Fayat BOMAG BPR 25/40 D Operating Instructions Manual
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Fayat BOMAG BPR 25/40 D Operating Instructions Manual

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Operating Instruction
Maintenance Instruction
Original Operating Instructions
BPR 25/40 D - BPR 25/50 D
S/N 101 692 51 .... / S/N 101 692 70 .... / S/N 101 692 53 ....
Reversible Vibrating Plate
www.discount-equipment.com
Catalogue No.
© 09/2013
008 083 21

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Summary of Contents for Fayat BOMAG BPR 25/40 D

  • Page 1 Operating Instruction Maintenance Instruction Original Operating Instructions BPR 25/40 D - BPR 25/50 D S/N 101 692 51 ../ S/N 101 692 70 ../ S/N 101 692 53 ..Reversible Vibrating Plate www.discount-equipment.com Catalogue No. © 09/2013 008 083 21...
  • Page 2 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/ choose one of the options to help get the right parts and equipment you are looking for.

  • Page 3: Table Of Contents

    Table of contents Table of contents Foreword..............................5 Technical data............................9 Safety regulations..........................15 Display and control elements......................25 4.1 General notes..........................26 4.2 Description of indicators and control elements............... 27 Operation............................. 29 5.1 General............................30 5.2 Tests before taking into operation.................... 31 5.3 Folding down the steering rod....................
  • Page 4 Table of contents 6.11.1 Tightening the screws......................70 6.11.2 Engine conservation ........................ 70 Trouble shooting..........................73 7.1 General notes..........................74 7.2 Changing the injection pump..................... 75 7.3 Engine problems......................... 80 Disposal............................... 83 8.1 Final shut-down of machine....................... 84 BPR 25/40 D - BPR 25/50 D...

  • Page 5: Foreword

    Foreword Foreword BPR 25/40 D - BPR 25/50 D...
  • Page 6 Foreword 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.
  • Page 7 Foreword 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.
  • Page 8 Foreword Fig. 2 Fig. 3 BPR 25/40 D - BPR 25/50 D...

  • Page 9: Technical Data

    Technical data Technical data BPR 25/40 D - BPR 25/50 D...
  • Page 10 Technical data Fig. 4 BPR 25/40 D Dimensions in mm 1220 1460 Dimensions in inch 29.1 34.3 48.0 57.5 25.6 15.7 BPR 25/40 D Weights Operating weight (CECE) 140 kg 309 lbs Basic weight 137 kg 302 lbs Water sprinkling system (Optional equipment) + 13 kg + 29 lbs Transport wheels (Optional equipment)
  • Page 11 Technical data BPR 25/40 D Drive Engine manufacturer Hatz Hatz Type 1B20 1B20 Cooling Number of cylinders Rated power ISO 3046 IFN 3.1 KW 4.2 hp Rated speed 3000 rpm 3000 min Starting device Recoil starter Recoil starter Drive system mechanical mechanical Exciter system...
  • Page 12 Technical data Fig. 5 BPR 25/50 D Dimensions in mm 1220 1460 Dimensions in inch 29.1 34.3 48.0 57.5 25.6 19.7 BPR 25/50 D Weights Operating weight (CECE) 145 kg 320 lbs Basic weight 142 kg 313 lbs Water sprinkling system (Optional equipment) + 13 kg + 29 lbs Paving plate (Optional equipment)
  • Page 13 Technical data BPR 25/50 D Drive Engine manufacturer Hatz Hatz Type 1B20 1B20 Cooling Number of cylinders Rated power ISO 3046 IFN 3.1 KW 4.2 hp Rated speed 3000 rpm 3000 min Starting device Recoil starter Recoil starter Drive system mechanical mechanical Exciter system...
  • Page 14 Technical data BPR 25/40 D: L = 93 dB(A) with tube frame, determined acc. to ISO 11204 and EN 500 BPR 25/50 D: L = 95 dB(A) with tube frame, determined acc. to ISO 11204 and EN 500 Guaranteed sound power level: BPR 25/40 D: L = 108 dB(A) with tube frame, determined acc.

  • Page 15: Safety Regulations

    Safety regulations Safety regulations BPR 25/40 D - BPR 25/50 D...
  • Page 16 Safety regulations 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: it is used for purposes other than the ones it is intended for, it is operated by untrained personnel, it is changed or converted in an unprofessional way, the safety instructions are not observed.
  • Page 17 Safety regulations Remaining dangers, remaining Despite careful work and compliance with standards and regula- risks 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.
  • Page 18 Safety regulations Notes on safety in the operating and maintenance instructions 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.
  • Page 19 Safety regulations 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: the machine shows any obvious faults all guards and safety elements are in place the controls are fully functional the machine is free of oily and combustible material...
  • Page 20 Safety regulations 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.
  • Page 21 Safety regulations Mark defective machines by attaching a warning note to the steering handle. Welding Before starting welding work on the machine disconnect the battery and cover the fuel tank with insulating material. Safety stickers on the machine Keep safety stickers in good condition and legible and follow their meaning.
  • Page 22 Safety regulations Fig. 6: Stickers and decals Information sticker - Ultra-low sulphur fuel Information sticker - Lashing point Information sticker - Lifting point Information sticker - Throttle lever Information sticker - Travel lever Information sticker - Guaranteed sound capacity level Maintenance sticker Brief operating instructions BPR 25/40 D - BPR 25/50 D...
  • Page 23 Safety regulations Maintenance sticker "Engine" Fig. 7 BPR 25/40 D - BPR 25/50 D...

  • Page 24: Display And Control Elements

    Display and control elements Display and control elements BPR 25/40 D - BPR 25/50 D...

  • Page 25: General Notes

    Display and control elements 4.1 General notes If you are not yet familiar with the control and display elements on this machine you should read this section thoroughly before starting any operation on the machine. Here all functions are described in detail. The section "Operation"...

  • Page 26: Description Of Indicators And Control Elements

    Display and control elements 4.2 Description of indicators and control elements 1 - Steering rod height adjustment 2 - Steering rod lock The steering rod lock is released by pulling out the locking bolt. Fig. 8 3 - Travel lever 4 - Handle 5 - Throttle lever Fig.

  • Page 27: Operation

    Operation Operation BPR 25/40 D - BPR 25/50 D...

  • Page 28: General

    Operation 5.1 General If you are not yet acquainted with the controls and indicating elements on this machine you should thoroughly read chapter "Indicators and control elements" before starting work. All indicators and control elements are described in detail in this chapter.

  • Page 29: Tests Before Taking Into Operation

    Operation 5.2 Tests before taking into operation The following inspections must be carried out before each working day or before a longer working period. WARNING! Danger of accident! Please observe strictly the safety regulations in the corresponding section of this instruction manual! Park the machine on ground as level as possible.

  • Page 30: Folding Down The Steering Rod

    Operation 5.3 Folding down the steering rod Pull out and turn the locking bolt (2) Ä Fig. 12. Fold down the steering rod, so that it can swing freely. Adjust the steering rod with the height adjustment (1) to the height of your body.

  • Page 31: Starting The Engine

    Operation 5.4 Starting the engine WARNING! Exhaust gases are highly dangerous! Always ensure an adequate supply of fresh air when starting and operating in closed rooms and trenches! WARNING! Danger of accident! Before starting make sure that there are no persons in the danger area of engine or machine and that all safety installations are in place.
  • Page 32 Operation Shift the travel lever Ä Fig. 14 to position "0". Fig. 14 Slightly pull the starter handle Ä Fig. 15 two times, until resistance can be felt (compression pressure), and return it to initial position. Fig. 15 Pull the starter handle Ä Fig. 16 quickly and powerful as far out as possible.

  • Page 33: Work/Operation

    Operation Fig. 17 5.5 Work/operation WARNING! Danger of accident! 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. Always keep an eye on a running machine.
  • Page 34 Operation Drive backwards WARNING! Danger of accident! As a measure to avoid injury the machine must only be guided from the side by the steering handle Pull the travel lever Ä Fig. 20 back, until the vibratory plate has reached the desired speed in reverse. The machines vibrates backwards with a speed which corresponds to the travel lever position.

  • Page 35: Switching The Motor Off

    Operation 5.6 Switching the motor off NOTICE! Do not shut the engine down all of the sudden from full speed, but let it idle for a while for temperature equali- zation. Shift the throttle lever to position "MIN" Ä Fig. 23 and let the engine run with idle speed for a short while.

  • Page 36: Assembling The Transport Wheels

    Operation Optional equipment 5.7 Assembling the transport wheels WARNING! Danger of injury! By the machine tipping over when assembling or dis- assembling the transport wheels NOTICE! Shut down the engine. Adjust the steering rod upright and lock it. Engage the locking pin securely.
  • Page 37 Operation In the bracket secure the transport wheel with the spring cotter Ä Fig. 28. Insert the second wheel into the bracket on the opposite side of the base plate and secure it with the spring cotter. Fig. 28 Unlock the steering rod and fold it down Ä Fig. 29. Lock the steering rod in working position.

  • Page 38: Loading/Transport

    Operation 5.8 Loading/transport WARNING! Danger of accident! Life hazard! Make sure that persons are not endangered by the machine tipping or sliding off. Use only safe lifting gear of sufficient load bearing capacity Minimum lifting capacity of lifting gear: see operating weight in chapter "Technical Data".
  • Page 39 Operation Always attach the lifting tackle to the lifting eye to load the vibratory plate Ä Fig. 31 on a transport vehicle. Lash the vibratory plate down to the transport vehicle, so that it is secured against rolling, sliding and turning over. Fasten the lashing tackle at the marked lashing points.

  • Page 40: Maintenance

    Maintenance Maintenance BPR 25/40 D - BPR 25/50 D...

  • Page 41: General Notes On Maintenance

    Maintenance 6.1 General notes on maintenance When performing maintenance work ensure strict compliance with the respective safety instructions and particularly the safety regula- tions mentioned in the corresponding section of these operating and maintenance instructions. Thorough maintenance of the machine guarantees far longer safe functioning of the machine and prolongs the lifetime of important components.
  • Page 42 Maintenance If your engine has to work permanently in "thin air" (at higher alti- tudes) and under full load, you should consult our customer service or the customer service of the engine manufacturer. Frequent causes of faults Operating errors Incorrect, inadequate maintenance If you cannot locate the cause of a fault or rectify it yourself by fol- lowing the trouble shooting chart, you should contact our customer service department.

  • Page 43: Fuels And Lubricants

    Maintenance 6.2 Fuels and lubricants Engine oil Oil viscosity Choose the oil viscosity in dependence on the ambient tempera- ture at the operating location of the engine (see diagram). Occasional falling short of the temperature limit (e.g. use of SAE 15W/40 down to -15 °C (+5 °F)) may effect the cold starting ability of the engine, but will not cause any engine damage.

  • Page 44: Table Of Fuels And Lubricants

    Maintenance 6.3 Table of fuels and lubricants Assembly Fuel or lubricant Quantity approx. Summer Winter Attention Observe the level marks Motor - Engine oil API CD/CE/CF/CF-4/CG-4 approx. 0.9 l (0.24 gal SAE 5W/30 (-5°C to +35°C) (+23 °F to +95 °F) SAE 5W/40 (-5 °C bis +45 °C) (+23 °F bis +113 °F) SAE 10W/30 (-5 °C to +35 °C) (+23 °F to +95 °F) SAE 10W/40 (-5 °C to +45 °C) (+23 °F to +113 °F)

  • Page 45: Running-In Instructions

    Maintenance 6.4 Running-in instructions The following maintenance work must be performed when running in new machines or overhauled engines: NOTICE! During the running-in period, up to approx. 200 oper- ating hours, check the engine oil level twice every day. Depending on the load the engine is subjected to, the oil consumption will drop to the normal level after approx.

  • Page 46: Maintenance Table

    Maintenance 6.5 Maintenance table With all maintenance intervals perform also the work for shorter preceding service intervals. daily weekly monthly half- annu- Maintenance work Comment annu- ally required ally 6.6.1 Clean the machine 6.6.2 Checking the engine oil Dipstick mark level 6.6.3 Check the fuel level...
  • Page 47 Maintenance daily weekly monthly half- annu- Maintenance work Comment annu- ally required ally 6.10.6 Check the hydraulic oil level 6.10.7 Check the rubber buffers 6.11.1 Tighten all bolted connec- tions 6.11.2 Engine conservation BPR 25/40 D - BPR 25/50 D...

  • Page 48: Maintenance Every Day

    Maintenance 6.6 Maintenance every day 6.6.1 Clean the machine NOTICE! Perform cleaning work only after the engine has cooled down and with the engine stopped. Dirty operating conditions, particularly lubrication oil and fuel deposits on the cooling fins of the engine and the cooling air intake opening have an adverse effect on the cooling of the engine.

  • Page 49: Check The Fuel Level

    Maintenance Fig. 34 NOTICE! Operation with an oil level below the min mark or above the max mark can cause engine damage. The oil level should reach the upper mark on the dipstick. If the oil level is too low top up oil immediately. Check the seal on the dipstick, replace if necessary.

  • Page 50: Filling The Water Tank

    Maintenance Fig. 35 Fill in fuel through a funnel with screen. Close the tank again. Optional equipment 6.6.4 Filling the water tank NOTICE! Dirty or contaminated water can block the nozzles! Fill only with clean water. If there is a risk of frost the water sprinkler system must be emptied or filled with an anti-freeze mixture.

  • Page 51: Weekly Maintenance

    Maintenance 6.7 Weekly maintenance 6.7.1 Check, clean the water separator WARNING! Fire hazard! When working on the fuel system do not use open fire, do not smoke. Do not spill any fuel. Shut down the engine. WARNING! Health hazard! Do not inhale any fuel fumes. ENVIRONMENT! Any fuel must be caught and disposed of in an envi- ronmentally friendly manner.

  • Page 52: Maintenance Every Month

    Maintenance 6.8 Maintenance every month 6.8.1 Check, clean the air filter, replace if necessary NOTICE! Do not use gasoline or hot fluids to clean the air filter. Do not continue to use a damaged air filter. If in doubt use a new air filter. Replace the air filter after five times cleaning, but at the latest after half a year.

  • Page 53: Clean The Cooling Fins And The Cooling Air Intake Openings

    Maintenance WARNING! Danger of injury! Always wear protective clothes (goggles, gloves) when working with compressed air. Blow the air filter Ä Fig. 39 out from inside to outside with dry compressed air (max. 5 bar (73 psi)). Check the air filter for damage, replace if necessary. Fig.
  • Page 54 Maintenance Loosen dried on dirt with a suitable brush Ä Fig. 40 from all cooling fins and cooling air intake openings and blow it off with compressed air . WARNING! Fire hazard! Do not use any inflammable solvents. Fig. 40 NOTICE! Do not guide the water jet directly into the cooling air openings of the recoil starter, into the air filter and on...

  • Page 55: Maintenance Every 6 Months

    Maintenance 6.9 Maintenance every 6 months 6.9.1 Check the oil level in the exciter housing NOTICE! Park the machine on level ground. For quality and quantity of oil refer to the ”table of fuels and lubricants”. Clean the area around breather and drain plug. Unscrew the bleeding screw (1) Ä...

  • Page 56: Checking, Adjusting The Valve Clearance

    Maintenance Check condition and tightness of V-belt Ä Fig. 43. Compression measurement approx. 5 - 15 mm (0.2 - 0.6 in) NOTICE! Replace a damaged V-belt. Fig. 43 The V-belt cannot be tightened manually. Always replace the V-belt, if the compression measurement is exceeded.

  • Page 57: Maintenance Every Year

    Maintenance 6.10 Maintenance every year 6.10.1 Change the engine oil WARNING! Danger of scalding when draining off hot engine oil. NOTICE! Park the machine on level ground. Drain the engine oil only when the engine is warm. Change the engine oil at the latest after 250 operating hours.

  • Page 58: Clean The Engine Oil Filter

    Maintenance 6.10.2 Clean the engine oil filter WARNING! Danger of scalding! When draining off hot oil. By hot oil when unscrewing the engine oil filter. NOTICE! Remove and clean the engine oil filter only after draining off the engine oil. Park the machine on level ground so that the engine is in horizontal position.

  • Page 59: Replace The Fuel Filter

    Maintenance 6.10.3 Replace the fuel filter WARNING! Fire hazard! When working on the fuel system do not use open fire, do not smoke, do not spill any fuel. Do not refuel in closed rooms. Shut down the engine. WARNING! Health hazard! Do not inhale any fuel fumes.

  • Page 60: Replacing The Starter Rope

    Maintenance Push the new fuel filter into the holder. Push the fuel hose onto the new fuel filter. NOTICE! Do not insert the hose into the tank without a filter. Danger of contamination! Insert the holder with the fuel filter into the tank and attach the quick lock.

  • Page 61: Change The Oil In The Exciter Shaft Housing

    Maintenance Thread in the new starter rope and fix it with knots on both ends Ä Fig. 50. NOTICE! Incorrect sense of rotation will damage the spring ends of the recoil spring. Fig. 50 Pre-tension the coil by approx. 4 rotations in direction of arrow.
  • Page 62 Maintenance Tilt the machine to the side with the oil drain plug and support it safely. Unscrew the bleeding screw (1) Ä Fig. 53. Fig. 53 Unscrew oil drain plug (2), drain and catch running out old oil. Tilt the machine to the opposite side and secure it properly. Fill in fresh engine oil through the drain opening Ä...

  • Page 63: Check The Hydraulic Oil Level

    Maintenance 6.10.6 Check the hydraulic oil level NOTICE! Park the machine horizontally. For quality of oil refer to the "table of fuels and lubri- cants". ENVIRONMENT! Catch running out old oil, do not let it seep into the ground and dispose off environmentally. Adjust the steering rod with height adjustment Ä...
  • Page 64 Maintenance Filling up hydraulic oil Shift the travel lever forward against the stop Ä Fig. 59. Fig. 59 Lay a cloth down before loosening the venting screw. Fig. 60 Slacken the bleeding screw Ä Fig. 60. Wait until all air has escaped, then tighten the bleeding screw.

  • Page 65: Check The Rubber Buffers

    Maintenance Screw in and tighten the plug Ä Fig. 62. Fig. 62 6.10.7 Check the rubber buffers Check all rubber buffers Ä Fig. 63 for tight fit, cracks and damage and replace immediately if damaged. Fig. 63 BPR 25/40 D - BPR 25/50 D...

  • Page 66: As Required

    Maintenance 6.11 As required 6.11.1 Tightening the screws Self locking nuts must always be replaced by new ones after they have been unscrewed. *Strength classes for screws with untreated, non-lubricated sur- faces. The quality designations are stamped on the screw heads. 8.8 = 8 G 10.9 = 10 K 12.9 = 12 K...
  • Page 67 Maintenance Depending on weather conditions these conserving measures will provide protection for approx. 6 - 12 months. The conserving oil must be replaced by engine oil according to the API- (MIL) classification before taking the machine into service. Anti-corrosion oils are those that comply with the MIL- L-21260 or TL 9150-037/2 resp.

  • Page 68: Trouble Shooting

    Trouble shooting Trouble shooting BPR 25/40 D - BPR 25/50 D...

  • Page 69: General Notes

    Trouble shooting 7.1 General notes Please observe strictly the safety regulations in the corre- sponding section of these operating and maintenance instruc- tions. Malfunctions are frequently caused by incorrect operation of the machine or insufficient maintenance. Whenever a fault occurs you should therefore thoroughly read these instruction on correct oper- ation and maintenance.

  • Page 70: Changing The Injection Pump

    Trouble shooting 7.2 Changing the injection pump WARNING! Fire hazard! When working on the fuel system do not use open fire, do not smoke, do not spill any fuel. WARNING! Health hazard! Do not inhale any fuel fumes. NOTICE! Ensure strict cleanliness to keep dirt out of the fuel lines.
  • Page 71 Trouble shooting Fig. 66 Pull the fuel hose off the leak oil socket on the pump Ä Fig. 67. Place a suitable container under the hose socket to catch running out fuel. Fig. 67 Remove the injection nozzles Ä Fig. 68 completely with the nozzle base.
  • Page 72 Trouble shooting Remove the cover plate Ä Fig. 71. Fig. 71 Unhook pump piston Ä Fig. 72 from the rokker arm to the injection pump. Fig. 72 Unscrew the pressure valve holder (1) Ä Fig. 73 with O-ring (2). Remove filling piece (3), spring (4), seal ring (5) and pressure valve (6).
  • Page 73 Trouble shooting Press the pump element Ä Fig. 74 through the lateral opening up with your fingers and lift it out with a magnetic rod. Remove shim (8) Ä Fig. 73. The control bushing (13) is located by the bracket (14) and does not need to be removed.
  • Page 74 Trouble shooting Fig. 76 When inserting the element group make sure that the plunger flag also is inserted through the control sleeve (is achieved by turning the regulating sleeve slightly to and fro) and that the eccentric peg (11) also engages in the groove of the ele- ment cylinder Ä...

  • Page 75: Engine Problems

    Trouble shooting 7.3 Engine problems Fault description Cause Remedy No or poor starting of engine Fuel tank empty Fill in fuel No fuel at the injection pump, Check the fuel supply supply not correct, fuel filter Check the fuel supply line to the clogged (can be notice if no fuel engine runs out when the fuel supply...
  • Page 76 Trouble shooting Fault Possible cause Remedy Air in the fuel system Check the fuel system for air Check the bleeding valve Engine runs with high speed, but Centrifugal clutch defective Change the centrifugal clutch no vibration V-belt Check tension, replace if neces- sary BPR 25/40 D - BPR 25/50 D...

  • Page 77: Disposal

    Disposal Disposal BPR 25/40 D - BPR 25/50 D...

  • Page 78: Final Shut-Down Of Machine

    Disposal 8.1 Final shut-down of machine If the machine can no longer be used and needs to be finally shut down you must carry out the following work and have the machine disassembled by an officially recognized specialist workshop. ENVIRONMENT! Catch all fuels and lubricants, do not let them seep into the ground and dispose of in compliance with legal regulations.
  • Page 79 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/ choose one of the options to help get the right parts and equipment you are looking for.

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Bomag bpr 25/50 d

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