Fayat Bomag BP 25/50 Instructions for use

BP 25/50
Single direction vibratory plate
Operating Instruction
Maintenance Instruction
Original Operating Instructions
S/N 101 230 17 1001>
© 12/2014008 201 17 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 General prerequisites................................................................................................................. 16
3.1.1 General...................................................................................................................................... 16
3.1.2 Explanations to signal words used:............................................................................................ 16
3.1.3 Personal protective outfit............................................................................................................ 17
3.1.4 Intended use.............................................................................................................................. 18
3.1.5 Unintended use.......................................................................................................................... 18
3.2 Terminological definition of the responsible persons............................................................ 20
3.2.1 Operating company.................................................................................................................... 20
3.2.2 Expert / qualified person............................................................................................................ 20
3.2.3 Driver / operating personnel....................................................................................................... 20
3.3 Fundamentals for safe operation.............................................................................................. 22
3.3.1 Remaining dangers, remaining risks.......................................................................................... 22
3.3.2 Regular safety inspections......................................................................................................... 22
3.3.3 Changes and conversions to the machine................................................................................. 22
3.3.4 Damage, deficiencies, misuse of safety installations................................................................. 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 oil............................ 24
3.4.3 Safety regulations and environmental protection regulations for handling gasoline.................. 25
3.4.4 Safety regulations and environmental protection regulations for handling fuel stabiliser........... 26
3.5 Loading/transporting the machine............................................................................................ 27
3.6 Taking the machine into service................................................................................................ 28
3.6.1 Before commissioning................................................................................................................ 28
3.6.2 Spark protection......................................................................................................................... 28
3.6.3 Starting the engine..................................................................................................................... 28
3.7 Operation..................................................................................................................................... 29
3.7.1 Persons in the danger area........................................................................................................ 29
3.7.2 Operation................................................................................................................................... 29
3.7.3 Parking the machine.................................................................................................................. 29
3.8 Refuelling..................................................................................................................................... 30
3.9 Maintenance work....................................................................................................................... 31
3.9.1 Preliminary remarks................................................................................................................... 31
3.9.2 Maintenance work on the engine............................................................................................... 31
3.9.3 Cleaning work............................................................................................................................ 31
3.9.4 After maintenance work............................................................................................................. 31
3.10 Repair......................................................................................................................................... 32
Table of contents
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3.11 Stickers and decals................................................................................................................... 33
4 Display and control elements............................................................................................................ 35
4.1 Engine.......................................................................................................................................... 36
4.1.1 Overview.................................................................................................................................... 36
4.1.2 Start switch................................................................................................................................. 36
4.1.3 Throttle lever.............................................................................................................................. 37
4.1.4 Choke lever................................................................................................................................ 37
4.1.5 Recoil starter.............................................................................................................................. 37
4.1.6 Fuel valve................................................................................................................................... 38
4.2 Water sprinkling system............................................................................................................. 39
4.2.1 Rotary button for water sprinkling system.................................................................................. 39
4.3 Transport wheels........................................................................................................................ 40
4.3.1 Transport wheels with steering bow in middle position.............................................................. 41
5 Tests before taking into operation.................................................................................................... 43
5.1 Notes on safety........................................................................................................................... 44
5.2 Visual inspections and function tests....................................................................................... 45
5.3 Checking the engine oil level..................................................................................................... 46
5.4 Checking the fuel level, topping up fuel................................................................................... 47
5.5 Checking the water level, topping up........................................................................................ 48
6 Operation............................................................................................................................................. 49
6.1 Assembling the steering bow.................................................................................................... 50
6.2 Start the engine........................................................................................................................... 51
6.3 Operation..................................................................................................................................... 54
6.4 Switching the water sprinkling system on/off.......................................................................... 55
6.5 Park the machine in secured condition.................................................................................... 56
7 Loading/transporting the machine.................................................................................................... 57
7.1 Loading the machine.................................................................................................................. 58
7.2 Lashing the machine to the transport vehicle.......................................................................... 59
7.3 Transport wheels........................................................................................................................ 60
7.3.1 Transport wheels with steering bow in middle position.............................................................. 61
8 Maintenance........................................................................................................................................ 63
8.1 Preliminary remarks and safety notes...................................................................................... 64
8.2 Fuels and lubricants................................................................................................................... 65
8.2.1 Engine oil................................................................................................................................... 65
8.2.2 Fuel............................................................................................................................................ 65
8.3 Table of fuels and lubricants..................................................................................................... 67
8.4 Running-in instructions.............................................................................................................. 68
8.4.1 General...................................................................................................................................... 68
8.4.2 After 25 operating hours............................................................................................................. 68
8.5 Maintenance table....................................................................................................................... 69
8.6 Weekly.......................................................................................................................................... 70
8.6.1 Check, clean the air filter, replace if necessary.......................................................................... 70
8.7 Monthly........................................................................................................................................ 73
8.7.1 Clean the cooling fins and the cooling air intake openings........................................................ 73
8.8 Half-annually................................................................................................................................ 75
Table of contents
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8.8.1 Changing the engine oil............................................................................................................. 75
8.8.2 Cleaning, checking the spark plug, replacing if necessary........................................................ 76
8.8.3 Cleaning the slurry filter............................................................................................................. 77
8.8.4 Checking the oil level in the exciter housing.............................................................................. 78
8.8.5 Servicing the V-belt.................................................................................................................... 78
8.9 Annually....................................................................................................................................... 81
8.9.1 Checking, adjusting the valve clearance.................................................................................... 81
8.9.2 Cleaning the fuel screen............................................................................................................ 83
8.9.3 Replacing the starter rope.......................................................................................................... 85
8.9.4 Change the oil in the exciter housing......................................................................................... 87
8.9.5 Checking the rubber buffers....................................................................................................... 87
8.10 As required................................................................................................................................ 89
8.10.1 Cleaning the machine.............................................................................................................. 89
8.10.2 Cleaning the water sprinkling system....................................................................................... 89
8.10.3 Measures to be applied for longer periods of rest.................................................................... 90
9 Trouble shooting................................................................................................................................. 93
9.1 Preliminary remarks.................................................................................................................... 94
9.2 Engine faults................................................................................................................................ 95
9.3 What to do if the engine has flooded........................................................................................ 97
10 Waste disposal.................................................................................................................................... 99
10.1 Final shut-down of machine................................................................................................... 100
11 List of special tools........................................................................................................................... 101
Table of contents
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1 Introduction
Introduction
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1.1 Foreword
BOMAG manufactures machines for earth, asphalt and refuse
compaction, stabilizers/recyclers as well as milling machines
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.
The machine described in this manual complies with the applicable
standards and safety regulations.
If your machine is used in traffic on public roads, it must comply
with all applicable national legal regulations. The driving permit
must be acquired from the responsible authorities.
The machine is equipped with latest technology. Now it's a matter
of handling your machine properly and keeping it in good shape.
These instructions will provide you with all necessary information.
Read and follow these notes before starting to operate your
machine!
In case of operating errors, inadequate maintenance or the use of
unapproved fuels and lubricants all warranty claims will become
null and void.
This manual was written for operators and maintenance personnel.
These operating and maintenance instructions are part of the
machine.
You should only operate the machine in compliance with these
instructions.
Strictly observe the safety regulations.
If you are not yet acquainted with the controls and indicating ele-
ments on this machine, you should thoroughly read the corre-
sponding section
Ä Chapter 4 ‘Display and control elements’
on page 35beforehand.
The description of the individual operating steps, including the
notes on safety to be followed, can be found in chapter "Opera-
tion"
Ä Chapter 6 ‘Operation’ on page 49.
Thorough maintenance of the machine guarantees far longer safe
functioning of the machine and prolongs the lifetime of important
components. The effort required for this purpose is by any means
lower than the faults that may occur in case of non-compliance.
The machine must only be serviced by qualified and authorized
personnel. A description of all necessary service work as well as
information on fuels and lubricants can be found in the chapter
"Maintenance"
Ä Chapter 8 ‘Maintenance’ on page 63.
For your own personal safety you should only use original spare
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.
Introduction – Foreword
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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.
We wish you successful work with your BOMAG machine.
Introduction – Foreword
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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:
Engine number:
Fig. 1: Machine type plate (example)
Engine type and engine number
Fig. 2
Introduction – Machine type plate and engine type plate
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2 Technical data
Technical data
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Fig. 3
H H1H2L L1W
658
(25.9)
962
(37.9)
700
(27.6)
1084
(42.7)
542
(21.3)
500
(19.7)
Dimensions in millimetre
(Dimensions in inch)
Weights
Operating weight (CECE) 108
(238)
kg
(lbs)
Basic weight 107
(236)
kg
(lbs)
Water sprinkling system (optional equipment) + 10
(+ 22)
kg
(lbs)
Transport wheels (optional equipment) + 4
(+ 9)
kg
(lbs)
Dimensions
Technical data
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Travel characteristics
Max. working speed 30
(98)
m/min
(ft/min)
Max. gradability (depending on soil) 30 %
Drive
Engine manufacturer Honda
Type GX 160
Cooling Air
Number of cylinders 1
Rated power SAE J 1349 3.6
(4.8)
kW
(hp)
Rated speed 3600 min-1
Drive system mechanical
Exciter system
Frequency 92
(5520)
Hz
(vpm)
Centrifugal force 25
(5620)
kN
(lbf)
Amplitude 1.11
(0,044)
mm
(in)
Water sprinkling system (optional equipment)
Type of sprinkling Gravity feed
Filling capacities
Fuel (gasoline) 3.1
(0.8 each)
l
(gal us)
Water sprinkling system 13.5
(3.6 each)
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 = 94 dB(A), determined acc. to ISO 11204 and EN 500.
WARNING!
Loos of hearing caused by too high noise burdens!
– Wear your personal protective outfit (ear
defenders).
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:
Weighted total vibration value
ahv = 5.2 m/s2 on crushed rock determined acc. to ISO 5349 and
EN 500.
Observe the daily vibration load (Industrial safety acc. to 2002/44/
EEC).
Sound pressure level at the opera-
tor's place
Guaranteed sound power level
Hand-arm vibration
Technical data – Noise and vibration data
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3 Concerning your safety
Concerning your safety
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3.1 General 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 Explanations to signal words used:
DANGER!
Danger to life if failing to comply!
Sections marked like this point to an extremely dan-
gerous situation that could lead to fatal or severe inju-
ries, if this warning is disregarded.
WARNING!
Danger to life or danger of severe injuries if failing
to comply!
Sections marked like this point to a dangerous situa-
tion that could lead to fatal or severe injuries, if this
warning is disregarded.
Concerning your safety – General prerequisites
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CAUTION!
Danger of injury if failing to comply!
Sections marked like this point to a dangerous situa-
tion that could lead to minor injuries, if this warning is
disregarded.
NOTICE!
Danger of material damage if failing to comply!
Sections marked like this highlight possible dangers for
machines or components.
Sections marked like this provide technical information
or notes on using the machine or its components.
ENVIRONMENT!
Environmental damage if failing to comply!
Paragraphs marked like this point out practices for
safe and environmental disposal of fuels and lubricants
as well as replacement parts.
3.1.3 Personal protective outfit
Depending on the work to be carried out, personal protective outfit 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 – General prerequisites
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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 Unintended use
Dangers may arise from the machine when it is used for purposes
other than the one it is intended for.
Any danger caused by intended use is the sole 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.
Concerning your safety – General prerequisites
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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.
Concerning your safety – General prerequisites
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3.2 Terminological definition of the 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 operation. 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 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 / operating personnel
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 / operating per-
sonnel:
The driver or the operating personnel must:
nbe instructed about his rights and obligations,
nwear protective equipment as appropriate for the application,
nhave read and understood the operating instructions,
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.
Concerning your safety – Terminological definition of the responsible persons
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Maintenance and repair work requires specific knowledge and
must therefore only be performed by trained specialists.
Concerning your safety – Terminological definition of the responsible persons
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