Bomag BPR 30/38-3 Instructions for use

Operating instructions
Maintenance instructions
Catalogue number
008 156 55 02/2006
BPR 30/38-3 - BPR 35/38-3
S/N10168036....
Honda
Vibratory plate
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Foreword
BOMAG 3 BPR 30/38-3 / BPR 35/38-3
F oreword
The BOMAG - machines are products from the
wide range of BOMAG soil compaction ma-
chines. BOMAG's vast experience as well as
most up-to-date production and testing proce-
dures, such as lifetime tests of all important
components and highest quality demands,
guarantee maximum reliability of your ma-
chine.
Using this manual will
lhelp youto understand the machine.
lavoid malfunctions caused by faulty operation.
Refering to the maintenance instructions will
lincreasethe reliability of the machine on the
site,
lincreasethe service life of your machine,
lreducerepair costs and downtimes.
BOMAG shall not assume liability for safe func-
tioning of the machine
lif it is handled in a way which does not comply
with the usual modes of use,
lif it is used for purposes other than those men-
tioned in the instructions.
No warranty claims may be lodged in case of dam-
ages caused by
loperating mistakes,
linsufficient maintenance and
lwrong fuels and lubricants.
Please note!
This manual has been written to be used by oper-
ators and service personnel on the site.
You should only operate the machine if you are ful-
ly conversant with the contents of these instruc-
tions.
Please strictly observe the safety regulations.
Please observe also the guidelines of the civil en-
geneering liability association "Safety Rules for
the Operation of Road Rollers and soil Compac-
tors" and all relevant accident prevention instruc-
tions.
For your own safety you should only use
BOMAG spare parts.
We reserve the right for technical modifica-
tions without prior notification.
These operating and maintenance instructions are
also available in other languages.
You can also receive the spare parts catalogue
from your BOMAG dealer when giving the serial
number of your machine.
You can also obtain informations about the correct
use of our machines for soil- and asphalt compac-
tion from your BOMAG dealer.
The above mentioned notes do not constitute an
extension of the warranty and liability conditions
specified in the general terms of business of
BOMAG.
We wish you much success with your BOMAG
machine.
BOMAG GmbH
PrintedinGermany
Copyright by BOMAG
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Foreword
BOMAG 4 BPR 30/38-3 / BPR 35/38-3
Please fill in
............................
Machinetype(Fig.1)
............................
Serial No. (Fig. 1 and 2)
............................
Engine type (Fig. 3)
............................
Engine No. (Fig. 3)
i
Note
Fill in the above listed data when receiving the ma-
chine.
Upon receipt of the machine our organization will
instruct you about correct operation and mainte-
nance.
Please observe strictly all safety regulations and
notes on potential dangers!
Fig. 1
Fig. 2
Fig. 3
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Table of Contents
BOMAG 5 BPR 30/38-3 / BPR 35/38-3
Technical Data 7
Safety regulations 11
Operation 15
3.1 General notes 16
3.2 Inspections before starting operation 16
3.3 Filling in fuel 17
3.4 Checking the engine oil level 18
3.5 Folding the steering rod down 18
3.6 Starting the engine 19
3.7 Starting under cold conditions 21
3.8 Wrong starting of engine 22
3.9 Work/operation 22
3.10 Shutting the engine down 24
3.11 Loading 25
Maintenance 27
4.1 General Notes for Maintenance 28
4.2 Fuels 28
4.3 Table of fuels and lubricants 30
4.4 Running-in Instructions 31
4.5 Maintenance table 32
4.6 Cleaning the machine / engine 33
4.7 Cleaning the air filter 33
4.8 Checking the engine oil level 34
4.9 Checking the fuel level 35
4.10 Checking the oil level in the vibrator housing 36
4.11 Cleaning cooling fins and cooling air openings 36
4.12 Changing the engine oil 37
4.13 Cleaning, checking the spark plug 38
4.14 Cleaning the fuel sludge filter 38
4.15 Checking, tensioning, changing the V-belt 39
4.16 Cleaning/changing the air filter 41
4.17 Checking, adjusting the valve clearance 41
4.18 Cleaning the fuel screen 42
4.19 Changing the oil in the vibrator shaft housing 43
4.20 Check the hydraulic oil level 44
4.21 Checking the rubber buffers 46
4.22 Retighten bolted connections, inspect the machine visually 47
4.23 Tightening torques for screws with metric unified thread 47
Trouble shooting 49
5.1 General Troubleshooting Instructions 50
5.2 Engine problems 51
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Table of Contents
BOMAG 6 BPR 30/38-3 / BPR 35/38-3
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BOMAG 7 BPR 30/38-3 / BPR 35/38-3
1 Technical Data
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Technical Data
BOMAG 8 BPR 30/38-3 / BPR 35/38-3
Fig. 4
Dim. mm (inch) HH1 LL1 WW1 W2 W3
BPR 30/38-3 690 1070 1440 720 380 500 580 700
BPR 35/38-3 690 1070 1440 720 380 500 580 700
*BPR 30/38-3 BPR 35/38-3
Weights
Basic weight kg 198 198
Operating weight (CECE) kg 210 210
Operating weight (CECE)
with extension plates
kg 215 215
Drive
Engine manufacturer Honda Honda
Type GX160 GX160
Cooling air air
Working cycles 4 4
Number of cylinders 1 1
Rated power ISO 9249 kW (PS) 4 (5,4) 4 (5,4)
Rated speed rpm 3600 3600
Starting device Recoil starter Recoil starter
Fuel Standard gasoline Standard gasoline
Fuel tank capacity l 4 4
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Technical Data
BOMAG 9 BPR 30/38-3 / BPR 35/38-3
Drive system mechanical mechanical
Working speed m/min 0...22 0...22
max. gradability % 30 30
Vibration system
Frequency Hz 75 89
Amplitude mm 1,1 0,8
* Technical modifications reserved
*BPR 30/38-3 BPR 35/38-3
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Technical Data
BOMAG 10 BPR 30/38-3 / BPR 35/38-3
The following noise and vibration data acc. to
- EC Machine Regulation edition 98/37/EC and
- the noise regulation 2000/14/EC, noise protection guideline 2003/10/EC
- Vibration Protection Regulation 2002/44/EC
were determined during conditions typical for this type of equipment and by application of harmo-
nized standards.
During operation these values may vary because of the existing operating conditions.
Noise value
sound pressure level on the operator’s stand:
LpA = 91 dB(A), determined acc. to ISO 11204 and EN 500
Garanteed sound capacity level:
LWA = 105 dB(A), determined acc. to ISO 3744 and EN 500
!
Danger
Loss of hearing!
Wear your personal noise protection means (ear defenders) before starting operation.
Vibration value
Hand-arm vibration:
Vector total of the weighted effective acceleration in three orthogonal directions:
Weighted total vibration value
ahw = 11.6 m/sec2on crushed rock determined acc. to ISO 5349 and EN 500
!
Caution
Observe the daily vibration load (Industrial safety acc. to 2002/44/EC).
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BOMAG 11 BPR 30/38-3 / BPR 35/38-3
2 Safety regulations
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Safety regulations
BOMAG 12 BPR 30/38-3 / BPR 35/38-3
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:
lthe machine is used for purposes other than
those it is intended for
lthe machine is operated by untrained person-
nel
lthe machine is modified or converted in an un-
professional way
lthe applicable safety regulations are not ob-
served.
Each person involved in operation, mainte-
nance and repair of the machine must there-
fore read and apply these safety regulations.
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:
lapplicable accident prevention instructions
lgenerally acknowledged safety and road traffic
regulations
lcountry 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:
lthe compaction of all types of soil
lrepair work on all types of soil
lenforcement of paths and walkways
lwork in trenches
lbackfills and compaction of hard shoulders
lHave the machine inspected by an expert
once every year.
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.
Maintenance and repair work requires specific
knowledge and must therefore only be performed
by trained specialists.
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
Sections marked like this highlight possible
dangers for persons.
!
Caution
Sections marked like this highlight possible
dangers for the amchine or parts of the ma-
chine
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Safety regulations
BOMAG 13 BPR 30/38-3 / BPR 35/38-3
i
Note
Sections marked like this contain 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, lubricants and exchanged parts.
Observeallregulationsfortheprotectionof
the environment.
Safety stickers on the machine
Do not destroy safety stickers (see spare parts
list), keep them legible and observe their meaning.
Replace damaged or illegible safety stickers.
Loading the machine
Secure the machine against tipping or slipping off.
Persons are highly endangered when
lstepping under loads being lifted or
lstanding under loads being lifted.
Secure the machine on the transport vehicle
against rolling, slipping and turning over.
Starting the machine
Before starting
Become acquainted with the equipment, the con-
trol elements, the working principle of the machine
and the working area.
Wear your personal protective outfit (hard hat,
safety boots, etc.). Wear ear defenders.
Before starting the machine check whether:
lthe machine shows any obvious faults
lall guards and safety elements are in place
lthe control elements are fully functional
lthe machine is free of oily and combustible
material
lall handles are free of grease, oils, fuel, dirt,
snow and ice.
Use only machines which are serviced at regular
intervals.
For starting move your feet out of the danger zone
of the base plate.
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 only be 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
If possible park the machine on level and firm
ground.
Before leaving the machine:
lsecure the machine against turning over,
lshut the engine down.
Mark parked machines, which could be in the way,
with noticeable means.
Refueling
Refuel only with the engine shut down.
Do not refuel in closed rooms.
Do not use 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.
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Safety regulations
BOMAG 14 BPR 30/38-3 / BPR 35/38-3
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.
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
Repairs must only be carried out by qualified and
authorized personnel and by following our repair
instructions.
Exhaust gases are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
the engine indoors!
Always mark defective machines by attaching a
sign to the steering rod.
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BOMAG 15 BPR 30/38-3 / BPR 35/38-3
3Operation
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Operation
BOMAG 16 BPR 30/38-3 / BPR 35/38-3
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
The following inspections must be carried out
before each working day or before a longer
working period.
i
Note
The running-in period for the vibratory plate is 20
operating hours.
lFill the fuel tank.
lCheck fuel tank and fuel lines for leaks.
lCheck the condition of the entire machine.
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Operation
BOMAG 17 BPR 30/38-3 / BPR 35/38-3
3.3 Filling in fuel
! Danger
Refuel only with the engine shut down and the
fuel cock valve closed.
Do not spill any fuel!
No open fire, do not smoke!
lRun the engine only on standard grade gaso-
line (DIN 51600) and/or unleaded standard
grade gasoline (DIN 51607).
lUse a fuel screen when filling from a spare fuel
drum.
Fig. 5
i
Note
During refuelling the fuel cock valve (Fig. 5) must
be closed.
lClean the area around the fuel filler cap, un-
screw the filler cap.
Fig. 6
lFill in fuel (Fig. 6). Tank capacity max. 4 l.
lClose the filler cap again tightly after refuelling.
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Operation
BOMAG 18 BPR 30/38-3 / BPR 35/38-3
3.4 Checking the engine oil lev-
el
Fig. 7
lPark the machine on level ground so that the
engine is in horizontal position.
lCheck engine oil level, correct if necessary.
lThe oil level must reach up to the bottom edge
of the filler opening (Fig. 7).
3.5 Folding the steering rod
down
!
Danger
Danger of injury!
Shockbyspringforce!
The steering rod is elastically suspended in
operating position.
Fig. 8
lPush locking lever (Fig. 8) up and fold the rod
down, so that steering rod can swing freely.
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Operation
BOMAG 19 BPR 30/38-3 / BPR 35/38-3
3.6 Starting the engine
!
Caution
The engine is equipped with a low oil level
safety feature. If the oil level is too low, the en-
gine cannot be started or it goes out during op-
eration.
Fig. 9
lOpen the fuel cock valve (Fig. 9) completely by
turningindirectionofarrow.
Fig. 10
lClose the choke (Fig. 10) completely by shift-
ing the lever in direction of arrow.
i
Note
Do NOT operate the choke lever when the engine
is warm or at high ambient temperatures.
Also operation position.
Fig. 11
lShift the throttle lever (Fig. 11) to position
"MAX".
Fig. 12
lTurn ignition switch 1 (Fig. 12) to position
"ON".
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