Bomag BPR 35/42 D Instructions for use

Operating instructions
Maintenance instructions
Catalogue number
008 041 61 02/2007
BPR35/42D-BPR35/60D
S/N 101 690 41 ....> S/N 101 690 42 ....> S/N 101 690 43 ....> S/N 101 690 44 ....>
Vibratory plate
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Foreword
BOMAG 3 BPR 35/40 D BPR 35/60 D
F oreword
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
lhelp you to become acquainted with the ma-
chine.
lavoid faults caused by unprofessional opera-
tion.
Observing the maintenance instructions will
lincrease the reliability of the machine during
useonsite,
lprolong the lifetime of the machine,
lreduce repair costs and downtime.
BOMAG does not assume liability for the function
of the machine
lif the machine is handled in a way, which does
not comply with the use it is intended for,
lif it is used for purposes other then the ones
mentioned in these instructions.
No warranty claims can be lodged for damage re-
sulting from
loperating errors,
linsufficient maintenance and
lthe 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.
These operating and maintenance 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
PrintedinGermany
Copyright by BOMAG
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Foreword
BOMAG 4 BPR 35/40 D BPR 35/60 D
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 35/40 D BPR 35/60 D
Technical Data 7
Safety regulations 13
Indicators and Controls 17
3.1 General notes 18
3.2 Controls 18
Operation 21
4.1 General 22
4.2 Before starting work 22
4.3 Folding down the steering rod 23
4.4 Starting with recoil starter 23
4.5 Start the engine electrically. 25
4.6 Starting with jump leads 26
4.7 Work/operation 26
4.8 Shutting the engine down 28
4.9 Loading 29
Maintenance 31
5.1 General notes on maintenance 32
5.2 Fuels and lubricants 33
5.3 Table of fuels and lubricants 35
5.4 Running-in instructions 36
5.5 Maintenance chart 37
5.6 Clean machine/engine 38
5.7 Checking the fuel level 38
5.8 Checking the engine oil level 39
5.9 Checking the condition of the battery, greasing the poles 40
5.10 Check the air filter, replace if necessary. 41
5.11 Checking the oil level in the vibrator housing 43
5.12 Changing the engine oil 43
5.13 Clean the engine oil filter 44
5.14 Check, tighten, replace the V-belt 45
5.15 Check, adjust the valve clearance 47
5.16 Cleaning cooling fins and cooling air intake opening 47
5.17 Cleaning the exhaust screen 48
5.18 Changing the dry air filter 49
5.19 Changing the fuel filter 51
5.20 Change the oil in the exciter shaft housing 51
5.21 Checking the hydraulic oil level and topping up 52
5.22 Checking the rubber buffers 54
5.23 Drawing the water out of the fuel tank 55
5.24 Retightening the bolted connections 57
5.25 Tightening the screws 57
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Table of Contents
BOMAG 6 BPR 35/40 D BPR 35/60 D
5.26 Engine conservation 58
Trouble shooting 59
6.1 General notes 60
6.2 Replacing the injection pump 61
6.3 Engine faults 65
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BOMAG 7 BPR 35/40 D BPR 35/60 D
1 Technical Data
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Technical Data
BOMAG 8 BPR 35/40 D BPR 35/60 D
Fig. 4
Dimensions in mm Working width W lowest passing height H
BPR 35/42 D BPR 35/42 D (E-Start) 420 687
*BPR 35/42 D BPR 35/42D with E-Start
Weights
Operating weight (CECE) kg 205 225
Travel characteristics soil dependent
Working speed m/min 27 27
Gradability % 32 32
Drive
Engine manufacturer Hatz Hatz
Type 1B20 1B20
Cooling Air Air
Number of cylinders 1 1
Rated power ISO 9249 kW 3,1 3,1
Rated speed min-1 3000 3000
Starting device Recoil starter Electric starter
Fuel Diesel Diesel
Drive system mechanical (V-belt) mechanical (V-belt)
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Technical Data
BOMAG 9 BPR 35/40 D BPR 35/60 D
Exciter system
Frequency Hz 80 80
Centrifugal force kN 35 35
Filling capacities
Fuel l 3 3
* The right for technical modifications remains reserved
*BPR 35/42 D BPR 35/42D with E-Start
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Technical Data
BOMAG 10 BPR 35/40 D BPR 35/60 D
Fig. 5
Dimensions in mm Working width W lowest passing height H
BPR 35/60 D BPR 35/60 D with E-Start 600 687
*BPR 35/60 D BPR 35/60 D
with E-Start
Weights
Operating weight (CECE) kg 220 240
Travel characteristics soil dependent
Working speed m/min 27 27
Gradability % 32 32
Drive
Engine manufacturer Hatz Hatz
Type 1B20 1B20
Cooling Air Air
Number of cylinders 1 1
Rated power ISO 9249 kW 3,1 3,1
Rated speed rpm 3000 3000
Starting device Recoil starter Electric starter
Fuel Diesel Diesel
Drive system mechanical (V-belt) mechanical (V-belt)
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Technical Data
BOMAG 11 BPR 35/40 D BPR 35/60 D
Exciter system
Frequency Hz 80 80
Centrifugal force kN 35 35
Filling capacities
Fuel l 3 3
* The right for technical modifications remains reserved
*BPR 35/60 D BPR 35/60 D
with E-Start
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Technical Data
BOMAG 12 BPR 35/40 D BPR 35/60 D
The following noise and vibration data acc. to
- EC Machine Regulation edition 98/37/EC and
- the noise regulation 2000/14/EG, 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) BPR 35/42 D with tube frame, determined acc. to ISO 11204 and EN 500
LpA = 92 dB(A) BPR 35/60 D with tube frame, determined acc. to ISO 11204 and EN 500
Guaranteed sound power level:
LWA = 103 dB(A) BPR 35/42 D with tube frame, determined acc. to ISO 3744 and EN 500
LWA = 105 dB(A) BPR 35/60 D with tube frame, 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
BPR 35/42 D ahw =6.2m/sec
2with hood on crushed rock determined acc. to ISO 5349 and EN 500
BPR 35/42 D ahw =7.3m/sec
2with tube frame on crushed rock determined acc. to ISO 5349 and EN 500
BPR 35/60 D ahw =5.7m/sec
2with hood on crushed rock determined acc. to ISO 5349 and EN 500
BPR 35/60 D ahw =6.7m/sec
2with tube frame on crushed rock determined acc. to ISO 5349 and EN 500
!
Caution
Observe the daily vibration load (Industrial safety acc. to 2002/44/EEC).
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BOMAG 13 BPR 35/40 D BPR 35/60 D
2 Safety regulations
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Safety regulations
BOMAG 14 BPR 35/40 D BPR 35/60 D
General
This BOMAG machine is built in accordance
with the latest technical standard and the valid
technical rules and regulations. However, dan-
gers for persons and property may arise from
the machine if it is:
lput to unintended use,
loperated by untrained personnel,
lmodified or altered in an unprofessional 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. If
necessary this should be confirmed by obtain-
ing the signature of the customer.
Furthermore the following regulations and instruc-
tions are obviously also valid:
lall applicable instructions for the prevention of
accidents,
lgenerally acknowledged safety and road traffic
regulations,
lcountry specific regulations.
Intended use
This machine must only be used for:
lcompaction of all types of soil,
lrepair work on all types of soil,
lreinforcement of pedestrian walkways,
lwork in trenches,
lfilling and compaction of hard shoulders.
lThe 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.
i
Note
Sections marked like this provide technical infor-
mation concerning the optimal economical use of
the machine.
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Safety regulations
BOMAG 15 BPR 35/40 D BPR 35/60 D
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
lstep under loads being lifted or
lstand 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 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 controls are fully functional
lthe machine is free of oily and combustible
material
lall grips are free of grease, oils, fuel, dirt, snow
and ice.
Use only machines which are serviced at regular
intervals.
Do not use any starting aids like start pilot or ether.
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
Operate the machine only with the steering rod
folded down.
Guide the machine so hat your hands do not hit
against solid objects, danger of injury.
Watch out for unusual noises and development of
smoke. Perform trouble shooting and have the
fault corrected.
Operate the machine only with full engine speed,
as otherwise the centrifugal clutch will be de-
stroyed.
Do not let the machine run unattended.
Parking the machine
Park the machine on level, firm ground.
Before leaving the machine:
lpark the machine so that it cannot turn over,
lshut the engine down.
Mark machines, which could be in the way, with a
clearly visible sign.
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.
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.
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Safety regulations
BOMAG 16 BPR 35/40 D BPR 35/60 D
Store used filters and other oil containing materials
in a specially marked container and dispose of en-
vironmentally.
Workingonelectriccomponents
Before starting to work on electric components dis-
connect the battery and cover it with insulating ma-
terial.
Workingonthebattery
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
subject electric parts to the direct water jet or cover
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
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.
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BOMAG 17 BPR 35/40 D BPR 35/60 D
3 Indicators and Controls
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Indicators and Controls
BOMAG 18 BPR 35/40 D BPR 35/60 D
3.1 General notes
Please read this section thoroughly before operat-
ing this machine if you are not yet conversant with
the indicators and control elements. All functions
are described in detail hereunder.
Paragraph 4 Operation contains only concise de-
scriptions of the individual operating steps.
3.2 Controls
Fig. 6
Locking lever (Fig. 6)
Fig. 7
Height adjustment (Fig. 7) of steering rod.
i
Note
Pull the locking lever up to fold the steering rod
down.
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Indicators and Controls
BOMAG 19 BPR 35/40 D BPR 35/60 D
Fig. 8
Controls (Fig. 8).
1 Throttle lever
2 Steering rod
3 Travel lever
Fig. 9
Optional equipment
Start the engine electrically (Fig. 9).
Ignition key position "0", warning buzzer off.
Ignition key position "I", warning buzzer on.
Ignition key position "II", the engine will start.
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