Fayat Group Bomag BPR 70/70 D Instructions for use

Operating instructions
Maintenance instructions
Original operating instructions
Catalogue No.
008 067 61 10/2010
BPR 70/70 D
S/N 101 692 26 .... >
Reversible Vibrating Plate
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Foreword
BOMAG 3 BPR 70/70 D
F oreword
These BOMAG machines are products from
the wide range of BOMAG machines for earth
work, asphalt and refuse compaction as well
as stabilizers/recyclers.
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.
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.
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.
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
PrintedinGermany
Copyright by BOMAG
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Foreword
BOMAG 4 BPR 70/70 D
Please fill in
............................
Machinetype(Fig.1)
............................
Serial-number (Fig. 1 and 2)
............................
Engine type (Fig. 3)
............................
Engine number (Fig. 3)
i
Note
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
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Table of Contents
BOMAG 5 BPR 70/70 D
Technical Data 7
Safety regulations 11
Indicators and Controls 17
3.1 General notes 18
3.2 Description of indicators and control elements 18
3.3 Function of the Economizer 20
Operation 23
4.1 General 24
4.2 Tests before taking into operation 24
4.3 Folding down the steering rod 25
4.4 Operating the low oil level safety device 25
4.5 Starting the engine 26
4.6 Starting with jump wires 27
4.7 Emergency starting with safety crank handle 28
4.8 Operation of Economizer 30
4.9 Work/operation 31
4.10 Backup protection 33
4.11 Stopping the vibratory plate, shutting down the engine 33
4.12 Loading 34
Maintenance 37
5.1 General notes on maintenance 38
5.2 Fuels and lubricants 39
5.3 Table of fuels and lubricants 41
5.4 Running-in instructions 42
5.5 Maintenance table 43
5.6 Cleaning the machine 45
5.7 Check the engine oil level 45
5.8 Checking the fuel level 46
5.9 Check the hydraulic oil level 46
5.10 Checking the air filter service indicator 47
5.11 Clean the cooling fins and the cooling air intake openings 49
5.12 Draining the sludge from the fuel tank 50
5.13 Check the battery condition, grease the poles 51
5.14 Check, adjust the valve clearance 52
5.15 Check the oil level in the vibrator housing 53
5.16 Changing the engine oil 55
5.17 Changing the engine oil filter 56
5.18 Changing the fuel filter 57
5.19 Change the oil in the exciter shaft housing 57
5.20 Check the rubber buffers 58
5.21 Check the V-belt tension, if necessary replace the V-belt 59
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Table of Contents
BOMAG 6 BPR 70/70 D
5.22 Change hydraulic oil and filter 61
5.23 Check, clean the dry air filter 63
5.24 Tightening the screws 64
5.25 Engine conservation 65
Trouble shooting 67
6.1 General notes 68
6.2 Engine problems 69
6.3 Trouble shooting Economizer 72
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BOMAG 7 BPR 70/70 D
1 Technical Data
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Technical Data
BOMAG 8 BPR 70/70 D
Fig. 4
Dimensions in
mm
H H1L L1W W1W2
BPR 70/70 D 870 1030 1860 980 550 700 850
*BPR 70/70 D
Weights
Operating weight (CECE) W kg 556
Operating weight (CECE) W1 kg 579
Operating weight (CECE) W2 kg 595
Basic weight kg 570
Travel characteristics
Working speed max. m/min 28
Max. gradability (depending on soil) % 35
Drive
Engine manufacturer Hatz
Type 1D 81
Cooling Air
Number of cylinders 1
Rated power ISO 9249 kW 9.8
Rated speed rpm 2700
Drive system mechanical
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Technical Data
BOMAG 9 BPR 70/70 D
Vibration system
Frequency Hz 68
Centrifugal force kN 70
Filling capacities
Fuel tank (diesel) l 10
Engine oil l 1.9
* The right for technical modifications remains reserved
*BPR 70/70 D
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Technical Data
BOMAG 10 BPR 70/70 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:
LpA = 95 dB(A), determined acc. to ISO 11204 and EN 500
Guaranteed sound power level:
LWA = 109 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
ahv =6.9m/s
2on 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 11 BPR 70/70 D
2 Safety regulations
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Safety regulations
BOMAG 12 BPR 70/70 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 (proper-
ly trained person) once every year.
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
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Safety regulations
BOMAG 13 BPR 70/70 D
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.
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.
i
Note
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 environmental regulations.
Loading the machine
Use only safe lifting gear of sufficient load bearing
capacity
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.
Secure the machine against tipping or slipping off.
Persons are highly endangered if
lthe step under loads being lifted or
lstand under loads being lifted.
lThe machine must not swing about when be-
ing lifted.
Secure the machine on the transport vehicle
against rolling, slipping and turning over.
Starting the machine
Before starting
Become acquainted with the equipment, the con-
trol elements, the working principle of the machine
and the working area.
Wear your personal protective outfit (hard hat,
safety boots, etc.). Wear ear defenders.
Before starting the machine check whether:
lthe machine shows any obvious faults
lall guards and safety elements are in place
lthe 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.
For emergency starting take a correct position to
the engine and hold the crank handle correctly.
Do not use any starting aids like start pilot or ether.
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Safety regulations
BOMAG 14 BPR 70/70 D
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
The machine must only be operated with the steer-
ing rod folded down.
Guide the machine in a way that hands do not
knock against hard materials. Danger of injury.
Watch out for unusual noises and smoke when op-
erating the plate. Investigate the cause and have
the fault corrected.
The vibratory plate must only be operated at full
engine speed, as otherwise the centrifugal clutch
may be destroyed.
Never leave the plate unattended with the engine
running..
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.
Filling in fuel
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.
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 perform maintenance work while the motor
is running.
Park the machine on level, firm ground.
Pull the key out of the ignition switch.
Work on hydraulic lines
Relieve hydraulic pressures before working on hy-
draulic lines. Hydraulic oil escaping under pres-
sure can penetrate the skin and cause severe
injury. When being injured by hydraulic oil consult
a medical doctor immediately, as otherwise this
may cause severe infections.
Do not change the setting of pressure relief valves.
Drain the hydraulic oil at operating temperature –
danger of scalding!
Catch running out hydraulic oil and dispose of en-
vironmentally.
Always catch and dispose of hydraulic oils sepa-
rately.
Do not start the engine after draining the hydraulic
oil.
Once all work is completed (with the system still
depressurized!) check all connections and fittings
for leaks.
Changing hydraulic hoses
Hydraulic hoses must be visually inspected at reg-
ular intervals.
Hydraulic hoses must be immediately replaced if:
lthe outer layer is damaged down to the inlay
(e.g. chafing, cuts, cracks)
lthe outer layer is brittle (formation of cracks in
the hose material)
lthe hose shows deformations in pressurized
and depressurized condition, which do not
comply with the genuine shape of the hydrau-
lic hose
lthe hose shows deformations in bends, e.g.
squeezing, buckling, layer separation, forma-
tion of blisters
lparts of the hose are leaking.
lhoses are not correctly installed
lthe hydraulic hose has separated from the fit-
ting
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Safety regulations
BOMAG 15 BPR 70/70 D
lhoses are mixed up by mistake.
lthe fitting shows corrosion that impairs both
function and strength.
lfittings are damaged or deformed, whereby
the function and strength of the hose/hose
connection is impaired.
Only genuine BOMAG replacement hydraulic hos-
es ensure that the correct hose type (pressure
range) is used at the right location.
Working on the engine
Drain the engine oil at operating temperature –
danger of scalding!
Wipe off spilled oil, catch running out oil and dis-
pose of environmentally.
Store used filters and other oil contaminated ma-
terials in a separate, specially marked container
and dispose of environmentally.
Working on 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.
Workingonthebattery
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.
Do not lay any tools on the battery.
For recharging remove the plugs from the battery
to avoid an accumulation of highly explosive gas-
es.
Dispose of old batteries according to regulations.
Working on the fuel system
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.
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Safety regulations
BOMAG 16 BPR 70/70 D
Fig. 5
1 Information sticker "Lashing point"
2 Information sticker "Lifting point"
3 Instruction sticker "Low sulphur fuel"
4 Maintenance sticker
5 Operation sticker "Throttle lever"
6 Information sticker "Guaranteed sound capac-
ity level"
7 Operation sticker "Travel lever"
8 Instruction sticker "Wear ear defenders"
9 Brief operating instructions
10 Information sticker "Hydraulic oil"
Stickers and decals
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BOMAG 17 BPR 70/70 D
3 Indicators and Controls
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Indicators and Controls
BOMAG 18 BPR 70/70 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 Description of indicators
and control elements
Fig. 6
No. 1 = Steering rod height adjustment
No. 2 = Locking pawl lever
Fig. 7
No. 3 = Throttle lever
No. 4 = Handle
No. 5 = Travel lever (tip switch)
No. 6 = Backup protection
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Indicators and Controls
BOMAG 19 BPR 70/70 D
Fig. 8
No. 7 = Decompression lever
Fig. 9
No. 8 = Safety crankhandle
Fig. 10
No. 9 = Ignition switch
i
Note
Only machines with electric starter.
Position "0" = Ignition off, warning buzzer off
Position "I" = Ignition on, warning buzzer on
Position "II" = Engine starts, warning buzzer
off
Fig. 11
No. 10 = Fuse (25 A)
i
Note
Only machines with electric starter.
!
Caution
Always cover the fuse with the protective cov-
er.
Machines with Economizer*are protected by
an additional fuse (5 A).
!
Danger
Fire hazard!
Do not use fuses with higher ampere ratings
and do not bridge fuses.
* Optional equipment
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