Bomag BPR 25/32 User manual

Operating instructions
Maintenance instructions
Catalogue number
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S/N 101 730 00 ..... S/N 101 730 10 .....
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Foreword
BOMAG machines are products from the wide
range of BOMAG compaction equipment.
BOMAG’s vast experience in connection with
state-of-the-art production and testing meth-
ods, such as lifetime tests of all important
components and highest quality demands
guarantee maximum reliability of your ma-
chine.
Using this manual will
●help youto become acquainted with the ma-
chine.
●avoidmalfunctions caused by operating errors.
Compliance with the maintenance instructions will
●increasethe reliability of the machine on the
site,
●prolongthe lifetime of the machine,
●reducerepair costs and downtime.
BOMAG will not assume liability for the function of
the machine
●if it is handled in a way not complying with the
usual modes of use,
●if it is used for purposes other than those men-
tioned in these instructions.
No warranty claims can be lodged in case of dam-
age resulting from
●operating errors,
●insufficient maintenance and
●wrong fuels and lubricants.
Please note!
This manual was written for operators and mainte-
nance personnel on construction sites.
You should only operate the machine if you are ful-
ly acquainted with the contents of these instruc-
tions.
Strictly observe the safety regulations.
Please observe also the guidelines of the Civil En-
gineering Liability Association "Safety Rules for
the Operation of Road Rollers and Soil Compac-
tors" and all relevant accident prevention regula-
tions.
For your own personal safety you should only
use original spare parts from BOMAG.
In the course of technical development we re-
serve the right for technical modifications
without prior notification.
Theseoperatingandmaintenance instructions are
also available in other languages.
Furthermore, the spare parts catalogue is availa-
ble from your BOMAG dealer against the serial
number of your machine.
Your BOMAG dealer will also supply you with in-
formation about the correct use of our machines in
soil and asphalt construction.
The above notes do not constitute an extension of
thewarrantyandliabilityconditionsspecifiedinthe
general terms of business of BOMAG.
We wish you successful work with your BOMAG
machine.
BOMAG GmbH & Co. OHG
Printed in Germany
Copyright by BOMAG
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Please fill in
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine type (Fig. 1)
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Serial No. (Fig. 1 and 2)
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine type (Fig. 3)
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine No. (Fig. 3)
L
Note
Fill in the above listed data when receiving the ma-
chine.
Upon receipt of the machine our organization will
instruct you about correct operation and mainte-
nance.
Please observe strictly all safety regulations and
notes on potential dangers!
Fig. 1
Fig. 2
Fig. 3
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Table of Contents
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3.1 General notes 18
3.2 Inspections before starting operation 18
3.3 Folding the steering rod down 19
3.4 Starting the engine 19
3.5 Work/operation 21
3.6 Vibratory plate getting stuck 22
3.7 Stopping the engine 23
3.8 Loading 24
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4.1 General notes on maintenance 26
4.2 Fuels and lubricants 27
4.3 Fuels, lubricants and filling capacities 28
4.4 Running-in instructions 29
4.5 Maintenance table 30
4.6 Cleaning the machine 31
4.7 Checking the engine oil level 31
4.8 Checking the fuel level 32
4.9 Checking/cleaning the air filter (under extremely dusty conditions) 33
4.10 Cleaning cooling fins and air intake openings 34
4.11 Checking the oil level in the vibrator shaft housing 34
4.12 Changing the engine oil 35
4.13 Cleaning, checking the spark plug 36
4.14 Cleaning the fuel sludge filter 37
4.15 Checking, tensioning, changing the V-belt 37
4.16 Cleaning/changing the air filter 39
4.17 Checking, adjusting the valve clearance 40
4.18 Cleaning the fuel screen 41
4.19 Changing the oil in the vibrator shaft housing 43
4.20 Checking the rubber buffers 43
4.21 Tightening torques for screws with metric unified thread 45
4.22 Tightening bolted connections 45
4.23 Engine conservation 46
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5.1 General notes 48
5.2 Engine problems 49
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1 Technical Data
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Fig. 4
Dim. mm (inch) H L L1W
BPR 25/32 655 (25.79) 1440 (56.7) 760 (29.92) 320 (12.6)
BPR 25/40 655 (25.79) 1440 (56.7) 760 (29.92) 400 (15.7)
*BPR 25/32 BPR 25/40
Weights
Basic weight kg 117 (258) 121 (266.8)
Operating weight (CECE) kg 120 (264.6) 124 (273.4)
Area load kg/m21172 969
Dimensions
Dimensions see sketch
Drive
Engine manufacturer Honda Honda
Type GX 160 KIV GX 160 KIV
Cooling air air
Working cycles 4-stroke 4-stroke
Number of cylinders 1 1
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Rated power DIN 6271
IFN kW (PS) 4 (5,4) 4(5,4)
Speed rpm 3600 3600
Rated power SAE J 1349 kW (PS) 4 (5,4) 4(5,4)
Speed rpm 3600 3600
Starting device Recoil starter Recoil starter
Drive system mechanical mechanical
Max. working speed m/min 22 20
Max. gradability % 30 30
Vibration system
Frequency 1 or min. Hz 78 78
Centrifugal force 1 kN 25 25
Filling capacities
Fuel tank (standardgrade
gasoline) l 3,7 (1) 3,7 (1)
* Technical modifications reserved
*BPR 25/32 BPR 25/40
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The following noise and vibration values according to the EC-machine regulation of revision (93/68/
EEC) have been measured under typical operating conditions for this machine over a specified travel
distance (DIN 45635).
During operation these values may vary because of the existing operating conditions.
Noise values
The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is
Sound pressure level at the place of the operator:
LpA = 91,3 dB(A)
Sound capacity level:
LpA = 104,5 dB(A)
These sound values were determinedaccording to ISO 3744 for the sound capacity level(LWA) and ISO 6081
for sound pressure level (LpA) at the place of the operator.
Vibration values
The vibration values according to enclosure 1, paragraph 2.2 or 3. 6. 3. a of the EC-machine regulation are:
Hand-arm-vibration values
The weighted effective acceleration value determined according to ISO 8662 part 1, DIN 45675, part 9 is
4,5 m/sec2.
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2 Safety regulations
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General notes
This BOMAG machine has been built in ac-
cording to the latest technical standard and
complies with the applicable regulations and
technical rules. However, dangers for persons
and property may arise from this machine, if:
●it is used for purposes other than the ones it is
intended for
●it is operated by untrained personnel
●it is changed orconverted inan unprofessional
way
●the safety instructions are not observed
Each person involved in the operation, mainte-
nance and repair of the machine must there-
fore read and comply with these safety
regulations. If necessary, this must be con-
firmed by obtaining the signature of the cus-
tomer.
Furthermore, the following instructionsand regula-
tions must obviously also be complied with:
●applicable accident prevention regulations
●generally accepted safety and road traffic reg-
ulations
●regulations specific for a country
Intended use
This machine must only be used for:
●the compaction of all types of soil
●repair work on all types of soil
●enforcement of paths and walkways
●work in trenches
●backfills and compaction of hard shoulders
Unintended use
However, dangers may arise from this machine if
it is operated by untrained personnel or if it is sub-
ject of unintended use.
Who has permission to operate the ma-
chine?
Only trained and instructed persons of at least 18
years of age are permitted to drive and operate
this machine. For operation of the machine the re-
sponsibilities must be clearly specified and com-
plied with.
Persons under the influence of alcohol, medicine
or drugs are not allowed to operate, service or re-
pair the machine.
Conversions and changes to the ma-
chine
For safety reasons unauthorized changes to the
machine are not allowed.
Original parts and accessories have been special-
ly designed for this machine. We wish to make ex-
plicitly clear that we have not tested or approved
any parts or accessories not supplied by us. The
installation and/or use of such products may have
an adverse effect on the active and/or passive
driving safety. The manufacturer explicitly ex-
cludes any liability for damage caused by the use
of non-original parts or accessories.
Notes on safety in the operating and
maintenance instructions:

Danger
Paragraphs marked like this highlight possible
dangers for persons.

Caution
Paragraphs marked like this highlight possible
dangers for machines or parts of the machine.
L
Note
Paragraphs marked like this contain technical in-
formation for the optimal economical use of the
machine.
Safety stickers on the machine
Keep safety stickers in good condition and legible
and follow their meaning.
Replace damaged and illegible safety stickers.
Loading the machine
Secure the machine against turning over or slip-
ping off.
Persons are highly endagered if they
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●step or stand under loads being lifted,
●the machine must not swing about when being
lifted.
Secure the machine on the transport vehicle
against rolling off, slipping and turning over.
Starting the machine
Before starting
Familiarize yourself with the equipment, the con-
trol elements and the working principle of the ma-
chine and your working area.
Use your personal protective outfit (hard hat, safe-
ty boots etc.).
●Wear ear defenders.
Before starting the machine check whether:
●the machine shows any obvious faults
●all guards and safety elements are in place
●the control elements are fully functional
●the machine is free of oily and combustible
material
●all handles are free of grease, oils, fuel, dirt,
snow and ice.
●Always wear ear defenders when working with
the vibratory plate.
Use only machines which are serviced at regular
intervals.
For emergency starting take a correct position to
the engine and hold the crank handle correctly.
Do not use any starting aids like start pilot or ether.
Starting in closed rooms
Exhaust gases are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
in closed rooms!
Operation
The machine must onlybe operated with the steer-
ing rod folded down.
Guide the machine so that you to not hit your
hands against any hard obstacles. Danger of inju-
ry!
Stop the machine if you notice unusual noises and
the development of smoke, detect the cause and
have the fault corrected.
Operate the machine only at full engine speed, as
otherwise the centrifugal clutch will be damaged.
Never let the machine run unattented.
Parking the machine
Park the machine on level and firm ground.
Before leaving the machine:
●Park the machine so that it cannot tip over,
●shut the engine down and turn the ignition
switch to "OFF"-position.
Mark machines, which could be in the way, with a
clearly visible sign.
Filling the fuel tank
Refuel only with the engine stopped.
Do not refuel in closed rooms.
No open fire, do not smoke.
Do not spill any fuel. Catch running out fuel, do not
let it seep into the ground.
Do not inhale any fuel fumes.
Maintenance work
Maintenance work must only be performed by
qualified and authorized persons.
Keep unauthorized persons away from the ma-
chine.
Do not perform maintenance work on a running
engine.
Park the machine on level and firm ground.
Working on the engine
Drain the engine oil at operating temperature -
danger of scalding!
Wipe off spilled oil, catch running out oil and dis-
pose of environmentally.
Store used filters and other oil contaminated ma-
terials in a separate, specially marked container
and dispose of environmentally.
Working on the fuel system
No open fire, do not smoke, do not spill any fuel.
Catch running out fuel, do not let it seep into the
ground and dispose of environmentally.
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Cleaning work
Do not clean the machine while the engine is run-
ning.
Do not use gasoline or other inflammable sub-
stances for cleaning.
When using a steam cleaner for cleaning do not
subject electrical parts and insulation material to
the direct jet or cover these items beforehand.
Do not guide the water jet directly into the air filter
and into the air intake.
After maintenance work
After completion of maintenance work reinstall all
guards and safety features.
Repair
Repair work must only be performed by qualified
and authorized persons. Use our repair instruc-
tions for this work.
Exhaust gases are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
in closed rooms!
Mark defective machines by attaching a warning
note to the steering handle.
Welding
Before starting welding work on the machine dis-
connect the battery and cover it with insulation ma-
terial.
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3Operation
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3.1 General notes
Please read section 3 Indicators and Control Ele-
ments thoroughly before operating the machine if
you are not yet fully familiar with the indicators and
control elements of the machine.
All indicators and control elements are described
in detail in this chapter.
3.2 Inspections before starting
operation

Danger
Loss of hearing!
Wear your personal noise protection means
(ear defenders) before starting operation.
Observe the safety regulations.
Refer also to the detailed description in the
maintenance instructions.
●Top up missing lubricants according to the
maintenance instructions.
●Park the machine on level ground.
●Check fuel tank and fuel lines for leaks
●Check condition of engine and machine
●Check bolted connections for tight fit
●Check engine oil level
●Check fuel level
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3.3 Folding the steering rod
down

Danger
Danger of accident!
Operate the machine only withthe steering rod
folded down.
Guide the machine only by the steering rod.
The steering rod is elastically suspended in
operating position.
Fig. 5
●Push locking lever 3 (Fig. 5) in direction of ar-
row and fold the rod down, so that steering rod
(1) can swing freely.
3.4 Starting the engine
Fig. 6
●Set the travel lever (reversing lever) (Fig. 6) to
position ’0’.
Fig. 7
●Shift throttle lever (Fig. 7) to approx. 1/3 en-
gine speed.
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Fig. 8
●Open fuel cock 1(Fig. 8) completelyby turning
in direction of arrow.
●Close the choke completely by shifting lever
(2) in direction of arrow.
L
Note
With warm engine or high ambient temperature do
NOT operate chike lever (2).
Also operation position.
Fig. 9
●Turn ignition switch 1 (Fig. 9) to position "ON".

Caution
The engine is equipped with a low oil level
safety feature. The engine cannot be started if
the oil level is too low.
 Danger
Danger of burning!
Use safety gloves when the engine is hot.
Fig. 10
●Stand in a correct position to the machine.
●Slightly pull the starter handle (Fig. 10), until
resistancecan be felt(compressionpressure),
then pull with power, but do not pull the cord
out completely.
●Guide the starter rope back by hand.
L
Note
Do not let the starter handle hit back against the
engine.
●If the engine does not start during the first at-
tempt, repeat the starting process.
Fig. 11
●If the engine stops again under cold weather
conditions after approx. 3 to 5 seconds, close
the choke again with lever 2 (Fig. 11) and re-
peat the starting process.
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