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
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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
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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
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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
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1 Introduction
Introduction
BPR 60/65 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
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
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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
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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 60/65 D
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2 Technical data
Technical data
BPR 60/65 D
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Fig. 3
H H1H2L L1W W1W2W3
Dimensions standard
921
(36.3)
1153
(45.4)
1338
(52.7)
1653
(65.1)
898
(35.4)
450
(17.7)
550
(21.7)
650
(25.6)
750
(29.5)
Dimensions in millimetres
(Dimensions in inch)
Weights
Operating weight (CECE) (W) 440
(970)
kg
(lbs)
Operating weight (CECE) (W1) 460
(1014)
kg
(lbs)
Operating weight (CECE) (W2) 471
(1038)
kg
(lbs)
Basic weight 455
(1003)
kg
(lbs)
Dimensions
Technical data
BPR 60/65 D
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Weights
"STONEGUARD" (special base plate for paving stones) (optional
equipment)
+ 37
(+ 82)
kg
(lbs)
ECONOMIZER (optional equipment) + 5
(+ 11)
kg
(lbs)
Travel characteristics
Max. working speed 28
(92)
m/min
(ft/min)
Max. working speed with “STONEGUARD” 25
(82)
m/min
(ft/min)
Max. gradability (depending on soil) 35 %
Drive
Engine manufacturer Hatz
Type 1B40
Cooling Air
Number of cylinders 1
Rated power ISO 3046 6.7
(9.0)
kW
(hp)
Rated speed 3000 min-1
Drive system mechanical
Exciter system
Frequency 66
(3960)
Hz
(vpm)
Centrifugal force 60
(13489)
kN
(lbf)
Amplitude 1.96
(0,077)
mm
(in)
Filling capacities
Fuel (diesel) 5.0
(1.3)
l
(gal us)
Technical data
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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 = 95 dB(A), determined acc. to ISO 11204 and EN 500.
WARNING!
Loss of hearing caused by too high noise bur-
dens!
– Wear your personal protective equipment (ear
protection).
LWA = 108 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 £ 2.5 m/s2 on crushed rock determined
acc. to ISO 5349 and EN 500.
Associated uncertainty K = 0.3 m/s2, determined acc. to EN
12096.
Observe the daily vibration load (work safety acc. to 2002/44/EC).
Sound pressure level at the opera-
tor's place
Guaranteed sound power level
Hand-arm vibration
Technical data – Noise and vibration data
BPR 60/65 D
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3 Concerning your safety
Concerning your safety
BPR 60/65 D
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3.1 Basic prerequisites
3.1.1 General
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 reg-
ulations. If necessary, the customer must obtain the relevant signa-
tures as confirmation.
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 the safety regu-
lations and to apply these accordingly. This also applies for local
regulations amnd regulations concerning different types of handling
activities. Should the recommendations in these instructions be dif-
ferent from the regulations valid in your country, you must comply
with the safety regulations valid in your country.
3.1.2 Explanation of warning signs:
DANGER!
Danger to life if failing to comply!
Sections marked accordingly indicate an extremely
dangerous situation that could lead to fatal or
severe injuries, if this warning is disregarded.
WARNING!
Danger to life or danger of severe injuries if
failing to comply!
Sections marked accordingly indicate a dangerous
situation that could lead to fatal or severe injuries,
if this warning is disregarded.
Concerning your safety – Basic prerequisites
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CAUTION!
Danger of injury if failing to comply!
Sections marked accordingly indicate a dangerous
situation that could lead to fatal or severe injuries,
if this warning is disregarded.
NOTICE!
Danger of material damage if failing to comply!
Sections marked accordingly indicate possible
dangers for machines or components.
Sections marked accordingly indicate technical
information or notes on using the machine or its
components.
ENVIRONMENT!
Environmental damage if failing to comply!
Paragraphs marked accordingly indicate practices
for safe and environment-friendly disposal of fuels
and lubricants as well as replacement parts.
3.1.3 Personal protective equipment
Depending on the work to be carried out, personal protective equipment is required (to be provided
by the operating company):
Working clothes Tight fitting working clothes with low tear resistance, tight
sleeves and without any projecting parts protects against
being caught by moving components.
Safety shoes To protect against heavy falling parts and slipping on
slippery ground.
Protective gloves To protect the hands against excoriation, punctures or
deep injuries, against irritating and caustic substances
as well as against burns.
Concerning your safety – Basic prerequisites
BPR 60/65 D
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Safety goggles To protect the eyes against airborne particles and fluid
squirts.
Face protection To protect the face against airborne particles and fluid
squirts.
Hard hat To protect the head against falling parts and to protect
against injuries.
Hearing protection To protect the hearing against too loud noise.
3.1.4 Intended use
This machine must only be used for:
nCompaction of all types of soils
nRepair work on all types of soil
nPaving of walkways
nWork in trenches
nUnderfilling and compaction of hard shoulders
Intended use also includes compliance with the specified oper-
ating, maintenance and repair measures.
3.1.5 Improper use
Dangers may arise from the machine when it is used for purposes
other than the one it is intended for.
Any danger caused by improper use is the sole responsibility of the
operating company or driver/operator, the manufacturer cannot be
made liable.
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.
Concerning your safety – Basic prerequisites
BPR 60/65 D
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Lifting tackle must be removed before starting work.
Starting and operating the machine in explosive environments and
in underground mining is prohibited.
Concerning your safety – Basic prerequisites
BPR 60/65 D
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3.2 Definition of responsible persons
3.2.1 Operating company
The operating company is the natural or juridical person who uses
the machine or in who's name the machine is used.
The operating company must make sure that the machine is only
used for the purpose it is intended for and in strict compliance with
the safety regulations mentioned in these operating and mainte-
nance instructions.
The operating company must determine and assess the danger in
his company. It must then take appropriate action to ensure health
and safety at work for his employees and point out any remaining
dangers.
The operating company must determine whether there are special
operation hazards such as a toxic atmosphere or limiting soil con-
ditions. Such conditions requires special, additional measures to
remove or reduce the hazard.
The operating company must make sure that all users read and
understand the information concerning safety.
The operating company is responsible for the planning and profes-
sional execution of regular safety inspections.
3.2.2 Expert / qualified person
An expert / qualified person is a person who, based on his/her pro-
fessional education and experience, has profound knowledge in
the field of construction equipment and the machine in question in
particular.
This person is acquainted with the applicable governmental indus-
trial safety regulations, accident prevention instructions, guidelines
and generally acknowledged technical rules and regulations
(standards, directives, technical rules of other member states of
the European Union or other contractual states concerning the
agreement about the European Economic Area) in as far as is nec-
essary to be able to judge the safe condition of these machines.
3.2.3 Driver / operator
This machine must only be operated by trained, instructed persons
entrusted by the operating company aged 18 or more.
Observe your local laws and regulations.
Rights, obligations and rules of conduct for driver or operator:
The driver or operator must:
nbe instructed about his rights and obligations,
nwear protective equipment as appropriate for the application,
nhave read and understood the operating instructions,
Concerning your safety – Definition of responsible persons
BPR 60/65 D
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nhave made himself familiar with the operation of the machine,
nbe physically and psychologically able to drive and operate the
machine.
Persons under the influence of alcohol, 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.
Concerning your safety – Definition of responsible persons
BPR 60/65 D
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