oil................................... ..................... 25 3.4.4 Safety and environmental regulations in the handling of hydraulic
oil............ .................................... 26 3.4.5 Safety and environmental regulations in the handling of battery
acid.. ................................................... 27 3.4.6 Safety and environmental regulations in the handling of lubricating
grease..................................... ................... 28 3.5 Loading/transporting the
machine......................... ................................................... .......................... 29 3.6 Commissioning the
machine ................... ................................................ ................................................ 30 _
3.6.1 Before commissioning................................................ ................................................ .................... 30 3.6.2 Starting the
engine................... ................................................... ................................................ 30
3.7 Operation................................................... ................................................ ................................... 31
3.7.1 Persons in the risk zone............................................. ................................................... .................... 31
3.7.2 Drift............................................................................................................................................. 31
3.7.3 Park the machine............................................. ................................................... ....................... 31
3.8 Tanka............................................................................................................................................ 32
3.9 Maintenance work................................................... ................................................ ..................... 33
3.9.1 Introductory remarks............................................. ................................................ ............. 33 3.9.2 Actions on the
engine.............................. ................................................... .................................... 33 3.9.3 Work on electrical plant parts and
the battery.... ................................................... .......... 33 3.9.4
Cleaning................................... ................................................ .............................................. 33
BPR 100/80 D 3
Table of Contents
3.9.5 After performed service................................... ................................................ ....................... 34

3.10 Repairs................................................... ................................................ ............................ 35 3.11
Signs................... ................................................ ................................................ ................. 36
4 Displays and operating elements................................................ ................................................ ......... 39

4.1 Machine................................................... ................................................ ........................................ 40
4.1.1 Handle................................................ ................................................ ....................................... 40 4.1.2 Speed control

lever....... ................................................ ................................................... .... 40 4.1.3 Start
lock............................................ ................................................ ............................................ 40
4.1.4 Hour counter................................................ ................................................... ................................ 41
4.1.5 Control arm height adjustment............................................ ................................................ .................... 41 4.1.6 Latch

lever............................ ................................................ ................................................ .... 41 4.1.7 Display
ECONOMIZER............................................. ................................................ .................... 42 4.2
Engine............................ ................................................ ................................................ ............. 43
4.2.1 Ventilation lever............................................... ................................................... ......................... 43 4.2.2 Decompression
lever................... ................................................... ........................................... 43 4.2.3 Starter
crank.. ................................................... ................................................ ................................ 43
5 Checks before the start of operation................................................... ................................................ ................ 45
5.1 Safety instructions................................................ ................................................ ............... 46 5.2 Visual check and function
checks............................ ................................................ .... 47
5.3 Checking the engine oil level................................................ ................................................ ....... 48 5.4 Check the fuel level,
refuel...................................... ................................................ ......... 49 5.5 Checking the rubber
buffers................................... ................................................... ............ 50
6 Use................................................. ................................................ ...................................... 51 6.1 Lower the control
arm....... ................................................ ................................................ ........ 52 6.2 Starting the
engine...................................... ................................................... ...................................... 53
6.3 Operation................................................... ................................................ ................................... 55
6.4 Park the machine securely ............................................... ................................................ ............ 57
6.5 ECONOMIZER.............................................................................................................................. 58
7 Loading/transporting the machine................................................... ................................................... ............. 59

7.1 Load the machine................................................... ................................................ .......................... 60
7.2 Fasten the machine to the transport vehicle............................................. ................................... 61
8 Maintenance................................................. ................................................... ........................................... 63
8.1 Introductory remarks and safety instructions............................................ .................. 64 8.2 Preparatory/final

work.......................... ................................................ ................ 65
8.2.1 Open/close the service hatches............................................ ................................................ ........ 65 8.2.2 Bleed the fuel
system................................... ................................................ ....................... 66 8.3
Fuel............................ ................................................... ................................................ ......... 68
8.3.1 Engine oil................................................ ................................................ .................................... 68 8.3.2

Fuel......... ................................................ ................................................ .......................... 68
8.3.3 Oil for the vibration shaft housing............................................. ................................................ .......... 69 8.3.4 Mineral oil-
based hydraulic oil................................. ................................................ ................. 69 8.4 Fuel
table.............................. ................................................ ........................................ 71
8.5 Maintenance table................................................ ................................................ ........................ 72
8.6 Run-in regulation................................................... ................................................ .................. 73 8.6.1

General............................ ................................................ ................................................ ........ 73
4 BPR 100/80 D
Table of Contents
8.6.2 After 25 operating hours............................................ ................................................ ....................... 73
8.7 Every week................................................... ................................................ .................................... 74 8.7.1 Check/clean the

air filter........ ................................................ ............................................... 74 8.7. 2 Check, clean the water
separator................................... ............................................. 75 8.8 Every six
months. ................................................... ................................................... ............................. 76 8.8.1 Inspection of the
battery.............. ................................................... ................................................... .... 76 8.9 Once a year/every 250 operating
hours................................. ................................................... ...... 77 8.9.1 Change the V-
belt...................................... ................................................ .............................. ...... 77 8.9.2 Check, adjust the valve
clearance................................... ................................................ .............. 79 8.9.3 Change the engine oil and the oil filter
cartridge............................ ................................................ .............. 81 8.9.4 Replace the fuel
filter............................ ................................................ ...................................... 83 8.9.5 Change the air
filter...... ................................................ ................................................ ....................... 84 8.9.6 Change the oil in the vibration shaft
housing................... ................................................ ............................... 84 8.9.7 Checking the hydraulic oil
level.............. ................................................ ........................................ 86 8.9.8 Lubricate the
machine.... ................................................ ................................................ .. ............... 88 8.10 Every other year/after 500 operating
hours............................ ................................................ ............... 89
8.10.1 Change the hydraulic oil............................................. ................................................ ......................... 89 8.11 As

needed..................... ................................................ ................................................ ........ 91
8.11.1 Clean the machine................................................ ................................................... ...................... 91 8.11.2 Clean the

cooling fins and cooling air intakes................... ................................................... ............... 91 8.11.3 Maintenance of the V-
belt............................ ................................................ ................................ 92
8.11.4 Check the oil level in the vibration shaft housing............................................ .................................... 93 8.11.5 Actions before
the machine is shut down for a longer period of time.. ................................................ ........ 94
9 Help in case of errors................................... ................................................ ......................................... 97 9.1 Introductory
remarks..... ................................................... ................................................... .... 98 9.2 Emergency stop with starter
crank.......................................... ................................................... ................... 99 9.3 Starting the engine with the starter
cable............................ ................................................ ....................... 102
9.4 Fuse coating................................................... ................................................ ................ 103 9.5 Motor

fault............................ ................................................ ................................................ ... 104
9.6 Incorrect operation................................................... ................................................ ........................... 106
9.7 Fel i ECONOMIZERN............................................... ................................................ ................. 107
10 Waste management................................................... ................................................ .............................. 109 10.1 Scrapping the

machine............... ................................................ .......................................... 110
BPR 100/80 D 5
Table of Contents
6 BPR 100/80 D
Preface
1 Preface
BPR 100/80 D 7
Foreword - Foreword
1.1 Preface
BOMAG manufactures machines for compacting soil, asphalt and
waste, stabilizers/recyclers, cutters and pavers.
BOMAG's extensive experience and modern production and test methods, e.g.
durability tests on all important parts and high
quality requirements, guarantee that you get a machine with maximum
reliability.
These operating and maintenance instructions belong to your machine.
It gives you the necessary information to use your machine

safe and correct.
In addition, it contains information for necessary operation, maintenance and repair

actions.
Read your machine's operating and maintenance instructions carefully.
Observe the safety precautions and follow all instructions to

guarantee safe operation.
If you are not yet familiar with the machine's operating and indicating elements,
first carefully read each section before
you start working with the machine Chapter Ä 4 "Displays and control elements" on
page 39.
The description of the individual operating steps, including the safety instructions
that must be observed, can be found in the chapter Handling
Ä Chapter 6 “Usage” on page 51.
Carry out all prescribed visual and functional checks before

Ä
each commissioning Chapter 5 "Checks before commissioning"
on page 45.
Ensure that all prescribed operation, maintenance and repair measures are
followed to guarantee the functional safety of your machine.
The description of the maintenance to be carried out, prescribed

maintenance intervals and information on the operating items can be found in the chapter
Maintenance Ä Chapter 8 “Maintenance” on page 63.
Do not perform maintenance and repair the machine yourself to avoid

personal injury, property damage or environmental damage.
Maintenance and repair of the machine may only be carried out by qualified and
authorized personnel.
Contact our customer service for prescribed maintenance work or

necessary repairs.
In case of usage errors, lack of maintenance or if not approved

substances used for operation do not apply to the warranty.
For your own safety, use only BOMAG original parts.
We offer service sets for the machines to facilitate maintenance.
We reserve the right to make the changes caused by technical development

without prior information.
This driver and service manual is also available in other languages.
In addition, the spare parts catalog can be requested if the machine's

serial number is indicated.
The warranty and liability conditions according to the general business conditions
from BOMAG GmbH are not affected by these instructions.
8 BPR 100/80 D
Foreword - Foreword
We wish you the best of luck with your BOMAG machine.
BPR 100/80 D 9
Foreword – Machine nameplate and engine nameplate
1.2 Machine type plate and engine type plate
Enter here:
Machine type (1):
Serial number (2):
Figure 1: Machine nameplate (example)
Enter here:
Engine type (1):
Engine number (2):
Figure 2: Motor nameplate (example)
10 BPR 100/80 D
Technical data
2 Technical data
BPR 100/80 D 11
Technical data
Measure
picture 3
H H1 H2 L L1 In W1 W2
Dimensions standard
1035 1320 1560 1860 980 650 800 950
(40.7) (52.0) (61.4) (73.2) (38.6) (25.6) (31.5) (37.4)
Measurements in millimeters
(Measurements in inches)
Weights
Curb weight (CECE) (W) 677 kg
(1493) (lbs)
Operating weight (CECE) (W1 ) 700 kg
(1544) (lbs)
Operating weight (CECE) (W2 ) 716 kg
(1579) (lbs)
Dead weight 696 kg
(1535) (lbs)
12 BPR 100/80 D
Technical data
Weights
Starter crank (optional equipment) +3 kg
(+ 7) (lbs)
ECONOMIZER (optional equipment) +5 kg
(+ 11) (lbs)
Driving characteristics
Max. work speed 28 m/min
(92) (ft/min)
Max. hill climbing ability (terrain specific) 35 %
Power unit
Engine manufacturer finger
Type 1D90
Cooling system Air
Number of cylinders 1
Effect ISO 3046 10,3 kW
(13.8) (hk)
RPM 2600 min-1
Drive system mechanical
vibration system
Frequency 54 Hz
(3240) (v.p.m.)
Centrifugal force 100 kN
(22481) (lbf)
Amplitude 2,70 mm
(0,11) (in)
Refill volumes
Fuel (diesel) 10,0 l
(2.6) (gal us)
BPR 100/80 D 13
Technical data - Noise and vibration
2.1 Noise and vibrations

The noise and vibration data listed below have been determined according to the
following directives at the unit's typical operating conditions and using harmonized
standards:
n EC Machinery Directive in version 2006/42/EG

n Sound emission directive 2000/14/EC, noise protection directive
2003/10/EG
n Vibration Directive 2002/44/EG
In practical use, however, the values may deviate due to prevailing operating conditions.
2.1.1 Sound level value

Sound pressure level in the driver's seat LpA = 96 dB(A), determined according to ISO 11201 and EN 500.
WARNING!
Damage to the hearing at high noise levels.

– Use personal protective equipment (hearing protection).
Guaranteed sound pressure level LWA = 109 dB(A), determined according to ISO 3744 and EN 500.
2.1.2 Vibration values

Hand-arm vibration with control jumper Comfort The vector sum of weighted effective acceleration in the three perpendicular directions:
(optional equipment)
Total vibration value ahv £ 2.5 m/s2 , on gravel determined according to ISO 5349 and
EN 500.
Associated uncertainty K = 0.5 m/s2 , determined according to EN 12096.
Observe daily vibration load (occupational safety according to 2002/44/EC).
14 BPR 100/80 D
For your safety
3 For your safety
BPR 100/80 D 15
For your safety - Basic prerequisites
3.1 Basic prerequisites

3.1.1 General
This BOMAG machine corresponds to the current technical standard and is
designed and manufactured according to current regulations and technical rules.
The machine can still pose a danger to people and property, if: n it is not used in
the intended way, n it is driven or handled by untrained personnel, n it is modified

or rebuilt in an unprofessional manner, n the safety instructions are not followed.
Therefore, everyone who handles or drives the machine and who performs
service and repair on the machine must read and follow the safety regulations.
Where appropriate, the company that operates the machine can have the
personnel in question confirm these conditions in writing.
In addition, of course, the following also
apply: n applicable occupational health and safety

regulations, n generally accepted safety technical rules and road traffic rules
arrangements,
n for each country (each state) applicable national security measures
writings.
It is the user's responsibility to know and follow these safety regulations. This also
applies to local regulations and regulations for different types of handling. If the
recommendations in this manual deviate from current national regulations, the
regulations that apply in the respective country must be followed.
3.1.2 Explanations for the signal terms used:
GO!
Danger to life if these are not taken

into account Places marked in this way indicate an extremely
dangerous situation, which leads to death or serious personal
injury if the warning is not taken into account.
WARNING!
Danger to life or risk of severe personal injury if this is
not taken into account.
Places marked in this way indicate a dangerous situation,
which could lead to death or serious personal injury if the
warning is not heeded.
16 BPR 100/80 D
BEWARE!
Risk of personal injury if these are not heeded Places

marked in this way indicate a dangerous situation, which can
lead to minor personal injuries if the warning is not heeded.
REFERENCE!
Risk of material damage if these are not taken into account

Points marked like this indicate a possible risk of damage to the
machine or parts of the machine.
Places so marked provide technical information or instructions

regarding the use of the machine or components.
ENVIRONMENT!
Damage to the environment if these are not taken

into account Places marked like this give instructions on the safe
and environmentally friendly disposal of propellant and auxiliary
means as well as replacement parts.
3.1.3 Personal protective equipment Depending on the
current activity, personal protective equipment is required (must be made available by the operator):
Work protective clothing Tight-fitting work clothes with low tear resistance, with tight-fitting sleeves
and without protruding parts prevent the person from getting caught in
moving parts.
Safety shoes To protect against heavy falling parts and slipping on slippery surfaces.
Protective gloves To protect the hands against abrasions, punctures or deeper injuries,
against irritating and corrosive substances and against burns.
BPR 100/80 D 17
Safety glasses To protect the eyes from flying parts and splashes
from liquids.
Face protection To protect the face from flying parts and

splashes from liquids.
Protective helmet To protect the head against falling parts and for
protection against damage.
Ear protection To protect hearing against loud noises.
Respiratory protection To protect the respiratory tract against substances or particles.
3.1.4 Intended use

This machine may only be used for:
n Compaction of all types of soil

n Improvement and stabilization of all types of soil
n Road surface
n Dike works
n Filling and packing of ditches
The intended use also includes prescribed operating,

care and maintenance work is carried out.
3.1.5 Unintended use

In case of unintended use, risks may arise from the machine.
It is always the company that uses the machine or the driver/user responsible for
all possible risks due to non
intended use, not the manufacturer.
18 BPR 100/80 D
Examples of unintended use:

n If the machine is transported by towing after transport
the vehicle
n If the machine is thrown down from the loading surface of the transport
vehicle n If extra weights are attached to the machine
It is forbidden to stand on the machine during operation.

Fasteners must be removed before work use.
It is forbidden to start or use the machine in environments with
a risk of explosion or in underground facilities.
Prescribed lifting and lashing points according to this
instruction must be used. It is forbidden to use other lifting and
lashing points (e.g. handlebar, steering arm).
BPR 100/80 D 19
For your safety - Definitions of terms for the responsible persons
3.2 Concept definitions for the responsible persons

3.2.1 The operator
The operator is the natural or legal person who uses the
machine or on whose behalf the machine is used.
The operator must ensure that the machine is only used
appropriately and in compliance with the company's safety and
maintenance instructions.
The operator must determine and assess the hazards at the
workplace. This must determine the necessary occupational safety
measures for the employees and inform about remaining dangers.
The operator of the machine must determine whether there are
special hazards, such as when used in toxic ambient atmospheres
or used under restricted ground conditions. Such conditions require
additional measures to remedy or reduce a hazard.
The operator must ensure that all users read and understand the
safety information.
The operator is responsible for the planning and for the correct
implementation of regular safety checks.
3.2.2 Expert/authorized person

An expert/authorized person is a person who, due to their
professional training and experience, has sufficient knowledge in
the field of construction machinery and this specific machine.
The expert/authorized person is familiar with the applicable state

occupational safety regulations, accident prevention regulations,
directives and generally recognized technical rules (norms,
regulations, technical rules in other member states of the European
Union or EEA states) that he can assess whether the machine is in
a safe working condition.
3.2.3 Driver/operator
This machine may only be used by trained, instructed persons,
who work on behalf of the operator and who are at least 18 years
old.
Observe national laws and regulations.
Rights, obligations and rules of conduct for the driver/operator:
The driver or the operator must:

n know their rights and obligations, n use
protective equipment that is adapted to working conditions
the countries,
n having read and understood the operating instructions,
20 BPR 100/80 D
For your safety - Definitions of terms for the responsible persons
n have familiarized themselves with handling the machine,

n be physically and mentally able to drive and operate the
machine.
Persons under the influence of alcohol, drugs or narcotics may not
handle or drive the machine, nor perform service or repairs.
Special skills are required for service and repair. These works
may only be carried out by specially trained specialist personnel.
BPR 100/80 D 21
For your safety - The basics of safe operation
3.3 The basics of safe operation
3.3.1 Remaining dangers and risks
Despite the fact that the work is carried out with the utmost care and that all standards
and regulations are followed, it cannot be completely ruled out that additional risks
arise when the machine is handled.
Both the machine and all other system components correspond to the currently valid
safety regulations. Even though the machine is used in the intended way and even
though all instructions are followed, all risks cannot be completely excluded.
Nor can it be ruled out that a certain risk remains outside the machine's immediate
risk area. Persons staying in this area must pay attention to the machine in order
to react as quickly as possible in the event of a possible malfunction, incident,
breakdown, etc.
All persons who are within the area of operation of the machine must be informed
of the risks arising from the operation of the machine.
3.3.2 Regular security check

Depending on use and operating conditions, the machine must be checked by an
expert (authorized) person if necessary, but at least once a year.
3.3.3 Modifications and changes to the machine

For safety reasons, it is not permitted to carry out unauthorized changes to the
machine.
All original parts and accessories are specially designed for this machine.
We expressly point out that parts and accessories not supplied by us are also not
approved by us.
Installation and/or use of such products may affect the machine's active and/or
passive driving safety.
3.3.4 Damage, defects, misuse of safety devices

Machines that are neither functional nor traffic safe must be taken out of service
immediately and must not be used again until they have been repaired and restored
to faultless condition.
Safety devices and safety switches must not be removed or disabled.
22 BPR 100/80 D
For your safety - Handling of substances for the operation
3.4 Handling of substances for operation

3.4.1 Introductory remarks
The operator must ensure that all professional users are aware of
and consider the contents of the respective safety fact sheets.
Safety data sheets provide important information about the following

signs:
n Identification of the
substance n Potential
hazards n Composition/information on ingredients
n First aid measures n Fire-fighting measures n
Accidental release measures n Handling and
storage n Exposure controls/personal protective
equipment n Physical and chemical properties n
Stability and reactivity n toxicological data n environmental-
related data n data on waste management n data on
transport n legal regulations n other data
BPR 100/80 D 23
3.4.2 Safety and environmental regulations in the handling of diesel fuel
WARNING!
Risk of burns due to igniting diesel fuel.
- Diesel fuel must not end up in hot tanks

nenter.
- Smoking and open flames prohibited.
– Use personal protective equipment (protective gloves,
work protective clothing)
picture 4
BEWARE!
Danger to health in contact with diesel fuel.

work protective clothing)
- Do not inhale fuel fumes.
– Avoid contact
BEWARE!
Risk of slipping due to spilled diesel fuel.
– Immediately bind spilled diesel fuel with oil binding agent.
ENVIRONMENT!
Diesel fuel is an environmentally hazardous fuel.

- Always store diesel fuel in containers according to
the regulations.
– Bind spilled diesel fuel immediately and
dispose of it according to the regulations.
– Dispose of diesel fuel and fuel filters.
24 BPR 100/80 D
3.4.3 Safety and environmental regulations in the handling of oil
WARNING!
Risk of burns due to ignited oil.

- Oil must not get on hot components.
– Use personal protective equipment (protective gloves, work
protective clothing)
BEWARE!
picture 5
Danger to health in contact with oil.
– Do not inhale oil vapors – Avoid
contact
BEWARE!
Risk of slipping due to spilled oil.

– Immediately bind spilled oil with an oil binding agent.
ENVIRONMENT!
Oil is an environmentally hazardous substance.
- Always store oil in containers according to regulations

terns.
– Bind spilled oil immediately and dispose of waste
it according to the regulations.
- Oil and filter inserts must be disposed of according to the
regulations.
BPR 100/80 D 25
3.4.4 Safety and environmental regulations in the handling of hydraulic oil
WARNING!
Risk of personal injury due to extrusion

pressure fluid.
– Before any work on the hydraulic system
this must be done without pressure.
protective clothing, protective goggles)
picture 6
If pressure fluid penetrates the skin, immediate treatment is required
medical treatment.
WARNING!
Risk of burns due to ignited hydraulic oil.
– Hydraulic oil must not get on hot components.

BEWARE!
Danger to health in contact with hydraulic oil.

– Do not inhale oil fumes
– Avoid contact
BEWARE!
Risk of slipping due to spilled oil.

– Immediately bind spilled oil with an oil binding agent.
ENVIRONMENT!
Oil is an environmentally hazardous substance.
- Always store oil in containers according to regulations

terns.
– Bind spilled oil immediately and dispose of waste
it according to the regulations.
- Oil and filter inserts must be disposed of
according to the regulations.
26 BPR 100/80 D
3.4.5 Safety and environmental regulations in the handling of battery acid
WARNING!
Risk of personal injury due to acid.
work protective clothing, protective goggles)
- Acid must not get on clothes, the skin or in

the eyes.
– Immediately flush away spilled battery acid with
plenty of water.
Picture 7:
Acid on clothing, skin or eyes shall immediately

rinse with plenty of clean water.
See a doctor immediately in case of corrosion.
WARNING!
Risk of personal injury due to an exploding gas mixture.
- When recharging the battery, the sealing plugs must be

removed.
– Ensure sufficient ventilation.
– Do not place tools or other metal objects
on the battery.
– Do not wear jewelry (watch, chains, etc.).
work on the battery.
work protective clothing, protective goggles).
ENVIRONMENT!
Battery acid is an environmentally hazardous substance.
– Dispose of batteries and battery acid according to

the regulations.
BPR 100/80 D 27
3.4.6 Safety and environmental regulations in the handling of lubricating grease
BEWARE!
Danger to health in contact with lubricating grease!
– Use personal protective equipment (protective gloves, safety

glasses, work protective clothing).
– Avoid contact
B-SYM-0210
BEWARE!
picture 8
Danger of slipping through lubricating grease!
– Immediately wipe up and remove excess grease.
ENVIRONMENT!
Lubricating grease is an environmentally hazardous substance!
- Always store lubricating grease in containers according to regulations.
– Wipe up excess grease and dispose of

that according to current regulations.
– Dispose of rags soiled with lubricating grease according to
applicable regulations.
28 BPR 100/80 D
For your safety – Load/transport the machine
3.5 Loading/transporting the machine

Check that no one can be injured by the machine tipping over or sliding
off.
Anchor points that are damaged or whose functionality is limited must not be
used.
Always use suitable means of impact on the impact points.
The impact devices may only be used in the prescribed load direction.
Impactors must not be damaged by machine parts.
Secure the machine on the transport vehicle so that it does not roll, shift or tip
over.
Only an expert (authorized person) may attach and lift loads.
Only use lifting devices and impact devices with sufficient load capacity for
the weight to be loaded.
The lifting devices may only be attached to marked lifting points.
It is dangerous to walk or stand under a lifted load.
When lifting, check that the load does not start to swing uncontrollably. If
required, the load must be held using guide lines.
BPR 100/80 D 29
For your safety – Put the machine into operation
3.6 Put the machine into operation
3.6.1 Before commissioning

Only use machines that have received regular service.
Familiarize yourself with the machine's equipment, operating and indicating
elements, as well as its working method and working area.
Use personal safety equipment (safety helmet, safety shoes,
possibly also safety glasses and hearing protection).
Do not transport loose objects or do not attach any loose objects to
the machine.
Before commissioning, check that: n

no people or obstacles are next to or in front of the machine, n no oily or
flammable material is on the machine, n all protective devices are attached,
n all handles are clean of grease, oil, fuel, dirt, snow and ice.
Through all prescribed visual and functional checks for commissioning.
If damage or other defects are found during the checks, the machine
must not be used until it has been repaired.
Do not operate the machine with defective control and display elements.
3.6.2 Start the engine
Do not use a starting aid such as a starting pilot, ether or the like.
The machine must not be started if one or more safety devices are
damaged, not working or missing.
Before starting and before operating the machine, check that no one is in
the danger area.
When the engine is running, the machine must always be held and
supervised.
Do not inhale exhaust fumes. They contain toxic substances, which can
lead to damage to health, unconsciousness or death.
When operating in closed or partially closed premises or recesses in
the ground, there must be sufficient venting and ventilation.
30 BPR 100/80 D
For your safety - Work operation
3.7 Operation
3.7.1 Persons in the risk zone

Check before starting work, also after interruption of work, that there are no
people or obstacles in the risk area.
If applicable, give a warning signal. Stop work immediately if the person in

question does not leave the risk area despite a warning.
3.7.2 Drift
The machine may only be driven with the control arm folded down.
The machine may only be controlled using the control arm.
Move the machine so that your hands do not strike any solid objects.
Move the machine to the side by the handle when reversing.
Observe unusual noises and abnormal smoke development. Determine

the cause and have the damage repaired.
Always keep sufficient distance to construction site edges, slopes and edges.
Do not perform any work that affects the stability of the machine.
3.7.3 Park the machine

If possible, park the machine on a horizontal, flat, firm surface.
Before leaving the machine:
n Switch off the engine, remove the ignition key.

n Secure the machine against tipping. n Secure
the machine against unauthorized use.
Mark a parked machine in a clearly visible manner if it is an obstacle to other

vehicles.
BPR 100/80 D 31
For your safety – Refuel
3.8 Tanka
Do not inhale fuel fumes.
Refuel only when the engine is switched off.
Do not refuel indoors.
Smoking and open flames prohibited.

Ultra-low sulfur diesel fuel has a greater risk of ignition due to static
charging than higher sulfur diesel fuel.
Take measures against electrostatic charging.

Do not spill fuel. Catch spilled fuel so it doesn't seep into the ground.
Wipe up spilled fuel. Make sure the fuel does not come into contact with
water or contaminants.
Leakage in the fuel tank can cause an explosion. Check that the fuel
tank cap closes tightly. If applicable, replace the cover immediately.
32 BPR 100/80 D
For your safety – Maintenance work
3.9 Maintenance work

3.9.1 Preliminary remarks
Follow the prescribed operation, maintenance and repair procedures.
Maintenance of the machine may only be carried out by qualified personnel
authorized by the operator.
Do not allow unauthorized persons to come near the machine.

Maintenance work may only be carried out when the engine is at a standstill.
Ensure that the engine cannot be accidentally started during maintenance work.
3.9.2 Actions on the engine

Drain the engine oil when it is at operating temperature - risk of burns!
Wipe off excess oil, collect leaking oil and dispose of according to current
environmental protection regulations.
Make sure that no dirt falls into the air duct when working on the air filter.
Do not work on the exhaust system when it is hot. Risk of burns.
Store used filters and other oil-soaked materials in a separate container with a special
label and dispose of these parts according to applicable environmental regulations.
3.9.3 Work on electrical plant parts and the battery

Disconnect the battery and cover with insulating material before starting work on the
electrical system.
Do not insert fuses with a higher amperage than specified or do not jump fuses.
When working on the battery, smoking and open flames are prohibited!
Do not place tools or other metal objects on the battery.
Do not wear jewelry (watch, chains, etc.) when working on the battery.
The battery connection cable must not touch or rub against machine parts.
3.9.4 Cleaning
Cleaning must not take place while the engine is running.
Allow the engine to cool before cleaning.
Do not use gasoline or other flammable substances when cleaning.
BPR 100/80 D 33
For your safety – Maintenance work
3.9.5 After service performed
Replace all protective devices.
34 BPR 100/80 D
For your safety - Repairs
3.10 Repairs
Attach a clearly visible warning sign to the machine if the machine is
malfunction.
The machine must not be put back into operation until the necessary repairs have been made
performed.
When replacing safety-relevant components, only original service parts may be used.
Repairs may only be carried out by an expert/authorised person.
Cover the fuel tank with insulating material if welding work is to be carried out on the machine.
BPR 100/80 D 35
For your safety - Signs
3.11 Signs
Make sure all decals and signs are on the machine and are legible.
Replace damaged and illegible decals or signs immediately.
II
START
OPERATION
STOP
008 338 42
Made by
Designation Type
Nominal Power Operating Mass Year of Construction
Serial-No.
Patent Protection
56154 Boppard;GERMANY Made in Germany
B-692-0223
picture 9
36 BPR 100/80 D
Warning sign - observe the operating instructions
picture 10
Information sign - lashing point
picture 11
Information sign - lift point
picture 12
Instruction plate - drive lever
picture 13
BPR 100/80 D 37
Instruction plate - speed adjustment lever
picture 14
Mandatory sign - use hearing protection/short instruction sign
picture 15
Information sign - guaranteed sound pressure level
picture 16
Machine nameplate (example)
Made by
Designation Type
Nominal Power Operating Mass Year of Construction
Serial-No.
Patent Protection
56154 Boppard;GERMANY Made in Germany
B-DEC-0241
picture 17
38 BPR 100/80 D
Displays and control elements
4 Displays and control elements
BPR 100/80 D 39
Displays and operating elements – Machine
4.1 Machine
4.1.1 Handle
bring forward Forward driving
bring back Reverse drive
B-692-0224
Picture 18
4.1.2 Speed control lever

Position "STOP" Engine from
STOP
Position "MIN" Idle mode

I
Mode "I" Medium load mode
Mode "II" Full load mode

II
B-692-0225
picture 19
4.1.3 Start lock
Mode "P"/"0" Ignition from
Pull-out ignition key
Mode "I"/"II" Ignition ON
The warning buzzer sounds.
Position "III" Turn further against the spring pressure, the engine
starts
Return the ignition key to position "I" when

B-ELE-0069 the engine starts
picture 20
The starter lock has a lock against repeated starting. The start
key must first be turned to the "0" position before restarting
can happen.
40 BPR 100/80 D
4.1.4 Hour meter
B-692-0217
picture 21
4.1.5 Control arm height adjustment
turn clockwise Lift the steering arm
turn counterclockwise Lower the control arm
B-692-0218
picture 22
4.1.6 Locking lever
B-692-0219
picture 23
BPR 100/80 D 41
4.1.7 Display ECONOMIZER

The ECONOMIZER shows the compaction state of the layer to be
sealed.
Description of display options "ECONOMIZER"Ä Chapter 6.5

on page 58.
Additional equipment
picture 24
42 BPR 100/80 D
Displays and control elements – Motor
4.2 Motor
4.2.1 Ventilation lever
press for approx. 15 seconds The fuel system is bled
B-692-0157
picture 25
4.2.2 Decompression lever

Mode "Closed" The engine has compression
Normal operation
Mode "Open" The engine lacks compression
Only for emergency starting with starter crank (extra

equipment) and maintenance
REFERENCE!
B-834-0187
Risk of engine damage.
picture 26 Opening the decompression lever while the engine is running

will result in engine damage.
– Never use the decompression lever to stop the engine.
4.2.3 Startvev
Only start the engine with the starter crank if the battery is defective,
empty or missing.
B-692-0220
picture 27
BPR 100/80 D 43
Displays and control elements – Motor
44 BPR 100/80 D
Checks before the start of operation
5 Checks before the start of operation
BPR 100/80 D 45
Checks before the start of operation - Safety instructions
5.1 Safety instructions

If damage or other damage is found during the following checks
defects, the machine must not be used until it has been repaired.
Do not operate the machine with defective control and display elements.
Safety devices and switches must not be removed or removed

function.
Fixed setting values may not be changed.
WARNING!
Health hazard from operational substances.
– Observe safety and environmental regulations when
handling substances for operationÄChapter
substances
3.4 "Handling
for
operation" on page 23.
WARNING!
Risk of personal injury due to rotating parts.
– Before working on the machine, check that the diesel
engine cannot be started.
1. Park the machine securely Ä Chapter 6.4 "Park the machine

secured.” on page 57.
46 BPR 100/80 D
Checks before the start of operation – Visual check and functional checks
5.2 Visual inspection and functional checks

1. Check that the fuel tank and lines are in good condition
and dense.
2. Check the tightening of the screw connections.

3. Check the machine for dirt and damage.
4. Check air intake area for dirt.
BPR 100/80 D 47
Checks before starting operation – Check the engine oil level
5.3 Check the engine oil level
REFERENCE!
– Only use oil with an approved specification Chapter

Ä 8.3.1 "Engine oil" on page 68.
Protective equipment: n Work protective clothing

n Protective gloves
1. Clean around the dipstick.

2. Pull out the oil dipstick, wipe it with a clean, lint-free cloth and
insert it to the stop.
3. Pull out the oil dipstick again.
ð The oil level must be between the "MIN" and "MAX" marks
no.
4.
REFERENCE!
picture 28 – Do not overfill the engine oil.
Add engine oil up to the "MAX" mark if the oil level is too low.
5. Insert the oil dipstick.
48 BPR 100/80 D
Checks before the start of operation – Check the fuel level, refuel
5.4 Check the fuel level, refuel
REFERENCE!
- Constantly monitor refueling.

- Contaminated fuel can cause malfunctions
or damage the engine. If necessary,
the fuel is filled through a filter.
– Only use fuel with an approved specification
cation Ä Chapter 8.3.2 "Fuel" on page 68.

n Protective gloves
1. Clean around the filling hole.

2. Remove the cap and visually check the fill level.
3. If necessary, top up with fuel through a sieve-equipped funnel.
4. Close the lid.
If the fuel tank has been run completely empty or

at the first filling of the fuel tank,
Ä
bleed the fuel system before starting Chapter
picture 29
8.2.2 “Bleed the fuel system” on page 66
BPR 100/80 D 49
Checks before the start of operation – Check the rubber buffers
5.5 Check the rubber buffers

n Protective gloves
1. Park the machine securely secured.” Ä Chapter 6.4 "Park the machine
on page 57.
2. Allow the engine to cool.
3. Check that all rubber buffers are secure and that they are not
has some cracks or fraying.
4. Replace damaged rubber buffers immediately.
picture 30
50 BPR 100/80 D
Use
6 Use
BPR 100/80 D 51
Operation – Drop down the control arm
6.1 Lower the control arm

1. Pull down the latch (2) and fold down the control arm.
ð The control arm can swing freely.
2. Set the control arm using the height adjustment (1) to the desired height.
Picture 31
52 BPR 100/80 D
Use – Start the engine
6.2 Start the engine
Exhaust gases contain toxic substances, which can lead to damage to

health, unconsciousness or death.
WARNING!
Risk of poisoning due to exhaust gases.

– Do not inhale exhaust gases.
– When operating in closed or partially closed premises or
there must be recesses in the ground for sufficient
venting and ventilation.
WARNING!

Protective equipment: n Hearing protection

n Safety shoes
1. Set the speed control lever to the "MIN" position.
Picture 32
2. Bring the handle to the zero position.
Picture 33
BPR 100/80 D 53
Use – Start the engine
3. Turn the ignition key to position "I".
ð The warning buzzer sounds.
Picture 34
4.
The starter lock has a lock against repeated starting.

The ignition key must first be turned to the "0" position
before restarting can take place.
REFERENCE!
Machine parts can be damaged!
– Start a maximum of 30 seconds continuously or a maximum of

three times 10 seconds. Then let the starter cool down to
Picture 35 ambient temperature.
- If the engine has not started after the starting attempts, the
cause must be determined.
Turn the ignition key via position "II" to position "III".
ð The starter pulls the engine.
The warning buzzer goes silent.
REFERENCE!
– Warm up the engine briefly before starting work. Do

not load the engine with full load immediately.
54 BPR 100/80 D
Use – Work operation
6.3 Operation
The machine may only be driven with the control arm folded down.
The machine may only be controlled using the control arm.
Move the machine so that your hands do not strike any solid objects.
Remove your feet from the vibrating base plate.
BEWARE!
Risk of personal injury due to uncontrolled machine

movement.
- Always hold the machine when it is running.

- Always keep the machine under supervision when it is in
walk.

n Safety shoes
1. Make sure no one is in the danger zone.
2.
II REFERENCE!
I The centrifugal force coupling may be damaged.

– Only operate the machine at full throttle.
Set the speed control lever to position "I" or "II".
B-692-0195
Picture 36
3. Move the grip forward.
ð The machine vibrates forward at a speed corresponding to the movement

of the drive lever.
Picture 37
BPR 100/80 D 55
Use – Work operation
4.
BEWARE!
Risk of personal injury due to crushing

of body parts!
– Move the machine to the side by the handle
reversing.
Move the handle back.
ð The machine vibrates backwards at a speed corresponding to

the rash of the grip.
Picture 38
5. Return the grip to the zero position.
ð The machine stops and vibrates in place.
Picture 39
6. Set the speed control lever to the "MIN" position (idle) after
short work breaks.
ð The vibration is off.
7. Always switch off the machine safely during longer work breaks
Ä Chapter 6.4 "Park the machine securely." on page 57.
B-692-0180
picture 40
Action in the event of a stuck machine 1. Park the machine securely secured.” Ä Chapter 6.4 "Park the machine
on page 57.
2. Lift the machine with a suitable lifting device and fastening device
intended lifting point until it hangs freely Chapter Ä
7 "Loading/ transporting the
machine" on page 59.
56 BPR 100/80 D
Use – Park the machine securely.
6.4 Park the machine securely.

1. Move the machine to an even and firm surface.
2. Return the grip to the zero position. ð The
machine stops and vibrates in place.
Picture 41
3. Set the speed control lever to the "MIN" (idle) position.
ð The vibration is switched off.
B-692-0180
Picture 42
4.
REFERENCE!
Risk of engine damage
- Do not suddenly switch off the engine when it is running at full

load, but first let it idle for about 2 minutes.
Set the speed control lever to the “STOP” position.
B-692-0181 ð The engine is switched off.
Picture 43 The warning buzzer sounds.
5. Set the ignition key to "0" and pull it out. ð The warning
buzzer goes silent.
Picture 44
BPR 100/80 D 57
Usage – ECONOMIZER
6.5 ECONOMIZER
The ECONOMIZER shows the road substructure's compaction condition and
makes it possible to find and target local worse places.
With an acceleration sensor at the base plate, the reaction of the road infrastructure
on the base plate of the vibrator plate is measured.
Start procedure When the ignition is switched on, ENONOMI ZERN is also automatically started.
The ECONOMIZER first performs an LED test. The LEDs light up in individual steps
starting with LED (1). When all ten LEDs light up, the indication goes out in individual
steps again.
Metering operation
When vibration is switched on, the measured value is shown with the LED displays (1 -
10).
If the displayed value does not rise, no increased compression can be achieved with the
machine used.
Maximum displayed value (LED displays 1–10 and the warning display is reached a) not
in every case.
Due to fluctuations in the measured value, the display value during

a drive over a distance can vary up/ down by one step.
Decisive is the average value during the last over.
Picture 45 The warning display (a): n
flashes for about 1 - 2 seconds after the vibration is switched on. The display turns off
as soon as the vibration frequency is reached. n flashes when the vibration
frequency is too low. n lights up while at the same time the LED displays (1–10) have
gone out if no vibration is detected.
Comparability of measurement values In order to achieve the desired compaction state of the road substructure, a suitable
reference measurement must always be made before the material is compacted.
With the reference measurement, it is determined which of the ECONOMIZERN's

displayed values corresponds to the measured value for the ground stiffness.
58 BPR 100/80 D
Load/transport the machine
7 Load/transport the machine
BPR 100/80 D 59
Load/transport the machine – Load the machine
7.1 Load the machine

Only an expert (authorized person) may attach and lift loads.
Anchor points that are damaged or whose functionality is

restricted must not be used.
Only use lifting devices and impact devices with sufficient load capacity
for the weight to be loaded. The lifting device's minimum load capacity: see service
weightÄ Chapter 2 "Technical data" on page 11.
When lifting, check that the load does not start to swing uncontrollably. If
if required, the load must be held using guide lines.

n Protective gloves
on page 57.
3. Ensure that the protective hood is correctly screwed on 8.2.1.2 Ä Chapter

"Close the protective hood" on page 66.
4. Set the control arm vertically and let the latch engage.
Picture 46
5. Hang the lifting devices in the intended lifting eye.

6.
GO!
Danger to life with hanging loads.

– Do not stay under suspended loads.
Carefully lift the machine and set it down on the intended

the place.
Picture 47
60 BPR 100/80 D
Loading/transporting the machine – Fasten the machine to the transport vehicle
7.2 Secure the machine to the transport vehicle

Anchor points that are damaged or whose functionality is limited
must not be used.


n Protective gloves
1. Cross at least two suitable tensioning straps over the marked anchor
point.
Picture 48
2. Securely lash the machine to the transport vehicle as

all.
Picture 49
BPR 100/80 D 61
Loading/transporting the machine – Fasten the machine to the transport vehicle
62 BPR 100/80 D
Maintenance
8 Maintenance
BPR 100/80 D 63
Maintenance - Introductory Notes and Safety Instructions
8.1 Preliminary remarks and safety instructions
GO!
Danger to life if the machine is not operable.
- Maintenance of the machine may only be done by

qualified and authorized personnel.
– Observe safety regulations during maintenance work Chapter
3.9 "Maintenance
Ä work"
on page 33.
WARNING!
– Observe safety and environmental regulations when handling

Ä "Handling
substances for operation Chapter 3.4 for operation"
substances
on
page 23.
Use personal protective equipment.

Do not touch the hot parts of the engine.
Park the machine on a horizontal, level, firm surface.

Maintenance work may only be carried out when the engine is at a standstill.
Ensure that the engine cannot be accidentally started in connection with

the maintenance work.
Clean the machine and engine thoroughly before any service.
Do not leave tools or other objects that could cause

damage in or on the machine.
Dispose of propellant, filters, sealing elements and rags in accordance with

applicable environmental protection regulations after maintenance work has been carried out.
Refit all protective devices after servicing.
64 BPR 100/80 D
Maintenance – Preparatory/finishing works
8.2 Preparatory/final work

Some maintenance work requires preparatory and finishing work.
These include e.g. to open and close maintenance hatches and maintenance
doors and to secure certain components.
After the work has been completed, all maintenance hatches and under-doors must
be closed again and all components made ready for operation.
8.2.1 Open/close the service hatches 8.2.1.1 Open
protective hood
Protective equipment: n Work protective clothing n

Protective gloves
1. Unscrew the rear screws (2) on both sides of the machine.
2. Put the screws (2) and associated washers aside.
3. Loosen the front screw (1) on both sides.

4. Fold the protective hood forward.
picture 50
5. Secure the protective hood against accidental closing.
Tighten the screw (1) on both sides.
Picture 51
BPR 100/80 D 65
8.2.1.2 Close the protective hood
Use only original screws to screw the protective hood.

Always screw in and tighten all screws with washers.

n Protective gloves
1. Loosen the screw (1) on both sides.
2. Close the protective hood.
Picture 52
3. Tighten the screw (1) on both sides.
4. Screw in the screws (2) with washers on both sides and tighten
At them.
Picture 53
8.2.2 Bleed the fuel system

The fuel cut-off valve automatically cuts off the fuel supply to the engine if the oil
pressure is too low.
This makes bleeding the fuel system necessary in the following situations:
n After an engine shutdown because the fuel tank has been run empty. n After the
first filling of the fuel tank. n After turning the starter crank without starting, e.g. at low
temperatures
peratures. n
After several failed start attempts. n After replacing
the fuel filter.
66 BPR 100/80 D

n Safety shoes
n Protective gloves
2. Check engine oil level, top up if necessary.
The fuel tank must be full for bleeding.
3. Check the fuel level, top up if necessary
4. Press the venting lever for about 15 seconds against the spring.
ð The engine is ready to start.
If the engine does not start after bleeding,

contact our customer service.
Picture 54
BPR 100/80 D 67
Maintenance – Fuel
8.3 Fuel
8.3.1 Engine oil
8.3.1.1 Oil quality
The following engine oil specifications are permitted:
n API CF/CH-4 or higher grade n ACEA B3/E4 or

higher quality Avoid mixtures of engine oil.
8.3.1.2 Oil viscosity
Since the viscosity (inertia) of the engine oil changes depending on the
temperature, the ambient temperature of the engine's working place is decisive
when selecting the viscosity class (SAE class).
The temperature data for the SAE class always refer to fresh oil. When driving,
engine oil ages due to soot and fuel residues. As a result, the engine oil's
properties deteriorate significantly, above all at low outside temperatures.
Optimum operating conditions can be achieved if you orient yourself according to

the oil viscosity diagram.
Figure 55: Oil viscosity diagram
8.3.1.3 Oil change intervals
Once a year or every 250 operating hours.
When changing to an oil quality with a higher alloy after a

longer operating time, we recommend that the first change of
the high-quality oil is carried out after 25 operating hours.
8.3.2 Fuel
8.3.2.1 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 comply with the national emission regulations, the legally prescribed
fuels must be used (e.g. sulfur content).
68 BPR 100/80 D
8.3.2.2 Winter fuel
In winter, only winter diesel should be used to prevent plugs of

precipitated paraffin from forming.
At very low temperatures, you have to count on disturbing precipitations
also when using winter diesel.
For arctic climates, diesel fuels down to -44 °C (-47 °F) are available.
REFERENCE!
- It is not permitted to mix in kerosene or other fuel

additives.
8.3.2.3 Storage
Even traces of zinc, lead and copper can lead to deposits in the
injection nozzles, especially on the modern Common Rail injection
systems.
Therefore, zinc or lead surface treatments not permitted in tank
installations and fuel lines. Copper-containing materials (coupler lines,
metering parts) must also be avoided, as they can lead to catalytic
reactions in the fuel with subsequent deposits in the injection system.
8.3.3 Oil for the vibration shaft housing

Use only engine oil according to the following specifications: n
API CI-4 or higher grade Avoid mixtures of engine oil.
REFERENCE!
– Do not use motor oils with a low ash content

for the vibration shaft housing.
8.3.4 Mineral oil-based hydraulic oil

The hydraulic system is operated with hydraulic oil HV 32 (ISO) with a
kinem. viscosity of 32 mm2 /s at 40 °C (104 °F).
For refilling or oil change can only use hydraulic oil of type HVLP
according to DIN 51524, part 3, resp. hydraulic oils of type HV according
to ISO 6743/4 are used.
BPR 100/80 D 69
The oil's viscosity index must be at least 150 (observe the manufacturer's information).
70 BPR 100/80 D
Maintenance - Fuel Table
8.4 Fuel table

Unit Fuel Refill quantity
Summer Winter Note the level
marking!
Engine oil SAE 10W-40 1,9 l
Specification: Ä Chapter 8.3.1 "Engine oil" on page 68 (0.5 gal us)

SAE 15W-40
SAE 10W-30
SAE 30 SAE 10W
Fuel Diesel Winter diesel 10,0 l
Specification: Ä Chapter 8.3.2 "Fuel" on page 68 (2.6 gal us)
Vibration shaft housing SAE 10W-40 0,8 l
Specification: Ä Chapter 8.3.3 "Oil for vibration shaft (0.21 gal us)
housing" on page 69
SAE 15W-40
SAE 10W-30
Steering arm Hydraulolja (ISO), HV 32 0,4 l
Specification: Ä Chapter 8.3.4 "Mineral oil-based hydraulic (0.11 gal us)

oil" on page 69
BPR 100/80 D 71
Maintenance – Maintenance table
8.5 Maintenance table

No. Maintenance Like
Run-in regulations
8.6.1 Generally 73
8.6.2 After 25 operating hours 73
Every week
8.7.1 Check/ clean the air filter 74
8.7.2 Check, clean the water separator 75
Every six months
8.8.1 Supervision of the battery 76
Once a year/ every 250 operating hours
8.9.1 Byt kilremmen 77
8.9.2 Check, adjust the valve clearance 79
8.9.3 Change engine oil and oil filter cartridge 81
8.9.4 Replace the fuel filter 83
8.9.5 Change the air filter 84
8.9.6 Change the oil in the vibration shaft housing 84
8.9.7 Check the hydraulic oil level 86
8.9.8 Lubricate the machine 88
Every two years/ after 500 operating hours
8.10.1 Change the hydraulic oil 89
Based on needs
8.11.1 Clean the machine 91
8.11.2 Clean the cooling fins and cooling air intakes 91
8.11.3 Maintain the V-belt 92
8.11.4 Check the oil level in the vibration shaft housing 93
8.11.5 Actions before the machine is shut down for a longer period of time 94
72 BPR 100/80 D
Maintenance – Run-in regulations
8.6 Run-in regulation

8.6.1 General
When new machines or refurbished engines are put into operation, the following must
maintenance work is carried out.
8.6.2 After 25 operating hours

1. Change engine oilÄChapter 8.9.3 "Change engine oil and oil filter cartridge" on
page 81.
2. Check and prioritize. drop in valve clearance “Check, adjust Ä Chapter 8.9.2
valve clearance” on page 79.
3. Check for leaks in the engine and machine.

4. Tighten the fixing screws for the air filter, muffler and others
additional parts.
5. Retighten all screw connections on the machine.

6. Check the V- belt the belt” Ä Chapter 8.11.3 "Maintenance wedge
on page 92.
7. Check the oil level in the vibration shaft housing ChapterÄ8.11.4
“Check oil level in vibration shaft housing” on page 93.
BPR 100/80 D 73
Maintenance – Weekly
8.7 Every week

8.7.1 Check/clean the air filter
REFERENCE!
– Never start the engine when the air filter is removed.

- The air filter can be cleaned up to six times if necessary.
- In case of soot deposits on the air filter, a cleaning

is pointless.
- Never use gasoline or hot liquids for cleaning.
– After cleaning, the air filter must be examined

carefully with a flashlight for damage.
– A damaged air filter must not be reused. In the same

case, a new air filter must be inserted.

Protective gloves n Safety
glasses

3. Remove the cover (1) .

4. Pull out the air filter.
5. Clean the lid.

6.
REFERENCE!
– Avoid dirt getting into the air intake opening.
– Do not clean the filter housing with compressed air.

Picture 56
Clean the filter housing with a clean, lint-free cloth.

7.
BEWARE!
Risk of damage to the eyes due to flying
particles.
– Use personal protective equipment
(protective gloves, work protective clothing,
safety glasses).
Blow out the air filter with dry compressed air (max. 5 bar (73 psi))
from the inside out by running the tube up and down the element until
Picture 57 no more dust comes out.
74 BPR 100/80 D
Maintenance – Weekly
8. Check the air filter with a flashlight for cracks and holes.
9. Replace the air filter if damaged.
10. Carefully insert the air filter (2) into the filter housing.
11. Check the contact surface (3) on the cover.

12.
REFERENCE!
– Check that the lid and seal are correctly fitted.
Close the cover (1).

Picture 58
8.7.2 Check, clean the water separator
Since the service requirement for the water separator

depends on the water content of the fuel, it is not possible to
specify any general service intervals.
Therefore, check daily after starting the engine for signs of water
and dirt.

Protective gloves
on page 57.
2. Hold a clear container under the drain screw.
3. Loosen the drain screw a couple of turns and catch the flowing liquid.
4. Drain fuel until no more water is visible.
If the fuel tank has been run completely empty, bleed the
fuel system before starting
Ä Chapter 8.2.2 “Bleed the fuel system” on page 66
Picture 59
5. Screw the drain plug back on. Be careful with the tightness.
6. Dispose of liquid in an environmentally friendly manner.
BPR 100/80 D 75
Maintenance – Every six months
8.8 Every six months
8.8.1 Supervision of the battery
Even service-free batteries need maintenance. Service-

free only means that you don't need to check the fluid level.
Each battery discharges by itself and if you don't

monitoring this can damage the battery due to
full discharge.
The warranty does not apply to completely discharged

batteries (batteries where sulphate has formed on the plates)!

n Protective gloves
n Safety glasses

2. Remove the battery holder (1).
3. Remove battery (2) and vibration damping mat (3).

4. Check that the vibration damping mats are in good condition,
replace if necessary.
5. Clean the outside of the battery.
6. Clean the battery poles and connections and lubricate with pole grease
(vaseline).
7. On non-service-free batteries, the acid level is checked, top up with

distilled water up to the level mark if necessary.
Picture 60
8. Install the battery and vibration damping mats.
9. Unscrew the battery holder.
76 BPR 100/80 D
Maintenance – Once a year/every 250 operating hours
8.9 Once a year/every 250 operating hours

8.9.1 Byt kilremmen
n Protective gloves
on page 57.
3. Unscrew (1) V-belt cover.
Picture 61
4. Unscrew (1) the protective plate
Picture 62
5. Unscrew (1) V-belt pulley.

6. Replace the V-belt (3).
7. If applicable, fit the removed spacer there

(2).
8. Screw on the V-belt pulley.
Picture 63
BPR 100/80 D 77
9. Check the shaft distance (x) between the centrifugal force coupling (1)
and the V-belt pulley (2).
ð Set value: 424 ± 1 mm
Contact our customer service in case of wrong axle

distance.
Picture 64
10. Tighten protective plate (1), tightening torque: 15 Nm (11 ft·lbf).
Picture 65
11. Screw on (1) V-belt cover.
Picture 66
8.9.1.1 Check the bottom plate frequency
Remove feet and hands from the vibrating base plate.
BEWARE!

movement.

walk.
78 BPR 100/80 D

n Safety shoes
Special tools: n Sirometer
1. Place the machine on a rubber mat.

2. Start the engine Ä Chapter 6.2 "Starting the engine" on page 53.
3. Run the machine for one minute at maximum speed.
4. Check the frequency of the base plate with a suitable measuring device
(e.g. sirometer).
ð Börvärde: Ä Chapter 2 “Technical data” on page 11
on page 57.
6. In case of wrong frequency:
n Check the engine speed.

n Check the V-belt.
n Contract our customer service if necessary.
8.9.2 Check, adjust the valve clearance
REFERENCE!
We recommend that this work is only carried out by
trained staff or by our service technicians.
– Allow the engine to cool before checking the valve clearance

is muddled.
Preparatory works Protective equipment: n Work protective clothing

n Protective gloves
on page 57.
2. Allow the engine to cool to ambient temperature.
3. Check the position of the decompression lever, set to the output position
if necessary.
Picture 67
BPR 100/80 D 79
4. Dismantle the valve cover incl. sealing.
Picture 68
Check valve clearance

Valve clearance:
inlet valve (IN) 0,30 mm (0.012 in)
Outlet valve (EX) 0,30 mm (0.012 in)
1. Rotate the engine in the direction of rotation until the outlet valve (EX)
is completely open.
2. Check the valve clearance at the inlet valve (IN) with a feeler gauge
(1) and adjust as necessary.
3. Continue rotating the engine in the direction of rotation until the exhaust valve is
fully open.
4. Check and prioritize. drop in the valve clearance on the outlet valve.
Picture 69
Adjust the valve clearance
1. Loosen the hexagon nut (3) on the rocker arm.
2. Adjust the screw (2) in such a way that the blade gauge (1) moves
to pull through with a noticeable resistance when the hex nut (3) is tightened.
Picture 70
80 BPR 100/80 D
Final works
1. Install the valve cover with a new gasket and tighten the screws
even.
2. Briefly test the tightness of the valve cover and then check that
the valve cover is tight.
Picture 71
8.9.3 Change engine oil and oil filter cartridge
REFERENCE!
– Oil changes may only be carried out when the engine is running
warm.
– Use only oil with an approved specification
Ä Chapter 8.3.1 "Engine oil" on page 68.
Ä
– Volume: Chapter 8.4 "Fuel table"
on page 71

n Protective gloves
n Safety glasses
Drain engine oil
2. Clean the area around the dipstick and then pull out
oil dipstick.
Picture 72
BPR 100/80 D 81
3. Clean around the drain hose.
WARNING!
Burns due to hot components!
– Use personal protective equipment (protective
gloves, work protective clothing).
– Avoid contact with hot components.
4. Unscrew the drain screw and drain the oil into a container.
Picture 73 5. Clean the drain screw and screw it in, tightening torque: 20 Nm (15
ft·lbf).
Replace the oil filter insert
6. Clean around the lid.

7. Unscrew the cover and replace the oil filter insert.
8. Clean the contact surface of the motor.
9. Insert new oil filter insert with the tab facing down.
10. Check that the sealing ring is not damaged. Replace if necessary.
11. Lightly oil the sealing ring.
12. Screw the lid on.
Picture 74
Top up engine oil

13. Add fresh engine oil through the filler hole.
14. Insert the oil dipstick.
15. Test drive briefly and then check the oil level using the oil dipstick,
top up if necessary.
Picture 75
Final works 16. Check the tightness of the oil filter and drain screw.
17. Oil and oil filter insert must be disposed of in an environmentally friendly way.
82 BPR 100/80 D
8.9.4 Replace the fuel filter
REFERENCE!
- Pay attention to cleanliness! First, thoroughly clean

the area around the fuel tank.
– Never run the engine with an extended fuel filter.

n Protective gloves

2. Prepare suitable container to catch spillage
fuel.
3. Release fuel.
4. Clean around the fuel filter.
5. Unscrew the hose clamps from the holders.
6. Pull the fuel filter with the fuel connections out of the hose clamp
warm.
7. Disconnect the fuel hose from the fuel filter.

8. Replace the fuel filter.
9. Connect the fuel lines.
Note the flow direction of the new fuel filter.
Picture 76
10. Insert the fuel filter with the fuel connections into the hose clamps.
11. Screw the hose clamps to the holders.
12. Fill the fuel tank.
13. Bleed the fuel system before starting the Ä Chapter 8.2.2 ”Avlufta
fuel system” on page 66.
14. After a short test run, check that the fuel filter and fuel lines are
tight.
15. Fuel and fuel filters must be disposed of according to current
environmental protection regulations.
BPR 100/80 D 83
8.9.5 Change the air filter
REFERENCE!
– Never start the engine when the air filter is removed.
Protective equipment: n Work protective clothing n Protective

gloves
on page 57.
3. Remove the cover (1) .

4. Pull out the air filter.
5. Clean the lid.

6.
REFERENCE!
– Avoid dirt getting into the air intake opening.
– Do not clean the filter housing with compressed air.

Picture 77
Clean the filter housing with a clean, lint-free cloth.

7. Change the air filter.
8. Carefully insert the air filter (2) into the filter housing.
9. Check the contact surface (3) on the cover.
10.
REFERENCE!
– Check that the lid and seal are correctly fitted.
Close the cover (1).

Picture 78
8.9.6 Change the oil in the vibration shaft housing
REFERENCE!
– Only use oil with an approved specification Chapter 8.4 "Fuel

Ä table" on page 71.
84 BPR 100/80 D

n Protective gloves
1. Place the machine on level ground.

3. Clean the area around the ventilation screw (1) and the filling/
the drain screw (2).
4. Tilt the machine slightly towards the oil drain side and pallet
up it safely.
5. Unscrew the ventilation screw.
6. Unscrew the fill/drain plug and drain the oil

2 in a vessel.
1
B-692-0196
Picture 79
7. Tip the machine to the other side and pallet under it safely.
8. Fill in new oil.
B-692-0198
Picture 80
9. Stand the machine straight and check the oil level.
ð Setpoint: Lower edge of filling/draining opening.
10. Clean the ventilation screw (1) and the filling/draining screw (2) and insert
with sealant (e.g. spare part number: 009 700 16).
11. Dispose of the oil in an environmentally friendly way.
1 2
B-692-0197
Picture 81
BPR 100/80 D 85
8.9.7 Check the hydraulic oil level

Protective equipment: n Work protective
clothing n Protective gloves
2. Adjust the control arm with height adjustment so that the surface where the
control screw is located is in a vertical position.
3. Unscrew the filling screw.
Picture 82
4. Push the grip forward to the stop and lock with a suitable aid.
Picture 83
5. The oil should reach up to the mark at the rod head, add
hydraulic oil if necessary.
Marking: approx. 40 mm (1.6 in) below the filler opening
Picture 84
Fill hydraulic oil, vent

REFERENCE!
– Use only oil with an approved specification.
86 BPR 100/80 D
6. Push the grip forward to the stop and lock with a suitable aid.
Picture 85
7. Place rags under the vent screw to catch leaking oil.
8. Loosen the vent screw.

9. Wait until no more air comes out and tighten the vent
the screw.
Picture 86
10. Fill hydraulic oil to the mark at the rod head.
Picture 87
Final works
11. Screw in the filling screw.
Picture 88
BPR 100/80 D 87
8.9.8 Lubricate the machine

n Protective gloves
on page 57.
2. Unscrew the fastening screws (1) and remove the hood (2).
Picture 89
3.
REFERENCE!
Components are damaged if there is a lack of

lubrication.
– Only use grease with an approved specification.
(Spare part number lubricating grease: 009 960

17)
Grease the mechanics between fork head (1), lever (2) and bolt
Picture 90 (3).
4. Screw the hood (2) with four fastening screws, tightening mo

ment: 10 Nm (7.5 ft·lbf).
Picture 91
88 BPR 100/80 D
Maintenance – Every two years/after 500 operating hours
8.10 Every other year/after 500 operating hours
8.10.1 Replace hydraulic oil

n Protective gloves
2. Adjust the control arm with height adjustment so that the surface where the
control screw is located is in a vertical position.
3. Unscrew the filling screw.
Picture 92
4. Push the grip forward to the stop and lock with the appropriate
aid.
Picture 93
5. Unscrew the venting screw and drain the oil into a container.
6. Screw in the venting screw.
Picture 94
BPR 100/80 D 89
Maintenance – Every two years/after 500 operating hours
7.
REFERENCE!
– Only use oil with an approved specification.
Add hydraulic oil to the mark at the rod head.
Marking: approx. 40 mm (1.6 in) below the filler opening
Picture 95
8. Loosen the vent screw.
9. Wait until no more air comes out and tighten the vent
the screw.
Picture 96
10. Fill hydraulic oil to the mark at the rod head.
Picture 97
11. Screw in the filling screw.
12. Dispose of the oil in an environmentally friendly way.
Picture 98
90 BPR 100/80 D
Maintenance – As needed
8.11 As required
8.11.1 Clean the machine

n Safety shoes
n Protective gloves
on page 57.
2. Allow the engine to cool for at least 30 minutes.
3.
REFERENCE!
Components may be damaged if water penetrates.
– Do not direct the water jet directly into the opening of the
starter crank, the air filter and the electrical
components of the machine.
Clean the machine outside and inside with a water jet.

4. Warm up the engine briefly to prevent rust from forming.
Figure 99: Clean the machine (example)
8.11.2 Clean the cooling fins and cooling air intakes
The contamination of the cooling fins and cooling air intakes is

highly dependent on the machine's operating conditions, clean
daily if necessary.
Protective equipment: n Work protective clothing n Protective

gloves n Safety glasses
on page 57.
3. Remove dry contamination from all cooling fins and cooling air openings with a brush.
4.
BEWARE!
Risk of damage to the eyes due to flying particles.
– Use personal protective equipment

(protective gloves, work protective clothing, safety
glasses).
picture 100 Blow out cooling fins and cooling air openings with compressed air.
5. In the case of damp or oily dirt, contact our customer service.
BPR 100/80 D 91
8.11.3 Maintain the V-belt

Preparatory works Protective equipment: n Work protective clothing
n Protective gloves
1. Park the machine securely secured.”Ä Chapter 6.4 "Park the machine
on page 57.
3. Unscrew (1) V-belt cover.
Picture 101
Check the V-belt
1. Check the V-belt and V-belt tension.
ð Penetration dimensions: 15 - 20 mm (0.6 - 0.8 in).
2. Tighten the V-belt if the through pressure measurement is exceeded.

3. Replace V-belt if damaged Ä Chapter 8.9.1 "Replace the V-belt"
on page 77.
Picture 102
Tighten the V-belt
1. Loosen the threaded pins.
Picture 103
92 BPR 100/80 D
2. Turn the outer V-belt pulley with a suitable tool until it

the necessary belt tension has been achieved.
Hold against the inner V-belt pulley with a

appropriate tool.
3. Tighten the threaded pins again, tightening torque: 10 Nm

(7.4 ft·lbf).
Picture 104
Final works
1. Screw on (1) V-belt cover.
Picture 105
8.11.4 Check the oil level in the vibration shaft housing
REFERENCE!
– Use only oil with an approved specification

Ä Chapter 8.4 "Fuel table" on page 71.

n Protective gloves
1. Place the machine on level ground.

2. Park the machine securely secured.”Ä Chapter 6.4 "Park the machine
on page 57.
3. Allow the machine to cool.
BPR 100/80 D 93
4. Clean the area around the ventilation screw (1) and the filling/
the drain screw (2).
5. Unscrew the ventilation screw.
6. Unscrew the fill/drain screw and check

oil level, top up if necessary.
ð Setpoint: Lower edge of filling/draining opening.
1 2
7. Clean the vent screw and fill/drain screw and insert with sealant (eg spare
part number: 009 700 16).
B-692-0197
Picture 106
8.11.5 Measures before stopping the machine for a longer period of time
8.11.5.1 Actions before shutdown
If the machine is to be taken out of operation for a longer period of time, e.g. over the winter,
the following work must be carried out:
1. Clean the machine thoroughly.
2. Clean the water separator.

3. Fill the fuel tank with diesel fuel to prevent condensation in the fuel tank.
4. Change the engine oil and oil filter if the oil change was carried out for longer than
300 operating hours ago.
5. Change the fuel filter.
6. When decommissioning, place the machine under cover in a dry and

well ventilated premises.
7. Protect the cooled engine against dust and moisture.
8.11.5.2 Maintain the battery during longer machine downtimes
WARNING!
Risk of personal injury due to an exploding gas mixture.
- When recharging the battery, the sealing plugs must be

removed.
– Ensure sufficient ventilation.
– Do not place tools or other metal objects
on the battery.
– Do not wear jewelry (watch, chains, etc.).
work on the battery.
work protective clothing, protective goggles).
94 BPR 100/80 D

n Protective gloves
n Safety glasses
1. Switch off all consumers (e.g. ignition, lights).
2. Measure the battery's resting voltage regularly (at least 1 time/

month).
ð Guideline values: 12.6 V = fully charged; 12.3 V = 50% charge.
3. Maintenance Charge the battery immediately when the resting voltage is

12.25 V or less. Do not fast charge the battery.
ð The battery's resting voltage enters approx. 10 hours after that

last charge or one hour after the last discharge.
4. Turn off the charging current before removing the charging plug
away.
5. Always let the battery rest for an hour after charging before that
put into operation again.
6. Disconnect the battery in the event of a longer shutdown period than one month.
Don't forget to check the battery's idle voltage regularly.
8.11.5.3 Actions before re-commissioning
1. Replace the fuel filter
2. Change the air filter
3. Change the engine oil and clean the oil filter.
4. Check cables, hoses and wires for cracks and

density.
5. Start the engine and let it run for 15 to 30 minutes at idle speed.
6. Check oil levels.
7. Clean the machine thoroughly.
BPR 100/80 D 95
96 BPR 100/80 D
Help with errors
9 Help with errors
BPR 100/80 D 97
Help with Errors - Introductory Notes
9.1 Preliminary remarks

Disturbances and problems often arise because the machine is not handled or
maintained properly. Therefore, always once again carefully read the instructions
regarding correct handling and service if an error occurs.
Contact our customer service if you cannot determine the cause of a malfunction
using the troubleshooting table or if you cannot fix the problem yourself.
98 BPR 100/80 D
Help in the event of a fault – Emergency stop with starter crank
9.2 Emergency stop with starter crank
Only start the engine with the starter crank if the battery is
defective, empty or missing.
Exhaust gases contain toxic substances, which can lead to damage to health,
unconsciousness or death.
WARNING!
Risk of poisoning due to exhaust gases.

– Do not inhale exhaust gases.
- When operating in closed or partially closed premises or recesses
in the ground, there must be sufficient venting and ventilation.
WARNING!


n Safety shoes
1. Set the speed control lever to the "MIN" position.
Picture 107
BPR 100/80 D 99
2. Bring the handle to the zero position.
Picture 108
3. Turn the ignition key to position "I".
ð The warning buzzer does not sound.
When the ignition key is in position "I", the battery is charged

when the engine runs for as long as at least 9 V
located at the battery.
Picture 109
4. Pull the decompression lever in the direction of the arrow until it stops
end position.
ð The decompression lever engages with an audible sound.
Picture 110
5. Fold up the hood.
6. Remove the starter crank from the holder and insert.
7. Stand in the correct position parallel to the machine.
B-692-0220
Picture 111
100 BPR 100/80 D

8. Grasp the starter crank with both hands as shown.
9. Slowly turn the starter crank with both hands in the direction of the arrow until the
crank engages.
BEWARE!

movement.

walk.
Picture 112
10. Then turn the starter crank faster and faster until the engine starts.
The power transfer between the engine and the starter

must be ensured by fast cranking.
Never interrupt the boot procedure.
When the decompression lever closes and engages (after

five revolutions), the highest revolutions must have been
reached.
11. Pull out the starter crank as soon as the engine starts.
12. Repeat the start if the engine does not start on the first start
the search.
ð Always open the decompression lever when starting up

meal.
REFERENCE!
– Warm up the engine briefly before starting work.
Do not load the engine with full load
immediately.
13. Hang the starter crank in the holder.
14. Close the lid.
REFERENCE!
– Warm up the engine briefly before starting work.

Do not load the engine with full load immediately.
B-692-0220
Picture 113
BPR 100/80 D 101

Help in the event of a fault – Start the engine with the starter cable
9.3 Start the engine with the starter cable
REFERENCE!
An incorrect connection can cause serious damage

on the electrical system.
- The machine can only be equipped with a 12 V start

bacteria.
1. Open the protective hood and secure against accidental closing.
2. Disassemble the battery holder.
3. First connect the positive pole of the external battery with the positive pole of the vehicle
battery.
4. Then the second battery connection cable first to the minus pole of the powering
auxiliary battery and then to the earth point in the engine compartment.
5. Start the engine: Ä Chapter 6.2 "Starting the engine" on page 53.
6. After the start, the minus poles are disconnected first and then the plus poles.
7. Unscrew the battery holder.
Picture 114 8. Close the protective hood.
102 BPR 100/80 D

Help in the event of a fault - Fuse coating
9.4 Security coating
WARNING!
Risk of personal injury if the machine catches fire.
- Do not insert fuses with a higher amperage than what
as stated respectively do not jump fuses.
Pos. Ström's Turk Designation
1 25 A Main fuse
5A Fuse Economizer (optional equipment)
Picture 115
BPR 100/80 D 103

Help in the event of a fault - Engine fault
9.5 Engine failure
Up Possible cause Measure
The engine does not start The fuel tank is empty Check the fuel level, refill if necessary
or starts poorly is needed.
The fuel filter is clogged Check the fuel filter, replace if necessary
Leakage in the fuel lines Check the fuel lines
The fuel shut-off valve has tripped Check the engine oil level, top up regularly
automatically need.
Check the fuel level, refill if necessary

is needed.
If necessary, check further

causes of ejaculation.
Bleed the fuel system via the bleed lever at the

fuel shut-off valve.
Incorrectly set valve clearance Check and prioritize. fall into valve's pellet
Cylinder or piston ring wear Have qualified personnel check
The injection nozzle does not work Have qualified personnel check
The engine does not start Fuel filter clogged with paraffin secretions Change the fuel filter, use winter fuel
or starts sluggishly at
low temperatures
The engine oil has the wrong SAE viscosity class Change engine oil
The battery is not sufficiently charged Check and charge the battery if necessary
The engine fires, but The fuel filter is clogged Check the fuel filter, replace if necessary
does not proceed
The starter is connected Main fuse defective Replace the main fuse
not on or
the motor does not rotate. Battery or other cable connections are Verify
incorrectly connected
The battery is defective or not charged Check, charge or replace the battery at
need
The starter is defective Replace starter
The engine stops The fuel tank is empty Check the fuel level, refill if necessary
is needed.
The fuel filter is clogged Replace the fuel filter
Tank ventilation clogged Ensure that the ventilation of the tank is

sufficient.
Air in the fuel system Check for air entering the fuel system.
Check the vent valve.
104 BPR 100/80 D

Help in the event of a fault - Engine fault
The fuel shut-off valve has tripped Check the engine oil level, top up regularly
automatically need.
Check the fuel level, refill if necessary

is needed.
If necessary, check further

causes of ejaculation.
Bleed the fuel system via the bleed lever at the fuel
shut-off valve.
Mechanical defect Have qualified personnel check.
The power of the engine and The fuel tank is empty Check the fuel level, refill if necessary
rpm decreases is needed.
The fuel system is clogged Replace the fuel filter
Tank ventilation clogged Ensure that the ventilation of the tank is sufficient.
Air in the fuel system Check for air entering the fuel system.
Check the vent valve.
Too much oil in the crankcase Drain the oil from the crankcase
The power of the engine and Contaminated air filter Clean the air filter, replace if necessary
rpm decreases, black
Incorrectly set valve clearance Check and prioritize. fall into valve's pellet
exhaust fumes
The injection nozzle does not work Have qualified personnel check
Engine overheats Engine oil level too high Check engine oil level, drain
engine oil if needed
Contaminated air filter Clean the air filter, replace if necessary
Lack of cooling air Clean the cooling fins and cooling air intakes.
Check that all the cooling air guide plates

respectively the shafts are complete and that they are
seal.
The engine revs high The centrifugal clutch is defective Have qualified personnel check
rpm but without
vibration V-belt is worn Byt kilremmen
BPR 100/80 D 105

Help in the event of an error - Incorrect operation
9.6 Incorrect operation
The machine vibrates Air in the control arm hydraulic system Release the pressure from the steering shaft
forward with strong
reduced speed Oil level in vibration shaft housing too high Check the oil level in the vibration shaft housing
Release the pressure from the steering shaft Protective equipment: n Protective gloves

2. Push the grip forward to the stop and hold.
3. Carefully loosen the filling screw (1).
ð The incoming air emits a slight hiss.
4. Wait until no more air comes out and tighten the filling
the screw.
Picture 116
106 BPR 100/80 D

Help with errors - Errors in the ECONOMIZER
9.7 Fel i ECONOMIZERN
Figure 117: Display Economizer
LED (a) flashes Connection process: LED (a) flashes for approx. 1
- 2 seconds after the vibration is switched on
on.
too low vibration frequency.
LED (a) lights up No vibration is detected. Start the engine, set the speed control lever to
the "MAX" position (switch on vibration).
Check the acceleration sensor connection.
The acceleration sensor is not connected. Check the acceleration sensor connection.
Cable break. Notify our customer service.
The measured values The acceleration sensor is not properly attached. Turn off the engine and check the acceleration sensor
shown are not reasonable mounting screws.
Weak points in the road infrastructure. Large variations in the composition of the material
or humidity in the road substructure can adversely
affect
the measurement results.
If the material is significantly too dry or if the material

is too moist, the measured values are too low.
BPR 100/80 D 107

Help with errors - Errors in the ECONOMIZER
108 BPR 100/80 D

Waste disposal
10 Waste disposal
BPR 100/80 D 109

Disposal – Scrapping the machine
10.1 Scrapping the machine

If the machine can no longer be used and is to be scrapped
the following work must be carried out, after which the machine must be dismantled
by an authorized company.
WARNING!
– Observe safety and environmental regulations when handling

Ä "Handling
substances for operation Chapter 3.4 for operation"
substances
on
page 23.

n Safety shoes
n Protective gloves
n Safety glasses
1. Remove batteries and dispose of them according to the law

stipulated regulations.
2. Empty the fuel tank.
3. Drain the engine oil from the engine and vibration shaft housing.
4. Drain hydraulic oil.
110 BPR 100/80 D

Head Office/Headquarters
BOMAG
Hellerwald
D-56154 Boppard
Germany
Phone: +49 6742 100-0
Fax: +49 6742 3090
email: info@bomag.com
BOMAG BOMAG BOMAG

Berlin office Boppard branch Chemnitz branch
Commercial Street 3 Hellerwald Querstraße 6
15366 Hoppegarten 56154 Boppard 09247 Chemnitz
GERMANY GERMANY GERMANY
Tel.: +49 3342 369410 Tel .: +49 6742 100360 Tel .: +49 3722 51590
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Hanover branch Munich office Office in Stuttgart
Dieselstraße 44 Otto-Hahn-Ring 3 Uferstrasse 22
30827 Garbsen-Berenbostel 85301 Schweitenkirchen 73630 Remshalden-Grunbach
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BOMAG Maschinenhandelsgesellschaft mbH BOMAG MARINI EQUIPAMENTOS LTDA BOMAG (CANADA), INC.
Klausenweg 654 Rua Comendador Clemente Cifali, 530 3455 Semenyk Court
2534 Alland Ritter Industrial District Missisauga, Ontario
AUSTRIA Cachoeirinha – RS L5C 4P9
BRAZIL CANADA
ZIP code 94935-225
Tel.: +43 2258 20202 Tel.: +55 51 2125-6677 Tel .: +1 905 361 9961
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Machinery Co. ,
Ltd 2, avenue du General de Gaulle Sheldon Way, Larkfield
No. 2808, West Huancheng Road, 91170 VIRY-CHATILLON Aylesford
Shanghai Comprehensive Industrial FRANCE Kent ME20 6SE
Zone Fengxian Shanghai 201401 GREAT BRITAIN
CHINA
Tel.: +86 21 3365 5566 Tel.: +33 1 69578600 Tel.: +44 1622 716611
Fax: +86 21 3365 5508 Fax: +33 1 69962660 Fax: +44 1622 710233
email: china@bomag.com email: france@bomag.com email: gb@bomag.com
BOMA Equipment Hong Kong LTD BOMAG Italia Srl. FAYAT BOMAG Polish Sp. zoo
Room 1003, 10/F Charm Centre Via Roma 50 Ul. Szyszkowa 52
700, Castle Peak Road 48011 Alfonsine 02-285 Warzawa
Kowloon, ITALY POLAND
HONG KONG
Tel.: +852 2721 6363 Tel.: +39 0544 864235 Tel .: +48 22 4820400
Fax: +852 2721 3212 Fax: +39 0544 864367 Fax: +48 22 4820401
email: bomahk@bomag.com email: italy@bomag.com e-mail: poland@bomag.com
FAYAT BOMAG Russia OOO BOMAG GmbH, Singapore BOMAG Americas, Inc.
Klyazma block, h 1-g 300, Beach Road 125 Blue Granite Parkway
141400 Khimki, Moscow region The Concourse, ‚ 18-06 Ridgeway SC 29130
RUSSIA Singapore 199555 deer
SINGAPORE
Tel.: +7 (495) 2879290 Tel.: +65 294 1277 Tel.: +1 803 3370700
Fax: +7 (495) 2879291 Fax: +65 294 1377 Fax: +1 803 3370800
email: russia@bomag.com email: singapore@bomag.com email: usa@bomag.com

BPR 100 80d

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Use and maintenance instructions

Original instruction manual

S/N 101 692 38 1001>

Reversible vibrator plate

3 For your safety................................................... ................................................ ................................... 15

3.1 Basic conditions................................................... ................................................ 16 3.1.1

3.9.5 After performed service................................... ................................................ ....................... 34

4 Displays and operating elements................................................ ................................................ ......... 39

4.1.1 Handle................................................ ................................................ ....................................... 40 4.1.2 Speed control

4.1.5 Control arm height adjustment............................................ ................................................ .................... 41 4.1.6 Latch

5 Checks before the start of operation................................................... ................................................ ................ 45

7 Loading/transporting the machine................................................... ................................................... ............. 59

8.1 Introductory remarks and safety instructions............................................ .................. 64 8.2 Preparatory/final

8.3.1 Engine oil................................................ ................................................ .................................... 68 8.3.2

8.6 Run-in regulation................................................... ................................................ .................. 73 8.6.1

8.6.2 After 25 operating hours............................................ ................................................ ....................... 73

8.7 Every week................................................... ................................................ .................................... 74 8.7.1 Check/clean the

8.10.1 Change the hydraulic oil............................................. ................................................ ......................... 89 8.11 As

8.11.1 Clean the machine................................................ ................................................... ...................... 91 8.11.2 Clean the

9.4 Fuse coating................................................... ................................................ ................ 103 9.5 Motor

10 Waste management................................................... ................................................ .............................. 109 10.1 Scrapping the

These operating and maintenance instructions belong to your machine.

It gives you the necessary information to use your machine

In addition, it contains information for necessary operation, maintenance and repair

Read your machine's operating and maintenance instructions carefully.

Observe the safety precautions and follow all instructions to

Carry out all prescribed visual and functional checks before

The description of the maintenance to be carried out, prescribed

Do not perform maintenance and repair the machine yourself to avoid

Contact our customer service for prescribed maintenance work or

In case of usage errors, lack of maintenance or if not approved

For your own safety, use only BOMAG original parts.

We offer service sets for the machines to facilitate maintenance.

We reserve the right to make the changes caused by technical development

This driver and service manual is also available in other languages.

In addition, the spare parts catalog can be requested if the machine's

We wish you the best of luck with your BOMAG machine.

Foreword – Machine nameplate and engine nameplate

1.2 Machine type plate and engine type plate

Machine type (1):

Serial number (2):

Figure 1: Machine nameplate (example)

Engine type (1):

Engine number (2):

Figure 2: Motor nameplate (example)

1035 1320 1560 1860 980 650 800 950

(40.7) (52.0) (61.4) (73.2) (38.6) (25.6) (31.5) (37.4)

Curb weight (CECE) (W) 677 kg

Operating weight (CECE) (W1 ) 700 kg

Operating weight (CECE) (W2 ) 716 kg

Dead weight 696 kg

Starter crank (optional equipment) +3 kg

ECONOMIZER (optional equipment) +5 kg

Max. work speed 28 m/min

Max. hill climbing ability (terrain specific) 35 %

Engine manufacturer finger

Cooling system Air