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Bomag BPR 45/55 D, Operating Instructions Manual

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Bomag BPR 45/55 D Operating Instructions Manual Download Page 6

 Table of Contents

BOMAG

6

BPR 45/55 D, BPR 55/65 D

6.16 Replacing the fuel filter 

54

6.17 Change the oil in the exciter housing 

55

6.18 Check the hydraulic oil level 

56

6.19 Check the rubber buffers  

58

As required

59

6.20 Tightening the screws 

59

6.21 Engine conservation 

59

7

Trouble shooting

61

7.1

General notes 

62

7.2

Starting with jump wires 

62

7.3

Fuses 

63

7.4

Engine problems 

64

7.5

Trouble shooting Economizer 

66

8

Disposal

67

8.1

Final shut-down of machine 

68

Summary of Contents for BPR 45/55 D

Page 1: ...nstructions Maintenance instructions Original operating instructions 12 2012 Catalogue No 008 051 21 BPR 45 55 D BPR 55 65 D S N 101 692 14 S N 101 692 33 S N 101 692 16 S N 101 692 34 Reversible Vibr...

Page 2: ......

Page 3: ...l wrong fuels and lubricants Please note This manual was written for operators and mainte nance personnel on construction sites These operating and maintenance instructions are part of the machine You...

Page 4: ...ype Fig 3 Engine number Fig 3 Note i Supplement the above data together with the com missioning protocol During commissioning our organisation will in struct you in the operation and maintenance of th...

Page 5: ...aintenance 35 6 1 General notes on maintenance 36 6 2 Fuels and lubricants 37 6 3 Table of fuels and lubricants 39 6 4 Running in instructions 40 6 5 Maintenance table 41 Maintenance every day 43 6 6...

Page 6: ...Check the hydraulic oil level 56 6 19 Check the rubber buffers 58 As required 59 6 20 Tightening the screws 59 6 21 Engine conservation 59 7 Trouble shooting 61 7 1 General notes 62 7 2 Starting with...

Page 7: ...BOMAG 7 BPR 45 55 D BPR 55 65 D 2 Technical Data...

Page 8: ...45 55 D Weights Operating weight CECE W 381 kg 840 lbs Operating weight CECE W1 396 kg 873 lbs Operating weight CECE W2 412 kg 908 lbs Basic weight 391 kg 862 lbs Economizer1 5 kg 11 lbs Travel charac...

Page 9: ...Rated power ISO 9249 6 6 KW 8 9 hp Rated speed 3000 min 1 3000 rpm Drive system mechanical mechanical Exciter system Frequency 70 Hz 4200 vpm Centrifugal force 45 kN 10116 lbf Filling capacities Fuel...

Page 10: ...55 65 D Weights Operating weight CECE W 436 kg 961 lbs Operating weight CECE W1 456 kg 1005 lbs Operating weight CECE W2 467 kg 1030 lbs Basic weight 451 kg 994 lbs Economizer1 5 kg 11 lbs Travel char...

Page 11: ...s Rated power ISO 9249 6 6 KW 8 9 hp Rated speed 3000 min 1 3000 rpm Drive system mechanical mechanical Exciter system Frequency 66 Hz 3960 vpm Centrifugal force 55 kN 12365 lbf Filling capacities Fue...

Page 12: ...ed acc to ISO 11204 and EN 500 BPR 55 65 D LpA 95 dB A determined acc to ISO 11204 and EN 500 Guaranteed sound power level BPR 45 55 D LWA 108 dB A determined acc to ISO 3744 and EN 500 BPR 55 65 D LW...

Page 13: ...BOMAG 13 BPR 45 55 D BPR 55 65 D 3 Safety regulations...

Page 14: ...machine when it is used for purposes other than the one it is intended for Any danger caused by intended use is the sole re sponsibility of the customer or driver operator the manufacturer cannot be m...

Page 15: ...otes on safety in the operating and maintenance instructions Danger Paragraphs marked like this highlight possible dangers for persons Caution Paragraphs marked like this highlight possible dangers fo...

Page 16: ...shooting and have the fault corrected Operate the machine only with full engine speed as otherwise the centrifugal clutch will be de stroyed Parking the machine Park the machine on level and firm gro...

Page 17: ...he fuel system Do not inhale any fuel fumes Avoid open fire do not smoke do not spill any fuel Catch running out fuel do not let it seep into the ground and dispose off environmentally Cleaning work D...

Page 18: ...Information sticker Lashing point 4 Maintenance sticker 5 Information sticker Throttle lever 6 Information sticker Guaranteed sound capac ity level 7 Information sticker Travel lever 8 Brief operatin...

Page 19: ...BOMAG 19 BPR 45 55 D BPR 55 65 D 4 Indicators and Controls...

Page 20: ...this section thoroughly before starting any opera tion on the machine Here all functions are de scribed in detail The section Operation contains only brief de scriptions of the individual control step...

Page 21: ...9 No 6 Recoil starter Fig 10 No 7 Start switch Position 0 Ignition off warning buzzer off Position I Ignition on warning buzzer on Position II Engine starts warning buzzer off Fig 11 No 8 Operating ho...

Page 22: ...ynamic load plate must be made before the material is compacted This is necessary to find out how many LEDs in the Economizer display correspond with the re quired value in MN m2 on the soil being com...

Page 23: ...BOMAG 23 BPR 45 55 D BPR 55 65 D 5 Operation...

Page 24: ...ours The following inspections must be carried out be fore each working day or before a longer working period Danger Danger of accident Please observe strictly the safety regulations in the correspond...

Page 25: ...are highly dangerous Always ensure an adequate supply of fresh air when starting and operating in closed rooms and trenches Danger Danger of accident Before starting make sure that there are no person...

Page 26: ...irst back to position 0 Fig 18 l Turn the ignition key to position I Fig 18 the warning buzzer sounds l Then turn the ignition key further to position II to start the engine l As soon as the engine ru...

Page 27: ...ersons in the danger area of engine or ma chine and that all safety installations are in place Before starting check the starter rope for chaf ing replace if necessary A damaged rope can break and cau...

Page 28: ...quickly and powerful as far out as possible Caution Do not let the starter handle hit back but guide it back l If the engine does not start during the first at tempt repeat the starting process Fig 2...

Page 29: ...the mean value indicat ed during the last pass is decisive l The displayed value rises when changing the travel direction the effective force applied to the soil by the vibratory plate rises when reve...

Page 30: ...ering rod folded down Guide the machine only by the steering rod Guide the machine so hat your hands do not hit against solid objects Always keep an eye on a running machine Caution Operate the vibrat...

Page 31: ...again Drive backwards Danger Danger of accident As a measure to avoid injury the machine must only be guided from the side by the steering handle Fig 30 l Pull the travel lever Fig 30 back until the...

Page 32: ...a while for temperature equalization Fig 32 l Shift the throttle lever to position MIN Fig 32 and let the engine run with idle speed for a short while l Vibration is shut down Fig 33 l Set the throttl...

Page 33: ...ed lifting eye Do not lift or lower the machine jerkily The tension must always be effective in verti cal direction The machine must not swing about when be ing lifted Do not step or stand under suspe...

Page 34: ...Operation BOMAG 34 BPR 45 55 D BPR 55 65 D...

Page 35: ...BOMAG 35 BPR 45 55 D BPR 55 65 D 6 Maintenance...

Page 36: ...environmentally Keep used filters in a separate waste container and dispose of environmentally l Open the hood to perform maintenance work Fig 38 l Loosen the hood fasteners 1 on both sides and remove...

Page 37: ...customer service depart ment 6 2 Fuels and lubricants Engine oil Oil viscosity Fig 39 Choose the oil viscosity in dependence on the am bient temperature at the operating location of the engine see dia...

Page 38: ...s are permitted l EN 590 l ASTM D 975 1 D and 2 D Winter fuel For winter operation use only winter diesel fuel to avoid clogging because of paraffin separation At very low temperatures disturbing para...

Page 39: ...ngine oil approx 1 5 l 0 4 gal us up to oil level mark SAE 15W 40 15 C to 40 C 5 F to 104 F SAE 30 5 C to 35 C 23 F to 95 F SAE 10W 25 C to 0 C 13 F to 32 F SAE 40 10 C to 45 C 50 F to 113 F SAE 20 10...

Page 40: ...twice every day Depending on the load the engine is subjected to the oil consumption will drop to the normal level after approx 100 to 200 operating hours After approx 50 operating hours l Change the...

Page 41: ...and the cooling air intake openings X 6 11 Drain the sludge from the fuel tank X 6 12 Check condition of battery X 6 13 Check the oil level in the exciter housing X 6 14 Check the V belt tension if n...

Page 42: ...Maintenance BOMAG 42 BPR 45 55 D BPR 55 65 D...

Page 43: ...d to avoid cor rosion 6 7 Check the engine oil level Caution Park the machine on level ground so that the engine is in horizontal position For quality of oil refer to the table of fuels and lubricants...

Page 44: ...umes Environment Catch running out fuel do not let it seep into the ground l Open the opper rubber cover Fig 42 l Clean the area around the filler opening l Open the filler cap on the fuel tank Fig 42...

Page 45: ...leaning does not make sense if the air filter element is covered with a sooty deposit Use a new air filter Incorrectly handled air filters may become in effective because of damage e g cracks and caus...

Page 46: ...f injury Always wear protective clothes goggles gloves when working with compressed air Fig 47 l Blow the air filter out from inside to outside with dry compressed air max 5 bar 72 psi Fig 47 l Check...

Page 47: ...fuel tank cylinder or cooling air intake Fig 48 l Loosen dried on dirt with a suitable brush Fig 48 from all cooling fins and cooling air intake openings and blow it off with compressed air Danger Fi...

Page 48: ...moke do not spill any fuel Danger Health hazard Do not inhale any fuel fumes Environment Any fuel must be caught and disposed of in an environmentally friendly manner Note i For this work the fuel tan...

Page 49: ...battery compartment l Open plugs and check the acid level With control inserts l Check whether the acid level reaches the bot tom end of the control inserts With transparent battery housing l Check wh...

Page 50: ...m edge of the inspection opening if necessary fill in oil For quality of oil refer to the table of fuels and lubricants l Clean the oil level inspection plug and screw in with sealing agent e g BOMAG...

Page 51: ...is exceeded Replacing the V belt Fig 56 l Remove the safety cover 3 Fig 56 l Loosen screw 2 l Remove the front disc 1 from the centrifugal clutch l Take off the V belt and replace it by a new one l At...

Page 52: ...Maintenance every 6 months BOMAG 52 BPR 45 55 D BPR 55 65 D...

Page 53: ...and dispose of environ mentally together with the oil filter Fig 57 l Unscrew the oil filler cap Fig 57 Fig 58 l Clean the drain hose from dust and dirt l Unscrew the oil drain plug and catch any oil...

Page 54: ...16 Replacing the fuel filter Danger Fire hazard When working on the fuel system do not use open fire do not smoke do not spill any fuel Danger Health hazard Do not inhale any fuel fumes Environment Ca...

Page 55: ...the fuel tap Fig 64 set the handle to vertical position 6 17 Change the oil in the exciter housing Caution Park the machine on level ground For quality and quantity of oil refer to the ta ble of fuel...

Page 56: ...pection bore l Clean level plug 2 and screw in with sealing agent e g BOMAG 009 700 16 l Screw vent plug 1 tightly back in 6 18 Check the hydraulic oil level Caution Park the machine horizontally Envi...

Page 57: ...ing up hydraulic oil For quality and quantity of oil refer to the table of fuels and lubricants Fig 71 l Shift the travel lever forward against the stop Fig 71 Fig 72 Note i Lay a cloth down before lo...

Page 58: ...ar BOMAG 58 BPR 45 55 D BPR 55 65 D Fig 74 l Screw in and tighten the plug Fig 74 6 19 Check the rubber buffers Fig 75 l Check all rubber buffers Fig 75 for tight fit cracks and damage and replace imm...

Page 59: ...ange the fuel filter l Drain the fuel from the fuel tank mix it well with 10 anti corrosion oil and fill it back in In stead of mixing the fuel with anti corrosion oil you may also fill the tank with...

Page 60: ...fuels and lubricants according to API MIL classification Anti corrosion oils are all oils which comply with the specification MIL L 21260 B or TL 9150 037 2 o Nato Code C640 642 Caution A machine with...

Page 61: ...BOMAG 61 BPR 45 55 D BPR 55 65 D 7 Trouble shooting...

Page 62: ...elf by following the trouble shooting chart you should contact our customer service depart ment 7 2 Starting with jump wires Note i Choose this type of starting if the starter battery is flat and the...

Page 63: ...nning remove the jump start cable from the two negative poles first and from the positive poles after Note i This work sequence is necessary to avoid short circuit caused by contact between positive a...

Page 64: ...Temperature below starting limit Observe cold start instructions Fuel gelled because of insufficient cold compatibility Pull the fuel hose off the fuel lift pump and check whether fuel runs out of the...

Page 65: ...d Tank empty Fill in fuel activate the mechanical oil pressure monitoring system Fuel filter clogged Replace the fuel filter Insufficient tank ventilation Ensure sufficient ventilation of the tank Lin...

Page 66: ...us LED off Operation Status LED on no frequency detected Engine not running Plug in connector defective Sensor cable defective Status LED flashing Frequency detected but outside permis sible range Eng...

Page 67: ...BOMAG 67 BPR 45 55 D BPR 55 65 D 8 Disposal...

Page 68: ...open fire do not smoke The battery contains acid Do not let acid come in contact with skin or clothes Wear protective clothing l Remove the batteries and dispose of in com pliance with legal regulatio...

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