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Fayat BOMAG BPR 50/55 D Operating Instruction

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Operating Instruction
Maintenance Instruction
Original Operating Instructions
BPR 50/55 D
S/N 101 695 29 1001>
Reversible vibratory plate
www.discount-equipment.com
008 204 51 EN
© 07/2019

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Summary of Contents for Fayat BOMAG BPR 50/55 D

  • Page 1 Operating Instruction Maintenance Instruction Original Operating Instructions BPR 50/55 D S/N 101 695 29 1001> Reversible vibratory plate www.discount-equipment.com 008 204 51 EN © 07/2019...
  • 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 WARNING: Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Always start and operate the engine in a well-ventilated area. If in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system.

  • Page 4: Table Of Contents

    Table of contents Table of contents Introduction............................7 1.1 Foreword............................8 1.2 Machine type plate and engine type plate................10 Technical data............................11 2.1 Noise and vibration data......................14 2.1.1 Noise data..........................14 2.1.2 Vibration data..........................14 Concerning your safety........................15 3.1 Basic prerequisites........................
  • Page 5 Table of contents 3.9.3 Maintenance work on electric components and battery............. 33 3.9.4 Cleaning work..........................33 3.9.5 Measures for longer shut-down periods..................34 3.9.6 After maintenance work......................34 3.10 Repair............................35 3.11 Signage............................36 3.12 Safety Components........................40 Indicators and control elements......................41 Checks prior to start up........................
  • Page 6 Table of contents 8.9.3 Changing the engine oil and cleaning the oil filter..............79 8.9.4 Replacing the fuel filter....................... 81 8.9.5 Replacing the air filter........................ 82 8.9.6 Changing the oil in the exciter housing..................83 8.9.7 Checking the hydraulic oil level....................85 8.9.8 Replacing the starter rope......................
  • Page 7 Table of contents BPR 50/55 D...

  • Page 8: Introduction

    Introduction Introduction BPR 50/55 D...

  • Page 9: Foreword

    Introduction – Foreword 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.
  • Page 10 Introduction – Foreword 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.

  • Page 11: Machine Type Plate And Engine Type Plate

    Introduction – Machine type plate and engine type plate 1.2 Machine type plate and engine type plate Please enter here: Machine type (1): Made by Designation Type Serial number (2): Nominal Power Operating Mass Year of Construction Serial-No. Patent Protection 56154 Boppard;GERMANY Made in Germany B-DEC-0270...

  • Page 12: Technical Data

    Technical data Technical data BPR 50/55 D...
  • Page 13 Technical data Dimensions B-692-0239 Fig. 3 Dimensions standard 1350 1700 (31.1) (38.6) (53.1) (66.9) (35.4) (17.7) (21.7) (29.5) Dimensions with "STONEGUARD" (special base plate for paving stones) 1360 1735 (31.5) (39) (53.5) (68.3) (38.1) (26.8) Dimensions in millimetres (Dimensions in inch) Weights Operating weight (CECE) (W) (860)
  • Page 14 Technical data Weights “STONEGUARD” (special base plate for paving stones) (optional + 35 equipment) (+ 77) (lbs) ECONOMIZER (optional equipment) (+ 11) (lbs) Travel characteristics Max. working speed m/min (92) (ft/min) Max. working speed with “STONEGUARD” m/min (82) (ft/min) Max. gradeability (depending on soil) Drive Engine manufacturer Hatz...

  • Page 15: Noise And Vibration Data

    Technical data – Noise and vibration data 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: EU Machine Directive edition 2006/42/EU Noise Emission Directive 2000/14/EU, Noise Protection Direc- tive 2003/10/EU Vibration Protection Directive 2002/44/EU...

  • Page 16: Concerning Your Safety

    Concerning your safety Concerning your safety BPR 50/55 D...

  • Page 17: Basic Prerequisites

    Concerning your safety – Basic prerequisites 3.1 Basic prerequisites 3.1.1 General This machine has been built in compliance with the latest technical standard and complies with the applicable regulations and tech- nical 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,...

  • Page 18: Personal Protective Equipment

    Concerning your safety – Basic prerequisites 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.

  • Page 19: Intended Use

    Concerning your safety – Basic prerequisites Safety goggles To protect the eyes against airborne particles and squirting fluids. Face protection To protect the face against airborne particles and squirting fluids. Hard hat To protect the head against falling parts and to protect against injuries.

  • Page 20: Estimated Service Life Of The Machine

    Concerning your safety – Basic prerequisites Examples for improper use are: dragging the machine along as a measure of transportation throwing the machine off the transport vehicle attaching an additional weight to the machine It is not permitted to stand on the machine while working. Lifting tackle must be removed before starting work.

  • Page 21: Definition Of Responsible Persons

    Concerning your safety – Definition of responsible persons 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.
  • Page 22 Concerning your safety – Definition of responsible persons have made himself familiar with the operation of the machine, be physically and psychologically able to drive and operate the machine. Persons under the influence of alcohol, medication or drugs are not allowed to operate, service or repair the machine.

  • Page 23: Basic Safety Regulations For Safe Operation

    Concerning your safety – Basic safety regulations for safe operation 3.3 Basic safety regulations for safe operation 3.3.1 Remaining dangers, remaining risks Despite careful work and compliance with standards and regula- tions it cannot be ruled out that further dangers may arise when working with and handling the machine.

  • Page 24: Handling Fuels And Lubricants

    Concerning your safety – Handling fuels and lubricants 3.4 Handling fuels and lubricants 3.4.1 Preliminary remarks The operating company must ensure that all professional users have read and follow the corresponding safety data sheets for the individual fuels and lubricants. Safety data sheets provide valuable information about the following characteristics: name of substance...

  • Page 25: Safety Regulations And Environmental Protection Regulations For Handling Diesel Fuel

    Concerning your safety – Handling fuels and lubricants 3.4.2 Safety regulations and environmental protection regulations for handling diesel fuel WARNING! Danger of burning by ignited diesel fuel! – Do not allow diesel fuel to come into contact with hot components. –...

  • Page 26: Safety Regulations And Environmental Protection Regulations For Handling Oil

    Concerning your safety – Handling fuels and lubricants 3.4.3 Safety regulations and environmental protection regulations for handling oil WARNING! Danger of burning by ignited oil! – Do not allow oil to come into contact with hot components. – Smoking and open fire is prohibited! –...

  • Page 27: Safety Regulations And Environmental Protection Regulations For Handling Hydraulic Oil

    Concerning your safety – Handling fuels and lubricants 3.4.4 Safety regulations and environmental protection regulations for handling hydraulic oil WARNING! Danger of injury caused by escaping pressure fluid! – Always depressurize the hydraulic system before starting work in the hydraulic system. –...

  • Page 28: Safety Regulations And Environmental Protection Regulations For Handling Battery Acid

    Concerning your safety – Handling fuels and lubricants 3.4.5 Safety regulations and environmental protection regulations for handling bat- tery acid WARNING! Danger of cauterization with acid! – Wear your personal protective equipment (pro- tective gloves, protective clothing, goggles). – Do not allow clothes, skin or eyes to come into contact with acid.

  • Page 29: Safety Regulations And Environmental Protection Regulations When Handling Lubrication Grease

    Concerning your safety – Handling fuels and lubricants 3.4.6 Safety regulations and environmental protection regulations when handling lubrication grease CAUTION! Health hazard caused by contact with lubrica- tion grease! – Wear your personal protective equipment (pro- tective gloves, safety goggles, protective clothing).

  • Page 30: Loading/Transporting The Machine

    Concerning your safety – Loading/transporting the machine 3.5 Loading/transporting the machine Make sure that persons are not endangered by the machine tipping or sliding off. Do not use damaged or in any other way impaired lashing points. Always use appropriate lifting and lashing means on the lifting and lashing points.

  • Page 31: Start-Up Procedure

    Concerning your safety – Start-up procedure 3.6 Start-up procedure 3.6.1 Prior to starting up Use only machines which are serviced at regular intervals. Become acquainted with the equipment, the indicators and control elements, the working principle of the machine and the working area.

  • Page 32: Operation

    Concerning your safety – Operation 3.7 Operation 3.7.1 Persons in the danger area Before taking up work, also after breaks, you should always con- vince yourself that the danger zone is free of persons or obstruc- tions. Give warning signals, if necessary. Stop work immediately if per- sons remain in the danger zone, despite the warning.

  • Page 33: Refuelling

    Concerning your safety – Refuelling 3.8 Refuelling Do not inhale any fuel fumes. Refuel only with the engine shut down. Do not refuel in closed rooms. No open fire, do not smoke. Ultra-low sulphur diesel fuel poses a higher risk of combustion caused by the static charging than diesel fuel with a higher sulphur content.

  • Page 34: Maintenance Work

    Concerning your safety – Maintenance work 3.9 Maintenance work 3.9.1 Preliminary remarks Always carry out the prescribed maintenance work and mainte- nance measures on time in order to maintain the safety, opera- tional readiness and long service life of the machine. The machine must only be serviced by qualified personnel author- ised by the operating company.

  • Page 35: Measures For Longer Shut-Down Periods

    Concerning your safety – Maintenance work 3.9.5 Measures for longer shut-down periods If the machine is taken out of operation for a longer period of time, various conditions must be met and maintenance work must be carried out both before and after shut-down Ä...

  • Page 36: Repair

    Concerning your safety – Repair 3.10 Repair Identify a defect machine with a warning sign. Only operate the machine after it has been repaired. When replacing safety relevant components, only original spare parts must be used. Repairs must only be performed by an expert/qualified person. When performing welding work on the machine you should cover the fuel tank with insulating material.

  • Page 37: Signage

    Concerning your safety – Signage 3.11 Signage Keep stickers and signage in good and legible condition and comply with their meaning. Replace damaged and illegible stickers or signage immediately. START 1-2 MINUTEN START OPERATION STOP STOP STOP 1-2 MINUTEN DIESEL ...
  • Page 38 Concerning your safety – Signage Warning sticker - Follow operating instructions Fig. 10 Warning sticker - Danger of injury due to defective starter rope Before use, check the starter rope for chafing. Do not use a defective starter rope. Fig. 11 Information sticker - Lashing point Fig.
  • Page 39 Concerning your safety – Signage Information sticker - Guaranteed sound capacity level Fig. 14 Operation sticker - Travel lever Fig. 15 Operation sticker - Throttle lever Fig. 16 Instruction sticker - Wear ear protection / brief operating instruc- tions START 1-2 MINUTEN START OPERATION...
  • Page 40 Concerning your safety – Signage Maintenance sticker DIESEL  before taking into operation weekly vor Inbetriebnahme wöchentlich avant la mise en service hebdomadairement anterior a la puesta en servicio cada semana annual / 250 h twice annual jährlich / 250 h halbjährlich tous les 6 mois annuellement / 250 h...

  • Page 41: Safety Components

    Concerning your safety – Safety Components 3.12 Safety Components B-695-0036 Fig. 20 Protection hood Heat protection cover Belt guard BPR 50/55 D...

  • Page 42: Indicators And Control Elements

    Indicators and control elements Indicators and control elements BPR 50/55 D...
  • Page 43 Indicators and control elements B-692-0238 Fig. 21 Economizer display (optional equipment) Recoil starter Operating hour meter Starter switch Handle Throttle lever Locking pawl lever Steering rod height adjustment BPR 50/55 D...

  • Page 44: Checks Prior To Start Up

    Checks prior to start up Checks prior to start up BPR 50/55 D...

  • Page 45: Notes On Safety

    Checks prior to start up – Notes on safety 5.1 Notes on safety If the following tests reveal damages or other defects, the machine must not be operated, until these deficiencies have been corrected. Do not operate the machine with defective indicators and control elements.

  • Page 46: Visual Inspections And Function Tests

    Checks prior to start up – Visual inspections and function tests 5.2 Visual inspections and function tests Check fuel tank and lines for condition and leaks. Check bolted connections for tight fit. Check machine for contamination and damage. Check the hydraulic oil cooler for dirt. Check starter rope for chafing.

  • Page 47: Checking The Engine Oil Level

    Checks prior to start up – Checking the engine oil level 5.3 Checking the engine oil level NOTICE! Danger of engine damage! – +Use only oil of the permitted specification Ä Chapter 8.3.1 ‘Engine oil’ on page 65. B-SYM-1068 Fig. 22 Protective equipment: Working clothes Safety shoes...

  • Page 48: Checking The Fuel Level; Topping Up Fuel

    Checks prior to start up – Checking the fuel level; topping up fuel 5.4 Checking the fuel level; topping up fuel NOTICE! Danger of engine damage! – Monitor the entire refuelling process. – Contaminated fuel can cause malfunction or B-SYM-1069 even damage of the engine.

  • Page 49: Checking The Rubber Buffers

    Checks prior to start up – Checking the rubber buffers 5.5 Checking the rubber buffers B-SYM-1073 Fig. 26 Protective equipment: Working clothes Safety shoes Protective gloves Ä Chapter 6.4 ‘Parking the machine Park the machine safely in secured condition’ on page 55. Allow the engine to cool down.

  • Page 50: Operation

    Operation Operation BPR 50/55 D...

  • Page 51: Folding Down The Steering Rod And Adjusting It

    Operation – Folding down the steering rod and adjusting it 6.1 Folding down the steering rod and adjusting it Pull the locking pawl lever (2) and fold down the steering rod. Do not click the locking pawl lever into posi- tion again.

  • Page 52: Starting The Engine

    Operation – Starting the engine 6.2 Starting the engine Exhaust fumes contain toxic substances and can damage your health, cause unconsciousness or even death. WARNING! Danger of poisoning by exhaust gases! – Do not inhale exhaust gases. – Avoid operation in closed or partly closed rooms, or ensure adequate ventilation when working in trenches.
  • Page 53 Operation – Starting the engine Turn the ignition key to position “I”. ð The warning buzzer sounds. B-ELE-0070 Fig. 31 The starter switch is designed with a re-start lock. The ignition key must first be turned back to position “0” before a new starting attempt can be made.

  • Page 54: Operation

    Operation – Operation 6.3 Operation Operate the machine only with the steering rod folded down and Ä Chapter 6.1 ‘Folding down the steering rod adjusted to height and adjusting it’ on page 50. Use only the steering rod to steer the machine. Guide the machine so that your hands do not hit against solid objects.
  • Page 55 Operation – Operation CAUTION! Danger of injury caused by the crushing of body parts! – When reversing, steer the machine from the side using the steering handle. Pull the handle back. ð The machines vibrates backwards with a speed which B-695-0058 corresponds with the handle position.

  • Page 56: Parking The Machine In Secured Condition

    Operation – Parking the machine in secured condition 6.4 Parking the machine in secured condition Park the machine on level and firm ground. Set the throttle lever to “MIN” position (idle speed). ð Vibration is shut down. B-695-0060 Fig. 39 NOTICE! Danger of engine damage! –...

  • Page 57: Economizer

    Operation – ECONOMIZER 6.5 ECONOMIZER The ECONOMIZER informs the driver about the compaction status of the road subbase and enables the detection and selected re- compaction of weak spots. An acceleration sensor on the base plate measures the reaction of the subsoil to the base plate of the machine.

  • Page 58: Loading/Transporting The Machine

    Loading/transporting the machine Loading/transporting the machine BPR 50/55 D...

  • Page 59: Loading The Machine

    Loading/transporting the machine – Loading the machine 7.1 Loading the machine Loads may only be attached and hoisted by an expert/qualified person. Do not use lifting points that are damaged or impaired in any other way. Only use lifting and lashing tackle with sufficient load bearing capacity for the weight to be loaded.
  • Page 60 Loading/transporting the machine – Loading the machine Attach the lifting tackle to the designated lifting eye (1). DANGER! Danger to life caused by suspended loads! – Do not step or stand under suspended loads. Lift the machine carefully and set down again at the intended B-692-0246 location.

  • Page 61: Lashing The Machine To The Transport Vehicle

    Loading/transporting the machine – Lashing the machine to the transport vehicle 7.2 Lashing the machine to the transport vehicle Do not use lifting points that are damaged or impaired in any other way. Always use appropriate lifting and lashing tackle at the lifting and lifting points.

  • Page 62: Maintenance

    Maintenance Maintenance BPR 50/55 D...

  • Page 63: Preliminary Remarks And Safety Notes

    Maintenance – Preliminary remarks and safety notes 8.1 Preliminary remarks and safety notes DANGER! Danger to life caused by an operationally unsafe machine! – The machine must only be serviced by quali- fied and authorized personnel. – Follow the safety regulations for maintenance Ä...

  • Page 64: Preparations / Concluding Work

    Maintenance – Preparations / concluding work 8.2 Preparations / concluding work Certain maintenance tasks require preparations and concluding activities. This includes e.g. opening and closing maintenance flaps and maintenance doors as well as securing certain components. After this work close all maintenance flaps and doors again and return all components to their operating condition.
  • Page 65 Maintenance – Preparations / concluding work 8.2.1.2 Closing the protection hood To fasten the protection hood, use only the prescribed original screws. Always screw in and tighten all screws and their washers. Protective equipment: Working clothes Protective gloves Loosen the screw (1) on both sides. Close the protection hood.

  • Page 66: Fuels And Lubricants

    Maintenance – Fuels and lubricants 8.3 Fuels and lubricants 8.3.1 Engine oil 8.3.1.1 Oil quality The following engine oil specifications are permitted: API CF/CH-4 or higher quality ACEA B3/E4 or higher quality Avoid mixing engine oils. 8.3.1.2 Oil viscosity Since engine oil changes its viscosity with the temperature, the ambient temperature at the operating location of the engine is of utmost importance when choosing the viscosity class (SAE-class).

  • Page 67: Oil For Exciter Shaft Housing

    Maintenance – Fuels and lubricants 8.3.2.2 Winter fuel For winter operation use only winter diesel fuel, to avoid clogging because of paraffin separation. At very low temperatures disturbing paraffin separation can also be expected when using winter diesel fuel. Diesel fuels suitable for temperatures down to -44 °C (-47 °F) are available for Arctic climates.
  • Page 68 Maintenance – Fuels and lubricants The viscosity index must be at least 150 (observe information of manufacturer). BPR 50/55 D...

  • Page 69: List Of Fuels And Lubricants

    Maintenance – List of fuels and lubricants 8.4 List of fuels and lubricants Assembly group Fuel or lubricant Filling quantity Summer Winter Observe the level mark! Engine oil SAE 10W-40 1.5 l Specification: Ä Chapter 8.3.1 ‘Engine oil’ on page 65 (0.4 gal us) SAE 15W-40 SAE 10W-30...

  • Page 70: Running-In Instructions

    Maintenance – Running-in instructions 8.5 Running-in instructions 8.5.1 General The following maintenance work must be performed when running in new machines or overhauled engines. 8.5.2 After 25 operating hours Change the engine oil. Check the valve clearance, adjust if necessary Ä...

  • Page 71: Maintenance Table

    Maintenance – Maintenance Table 8.6 Maintenance Table Maintenance works Page Weekly 8.7.1 Checking, cleaning the air filter 8.7.2 Checking and cleaning the water separator Semi-annually 8.8.1 Battery service Annually / every 250 operating hours 8.9.1 Replacing the V-belt 8.9.2 Checking, adjusting the valve clearance 8.9.3 Changing the engine oil and cleaning the oil filter 8.9.4...

  • Page 72: Weekly

    Maintenance – Weekly 8.7 Weekly 8.7.1 Checking, cleaning the air filter NOTICE! Danger of engine damage! – Do not start the engine after having removed the air filter. B-SYM-1074 – If necessary, the air filter may be cleaned up to Fig.
  • Page 73 Maintenance – Weekly CAUTION! Danger of eye injuries caused by particles flying around! – Wear your personal protective equipment (safety gloves, protective working clothes, goggles). Blow the air filter out with dry compressed air (max. 5 bar B-GEN-0042 (73 psi)) from inside to outside by moving the gun up and down inside the element, until it is free of dust.

  • Page 74: Checking And Cleaning The Water Separator

    Maintenance – Weekly 8.7.2 Checking and cleaning the water separator The service intervals for the water separator depend on the water content in the fuel and can therefore not be determined precisely. After taking the engine into operation you should B-SYM-1075 check for signs of water and dirt initially every day.

  • Page 75: Semi-Annually

    Maintenance – Semi-annually 8.8 Semi-annually 8.8.1 Battery service Maintenance free batteries also need care. Mainte- nance free only means that the fluid level does not need to be checked. Every battery has a self-discharge, which may, if B-SYM-1077 not checked occasionally, even cause damage to Fig.

  • Page 76: Annually / Every 250 Operating Hours

    Maintenance – Annually / every 250 operating hours 8.9 Annually / every 250 operating hours 8.9.1 Replacing the V-belt Protective equipment: Working clothes Safety shoes Protective gloves Ä Chapter 6.4 ‘Parking the machine Park the machine safely in secured condition’ on page 55. Allow the engine to cool down.
  • Page 77 Maintenance – Annually / every 250 operating hours Check the centre distance (x) between the centrifugal clutch (1) and the V-belt pulley (2). ð Nominal value: 382 ± 1 mm (15.0 ± 0.04 in) If the centre distance is incorrect, contact our customer service.

  • Page 78: Checking, Adjusting The Valve Clearance

    Maintenance – Annually / every 250 operating hours Protective equipment: Working clothes Hearing protection Safety shoes Special tool: Sirometer Park the machine on a rubber mat. Ä Chapter 6.2 ‘Starting the engine’ Start the engine on page 51. Run the machine at maximum speed for one minute. Check the base plate’s frequency with a suitable measuring instrument (e.g.
  • Page 79 Maintenance – Annually / every 250 operating hours Remove the air filter cover (2). Disassemble the covering (1). Fig. 66 Unscrew the fastening screws (1). Remove the valve cover (2) with gasket. Fig. 67 Checking the valve clearance Valve clearance: Intake valve (IN) 0.20 mm (0.008 in) Exhaust valve (EX)

  • Page 80: Changing The Engine Oil And Cleaning The Oil Filter

    Maintenance – Annually / every 250 operating hours Adjusting the valve clearance Loosen screw (3) on the rocker arm. Adjust the hexagon nut (2), until the feeler gauge (1) can be inserted and pulled out with noticeable resistance after the screw (3) has been tightened.
  • Page 81 Maintenance – Annually / every 250 operating hours Protective equipment: Working clothes Protective gloves Safety goggles Park the machine in secured condition Ä Chapter 6.4 ‘Parking the machine in secured condition’ on page 55. Draining off engine oil Clean the area around the dipstick and pull the dipstick out. Clean the area around the drain hose.

  • Page 82: Replacing The Fuel Filter

    Maintenance – Annually / every 250 operating hours Insert the oil filter (2) into the housing and press it against the end stop. Before tightening the screw (1) make sure that the tensioning springs touch the oil filter with both ends. Tighten the screw.

  • Page 83: Replacing The Air Filter

    Maintenance – Annually / every 250 operating hours Pull the fuel filter out of the tank by the string. Pull the fuel hose (3) off the fuel filter (2). Take the fuel filter out of the bracket (1) and replace it with a new one.

  • Page 84: Changing The Oil In The Exciter Housing

    Maintenance – Annually / every 250 operating hours Insert the air filter (1) carefully into the filter housing and fasten it with the knurled nut (2). NOTICE! Danger of engine damage! – Ensure correct fit of air filter cover and seal.
  • Page 85 Maintenance – Annually / every 250 operating hours Tilt the machine to the opposite side and secure it properly. Fill in new oil. B-692-0014 Fig. 81 Stand the machine horizontally and check the oil level. ð Nominal value: Bottom edge of filling/drain bore. Clean the bleed screw (1) and filling/drain plug (2) and screw them in with a low-strength sealing agent (e.g.

  • Page 86: Checking The Hydraulic Oil Level

    Maintenance – Annually / every 250 operating hours 8.9.7 Checking the hydraulic oil level Protective equipment: Working clothes Protective gloves Ä Chapter 6.4 Park the machine in secured condition ‘Parking the machine in secured condition’ on page 55. Adjust the steering rod with height adjustment so that the area with the filler screw is horizontal.
  • Page 87 Maintenance – Annually / every 250 operating hours Press the handle forward against the stop and secure it using suitable means. Fig. 86 Place a cloth underneath the bleeding screw to collect leaking oil. Slacken the bleeding screw. Wait until all air has escaped and then tighten the bleeding screw.

  • Page 88: Replacing The Starter Rope

    Maintenance – Annually / every 250 operating hours 8.9.8 Replacing the starter rope Protective equipment: Working clothes Protective gloves Ä Chapter 6.4 Park the machine in secured condition ‘Parking the machine in secured condition’ on page 55. Allow the engine to cool down. Unscrew the fastening screws (1) and disassemble the recoil starter (2).
  • Page 89 Maintenance – Annually / every 250 operating hours Pre-tension the coil by approx. 4 rotations in direction of arrow. Thereby place the starter rope into the recess in the coil . Fig. 93 CAUTION! Danger of injury caused by the starter handle hitting against your body! –...

  • Page 90: Lubricating The Machine

    Maintenance – Annually / every 250 operating hours 8.9.9 Lubricating the machine Protective equipment: Working clothes Safety shoes Protective gloves Park the machine safely Ä Chapter 6.4 ‘Parking the machine in secured condition’ on page 55. Unscrew the four fastening screws (1) and remove the cover (2).

  • Page 91: Every 2 Years / Every 500 Operating Hours

    Maintenance – Every 2 years / every 500 operating hours 8.10 Every 2 years / every 500 operating hours 8.10.1 Changing the hydraulic oil Protective equipment: Working clothes Protective gloves Ä Chapter 6.4 Park the machine in secured condition ‘Parking the machine in secured condition’ on page 55. Adjust the steering rod with height adjustment so that the area with the filler screw is horizontal.
  • Page 92 Maintenance – Every 2 years / every 500 operating hours NOTICE! Components may get damaged! – Use only oil of the permitted specifica- tion. Fill in hydraulic oil up to the mark on the steering rod head. Mark: approx. 40 mm (1.6 in) below the filler opening Fig.

  • Page 93: As Required

    Maintenance – As required 8.11 As required 8.11.1 Cleaning the machine Protective equipment: Working clothes Protective gloves Ä Chapter 6.4 Park the machine in secured condition ‘Parking the machine in secured condition’ on page 55. Allow the engine to cool down for at least 30 minutes. NOTICE! Electric components can be damaged by water entering into the system!

  • Page 94: Servicing The V-Belt

    Maintenance – As required In case of damp or oily contamination you should consult our customer service department. 8.11.3 Servicing the V-belt Protective equipment: Working clothes Safety shoes Protective gloves Ä Chapter 6.4 ‘Parking the machine Park the machine safely in secured condition’...

  • Page 95: Checking The Oil Level In The Exciter Housing

    Maintenance – As required 8.11.4 Checking the oil level in the exciter housing NOTICE! Components may get damaged! – Use only oil of the permitted specification Ä Chapter 8.4 ‘List of fuels and lubricants’ on page 68. – Do not use low-ash engine oils for the exciter shaft housing.
  • Page 96 Maintenance – As required Protect the cooled down engine against dust and moisture. 8.11.5.2 Battery service during prolonged machine downtimes WARNING! Danger of injury caused by exploding gas mix- ture! – Remove the plugs before starting to recharge the battery. –...
  • Page 97 Maintenance – As required Check cables, hoses and lines for cracks and leaks. Check the service life of hydraulic hoses and replace if nec- essary. Start the engine and run it for 15 to 30 minutes with idle speed. Check the oil levels. Clean the machine thoroughly.

  • Page 98: Troubleshooting

    Troubleshooting Troubleshooting BPR 50/55 D...

  • Page 99: Preliminary Remarks

    Troubleshooting – Preliminary remarks 9.1 Preliminary remarks Malfunctions are frequently caused by incorrect operation of the machine or insufficient maintenance. Whenever a fault occurs you should therefore thoroughly read these instructions on correct operation and 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 100: Starting The Engine With The Recoil Starter

    Troubleshooting – Starting the engine with the recoil starter 9.2 Starting the engine with the recoil starter Start the engine with the recoil starter only if the battery is defective, empty or missing. Exhaust fumes contain toxic substances and can damage your health, cause unconsciousness or even death.
  • Page 101 Troubleshooting – Starting the engine with the recoil starter Set the handle to position “0”. B-695-0056 Fig. 113 Lightly pull the rope twice with the starter handle, until resist- ance can be felt (compression pressure). Guide the starter handle back to initial position. B-GEN-0083 Fig.

  • Page 102: Starting The Engine With Jump Leads

    Troubleshooting – Starting the engine with jump leads 9.3 Starting the engine with jump leads NOTICE! A wrong connection will cause severe damage in the electric system. – Bridge the machine only with a 12 Volt auxiliary battery. Open the protection hood and secure it to prevent unin- tended closing.

  • Page 103: Fuse Assignment

    Troubleshooting – Fuse assignment 9.4 Fuse assignment WARNING! Danger of injury by fire in the machine! – Do not use fuses with higher ampere ratings and do not bridge fuses. Pos. Amperage Designation Economizer fuse (optional equipment) 25 A Main fuse B-692-0075 Fig.

  • Page 104: Engine Malfunctions

    Troubleshooting – Engine malfunctions 9.5 Engine malfunctions Malfunction Possible cause Remedy No or poor starting Fuel tank empty Check the fuel level, top up if necessary of engine Fuel filter clogged Check the fuel filter, replace if necessary Fuel lines leaking Check the fuel lines Incorrect valve clearance Check, adjust the valve clearance...
  • Page 105 Troubleshooting – Engine malfunctions Malfunction Possible cause Remedy Tank ventilation blocked Ensure sufficient ventilation of the tank Air in the fuel system Check the fuel system for air leaks. Check the ventilation valve. Engine looses Air filter dirty Clean, replace if necessary power and speed, Incorrect valve clearance Check, adjust the valve clearance...

  • Page 106: Malfunctions During Operation

    Troubleshooting – Malfunctions during operation 9.6 Malfunctions during operation Fault Possible cause Remedy The machines Air in the hydraulic system of the steering Release pressure from the steering rod vibrates forward with a strongly The oil level in the exciter shaft housing Check the oil level in the exciter shaft reduced speed is too high...

  • Page 107: Trouble Shooting Economizer

    Troubleshooting – Trouble shooting ECONOMIZER 9.7 Trouble shooting ECONOMIZER Fig. 119: Economizer display Fault Possible cause Remedy LED (a) flashes Switching on: The LED (a) flashes for approx 1 - 2 seconds after the vibration has been switched on. Vibration frequency too low. LED (a) lights up No vibration detected.

  • Page 108: Disposal

    Disposal Disposal BPR 50/55 D...

  • Page 109: Final Shut-Down Of Machine

    Disposal – Final shut-down of machine 10.1 Final shut-down of machine After the machine has reached the end of its service life, the indi- vidual components of the machine must be disposed of properly. Observe national regulations! Carry out the following work and have the machine dismantled by a state-approved recycling company.

  • Page 110: List Of Special Tools

    List of special tools List of special tools BPR 50/55 D...
  • Page 111 List of special tools Sirometer Measuring instrument for speed and frequency BOMAG 059 710 02 Fig. BPR 50/55 D...
  • Page 112 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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