Fayat Group BOMAG BP 10/35 User manual

BP 10/35 / BP 12/40 / BP 12/50 / BVP 10/36 /
BVP 12/50 / BVP 18/45
Vibratory plate
Service Manual
S/N 101 230 21 1001 / S/N 101 230 23 1001 / S/N 101 230
24 1001 / S/N 861 834 13 1001 /S/N 861 834 20 1001 / S/N
861 834 28 1001
© 09/2018008 402 40 EN
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Table of contents
1General................................................................................................................................................... 5
1.1 Introduction................................................................................................................................... 6
1.2 Concerning your safety................................................................................................................ 8
1.2.1 Basic prerequisites....................................................................................................................... 8
1.2.2 Definition of responsible persons............................................................................................... 11
1.2.3 Basic safety regulations for safe operation................................................................................ 12
1.2.4 Handling fuels and lubricants..................................................................................................... 13
1.2.5 Loading/transporting the machine.............................................................................................. 16
1.2.6 Start-up procedure..................................................................................................................... 17
1.2.7 Operation................................................................................................................................... 18
1.2.8 Refuelling................................................................................................................................... 19
1.2.9 Maintenance work...................................................................................................................... 19
1.2.10 Repair....................................................................................................................................... 20
1.2.11 Signage.................................................................................................................................... 20
1.3 Maintenance and repair.............................................................................................................. 28
1.3.1 Notes on repair........................................................................................................................... 28
1.3.2 Preliminary remarks and safety notes........................................................................................ 40
1.3.3 Parking the machine in secured condition................................................................................. 41
1.3.4 Running-in instructions............................................................................................................... 42
1.3.5 Cleaning the machine................................................................................................................ 42
2 Technical data...................................................................................................................................... 45
2.1 BP10/35........................................................................................................................................ 46
2.1.1 Technical data............................................................................................................................ 46
2.2 BP12/40........................................................................................................................................ 50
2.2.1 Technical data............................................................................................................................ 50
2.3 BP12/50........................................................................................................................................ 54
2.3.1 Technical data............................................................................................................................ 54
2.4 Fuels and lubricants................................................................................................................... 57
2.4.1 Engine oil................................................................................................................................... 57
2.4.2 Fuel............................................................................................................................................ 57
2.4.3 Oil for exciter shaft housing........................................................................................................ 58
2.5 List of fuels and lubricants........................................................................................................ 59
2.6 Terms and basis of calculation.................................................................................................. 60
3 Machine overview............................................................................................................................... 61
4Machine assemblies........................................................................................................................... 67
4.1 Engine.......................................................................................................................................... 69
4.1.1 Checking the engine oil level..................................................................................................... 70
4.1.2 Changing the engine oil............................................................................................................. 70
4.1.3 Checking, cleaning the air filter.................................................................................................. 71
4.1.4 Air filter maintenance................................................................................................................. 73
4.1.5 Cleaning the cooling fins and the cooling air intake openings................................................... 76
4.1.6 Cleaning the fuel strainer........................................................................................................... 78
4.1.7 Cleaning the slurry filter............................................................................................................. 80
4.1.8 Servicing the V-belt.................................................................................................................... 81
Table of contents
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4.1.9 Replacing the starter rope.......................................................................................................... 82
4.1.10 Checking, adjusting the valve clearance.................................................................................. 84
4.2 Exciter unit................................................................................................................................... 87
4.2.1 Changing the oil in the exciter housing...................................................................................... 88
4.2.2 Exciter repair.............................................................................................................................. 88
4.3 Chassis........................................................................................................................................ 95
4.3.1 Checking the rubber buffers....................................................................................................... 96
4.3.2 Checking the water level, topping up......................................................................................... 96
4.3.3 Check water supply, refill (compact water tank)......................................................................... 97
4.3.4 Cleaning the water spraying system.......................................................................................... 98
4.3.5 Cleaning the compact water spraying system............................................................................ 98
5 Troubleshooting................................................................................................................................ 101
5.1 Preliminary remarks.................................................................................................................. 102
5.2 Engine malfunctions................................................................................................................. 103
5.3 Power transmission.................................................................................................................. 105
5.4 What to do if the engine has flooded...................................................................................... 106
Appendix............................................................................................................................................ 109
Table of contents
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1 General
General
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1.1 Introduction
This manual:
naddresses the BOMAG Customer Service and professionally
trained personnel.
nprovides support for repair work or maintenance procedures on
the machine.
This manual described the deinstallation, dismantling , assembly,
installation as well as the repair of components and assembly
groups as far as this makes sense with respect to tools and spare
parts supply.
The index is a reference register that will help you to find informa-
tion in this Service Manual. The index lists keywords in alphabet-
ical order. Cross references (keywords related to page numbers)
enable quick and convenient search/navigation.
Keywords concerning the following subjects are listed in the index:
nElectrical operating means
nPlug designations
nOverviews
nFault codes
nTroubleshooting
n...
For the BOMAG machines described in this manual the following
documentation is additionally available:
nOperating and maintenance instructions
nSpare parts catalogue
nService information (if necessary)
nSpecialist teams are available for you in Germany, Europe and
overseas. This tight network ensures close customer contact
all over the world.
nParts for maintenance, service and repair are available from
our branch offices and dealers at very short notice.
nBOMAG guarantees long-term availability of all common parts.
nWell-designed catalogues provide an easy guide to finding and
ordering the required parts.
nOnly use genuine BOMAG parts. These have been specially
adapted to the corresponding machine. In this way, you will
prevent any problems arising and unnecessary downtimes of
your machine.
General
Index
Documentation
Maintenance/parts service
General – Introduction
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This manual is not subject of an updating service. For this reason
we would like to draw your attention to the additionally published
service informations.
In case of a new release all necessary changes will be included.
In the course of technical development we reserve the right for
technical modifications without prior notification.
Information and illustrations in this manual must not be reproduced
and distributed, nor must they be used for the purpose of competi-
tion without the consent of BOMAG. All rights according to the
copyright law remain expressly reserved.
Updating service
Copyright
General – Introduction
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1.2 Concerning your safety
1.2.1 Basic prerequisites
1.2.1.1 General
This machine has been built in compliance with the latest technical
standard and complies with the applicable regulations and tech-
nical 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 reg-
ulations. If necessary, the operating company must obtain the rele-
vant signatures as confirmation.
Furthermore, the following obviously also applies:
napplicable accident prevention instructions,
ngenerally accepted safety and road traffic regulations,
ncountry/state specific safety regulations.
It is the duty of the operator to be acquainted with the safety regu-
lations and to apply these accordingly. This also applies for local
regulations and regulations concerning different types of handling
activities. Should the recommendations in these instructions be dif-
ferent from the regulations valid in your country, you must comply
with the safety regulations valid in your country.
1.2.1.2 Explanation of signal words used:
DANGER!
Danger to life if failing to comply!
Sections marked accordingly indicate an extremely
dangerous situation that could lead to fatal or
severe injuries, if this warning is disregarded.
WARNING!
Danger to life or danger of severe injuries if
failing to comply!
Sections marked accordingly indicate a dangerous
situation that could lead to fatal or severe injuries,
if this warning is disregarded.
General – Concerning your safety
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CAUTION!
Danger of injury if failing to comply!
Sections marked accordingly indicate a dangerous
situation that could lead to fatal or severe injuries,
if this warning is disregarded.
NOTICE!
Danger of material damage if failing to comply!
Sections marked accordingly indicate possible
dangers for machines or components.
Sections marked accordingly indicate technical
information or notes on using the machine or its
components.
ENVIRONMENT!
Environmental damage if failing to comply!
Paragraphs marked accordingly indicate practices
for safe and environment-friendly disposal of fuels
and lubricants as well as replacement parts.
1.2.1.3 Personal protective equipment
Depending on the work to be carried out, personal protective equipment is required (to be provided
by the operating company):
Working clothes Tight fitting working clothes with low tear resistance, tight
sleeves and without any projecting parts protect against
being caught by moving components.
Safety shoes To protect against heavy falling parts and slipping on
slippery ground.
Protective gloves To protect the hands against excoriation, punctures or
deep injuries, against irritating and caustic substances
as well as against burns.
General – Concerning your safety
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Safety goggles To protect the eyes against airborne particles and
squirting fluids.
Face protection To protect the face against airborne particles and
squirting fluids.
Hard hat To protect the head against falling parts and to protect
against injuries.
Hearing protection To protect hearing against excessive noise.
Respiratory protection To protect respiratory tracts against substances or parti-
cles.
1.2.1.4 Intended use
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
Intended use also includes compliance with the specified oper-
ating, maintenance and repair measures.
1.2.1.5 Improper 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 improper use is the sole responsibility of the
operating company or driver/operator, the manufacturer cannot be
made liable.
General – Concerning your safety
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Examples for improper 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.
Lifting tackle must be removed before starting work.
Starting and operating the machine in explosive environments and
in underground mining is prohibited.
The lifting and lashing points specified in these instructions must
be used. It is prohibited to use other lifting and lashing points (e.g.
guide handle, steering rod).
1.2.2 Definition of responsible persons
1.2.2.1 Operating company
The operating company is the natural or juridical person who uses
the machine or in who's name the machine is used.
The operating company must make sure that the machine is only
used for the purpose it is intended for and in strict compliance with
the safety regulations mentioned in these operating and mainte-
nance instructions.
The operating company must determine and assess the danger in
its company. It must then take appropriate action to ensure health
and safety at work for its employees and point out any remaining
dangers.
The operating company must determine whether there are special
operational hazards such as a toxic atmosphere or limiting soil
conditions. Such conditions require special, additional measures to
remove or reduce the hazard.
The operating company must make sure that all users read and
understand the information concerning safety.
The operating company is responsible for the planning and profes-
sional execution of regular safety inspections.
1.2.2.2 Expert / qualified person
An expert / qualified person is a person who, based on his/her pro-
fessional education and experience, has profound knowledge in
the field of construction equipment and the machine in question in
particular.
This person is acquainted with the applicable governmental indus-
trial safety regulations, accident prevention instructions, guidelines
and generally acknowledged technical rules and regulations
(standards, directives, technical rules of other member states of
the European Union or other contractual states concerning the
agreement about the European Economic Area) in as far as is nec-
essary to be able to judge the safe condition of this machine.
General – Concerning your safety
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1.2.2.3 Driver / operator
This machine must only be operated by trained, instructed persons
entrusted by the operating company aged 18 or more.
Observe your local laws and regulations.
Rights, obligations and rules of conduct for driver or operator:
The driver or operator must:
nbe instructed about his rights and obligations,
nwear protective equipment as appropriate for the application,
nhave read and understood the operating instructions,
nhave made himself familiar with the operation of the machine,
nbe physically and psychologically able to drive and operate the
machine.
Persons under the influence of alcohol, medication 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.
1.2.3 Basic safety regulations for safe operation
1.2.3.1 Remaining dangers, remaining risks
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 in the area of the machine must be informed
about the dangers that arise from the operation of the machine.
1.2.3.2 Regular safety inspections
Have the machine inspected by an expert / qualified person as
required for the conditions the machine is working under, but at
least once every year.
1.2.3.3 Modifications and alterations to the machine
Unauthorized changes to the machine are prohibited for safety rea-
sons.
General – Concerning your safety
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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.
1.2.3.4 Damage, defects, misuse of safety devices
Machines which are not safe to operate or in traffic must be imme-
diately taken out of service and shall not be used, until these defi-
ciencies have been properly rectified.
Safety installations and switches must neither be removed nor
must they be made ineffective.
1.2.4 Handling fuels and lubricants
1.2.4.1 Preliminary remarks
The operating company must ensure that all professional users
have read and follow the corresponding safety data sheets for the
individual fuels and lubricants.
Safety data sheets provide valuable information about the following
characteristics:
nname of substance
npossible dangers
ncomposition / information on constituents
nfirst-aid measures
nfire fighting measures
nmeasures in case of accidental release
nhandling and storage
nlimitation and monitoring of exposure / personal protective
equipment
nphysical and chemical properties
nstability and reactivity
ntoxicological data
nenvironmental data
nnotes on waste disposal
ninformation on transport
nlegislation
nother data
General – Concerning your safety
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1.2.4.2 Safety regulations and environmental protection regulations for handling oil
WARNING!
Danger of burning by ignited oil!
– Do not allow oil to come into contact with hot
components.
–Smoking and open fire is prohibited!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
CAUTION!
Health hazard caused by contact with oil!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
– Do not inhale any oil vapours.
– Avoid contact.
CAUTION!
Danger of slipping on spilled oil!
– Immediately bind spilled oil with an oil-binding
agent.
ENVIRONMENT!
Oil is an environmentally hazardous substance!
– Always keep oil in proper containers.
–Immediately bind spilled oil with an oil-binding
agent.
– Dispose of oil and oil filter according to regula-
tions.
Fig. 1
General – Concerning your safety
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1.2.4.3 Safety regulations and environmental protection regulations for handling gasoline
DANGER!
Danger to life caused by explosive gas-air
mixes!
– Do not allow gasoline to come into contact with
hot components.
–Smoking and open fire is prohibited.
– Keep away from heat sources, sparks and
other sources of ignition.
– Do not spill any gasoline.
WARNING!
Health hazard caused by contact with gasoline!
– Wear your personal protective outfit (protective
gloves, protective clothing).
–Do not inhale any fuel fumes.
– Do not swallow gasoline.
– Avoid contact with gasoline.
ENVIRONMENT!
Gasoline is an environmentally hazardous sub-
stance!
– Always keep gasoline in proper containers.
–Immediately bind spilled gasoline with an oil-
binding agent and dispose of in accordance
with regulations.
– Dispose of gasoline and fuel filter according to
regulations.
Fig. 2
General – Concerning your safety
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1.2.4.4 Safety regulations and environmental protection regulations for handling fuel stabiliser
WARNING!
Danger of burning by ignited fuel stabilizer!
– Do not allow fuel stabilizer to come into contact
with hot components.
–Smoking and open fire is prohibited.
WARNING!
Health hazard caused by contact with fuel sta-
bilizer!
– Wear your personal protective outfit (protective
gloves, protective clothing).
– Do not inhale any fuel stabilizer fumes.
– Do not swallow fuel stabilizer.
– Avoid contact with fuel stabilizer.
ENVIRONMENT!
Fuel stabilizer is an environmentally hazardous
substance!
– Immediately bind spilled fuel stabilizer with an
oil-binding agent and dispose of according to
regulations.
–Dispose of fuel stabilizer according to regula-
tions.
1.2.5 Loading/transporting the machine
Make sure that persons are not endangered by the machine tipping
or sliding off.
Do not use damaged or in any other way impaired lashing points.
Always use appropriate lifting and lashing means on the lifting and
lashing points.
Use lifting and lashing gear only in the prescribed direction of load
application.
Lifting tackle must not be damaged by machine components.
Secure the machine on the transport vehicle against rolling, slip-
ping and turning over.
Loads must only be attached and hoisted by an expert / capable
person.
Use only lifting gear and lifting tackle with sufficient load bearing
capacity for the weight to be loaded.
Fasten the lifting gear only at the specified lifting points.
General – Concerning your safety
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Danger to the life of persons if they step or stand under a sus-
pended load.
When lifting the machine avoid uncontrolled movements of the
load. If necessary hold the load with guide ropes.
1.2.6 Start-up procedure
1.2.6.1 Prior to starting up
Use only machines which are serviced at regular intervals.
Become acquainted with the equipment, the indicators and control
elements, the working principle of the machine and the working
area.
Use your personal protective equipment (hard hat, safety boots, if
necessary also goggles and ear protection).
Do not take any loose objects with you or fasten them to the
machine.
Before start up, check whether:
npersons or obstructions are beside or in front of the machine,
nthe machine is free of oily and combustible materials,
nall safety elements are in place,
nall grips are free of grease, oils, fuel, dirt, snow and ice.
Before start up, carry out all required visual inspections and func-
tion tests.
If the following tests reveal damages or other faults, the machine
must not be operated, until these deficiencies have been corrected.
Do not operate the machine with defective indicators and control
elements.
1.2.6.2 Spark protection
The spark protection is optional.
In some areas of use operation of an engine without spark protec-
tion is not permitted.
Check the locally valid legislation and regulations.
1.2.6.3 Starting the engine
Do not use any starting aids like start pilot or ether.
The machine must not be operated with damaged, missing or non-
functional safety installations.
Before starting and moving the machine make sure that there are
no persons inside the danger zone.
Operate the machine only with the steering bow mounted and low-
ered.
General – Concerning your safety
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Always keep an eye on the machine when the engine is running
and hold it by the steering bow.
Do not inhale exhaust fumes, because they contain toxic sub-
stances, which could cause damage to health, unconsciousness or
even death.
Avoid operation in closed or partly closed rooms, or ensure ade-
quate ventilation when working in trenches.
1.2.6.4 Operation in trenches
Applies only to Germany.
The vibratory tamper or the vibratory plate were tested outdoors by
BG Bau (Germany) regarding CO emissions. The tests were car-
ried out in a trench with a width of 1.5 metres, a depth of 3 metres
and a length of 10 metres.
These test showed CO emissions below the occupational exposure
limit (OEL) according to TRGS 900 when operating a maximum of
4 times 15 minutes per shift (8 hours).
For this reason, take care to ensure sufficient ventilation when
operating the vibratory tamper or vibratory plate in more than
shoulder-deep trenches which have a width of less than
1.5 metres, a maximum depth of less than 3 metres or a maximum
length of less than 10 metres.
1.2.7 Operation
1.2.7.1 Persons in the danger area
Before taking up work, also after breaks, you should always con-
vince yourself that the danger zone is free of persons or obstruc-
tions.
Give warning signals, if necessary. Stop work immediately if per-
sons remain in the danger zone, despite the warning.
1.2.7.2 Operation
Guide the machine only by the guide handle.
Guide the machine so that your hands do not hit against solid
objects.
Watch out for unusual noises and development of smoke. Perform
trouble shooting and have the fault corrected.
Always keep a safe distance to excavation pit borders, embank-
ments and edges.
General – Concerning your safety
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Refrain from any work that could adversely affect the stability of the
machine.
Observe the daily vibration load (work safety acc. to 2002/44/EC).
1.2.7.3 Parking the machine
Park the machine on horizontal, level, firm ground.
Before leaving the machine:
nShut down the engine,
nSecure the machine against accidental tipping over,
nSecure the machine against unauthorized use.
Mark machines, which could be in the way, with a clearly visible
sign.
1.2.8 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.
Keep away from ignition and heat sources.
Apply measures against electrostatic charging.
Do not spill any fuel. Catch running out fuel, do not let it seep into
the ground.
Wipe off spilled fuel. Keep dirt and water away from the fuel.
A leaking fuel tank can cause an explosion. Ensure tight fit of the
fuel tank cover, if necessary replace immediately.
1.2.9 Maintenance work
1.2.9.1 Preliminary remarks
Adhere to the specified operating, maintenance and repair meas-
ures.
The machine must only be serviced by qualified personnel author-
ised by the operating company.
Keep unauthorised persons away from the machine.
Perform maintenance work only with the engine shut down and the
spark plug connector disconnected.
Make sure that the engine cannot be accidentally started during
maintenance work.
General – Concerning your safety
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1.2.9.2 Working on the engine
Drain the engine oil at operating temperature – danger of scalding!
Wipe off spilled oil, catch running out oil and dispose of environ-
mentally.
When working on the air filter no dirt should fall into the air duct.
Do not work on the hot exhaust - danger of burning!
Store used filters and other oil contaminated materials in a sepa-
rate, specially marked container and dispose of environmentally.
1.2.9.3 Cleaning work
Do not perform cleaning work while the motor is running.
Allow the engine to cool down before starting cleaning work.
Do not use gasoline or other easily inflammable substances for
cleaning.
1.2.9.4 After maintenance work
Reassemble all guards and protections.
1.2.10 Repair
Identify a defect machine with a warning sign.
Only operate the machine after it has been repaired.
When replacing safety relevant components, only original spare
parts must be used.
Repairs must only be performed by an expert/qualified person.
When performing welding work on the machine you should cover
the fuel tank with insulating material.
1.2.11 Signage
Keep stickers and signage in good and legible condition and
comply with their meaning.
Replace damaged and illegible stickers or signage immediately.
General – Concerning your safety
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