Fayat BOMAG BPR 35/42 D User manual

BPR 35/42 D - BPR 35/60 D
Reversible Vibrating Plate
Operating Instruction
Maintenance Instruction
Original Operating Instructions
S/N 101 692 54 .... / S/N 101 692 55 .... / S/N 101 692 57 .... / S/N 101 692 71 .... / S/N 101 692 58 ....
/ S/N 101 692 72 ....
© 09/2013
Catalogue No.
008 083 41
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Table of contents
1 Foreword................................................................................................................................................ 5
2Technical data....................................................................................................................................... 9
3 Safety regulations............................................................................................................................... 15
4 Display and control elements............................................................................................................ 25
4.1 General notes.............................................................................................................................. 26
4.2 Description of indicators and control elements....................................................................... 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 Starting with recoil starter.......................................................................................................... 33
5.5 Starting the engine electricallyOptional equipment .......................................................................... 35
5.6 Work/operation............................................................................................................................ 38
5.7 Shut down the engine................................................................................................................. 40
5.8 Assembling the transport wheelsOptional equipment ...................................................................... 41
5.9 Loading/transport....................................................................................................................... 43
6 Maintenance........................................................................................................................................ 45
6.1 General notes on maintenance.................................................................................................. 46
6.2 Fuels and lubricants................................................................................................................... 48
6.3 Table of fuels and lubricants..................................................................................................... 50
6.4 Running-in instructions.............................................................................................................. 51
6.5 Maintenance table....................................................................................................................... 52
6.6 Maintenance every day............................................................................................................... 54
6.6.1 Clean the machine..................................................................................................................... 54
6.6.2 Check the engine oil level.......................................................................................................... 54
6.6.3 Check the fuel level.................................................................................................................... 55
6.7 Weekly maintenance................................................................................................................... 57
6.7.1 Check, clean the water separator.............................................................................................. 57
6.8 Maintenance every month.......................................................................................................... 58
6.8.1 Battery serviceOnly machines with electric starter. ..................................................................................... 58
6.8.2 Check, clean the air filter, replace if necessary.......................................................................... 59
6.8.3 Clean the cooling fins and the cooling air intake openings........................................................ 61
6.9 Maintenance every 6 months..................................................................................................... 62
6.9.1 Check the oil level in the exciter housing .................................................................................. 62
6.9.2 Check the V-belt tension, if necessary replace the V-belt.......................................................... 62
6.9.3 Checking, adjusting the valve clearance.................................................................................... 63
6.10 Maintenance every year............................................................................................................ 64
6.10.1 Change the engine oil.............................................................................................................. 64
6.10.2 Clean the engine oil filter.......................................................................................................... 65
6.10.3 Replace the fuel filter............................................................................................................... 66
6.10.4 Replacing the starter rope........................................................................................................ 67
6.10.5 Change the oil in the exciter shaft housing ............................................................................. 68
6.10.6 Check the hydraulic oil level..................................................................................................... 70
Table of contents
BPR 35/42 D - BPR 35/60 D
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6.10.7 Check the rubber buffers ......................................................................................................... 72
6.11 As required................................................................................................................................ 73
6.11.1 Tightening the screws.............................................................................................................. 73
6.11.2 Engine conservation ................................................................................................................ 73
7 Trouble shooting................................................................................................................................. 75
7.1 General notes.............................................................................................................................. 76
7.2 Starting with jump wires............................................................................................................. 77
7.3 Fuses............................................................................................................................................ 78
7.4 Changing the injection pump..................................................................................................... 79
7.5 Engine problems......................................................................................................................... 84
8 Disposal............................................................................................................................................... 87
8.1 Final shut-down of machine....................................................................................................... 88
Table of contents
BPR 35/42 D - BPR 35/60 D
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1 Foreword
Foreword
BPR 35/42 D - BPR 35/60 D
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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 35/42 D - BPR 35/60 D
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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)
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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 35/42 D - BPR 35/60 D
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Fig. 2
Fig. 3
Foreword
BPR 35/42 D - BPR 35/60 D
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2 Technical data
Technical data
BPR 35/42 D - BPR 35/60 D
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Fig. 4
BPR 35/42 D H H1H2L L1W
Dimensions in mm 688 820 1220 1510 762 420
Dimensions in inch 27.1 32.3 48.0 59.4 30.0 16.5
BPR 35/42 D
Weights
Operating weight (CECE) (manual/electric starter) 205/225 kg 452/496 lbs
Basic weight (manual starter/electric starter) 202/222 kg 445/489 lbs
Full engine protection cover (Optional equipment) + 18 kg + 40 lbs
Transport wheels (Optional equipment) + 5 kg + 11 lbs
Travel characteristics
Working speed max. 27 m/min 89 ft/min
Max. gradability (depending on soil) 32% 32%
Technical data
BPR 35/42 D - BPR 35/60 D
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BPR 35/42 D
Drive
Engine manufacturer Hatz Hatz
Type 1B20 1B20
Cooling Air Air
Number of cylinders 1 1
Rated power ISO 3046 IFN 3.1 KW 4.2 hp
Rated speed 3000 min-1 3000 rpm
Drive system mechanical mechanical
Exciter system
Frequency 80 Hz 4800 vpm
Centrifugal force 35 kN 7868 lbf
Amplitude 1.5 mm 0.06 in
Filling capacities
Fuel (diesel) 3.0 l 0.8 gal us
Subject to technical alterations.
Technical data
BPR 35/42 D - BPR 35/60 D
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Fig. 5
BPR 35/60 D H H1H2L L1W
Dimensions in mm 688 820 1220 1510 762 600
Dimensions in inch 27.1 32.3 48.0 59.4 30.0 23.6
BPR 35/60 D
Weights
Operating weight (CECE) (manual/electric starter) 220/240 kg 485/529 lbs
Basic weight (manual starter/electric starter) 217/237 kg 478/523 lbs
Full engine protection cover (Optional equipment) + 18 kg + 40 lbs
Paving plate (Optional equipment) + 21 kg + 46 lbs
Transport wheels (Optional equipment) + 5 kg + 11 lbs
Travel characteristics
Working speed max. 27 m/min 89 ft/min
Max. gradability (depending on soil) 32% 32%
Technical data
BPR 35/42 D - BPR 35/60 D
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BPR 35/60 D
Drive
Engine manufacturer Hatz Hatz
Type 1B20 1B20
Cooling Air Air
Number of cylinders 1 1
Rated power ISO 3046 IFN 3.1 KW 4.2 hp
Rated speed 3000 min-1 3000 rpm
Drive system mechanical mechanical
Exciter system
Frequency 80 Hz 4800 vpm
Centrifugal force 35 kN 7868 lbf
Amplitude 1.3 mm 0.05 in
Filling capacities
Fuel (diesel) 3.0 l 0.8 gal us
Subject to technical alterations.
The following noise and vibration data acc. to
- EC Machine Regulation edition 2006/42/EG and
- 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 harmonized standards.
During operation these values may vary because of the
existing operating conditions.
Sound pressure level on the place of the operator:
BPR 35/42 D: LpA = 94 dB(A), determined acc. to ISO 11204 and
EN 500
Noise value
Technical data
BPR 35/42 D - BPR 35/60 D
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BPR 35/60 D: LpA = 94 dB(A), determined acc. to ISO 11204 and
EN 500
Guaranteed sound power level:
BPR 35/42 D: LWA = 108 dB(A), determined acc. to ISO 3744 and
EN 500
BPR 35/60 D: LWA = 108 dB(A), determined acc. to ISO 3744 and
EN 500
WARNING!
Loss of hearing!
Wear your personal noise protection means (ear
defenders) before starting operation.
Hand-arm vibration:
Vector total of the weighted effective acceleration in three orthog-
onal directions:
Weighted total vibration value
BPR 35/42 D: ahv = 7.3 m/s2 on crushed rock determined acc. to
ISO 5349 and EN 500
BPR 35/60 D: ahv = 6,7 m/s2 on crushed rock determined acc. to
ISO 5349 and EN 500
NOTICE!
Observe the daily vibration load (Industrial safety acc.
to 2002/44/EEC).
Vibration value
Technical data
BPR 35/42 D - BPR 35/60 D
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3 Safety regulations
Safety regulations
BPR 35/42 D - BPR 35/60 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 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 35/42 D - BPR 35/60 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 35/42 D - BPR 35/60 D
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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.
When lashing down the machine disassemble the transport wheels
from the base plate.Optional equipment
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 35/42 D - BPR 35/60 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.
When starting with recoil starter check the starter rope for chafing
before starting, replace if necessary. A damaged rope can break
and cause injuries during starting.
Use only machines which are serviced at regular intervals.
Do not use starting aid sprays or other inflammable fluids for
starting.
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.
Operation
Parking the machine
Refuelling
Safety regulations
BPR 35/42 D - BPR 35/60 D
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No open fire, do not smoke.
Do not spill any fuel. Catch running out fuel, do not let it seep into
the ground.
Keep dirt and water away from the fuel.
A leaking fuel tank can cause an explosion. 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.
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.
Wear gloves and goggles.
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.
Maintenance work
Safety regulations
BPR 35/42 D - BPR 35/60 D
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