Bomag BPR 50 User manual

BPR 50/55 D / BPR 60/65 D
Reversible Vibrating Plate
Operating Instruction
Maintenance Instruction
Original Operating Instructions
S/N 101 692 82 1001> / S/N 101 692 83 1001> / S/N 101 692 91 1001> / S/N 101 692 92 1001>
© 12/2014008 201 24 EN
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Table of contents
1 Foreword................................................................................................................................................ 5
2Technical data....................................................................................................................................... 9
2.1 Technical data BPR 50/55 D....................................................................................................... 10
2.1.1 Noise and vibration data............................................................................................................ 12
2.2 Technical data BPR 60/65 D....................................................................................................... 13
2.2.1 Noise and vibration data............................................................................................................ 15
3 Safety regulations............................................................................................................................... 17
4 Display and control elements............................................................................................................ 25
4.1 General notes.............................................................................................................................. 26
4.2 Description of indicators and control elements....................................................................... 27
4.3 Function of the Economizer....................................................................................................... 29
5 Operation............................................................................................................................................. 31
5.1 General......................................................................................................................................... 32
5.2 Tests before taking into operation............................................................................................ 33
5.3 Folding down the steering rod................................................................................................... 34
5.4 Starting the engine electrically ................................................................................................. 35
5.5 Starting with recoil starter.......................................................................................................... 37
5.6 Operation of Economizer........................................................................................................... 40
5.7 Work/operation............................................................................................................................ 42
5.8 Shutting down the engine.......................................................................................................... 44
5.9 Loading/transport....................................................................................................................... 45
6 Maintenance........................................................................................................................................ 47
6.1 General notes on maintenance.................................................................................................. 48
6.2 Fuels and lubricants................................................................................................................... 50
6.2.1 Engine oil................................................................................................................................... 50
6.2.2 Fuel............................................................................................................................................ 51
6.2.3 Mineral oil based hydraulic oil.................................................................................................... 52
6.3 Table of fuels and lubricants..................................................................................................... 53
6.4 Running-in instructions.............................................................................................................. 54
6.4.1 General...................................................................................................................................... 54
6.4.2 After 25 operating hours............................................................................................................. 54
6.5 Maintenance table....................................................................................................................... 55
6.6 Daily maintenance....................................................................................................................... 56
6.6.1 Clean the machine..................................................................................................................... 56
6.6.2 Checking the engine oil level..................................................................................................... 56
6.6.3 Check the fuel level.................................................................................................................... 57
6.6.4 Check, clean the water separator.............................................................................................. 58
6.7 Monthly maintenance................................................................................................................. 59
6.7.1 Battery service........................................................................................................................... 59
6.7.2 Air filter maintenance................................................................................................................. 60
6.7.3 Cleaning the cooling fins and the cooling air intake openings................................................... 62
6.8 Half-annual maintenance............................................................................................................ 63
6.8.1 Checking the oil level in the exciter housing.............................................................................. 63
6.8.2 Servicing the V-belt.................................................................................................................... 63
Table of contents
BPR 50/55 D / BPR 60/65 D
3
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6.8.3 Checking, adjusting the valve clearance.................................................................................... 64
6.8.4 Checking the screw joints on the diesel engine......................................................................... 66
6.9 Annual maintenance................................................................................................................... 68
6.9.1 Changing the engine oil and cleaning the oil filter...................................................................... 68
6.9.2 Replace the fuel filter................................................................................................................. 70
6.9.3 Replacing the starter rope.......................................................................................................... 71
6.9.4 Changing the oil in the exciter housing...................................................................................... 73
6.9.5 Check the hydraulic oil level....................................................................................................... 74
6.9.6 Check the rubber buffers ........................................................................................................... 76
6.10 As required................................................................................................................................ 77
6.10.1 Tightening the screws.............................................................................................................. 77
6.10.2 Engine conservation ................................................................................................................ 77
7 Trouble shooting................................................................................................................................. 79
7.1 General notes.............................................................................................................................. 80
7.2 Starting with jump wires............................................................................................................. 81
7.3 Fuses............................................................................................................................................ 82
7.4 Engine problems......................................................................................................................... 83
7.5 Trouble shooting Economizer................................................................................................... 85
8 Disposal............................................................................................................................................... 87
8.1 Final shut-down of machine....................................................................................................... 88
Table of contents
BPR 50/55 D / BPR 60/65 D
4
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1 Foreword
Foreword
BPR 50/55 D / BPR 60/65 D
5
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BOMAG manufactures machine for earth, asphalt and refuse
compaction, stabilizers/recyclers as well as milling machine
and finishers.
BOMAG’s vast experience in connection with state-of-the-art
production and testing methods, such as lifetime tests of all
important components and highest quality demands guar-
antee maximum reliability of your machine.
This manual comprises:
nSafety regulations
nOperating instructions
nmaintenance instructions
nTrouble shooting
Using these instructions will
nhelp you to become familiar with the machine.
navoid malfunctions caused by unprofessional operation.
Compliance with the maintenance instructions will
nenhance the reliability of the machine on construction sites,
nprolong the lifetime of the machine,
nreduce repair costs and downtimes.
BOMAG will not assume liability for the function of the machine
nif it is handled in a way not complying with the usual modes of
use,
nif it is used for purposes other than those mentioned in these
instructions.
No warranty claims can be lodged in case of damage resulting
from
noperating errors,
ninsufficient maintenance and
nwrong fuels and lubricants.
Please note!
This manual was written for operators and maintenance 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 Engineering Liability
Association ”Safety Rules for the Operation of Road Rollers and
Soil Compactors” and all relevant accident prevention regulations.
For your own personal safety you should only use original
spare parts from BOMAG.
For your machine BOMAG offers service kits to make mainte-
nance easier.
In the course of technical development we reserve the right
for technical modifications without prior notification.
Foreword
BPR 50/55 D / BPR 60/65 D
6
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These operating and maintenance instructions are also available in
other languages.
Apart from that, the spare parts catalogue is available from your
BOMAG dealer against the serial number of your machine.
Your BOMAG dealer will also supply you with information 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
Please fill in
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine type (Fig. 1)
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Serial No. (Fig. 1 and 2)
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine type (Fig. 3)
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine No. (Fig. 3)
Supplement the above data together with the commis-
sioning protocol.
During commissioning our organisation will instruct you
in the operation and maintenance of the machine.
Please observe strictly the safety regulations and all
notes on risks and dangers!
Fig. 1
Foreword
BPR 50/55 D / BPR 60/65 D
7
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Fig. 2
Fig. 3
Foreword
BPR 50/55 D / BPR 60/65 D
8
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2 Technical data
Technical data
BPR 50/55 D / BPR 60/65 D
9
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2.1 Technical data BPR 50/55 D
Fig. 4
H H1H2L L1W W1W2
790
(31.1)
980
(38.6)
1350
(53.2)
1700
(66.9)
900
(35.4)
450
(17.7)
550
(21.7)
750
(29.5)
Dimensions in millimetre
(Dimensions in inch)
Weights
Operating weight (CECE) (W) 385
(849)
kg
(lbs)
Operating weight (CECE) (W1) 400
(882)
kg
(lbs)
Operating weight (CECE) (W2) 415
(915)
kg
(lbs)
Basic weight 395
(871)
kg
(lbs)
Dimensions
Technical data – Technical data BPR 50/55 D
BPR 50/55 D / BPR 60/65 D
10
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Weights
"STONEGUARD" (special base plate for paving stones) (optional
equipment)
+ 27
(+ 60)
kg
(lbs)
ECONOMIZER (optional equipment) + 5
(+ 11)
kg
(lbs)
Travel characteristics
Max. working speed 28
(92)
m/min
(ft/min)
Max. gradability (depending on soil) 35 %
Drive
Engine manufacturer Hatz
Type 1B40
Cooling Air
Number of cylinders 1
Rated power ISO 3046 6.7
(9.0)
kW
(hp)
Rated speed 3000 min-1
Drive system mechanical
Exciter system
Frequency 66
(3960)
Hz
(vpm)
Centrifugal force 50
(11241)
kN
(lbf)
Amplitude 1.85
(0,073)
mm
(in)
Filling capacities
Fuel (diesel) 5.0
(1.3)
l
(gal us)
Technical data – Technical data BPR 50/55 D
BPR 50/55 D / BPR 60/65 D
11
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2.1.1 Noise and vibration data
The following noise and vibration data were determined in accord-
ance with the following guidelines under equipment specific condi-
tions and by using harmonized standards:
nEC Machine Directive edition 2006/42/EC
nNoise Emission Directive 2000/14/EC, Noise Protection Direc-
tive 2003/10/EC
nVibration Protection Directive 2002/44/EC
During operation these values may vary because of the prevailing
operating conditions.
2.1.1.1 Noise data
LpA = 95 dB(A), determined acc. to ISO 11204 and EN 500.
WARNING!
Loos of hearing caused by too high noise burdens!
– Wear your personal protective outfit (ear
defenders).
LWA = 108 dB(A), determined acc. to ISO 3744 and EN 500.
2.1.1.2 Vibration data
Vector total of the weighted effective acceleration in three orthog-
onal directions:
Weighted total vibration value
ahv = 8.7 m/s2 on crushed rock determined acc. to ISO 5349 and
EN 500.
Observe the daily vibration load (Industrial safety acc. to 2002/44/
EEC).
Sound pressure level at the opera-
tor's place
Guaranteed sound power level
Hand-arm vibration
Technical data – Technical data BPR 50/55 D
BPR 50/55 D / BPR 60/65 D
12
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2.2 Technical data BPR 60/65 D
Fig. 5
H H1H2L L1W W1W2
790
(31.1)
980
(38.6)
1350
(53.2)
1700
(66.9)
900
(35.4)
450
(17.7)
650
(25.6)
750
(29.5)
Dimensions in millimetre
(Dimensions in inch)
Weights
Operating weight (CECE) (W) 435
(959)
kg
(lbs)
Operating weight (CECE) (W1) 455
(1003)
kg
(lbs)
Operating weight (CECE) (W2) 466
(1027)
kg
(lbs)
Basic weight 450
(992)
kg
(lbs)
Dimensions
Technical data – Technical data BPR 60/65 D
BPR 50/55 D / BPR 60/65 D
13
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Weights
"STONEGUARD" (special base plate for paving stones) (optional
equipment)
+ 27
(+ 60)
kg
(lbs)
ECONOMIZER (optional equipment) + 5
(+ 11)
kg
(lbs)
Travel characteristics
Max. working speed 28
(92)
m/min
(ft/min)
Max. gradability (depending on soil) 35 %
Drive
Engine manufacturer Hatz
Type 1B40
Cooling Air
Number of cylinders 1
Rated power ISO 3046 6.7
(9.0)
kW
(hp)
Rated speed 3000 min-1
Drive system mechanical
Exciter system
Frequency 66
(3960)
Hz
(vpm)
Centrifugal force 60
(13489)
kN
(lbf)
Amplitude 1.96
(0,077)
mm
(in)
Filling capacities
Fuel (diesel) 5.0
(1.3)
l
(gal us)
Technical data – Technical data BPR 60/65 D
BPR 50/55 D / BPR 60/65 D
14
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2.2.1 Noise and vibration data
The following noise and vibration data were determined in accord-
ance with the following guidelines under equipment specific condi-
tions and by using harmonized standards:
nEC Machine Directive edition 2006/42/EC
nNoise Emission Directive 2000/14/EC, Noise Protection Direc-
tive 2003/10/EC
nVibration Protection Directive 2002/44/EC
During operation these values may vary because of the prevailing
operating conditions.
2.2.1.1 Noise data
LpA = 95 dB(A), determined acc. to ISO 11204 and EN 500.
WARNING!
Loos of hearing caused by too high noise burdens!
– Wear your personal protective outfit (ear
defenders).
LWA = 108 dB(A), determined acc. to ISO 3744 and EN 500.
2.2.1.2 Vibration data
Vector total of the weighted effective acceleration in three orthog-
onal directions:
Weighted total vibration value
ahv = 8.7 m/s2 on crushed rock determined acc. to ISO 5349 and
EN 500.
Observe the daily vibration load (Industrial safety acc. to 2002/44/
EEC).
Sound pressure level at the opera-
tor's place
Guaranteed sound power level
Hand-arm vibration
Technical data – Technical data BPR 60/65 D
BPR 50/55 D / BPR 60/65 D
15
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Technical data – Technical data BPR 60/65 D
BPR 50/55 D / BPR 60/65 D
16
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3 Safety regulations
Safety regulations
BPR 50/55 D / BPR 60/65 D
17
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This BOMAG machine has been built in compliance 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:
nit is used for purposes other than the ones it is intended for,
nit is operated by untrained personnel,
nit is changed or converted in an unprofessional way,
nthe safety instructions are not observed.
Each person involved in the operation, maintenance and
repair of the machine must therefore read and comply with
these safety regulations. If necessary, this must be confirmed
by obtaining the signature of the customer.
Furthermore, the following obviously also applies:
napplicable accident prevention instructions,
ngenerally accepted safety and road traffic regulations,
ncountry specific safety regulations. It is the duty of the operator
to be acquainted with these instructions and to apply these
accordingly. This applies also for local regulations concerning
different types of handling work. Should the recommendations
in these instructions be different from the regulations valid in
your country, you must comply with the safety regulations valid
in your country.
This machine must only be used for:
nCompaction of all types of soils
nRepair work on all types of soil
nPaving of walkways
nWork in trenches
nUnderfilling and compaction of hard shoulders
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 responsibility of the
customer or driver/operator, the manufacturer cannot be made
liable.
Examples for unintended use are:
nDragging the machine along as a measure of transportation
nThrowing the machine off the transport vehicle
nAttaching 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 prohibited.
General
Intended use
Unintended use
Safety regulations
BPR 50/55 D / BPR 60/65 D
18
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Despite careful work and compliance with standards and regula-
tions it cannot be ruled out that further dangers may arise when
working with and handling the machine.
Both the machine as well as all other system components comply
with the currently valid safety regulations. Nevertheless, remaining
risks cannot be ruled out completely, even when using the machine
for the purpose it is intended for and following 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.
Have the machine inspected by an expert (capable person) as
required for the conditiosn the machine is working under, but at
least once every year.
Only trained, instructed and authorized persons of at least 18 years
of age are permitted to drive and operate this machine. For opera-
tion of the machine 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 repair the machine.
Maintenance and repair work requires specific knowledge and
must therefore only be performed by trained specialists.
Unauthorized changes to the machine are prohibited for safety rea-
sons.
Original parts and accessories have been specially 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 passive safety.
The manufacturer explicitly excludes any liability for damage
caused by the use of non-original parts or accessories.
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.
Remaining dangers, remaining
risks
Regular safety inspections
Who is allowed to operate the
machine?
Changes and conversions to the
machine
Damage, deficiencies, misuse of
safety installations
Safety regulations
BPR 50/55 D / BPR 60/65 D
19
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WARNING!
Paragraphs marked like this highlight possible dangers
for persons.
NOTICE!
Paragraphs marked like this highlight possible dangers
for machines or parts of the machine.
Paragraphs marked like this contain technical informa-
tion for the optimal economical use of the machine.
ENVIRONMENT!
Paragraphs marked like this point out practices for
safe and environmental disposal of fuels and lubricants
as well as replacement parts.
Observe the regulations for the protection of the envi-
ronment.
Make sure that persons are not endangered by the machine tipping
or sliding off.
Use only safe lifting gear of sufficient load bearing capacity Min-
imum 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 direction.
The machine must not swing about when being lifted.
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.
Before starting
Become acquainted with the equipment, the control elements, the
working principle of the machine and the working area.
Notes on safety in the operating
and maintenance instructions
Loading/transporting the machine
Starting the machine
Safety regulations
BPR 50/55 D / BPR 60/65 D
20
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