Bomag BPR 45/55 D User manual

Operating instructions
Maintenance instructions
Original operating instructions
12/2012
Catalogue No.
008 051 21
BPR 45/55 D - BPR 55/65 D
S/N 101 692 14 .... / S/N 101 692 33 .... / S/N 101 692 16 .... / S/N 101 692 34 ....
Reversible Vibrating Plate

Foreword
BOMAG 3BPR 45/55 D, BPR 55/65 D
1 Foreword
BOMAG manufactures machine for earth, as-
phalt and refuse compaction, stabilizers/recy-
clers as well as milling machine and finishers.
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.
This manual comprises:
lSafety regulations
lOperating instructions
lmaintenance instructions
lTrouble shooting
Using these instructions will
lhelp you to become familiar with the machine.
lavoid malfunctions caused by unprofessional
operation.
Compliance with the maintenance instructions will
lenhance the reliability of the machine on con-
struction sites,
lprolong the lifetime of the machine,
lreduce repair costs and downtimes.
BOMAG will not assume liability for the function of
the machine
lif it is handled in a way not complying with the
usual modes of use,
lif 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
loperating errors,
linsufficient maintenance and
lwrong fuels and lubricants.
Please note!
This manual was written for operators and mainte-
nance personnel on construction sites.
These operating and maintenance instructions are
part of the machine.
You should only operate the machine after you
have been instructed and in compliance with these
instructions.
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.
For your machine BOMAG offers service kits
to make maintenance easier.
In the course of technical development we re-
serve the right for technical modifications
without prior notification.
These operating and maintenance instructions are
also available in other languages.
Apart from that, the spare parts catalogue is avail-
able 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
the warranty and liability conditions specified in the
general terms of business of BOMAG.
We wish you successful work with your BOMAG
machine.
BOMAG GmbH
Copyright by BOMAG

Foreword
BOMAG4BPR 45/55 D, BPR 55/65 D
Please fill in
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Machine type (Fig. 1)
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Serial-number (Fig. 1 and 2)
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Engine type (Fig. 3)
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Engine number (Fig. 3)
Note
i
Supplement the above data together with the com-
missioning protocol.
During commissioning our organisation will in-
struct you in the operation and maintenance of the
machine.
Please observe strictly the safety regulations and
all notes on risks and dangers!
Fig. 1
Fig. 2
Fig. 3

Table of Contents
BOMAG 5BPR 45/55 D, BPR 55/65 D
1Foreword 3
2 Technical Data 7
3 Safety regulations 13
4 Indicators and Controls 19
4.1 General notes 20
4.2 Description of indicators and control elements 20
4.3 Function of the Economizer 22
5 Operation 23
5.1 General 24
5.2 Tests before taking into operation 24
5.3 Folding down the steering rod 25
5.4 Starting the engine electrically 25
5.5 Starting with recoil starter 27
5.6 Operation of Economizer 29
5.7 Work/operation 30
5.8 Shutting down the engine 32
5.9 Loading/transport 33
6 Maintenance 35
6.1 General notes on maintenance 36
6.2 Fuels and lubricants 37
6.3 Table of fuels and lubricants 39
6.4 Running-in instructions 40
6.5 Maintenance table 41
Maintenance every day 43
6.6 Clean the machine 43
6.7 Check the engine oil level 43
6.8 Check the fuel level 44
6.9 Check, clean the air filter, replace if necessary 45
Maintenance every month 47
6.10 Clean the cooling fins and the cooling air intake openings 47
6.11 Drain the sludge from the fuel tank 48
Maintenance every 6 months 49
6.12 Check the battery condition, grease the poles 49
6.13 Check the oil level in the exciter housing 50
6.14 Check the V-belt tension, if necessary replace the V-belt 50
Maintenance every year 53
6.15 Change engine oil and oil filter 53

Table of Contents
BOMAG6BPR 45/55 D, BPR 55/65 D
6.16 Replacing the fuel filter 54
6.17 Change the oil in the exciter housing 55
6.18 Check the hydraulic oil level 56
6.19 Check the rubber buffers 58
As required 59
6.20 Tightening the screws 59
6.21 Engine conservation 59
7 Trouble shooting 61
7.1 General notes 62
7.2 Starting with jump wires 62
7.3 Fuses 63
7.4 Engine problems 64
7.5 Trouble shooting Economizer 66
8Disposal 67
8.1 Final shut-down of machine 68

BOMAG 7BPR 45/55 D, BPR 55/65 D
2 Technical Data

Technical Data
BOMAG8BPR 45/55 D, BPR 55/65 D
Fig. 4
BPR 45/55 D HH1 H2 LL1 WW1 W2
Dimensions in
mm 790 980 1350 1700 900 450 550 750
Dimensions in
inch 31.1 38.6 53.2 66.9 35.4 17.7 21.7 29.5
BPR 45/55 D
Weights
Operating weight (CECE) (W) 381 kg 840 lbs
Operating weight (CECE) (W1) 396 kg 873 lbs
Operating weight (CECE) (W2) 412 kg 908 lbs
Basic weight 391 kg 862 lbs
Economizer1+ 5 kg 11 lbs
Travel characteristics
Working speed max. 28 m/min 92 ft/min
Max. gradability (depending on soil) 35% 35%
Drive
Engine manufacturer Lombardini Lombardini
Type 15 LD 440 15 LD 440
Cooling Air Air
Number of cylinders 1 1

Technical Data
BOMAG 9BPR 45/55 D, BPR 55/65 D
Note
i
Subject to technical alterations.
Rated power ISO 9249 6.6 KW 8.9 hp
Rated speed 3000 min-1 3000 rpm
Drive system mechanical mechanical
Exciter system
Frequency 70 Hz 4200 vpm
Centrifugal force 45 kN 10116 lbf
Filling capacities
Fuel (diesel) 5.0 l 1.3 gal us
Engine oil 1.5 l 0.4 gal us
1 Optional equipment
BPR 45/55 D

Technical Data
BOMAG10 BPR 45/55 D, BPR 55/65 D
Fig. 5
BPR 55/65 D HH1 H2 LL1 WW1 W2
Dimensions in
mm 790 980 1350 1700 900 450 650 750
Dimensions in
inch 31.1 38.6 53.2 66.9 35.4 17.7 25.6 29.5
BPR 55/65 D
Weights
Operating weight (CECE) (W) 436 kg 961 lbs
Operating weight (CECE) (W1) 456 kg 1005 lbs
Operating weight (CECE) (W2) 467 kg 1030 lbs
Basic weight 451 kg 994 lbs
Economizer1+ 5 kg 11 lbs
Travel characteristics
Working speed max. 28 m/min 92 ft/min
Max. gradability (depending on soil) 35% 35%
Drive
Engine manufacturer Lombardini Lombardini
Type 15 LD 440 15 LD 440
Cooling Air Air
Number of cylinders 1 1

Technical Data
BOMAG 11BPR 45/55 D, BPR 55/65 D
Note
i
Subject to technical alterations.
Rated power ISO 9249 6.6 KW 8.9 hp
Rated speed 3000 min-1 3000 rpm
Drive system mechanical mechanical
Exciter system
Frequency 66 Hz 3960 vpm
Centrifugal force 55 kN 12365 lbf
Filling capacities
Fuel (diesel) 5.0 l 1.3 gal us
Engine oil 1.5 l 0.4 gal us
1 Optional equipment
BPR 55/65 D

Technical Data
BOMAG12 BPR 45/55 D, BPR 55/65 D
The following noise and vibration data acc. to
- EC Machine Regulation edition 2006/42/EC
- 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 place of the operator:
BPR 45/55 D: LpA = 95 dB(A), determined acc. to ISO 11204 and EN 500
BPR 55/65 D: LpA = 95 dB(A), determined acc. to ISO 11204 and EN 500
Guaranteed sound power level:
BPR 45/55 D: LWA = 108 dB(A), determined acc. to ISO 3744 and EN 500
BPR 55/65 D: LWA = 108 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
BPR 45/55 D: ahv = 4,6 m/s2, on crushed rock determined acc. to ISO 5349 and EN 500
BPR 55/65 D: ahv = 8,7 m/s2, on crushed rock determined acc. to ISO 5349 and EN 500
Caution
!
Observe the daily vibration load (Industrial safety acc. to 2002/44/EEC).

BOMAG 13BPR 45/55 D, BPR 55/65 D
3 Safety regulations

Safety regulations
BOMAG14 BPR 45/55 D, BPR 55/65 D
General
This BOMAG machine has been built in com-
pliance with 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:
lit is used for purposes other than the ones it is
intended for,
lit is operated by untrained personnel,
lit is changed or converted in an unprofessional
way,
lthe 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 obviously also applies:
lapplicable accident prevention instructions,
lgenerally accepted safety and road traffic reg-
ulations,
lcountry specific safety regulations. It is the
duty of the operator to be acquainted with
these instructions and to apply these accord-
ingly. This applies also for local regulations
concerning different types of handling work.
Should the recommendations in these instruc-
tions be different from the regulations valid in
your country, you must comply with the safety
regulations valid in your country.
Intended use
This machine must only be used for:
lCompaction of all types of soils
lRepair work on all types of soil
lPaving of walkways
lWork in trenches
lUnderfilling and compaction of hard shoulders
Unintended use
Dangers may arise from the machine when it is
used for purposes other than the one it is intended
for.
Any danger caused by intended use is the sole re-
sponsibility of the customer or driver/operator, the
manufacturer cannot be made liable.
Examples for unintended use are:
lDragging the machine along as a measure of
transportation
lThrowing the machine off the transport vehicle
lAttaching an additional weight to the machine
It is not permitted to stand on the machine while
working.
Any transport ropes fastened to the machine must
be removed before operation.
Starting and operation of the machine in explosive
environments and in underground mining is pro-
hibited.
Remaining dangers, remaining risks
Despite careful work and compliance with stand-
ards and regulations it cannot be ruled out that fur-
ther dangers may arise when working with and
handling the machine.
Both the machine as well as all other system com-
ponents comply with the currently valid safety reg-
ulations. Nevertheless, remaining risks cannot be
ruled out completely, even when using the ma-
chine for the purpose it is intended for and follow-
ing all information given in the operating
instructions.
A remaining risk can also not be excluded beyond
the actual danger zone of the machine. Persons
remaining in this area must pay particular attention
to the machine, so that they can react immediately
in case of a possible malfunction, an incident or
failure etc.
All persons remaining ion the area of the machine
must be informed about the dangers that arise
from the operation of the machine.
Regular safety inspections
Have the machine inspected by an expert (capa-
ble person) as required for the conditiosn the ma-
chine is working under, but at least once every
year.

Safety regulations
BOMAG 15BPR 45/55 D, BPR 55/65 D
Who is allowed to operate the ma-
chine?
Only trained, instructed and authorized persons of
at least 18 years of age are permitted to drive and
operate this machine. For operation of the ma-
chine the responsibilities must be clearly specified
and complied 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.
Changes and conversions to the ma-
chine
Unauthorized changes to the machine are prohib-
ited for safety reasons.
Original parts and accessories have been special-
ly designed for this machine.
We wish to make explicitly 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 pas-
sive safety.
The manufacturer explicitly excludes any liability
for damage caused by the use of non-original
parts or accessories.
Damage, deficiencies, misuse of safety
installations
Machines which are not safe to operate must be
immediately taken out of service and shall not be
used, until these deficiencies have been properly
rectified.
Safety installations and switches must neither be
removed nor must they be made ineffective.
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.
Note
i
Paragraphs marked like this contain technical in-
formation for the optimal economical use of the
machine.
Environment
Paragraphs marked like this point out practic-
es for safe and environmental disposal of fuels
and lubricants as well as replacement parts.
Observe the regulations for the protection of
the environment.
Loading/transporting the machine
Make sure that persons are not endangered by the
machine tipping or sliding off.
Use only safe lifting gear of sufficient load bearing
capacity Minimum lifting capacity of lifting gear:
see operating weight in chapter "Technical Data".
Loads must only be attached and hoisted by an
expert (capable person).
Fasten the lifting gear only at the specified lifting
points.
Check lifting eye for damage before use. Do not
use a damaged or in any other way impaired lifting
eye.
Do not lift or lower the machine jerkily.
The tension must always be effective in vertical di-
rection.
The machine must not swing about when being lift-
ed.
Do not step or stand under suspended loads.
Always use suitable lashing gear on the lifting
points to lash down the machine.
Lash the machine down, so that it is secured
against rolling, sliding 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.

Safety regulations
BOMAG16 BPR 45/55 D, BPR 55/65 D
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.
When starting with recoil starter check the starter
rope for chafing before starting, replace if neces-
sary. A damaged rope can break and cause inju-
ries during starting.
Use only machines which are serviced at regular
intervals.
Do not use starting aid sprays or other inflamma-
ble fluids for starting.
Starting and operation of the machine is
closed rooms and trenches
Exhaust gases are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
and operating in closed rooms and trenches!
Operation
Operate the machine only with the steering rod
folded down.
Guide the machine only by the steering rod.
Guide the machine so hat your hands do not hit
against solid objects, danger of injury.
As a measure to avoid injury the machine must
only be guided from the side by the steering han-
dle
Always keep an eye on a running machine.
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.
Parking the machine
Park the machine on level and firm ground.
Before leaving the machine:
lPark the machine so that it cannot tip over,
lshut the engine down and pull the ignition key
out.
Mark machines, which could be in the way, with a
clearly visible sign.
Refuelling
Do not inhale any fuel fumes.
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.
Keep dirt and water away from the fuel.
A leaking fuel tank can cause an explosion. En-
sure tight fit of the fuel tank cover, if necessary re-
place immediately.
Maintenance work
Comply with the maintenance work described in
the operating and maintenance instructions, in-
cluding the information concerning the replace-
ment of parts.
Maintenance work must only be performed by
qualified and authorized persons.
Keep unauthorized persons away from the ma-
chine.
Do not touch hot engine parts.
Do not perform maintenance work while the motor
is running.
Park the machine on level, firm ground.
Remove the key from the ignition switch.
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.

Safety regulations
BOMAG 17BPR 45/55 D, BPR 55/65 D
Working on electric parts of the machine
Before starting to work on electric parts of the ma-
chine disconnect the battery and cover it with insu-
lating material.
Do not use fuses with higher ampere ratings and
do not bridge fuses - fire hazard!
Working on the battery
When working on the battery do not smoke, do not
use open fire!
Do not let acid come in contact with hands or
clothes! When injured by acid flush off with clear
water and seek medical advice.
Wear gloves and goggles.
Metal objects (e.g. tools, rings, watch straps) must
not come in contact with the battery poles – dan-
ger of short circuit and burning!
For recharging remove the plugs from the battery
to avoid the accumulation of highly explosive gas-
es.
Observe the applicable instructions when starting
with an auxiliary battery.
Switch off the charging current before removing
the charging clamps.
Ensure sufficient ventilation, especially if the bat-
tery is to be charged in a closed room.
Dispose of old batteries according to regulations.
Working on the fuel system
Do not inhale any fuel fumes.
Avoid open fire, do not smoke, do not spill any fuel.
Catch running out fuel, do not let it seep into the
ground and dispose off environmentally.
Cleaning work
Do not perform cleaning work while the motor is
running.
Do not use gasoline or other easily inflammable
substances 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 air filter and
air intake or exhaust muffler.
After maintenance work
After all maintenance work is completed reinstall
all guards and safety installations.
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 the fuel tank with in-
sulating material.
Safety stickers on the machine
Keep safety stickers in good condition and legible
and follow their meaning.
Replace damaged and illegible safety stickers.

Safety regulations
BOMAG18 BPR 45/55 D, BPR 55/65 D
Fig. 6
1 Information sticker - Diesel
2 Information sticker - Ultra-low sulphur fuel
3 Information sticker - Lashing point
4 Maintenance sticker
5 Information sticker - Throttle lever
6 Information sticker - Guaranteed sound capac-
ity level
7 Information sticker - Travel lever
8 Brief operating instructions
9 Information sticker - Lifting point
692068
1
DIESEL
6
8
4
7
5
9
3
2
dB
LWA
Stickers and decals BPR 45/55 D, BPR 55/65 D

BOMAG 19BPR 45/55 D, BPR 55/65 D
4 Indicators and Controls

Indicators and Controls
BOMAG20 BPR 45/55 D, BPR 55/65 D
4.1 General notes
If you are not yet familiar with the control and dis-
play elements on this machine you should read
this section thoroughly before starting any opera-
tion on the machine. Here all functions are de-
scribed in detail.
The section "Operation" contains only brief de-
scriptions of the individual control steps.
4.2 Description of indicators
and control elements
Fig. 7
No. 1 = Steering rod height adjustment
No. 2 = Locking pawl lever
Fig. 8
No. 3 = Travel lever
No. 4 = Handle
No. 5 = Throttle lever