Bomag BPR 25/40 D Manual

Operating instructions
Maintenance instructions
Catalogue number
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Foreword
These BOMAG - machines are products from
the wide product range of BOMAG compaction
equipment. BOMAG’s vast experience, cou-
pled with the most modern production and
testing methods, such as lifetime tests of all
important components and highest quality de-
mands, ensure highest reliability of your ma-
chine.
Using these instructions will
●help you to become acquainted with the ma-
chine.
●avoid faults caused by unprofessional opera-
tion.
Observing the maintenance instructions will
●increase the reliability of the machine during
use on site,
●prolong the lifetime of the machine,
●reduce repair costs and downtime.
BOMAG does not assume liability for the function
of the machine
●if the machine is handled in a way, which does
not comply with the use it is intended for,
●if it is used for purposes other then the ones
mentioned in these instructions.
No warranty claims can be lodged for damage re-
sulting from
●operating errors,
●insufficient maintenance and
●the use of 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 after you
have been instructed to do so and by following
these instructions.
Please observe strictly 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 compaction
equipment", as well as the applicable instructions
for the prevention of accidents.
For your own safety you should only use gen-
uine BOMAG spare parts.
To comply with the technical development we
reserve the right of modifications without prior
notification.
Theseoperatingandmaintenance instructions are
also available in other languages.
In addition you can obtain a spare parts catalogue
from your BOMAG dealer by just stating the serial
number of your machine.
Information for the correct use of our machines in
earth and asphalt construction is also available
from your BOMAG-dealer.
The notes mentioned above do not constitute an
extension of the warranty and liability conditions,
which are part of the general terms of business of
BOMAG.
We wish you much success 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 Before starting work 18
3.3 Folding the steering rod down 19
3.4 Starting with recoil starter 19
3.5 Work/operation 21
3.6 Shutting the engine down 22
3.7 Loading 23
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4.1 General notes on maintenance 26
4.2 Fuels and lubricants 27
4.3 Table of fuels and lubricants 29
4.4 Running-in instructions 30
4.5 Maintenance chart 31
4.6 Cleaning machine/engine 32
4.7 Checking the fuel level 32
4.8 Checking the engine oil level 33
4.9 Checking the air filter, cleaning if necessary 34
4.10 Checking the oil level in the vibrator housing 36
4.11 Changing the engine oil 36
4.12 Cleaning the engine oil filter 37
4.13 Checking, tensioning, changing the V-belt 38
4.14 Checking, adjusting the valve clearance 39
4.15 Cleaning cooling fins and cooling air intake opening 40
4.16 Cleaning the exhaust screen 41
4.17 Changing the dry air filter 42
4.18 Changing the fuel filter 43
4.19 Changing the oil in the vibrator housing 43
4.20 Checking the rubber buffers 44
4.21 Drawing the water out of the fuel tank 44
4.22 Retightening the bolted connections 45
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5.1 General notes 48
5.2 Replacing the injection pump 49
5.3 Engine faults 53
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1 Technical Data
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Fig. 4
*BPR 25/40 D
Dimensions
(L) Overall length mm (inch) 1440 (56.69)
(L1) Length with base
plate mm (inch) 760 (29.92)
(W) Overall width mm (inch) 400 (15.74)
(H)Lowestpassingheight mm (inch) 685 (26.97)
(H1) Max. height with
steering rod in upright po-
sition
mm (inch) 1070 (42.13)
Weights
Basic weight kg (lbs) 148 (326.27)
Operating weight (CECE) kg (lbs) 149 (328.48)
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Drive
Engine manufacturer Hatz
Type 1B20
Cooling air
Working cycles 4
Number of cylinders 1
Rated power ISO 9249 kW (PS) 3,1 (4,2)
Rated speed rpm 3000
Starting device recoil starter
Fuel diesel
Fuel tank capacity l (USgal) 3 (0.79)
Drive system mechanical (V-belt)
Working speed m/min 0...20
max. gradability % 30
Vibration system
Frequency Hz 78
Amplitude mm (inch) 1,05 (0,041)
* Technical modifications reserved
*BPR 25/40 D
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The following noise and vibration data according to the EC-machine regulation, edition (93/68/EWG)
were determined at operating conditions, which are typical for the machine, with vibration and over
a pre-determined travel distance (DIN 45635).
During operation these values may vary because of the existing operating conditions.
Noise values
The noise measured according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is for the
sound pressure level at the operator’s place:
LpA = 96,0
sound capacity level:
LpA = 106,6
These noise values were determined according to ISO 6081 for the sound pressure level (LpA)and ISO 3744,
DIN 45635 for the sound capacity level (LWA).
Vibration values
The vibration data 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 according to ISO 8662 Part 1, DIN 45675, part 9 is
BPR 25/40 D = 4,5 m/sec2

Danger
Risk of hearing damage!
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2 Safety regulations
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General
This BOMAG machine is built in accordance
with the latest technical standard and the valid
technical rules and regulations. There is, how-
ever, a risk of danger for persons and property
if:
●the machine is used for purposes other than
those it is intended for
●the machine is operated by untrained person-
nel
●the machine is modified or converted in an un-
professional way
●the applicable safety regulations are not ob-
served.
Each person involved in operation, mainte-
nance and repair of the machine must there-
fore read and apply these safety regulations.
This should be confirmed by obtaining the sig-
natures of the customer, if necessary.
Furthermore the following regulations and instruc-
tions are obviously also valid:
●applicable accident prevention instructions
●generallyacknowledged safetyandroadtraffic
regulations
●country specific safety regulations. It is the
duty of the operator to know and observe
these regulations. This applies also for local
regulations and the regulations for various
types of manual work. If the recommendations
in this manual differ from the regulations valid
in your country, you must strictly observe the
regulations in your country.
Intended use
This machine must only be used for:
●compaction of all types of soil,
●repair work on all types of soil,
●reinforcement of pedestrian walkways,
●work in trenches,
●filling and compaction of hard shoulders.
●The machine should be checked by an expert
once every year.
Unintended use
Dangers may, however, arise from the machine if
it is used by untrained personnel in an unprofes-
sional way or if it is used for purposes other than
those mentioned in these instructions.
Who is allowed to work with the ma-
chine?
The machine must only be operated by trained
and authorized persons who are at least 18 years
of age. The responsibilities for the operation of the
machine must be clearly specified and complied
with.
Persons under the influence of alcohol, medica-
tion or drugs must not operate, service or repair
the machine.
Maintenance and repair tasks require specific
knowledge and must therefore only be carried out
by trained and qualified personnel.
Conversions and alterations to the ma-
chine
Unauthorized conversions to the machine are pro-
hibited for safety reasons.
Original parts and accessories have been special-
ly designed for this machine. We wish to make ex-
pressly clear that we have not tested or authorized
any original parts or special equipment not sup-
plied by us. The installation and/or use of such
products can impair the active and/or passive driv-
ing safety. The manufacturer expressly excludes
any liability for damage resulting from the use of
non-original parts or accessories.
Safety notes in the operating and main-
tenance instructions:

Danger
Paragraphs marked like this highlight possible
dangers for persons.

Caution
Paragraphs marked this way highlight possi-
ble dangers for machines or parts of the ma-
chines.
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L
Note
Sections marked like this provide technical infor-
mation concerning the optimal economical use of
the machine.
Environment
Sections marked like this highlight activities
for the safe and environmental disposal of fu-
els and lubricants as well as replaced parts.
Safety stickers on the machine
Keep safety stickers in good condition and legible
and follow their meaning.
Replace damaged and illegible safety stickers.
Loading the machine
Secure the machine against turning over or slip-
ping off.
Persons are highly endangered if they
●step under loads being lifted or
●stand under loads being lifted
Secure the machine on the transport vehicle
against rolling off, slipping and turning over.
Starting the machine
Before starting
Become acquainted with the equipment, the con-
trol elements, the working mode of the machine
and the area you will be working in.
Use your personal protective outfit (hard hat, safe-
ty boots etc.). Wear ear defenders.
Check before starting, whether:
●the machine shows any obvious defects
●all protective devices are properly secured in
their place
●the control elements are fully functional
●themachineisfreeof any oilyandcombustible
material
●all handles are free of grease, oils, fuels, dirt,
snow and ice.
Use only machines which have been serviced at
regular intervals.
Do not use any starting aids such as Startpilot or
ether.
Starting in closed rooms
Exhaust fumes are life threatening! Always ensure
an adequate supply of fresh air when starting in
closed rooms!
Operation
Guide the machine in such a way, that your hands
stay clear of any solid obstructions, risk of injury.
Watch out for unusual noises and development of
smoke. Detect the cause and have the fault cor-
rected.
Operatethe vibratoryplateonlywithfullthrottle,as
otherwise the centrifugal clutch may be damaged.
Never let the machine run unattended.
Parking the machine
If possible, park the machine on level ground.
Before leaving the machine:
●Park the machine so, that it cannot turn over.
●Shut the engine down and pull the ignition key
out.
Always secure parked machines, which could be
in the way, with appropriate measures.
Filling the fuel tank
Refuel only with the engine shut down.
Do not refuel in closed rooms.
No open fire, do not smoke.
Do not spill any fuel. Catch running out fuel, do not
let it seep into the ground.
Maintenance
Maintenance work must only be carried out by
qualified and authorized personnel.
Keep unauthorized persons away from the ma-
chine.
Do not perform service work while the engine is
running.
If possible, park the machine on level and firm
ground.
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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.
Storeusedfiltersandotheroilcontainingmaterials
in a specially marked container and dispose of en-
vironmentally.
Working on electric components
Before starting to work on electric components dis-
connect the battery and cover it with insulating ma-
terial.
Working on the battery
When working on the battery do not smoke, do not
use open fire.
Do not let skin and clothes come in contact with
acid.
In case of injuries caused by acid flush the respec-
tive parts with clear water and consult a doctor for
medical advice.
Do not place any tools on the battery, danger of
short circuit.
When recharging the battery remove all plugs to
avoid an accumulation of explosive gases.
Dispose of old batteries environmentally.
Working on the fuel system
No open fire, do not smoke, do not spill any fuel.
Catch running out fuel, do not let it seep into the
ground and dispose of environmentally.
Cleaning
Do not clean the machine while the engine is run-
ning.
Do not use gasoline or other combustible sub-
stances for cleaning purposes.
When using steam cleaning equipment do not
subjectelectricpartstothe direct waterjetorcover
it beforehand.
Do not guide the water jet directly into the air filter
and into the air intake opening.
After maintenance work
Reinstall all protective devices after completing
the maintenance work.
Repair
Repairs must only be performed by qualified and
authorized personnel. Use our repair instructions
for this purpose.
Exhaust gases are a threat to life! Always ensure
an adequate supply of fresh air when starting in
closed rooms!
Ifthe machine isdefective, attach a warning tag on
the steering handle.
Test
Depending on the type of applicational and the op-
erating conditions vibratory equipment has to be
examined by a specialist whenever required, but
at least once every year.
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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 Before starting work
Please observe strictly the safety regulations
in chapter 2 of these operating and mainte-
nance instructions.
Refer also to the detailed description in the
chapter "Maintenance".
Top up missing fuels and lubricants according to
the respective maintenance instruction.
●Stand the machine on level ground.
●Check fuel tank and lines for leaks.
●Check the engine oil level, if necessary top up
to the upper mark.
●Check the fuel level, if necessary top up.
●Check the dry air filter maintenance indicator.
●Check the condition of the entire machine and
check the screw connections for tight fit.
 Danger
Loss of hearing!
Wear your personal noise protection equip-
ment (ear defenders) before starting operation.
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3.3 Folding the steering rod
down

Danger
Danger of injury!
Impact caused by spring force!
The steering rod is resilient in operating posi-
tion.
Fig. 5
●Press the locking lever 3 (Fig. 5) in direction
ofarrowandfoldthesteering rod down, sothat
it can move freely.
3.4 Starting with recoil starter

Danger
Danger of explosion!
Do not use any starting aid sprays.
Before starting make sure that no persons are
in the danger zone around the engine or the
machine and that all guards and safety instal-
lations are in place.
Fig. 6
●Set the travel lever (reversing lever) (Fig. 6) to
position "0".
Fig. 7
●Shiftthethrottlelever(Fig.7)toposition"MIN."
(idle speed).
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Fig. 8
●Pullthe rope with the starterhandle (Fig.8) out
until a noticeable resistance can be felt.
●Let the starter handle run back to initial posi-
tion.
Fig. 9

Caution
Do not let the starter handle run back after pull-
ing.
●Pull the starter handle (Fig. 9) powerfully.
●If the engine does not start the first time, re-
peat the starting procedure.

Danger
Danger of explosion!
Do not use spray-type starting aids or other in-
flammable liquids to assist the starting proc-
ess.
Fig. 10

Caution
Before starting work allow the engine to warm
up for a short while (Fig. 10).
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