Fayat BOMAG BPR 60/65 D Instructions for use

BPR 60/65 D
Reversible vibratory plate
Operating Instruction
Maintenance Instruction
Original Operating Instructions
S/N 101 692 98 1001>
© 09/2016008 202 27 EN
www.discount-equipment.com
Go to Discount-Equipment.com to order your parts

Discount-Equipment.com is your online resource for quality parts & equipment.
Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101
Need parts?
Click on this link: http://www.discount-equipment.com/category/5443-parts/ and
choose one of the options to help get the right parts and equipment you are looking
for. Please have the machine model and serial number available in order to help us
get you the correct parts. If you don’t find the part on the website or on one of the
online manuals, please fill out the request form and one of our experienced staff
members will get back to you with a quote for the right part that your machine needs.
We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman,
Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,
Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack,
Lull, Skytrak, Tsurumi, Husquvarna Target, Stow, Wacker, Sakai, Mi-T-M, Sullair, Basic,
Dynapac, MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti,
Morrison, Contec, Buddy, Crown, Edco, Wyco, Bomag, Laymor, EZ Trench, Bil-Jax, F.S.
Curtis, Gehl Pavers, Heli, Honda, ICS/PowerGrit, IHI, Partner, Imer, Clipper, MMD, Koshin,
Rice, CH&E, General Equipment ,Amida, Coleman, NAC, Gradall, Square Shooter, Kent,
Stanley, Tamco, Toku, Hatz, Kohler, Robin, Wisconsin, Northrock, Oztec, Toker TK, Rol-Air,
APT, Wylie, Ingersoll Rand / Doosan, Innovatech, Con X, Ammann, Mecalac, Makinex, Smith
Surface Prep,Small Line, Wanco, Yanmar

Table of contents
1 Introduction........................................................................................................................................... 7
1.1 Foreword........................................................................................................................................ 8
1.2 Machine type plate and engine type plate................................................................................ 10
2 Technical data...................................................................................................................................... 11
2.1 Noise and vibration data............................................................................................................ 14
2.1.1 Noise data.................................................................................................................................. 14
2.1.2 Vibration data............................................................................................................................. 14
3 Concerning your safety...................................................................................................................... 15
3.1 Basic prerequisites..................................................................................................................... 16
3.1.1 General...................................................................................................................................... 16
3.1.2 Explanation of warning signs:.................................................................................................... 16
3.1.3 Personal protective equipment................................................................................................... 17
3.1.4 Intended use.............................................................................................................................. 18
3.1.5 Improper use.............................................................................................................................. 18
3.2 Definition of responsible persons............................................................................................. 20
3.2.1 Operating company.................................................................................................................... 20
3.2.2 Expert / qualified person............................................................................................................ 20
3.2.3 Driver / operator......................................................................................................................... 20
3.3 Basic safety regulations for safe operation............................................................................. 22
3.3.1 Remaining dangers, remaining risks.......................................................................................... 22
3.3.2 Regular safety inspections......................................................................................................... 22
3.3.3 Modifications and alterations to the machine............................................................................. 22
3.3.4 Damage, defects, misuse of safety devices............................................................................... 22
3.4 Handling fuels and lubricants.................................................................................................... 23
3.4.1 Preliminary remarks................................................................................................................... 23
3.4.2 Safety regulations and environmental protection regulations for handling diesel fuel............... 24
3.4.3 Safety regulations and environmental protection regulations for handling oil............................ 25
3.4.4 Safety regulations and environmental protection regulations for handling hydraulic oil............. 26
3.4.5 Safety regulations and environmental protection regulations for handling battery acid............. 27
3.5 Loading/transporting the machine............................................................................................ 28
3.6 Start-up procedure...................................................................................................................... 29
3.6.1 Prior to starting up...................................................................................................................... 29
3.6.2 Starting the engine..................................................................................................................... 29
3.7 Operation..................................................................................................................................... 30
3.7.1 Persons in the danger area........................................................................................................ 30
3.7.2 Operation................................................................................................................................... 30
3.7.3 Parking the machine.................................................................................................................. 30
3.8 Refuelling..................................................................................................................................... 31
3.9 Maintenance work....................................................................................................................... 32
3.9.1 Preliminary remarks................................................................................................................... 32
3.9.2 Working on the engine............................................................................................................... 32
3.9.3 Maintenance work on electric components and battery............................................................. 32
3.9.4 Cleaning work............................................................................................................................ 32
3.9.5 After maintenance work............................................................................................................. 33
Table of contents
BPR 60/65 D
3
Go to Discount-Equipment.com to order your parts

3.10 Repair......................................................................................................................................... 34
3.11 Signage...................................................................................................................................... 35
4 Display and control elements............................................................................................................ 39
5 Tests before taking into operation..................................................................................................... 41
5.1 Notes on safety........................................................................................................................... 42
5.2 Visual inspections and function tests....................................................................................... 43
5.3 Checking the engine oil level..................................................................................................... 44
5.4 Checking the fuel level, topping up fuel................................................................................... 45
5.5 Checking the rubber buffers...................................................................................................... 46
6 Operation............................................................................................................................................. 47
6.1 Folding down the steering rod................................................................................................... 48
6.2 Start the engine........................................................................................................................... 49
6.3 Operation..................................................................................................................................... 51
6.4 Park the machine in secured condition.................................................................................... 53
6.5 ECONOMIZER.............................................................................................................................. 54
7 Loading / transporting the machine.................................................................................................. 55
7.1 Loading the machine.................................................................................................................. 56
7.2 Lashing the machine to the transport vehicle.......................................................................... 57
8 Maintenance........................................................................................................................................ 59
8.1 Preliminary remarks and safety notes...................................................................................... 60
8.2 Preparations / concluding work................................................................................................. 61
8.2.1 Open protection hood................................................................................................................. 61
8.3 Fuels and lubricants................................................................................................................... 62
8.3.1 Engine oil................................................................................................................................... 62
8.3.2 Fuel............................................................................................................................................ 62
8.3.3 Mineral oil based hydraulic oil.................................................................................................... 63
8.4 List of fuels and lubricants........................................................................................................ 64
8.5 Running-in instructions.............................................................................................................. 65
8.5.1 General...................................................................................................................................... 65
8.5.2 After 25 operating hours............................................................................................................. 65
8.6 Maintenance table....................................................................................................................... 66
8.7 Weekly.......................................................................................................................................... 67
8.7.1 Checking, cleaning the water separator..................................................................................... 67
8.8 Monthly........................................................................................................................................ 68
8.8.1 Air filter maintenance................................................................................................................. 68
8.8.2 Cleaning the cooling fins and the cooling air intake openings................................................... 69
8.8.3 Battery service........................................................................................................................... 70
8.9 Semi-annually.............................................................................................................................. 71
8.9.1 Checking the oil level in the exciter housing.............................................................................. 71
8.9.2 Servicing the V-belt.................................................................................................................... 71
8.9.3 Checking the screw joints on the diesel engine......................................................................... 72
8.10 Annually..................................................................................................................................... 74
8.10.1 Changing the engine oil and cleaning the oil filter.................................................................... 74
8.10.2 Replacing the fuel filter............................................................................................................. 76
8.10.3 Replacing the starter rope........................................................................................................ 77
Table of contents
BPR 60/65 D
4
Go to Discount-Equipment.com to order your parts

8.10.4 Changing the oil in the exciter housing.................................................................................... 78
8.10.5 Checking the hydraulic oil level................................................................................................ 80
8.10.6 Checking, adjusting the valve clearance.................................................................................. 82
8.11 As required................................................................................................................................ 85
8.11.1 Cleaning the machine............................................................................................................... 85
8.11.2 Measures prior to extended shutdown period.......................................................................... 85
9 Troubleshooting.................................................................................................................................. 89
9.1 Preliminary remarks.................................................................................................................... 90
9.2 Starting the engine with the recoil starter................................................................................ 91
9.3 Starting the engine with jump leads.......................................................................................... 94
9.4 Fuse assignment......................................................................................................................... 95
9.5 Engine malfunctions................................................................................................................... 96
9.6 Malfunctions during operation.................................................................................................. 98
9.7 Trouble shooting ECONOMIZER................................................................................................ 99
10 Disposal............................................................................................................................................. 101
10.1 Final shut-down of machine................................................................................................... 102
Table of contents
BPR 60/65 D
5
Go to Discount-Equipment.com to order your parts

1 Introduction
Introduction
BPR 60/65 D
7
Go to Discount-Equipment.com to order your parts

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
Ä Chapter 4 „Display and control ele-
ments“ on page 39.
The description of the individual operating steps including the
notes on safety to be followed can be found in chapter “Operation”
Ä Chapter 6 „Operation“ on page 47.
Before every start up, carry out all required visual inspections and
function tests
Ä Chapter 5 „Tests before taking into opera-
tion“ on page 41.
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”
Ä Chapter 8 „Mainte-
nance“ on page 59.
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.
Introduction – Foreword
BPR 60/65 D
8
Go to Discount-Equipment.com to order your parts

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.
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 60/65 D
9
Go to Discount-Equipment.com to order your parts

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 60/65 D
10
Go to Discount-Equipment.com to order your parts

2 Technical data
Technical data
BPR 60/65 D
11
Go to Discount-Equipment.com to order your parts