Fayat Group Bomag BPR 70/70 D Operating manual

BPR 70/70 D
Reversible vibratory plate
Operating Instruction
Maintenance Instruction
Original Operating Instructions
S/N 101 692 75 1001>
© 09/2016008 200 14 EN
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Table of contents
1 Introduction........................................................................................................................................... 5
1.1 Foreword........................................................................................................................................ 6
1.2 Machine type plate and engine type plate.................................................................................. 8
2 Technical data........................................................................................................................................ 9
2.1 Noise and vibration data............................................................................................................. 11
2.1.1 Noise data.................................................................................................................................. 11
2.1.2 Vibration data............................................................................................................................. 12
3 Safety regulations............................................................................................................................... 13
4 Display and control elements............................................................................................................ 23
4.1 General notes.............................................................................................................................. 24
4.2 Description of indicators and control elements....................................................................... 25
4.3 Function of the Economizer....................................................................................................... 27
5 Operation............................................................................................................................................. 29
5.1 General......................................................................................................................................... 30
5.2 Tests before taking into operation............................................................................................ 31
5.3 Folding down the steering rod................................................................................................... 32
5.4 Operating the low oil level safety device.................................................................................. 33
5.5 Start the engine .......................................................................................................................... 34
5.6 Emergency starting with safety crank handle.......................................................................... 36
5.7 Operation of Economizer........................................................................................................... 39
5.8 Work/operation ........................................................................................................................... 41
5.9 Backup protection....................................................................................................................... 43
5.10 Stopping the vibratory plate, shutting down the engine....................................................... 44
5.11 Loading/transport...................................................................................................................... 45
6 Maintenance........................................................................................................................................ 47
6.1 General notes on maintenance.................................................................................................. 48
6.2 Fuels and lubricants................................................................................................................... 50
6.3 Table of fuels and lubricants ..................................................................................................... 52
6.4 Running-in instructions.............................................................................................................. 53
6.5 Maintenance table....................................................................................................................... 54
6.6 Daily maintenance....................................................................................................................... 56
6.6.1 Clean the machine..................................................................................................................... 56
6.6.2 Check the engine oil level.......................................................................................................... 56
6.6.3 Check the fuel level.................................................................................................................... 57
6.6.4 Check the hydraulic oil level....................................................................................................... 58
6.6.5 Check the air filter service indicator........................................................................................... 58
6.6.6 Check the rubber buffers ........................................................................................................... 59
6.7 Maintenance every month.......................................................................................................... 60
6.7.1 Clean the cooling fins and the cooling air intake openings........................................................ 60
6.7.2 Drain the sludge from the fuel tank............................................................................................ 61
6.8 Maintenance every 6 months..................................................................................................... 62
6.8.1 Battery service........................................................................................................................... 62
6.8.2 Check, adjust the valve clearance............................................................................................. 63
Table of contents
BPR 70/70 D
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6.8.3 Check the oil level in the exciter housing................................................................................... 65
6.9 Annual maintenance................................................................................................................... 66
6.9.1 Change engine oil and oil filter................................................................................................... 66
6.9.2 Replacing the fuel filter............................................................................................................... 67
6.9.3 Changing the oil in the exciter housing...................................................................................... 68
6.9.4 Check the V-belt tension, if necessary replace the V-belt.......................................................... 70
6.10 Maintenance every 2 years....................................................................................................... 71
6.10.1 Change hydraulic oil and filter.................................................................................................. 71
6.11 As required................................................................................................................................ 74
6.11.1 Check, clean the air filter, replace if necessary........................................................................ 74
6.11.2 Tightening the screws............................................................................................................... 75
6.11.3 Engine conservation................................................................................................................. 76
7 Trouble shooting................................................................................................................................. 77
7.1 General notes.............................................................................................................................. 78
7.2 Starting with jump wires............................................................................................................. 79
7.3 Fuses............................................................................................................................................ 80
7.4 Engine problems......................................................................................................................... 81
7.5 Trouble shooting Economizer.................................................................................................... 84
8 Disposal............................................................................................................................................... 85
8.1 Final shut-down of machine....................................................................................................... 86
Table of contents
BPR 70/70 D
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1 Introduction
Introduction
BPR 70/70 D
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1.1 Foreword
BOMAG manufactures machines for earth, asphalt and refuse
compaction, stabilizers/recyclers as well as planers and
pavers.
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.
These operating and maintenance instructions are part of your
machine.
They provide necessary information to operate your machine
safely and properly.
They also contain information on required operating, maintenance
and repair measures.
Carefully read the operating and maintenance instructions before
taking your machine into operation.
Please observe the safety regulations strictly and follow all instruc-
tions to ensure safe operation.
If you are not yet acquainted with the controls and indicating ele-
ments on this machine, you should thoroughly read the corre-
sponding chapter.
The description of the individual operating steps including the
notes on safety to be followed can be found in chapter “Operation”.
Before every start up, carry out all required visual inspections and
function tests.
Ensure the compliance with the specified operating, maintenance
and repair measures to maintain the functional safety of your
machine.
A description of all necessary maintenance work, maintenance
intervals as well as information on fuels and lubricants can be
found in the chapter “Maintenance”.
Do not service or repair your machine by yourself to avoid harming
persons or damaging material or environment.
The machine must only be serviced and repaired by qualified and
authorized personnel.
Contact our Customer Service to carry out the required mainte-
nance work or necessary repairs.
In case of operating errors, inadequate maintenance or the use of
unapproved fuels and lubricants all warranty claims will become
null and void.
For your own personal safety you should only use original parts
from BOMAG.
For your machine we offer service kits to make maintenance
easier.
In the course of technical development we reserve the right for
technical modifications without prior notification.
These operating and maintenance instructions are also available in
other languages.
Introduction – Foreword
BPR 70/70 D
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Apart from that, you can also order the spare parts catalogue
against the serial number of your machine.
The above notes do not constitute an extension of the warranty
and liability conditions specified in the general sales and delivery
conditions of BOMAG GmbH.
We wish you successful work with your BOMAG machine.
Introduction – Foreword
BPR 70/70 D
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1.2 Machine type plate and engine type plate
Please enter here:
Machine type (1):
Serial number (2):
Please enter here:
Engine type (1):
Engine number (2):
Fig. 1: Machine type plate (example)
Fig. 2: Engine type plate (example)
Introduction – Machine type plate and engine type plate
BPR 70/70 D
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2 Technical data
Technical data
BPR 70/70 D
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Fig. 3
BPR 70/70 D H H1H2L L1W W1W2
Dimensions in mm 870 1030 1470 1860 980 550 700 850
Dimensions in inch 34.3 40.6 57.9 73.2 38.6 21.7 27.6 33.5
BPR 70/70 D
Weights
Operating weight (CECE) W 553 kg 1219 lbs
Operating weight (CECE) W1 575 kg 1268 lbs
Operating weight (CECE) W2 591 kg 1303 lbs
Basic weight 570 kg 1257 lbs
Economizer (Optional equipment) + 5 kg + 11 lbs
Safety crank handle (Optional equipment) + 3 kg + 7 lbs
Travel characteristics
Working speed max. 28 m/min 92 ft/min
Max. gradability (depending on soil) 35% 35%
Drive
Engine manufacturer Hatz Hatz
Technical data
BPR 70/70 D
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BPR 70/70 D
Type 1D 81 1D 81
Cooling Air Air
Number of cylinders 1 1
Rated power ISO 3046 IFN 9.2 KW 12.3 hp
Rated speed 2700 min-1 2700 rpm
Drive system mechanical mechanical
Exciter system
Frequency 68 Hz 4080 vpm
Centrifugal force 70 kN 15737 lbf
Amplitude 1.80 mm 0.07 in
Filling capacities
Fuel (diesel) 10.0 l 2.6 gal us
Subject to technical alterations.
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.
2.1.1 Noise data
LpA = 94 dB(A), determined acc. to ISO 11204 and EN 500.Sound pressure level at the opera-
tor's place
Technical data – Noise and vibration data
BPR 70/70 D
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WARNING!
Loss of hearing caused by too high noise bur-
dens!
– Wear your personal protective equipment (ear
protection).
LWA = 109 dB(A), determined acc. to ISO 3744 and EN 500
2.1.2 Vibration data
Vector total of the weighted effective acceleration in three orthog-
onal directions:
Total vibration value ahv = 4.5 m/s2 on crushed rock determined
acc. to ISO 5349 and EN 500.
Associated uncertainty K = 0.5 m/s2, determined acc. to EN
12096.
Observe the daily vibration load (work safety acc. to 2002/44/EC).
Guaranteed sound power level
Hand-arm vibration
Technical data – Noise and vibration data
BPR 70/70 D
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3 Safety regulations
Safety regulations
BPR 70/70 D
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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 improper use is the sole responsibility of the
operating company or driver/operator, the manufacturer cannot be
made liable.
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.
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
Improper use
Safety regulations
BPR 70/70 D
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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 70/70 D
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WARNING!
Paragraphs marked like this highlight possible dan-
gers for persons.
NOTICE!
Paragraphs marked like this highlight possible dan-
gers for machines or parts of the machine.
Paragraphs marked like this contain technical infor-
mation for the optimal economical use of the
machine.
ENVIRONMENT!
Paragraphs marked like this point out practices for
safe and environmental disposal of fuels and lubri-
cants as well as replacement parts.
Observe the regulations for the protection of the
environment.
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
Notes on safety in the operating
and maintenance instructions
Loading/transporting the machine
Starting the machine
Safety regulations
BPR 70/70 D
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Become acquainted with the equipment, the control 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:
nthe machine shows any obvious faults
nall guards and safety elements are in place
nthe controls are fully functional
nthe machine is free of oily and combustible material
nall 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.
Starting and operation of the machine is closed rooms and
trenches
Exhaust gases are highly dangerous! Always ensure an adequate
supply of fresh air when starting and operating in closed rooms and
trenches!
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 handle
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 destroyed.
Park the machine on level and firm ground.
Before leaving the machine:
nPark the machine so that it cannot tip over,
nshut the engine down and pull the ignition key out.
Mark machines, which could be in the way, with a clearly visible
sign.
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.
Operation
Parking the machine
Refuelling
Safety regulations
BPR 70/70 D
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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. Ensure tight fit of the
fuel tank cover, if necessary replace immediately.
Comply with the maintenance work described in the operating and
maintenance instructions, including the information concerning the
replacement of parts.
Maintenance work must only be performed by qualified and author-
ized persons.
Keep unauthorized persons away from the machine.
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.
Work on hydraulic lines
Relieve hydraulic pressures before working on hydraulic lines.
Hydraulic oil escaping under pressure 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!
Any hydraulic oil must be caught and disposed of in an environ-
mentally friendly manner.
Always catch and dispose of hydraulic oils separately.
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 regular intervals.
Hydraulic hoses must be immediately replaced if:
nthe outer layer is damaged down to the inlay (e.g. chafing,
cuts, cracks).
nthe outer layer is brittle (formation of cracks in the hose mate-
rial).
nthe hose shows deformations in pressurized and depressurized
condition, which do not comply with the genuine shape of the
hydraulic hose.
nthe hose shows deformations in bends, e.g. squeezing, buck-
ling, layer separation, formation of blisters,
nparts of the hose are leaking.
nhoses are not correctly installed
nthe hydraulic hose has separated from the fitting
Maintenance work
Safety regulations
BPR 70/70 D
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nthe fitting shows corrosion that impairs both function and
strength.
nfittings are damaged or deformed, whereby the function and
strength of the hose - hose connection is impaired.
hoses are mixed up by mistake.
Only genuine BOMAG replacement hydraulic hoses 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 dispose of environ-
mentally.
Store used filters and other oil contaminated materials in a sepa-
rate, specially marked container and dispose of environmentally.
Working on electric parts of the machine
Before starting to work on electric parts of the machine disconnect
the battery and cover it with insulating 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.
Metal objects (e.g. tools, rings, watch straps) must not come in
contact with the battery poles – danger of short circuit and burning!
For recharging remove the plugs from the battery to avoid the
accumulation of highly explosive gases.
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 battery 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 dis-
pose 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.
Safety regulations
BPR 70/70 D
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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 work must only be performed by qualified and authorized
persons. Use our repair instructions for this work.
Exhaust gases are highly dangerous! Always ensure 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 disconnect the battery
and cover the fuel tank with insulating material.
Keep safety stickers in good condition and legible and follow their
meaning.
Replace damaged and illegible safety stickers.
Repair
Safety stickers on the machine
Safety regulations
BPR 70/70 D
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