Fayat Group BOMAG BPR 100/80 D Operating Instructions Manual
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Fayat Group BOMAG BPR 100/80 D Operating Instructions Manual

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Operating instructions
Maintenance instructions
BPR 100/80 D
S/N 101 690 35 .... >
Reversible Vibrating Plate
Catalogue No.
11/2009
008 046 01

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Summary of Contents for Fayat Group BOMAG BPR 100/80 D

  • Page 1 Operating instructions Maintenance instructions BPR 100/80 D S/N 101 690 35 ..> Reversible Vibrating Plate Catalogue No. 11/2009 008 046 01...
  • Page 3 These BOMAG machines are products from For your own personal safety you should only F oreword the wide range of BOMAG machines for earth use original spare parts from BOMAG. work, asphalt and refuse compaction as well In the course of technical development we re- as stabilizers/recyclers.
  • Page 4 Please fill in ......Machine type (Fig. 1) ......Serial-number (Fig.
  • Page 5 Table of Contents BPR 100/80 D...
  • Page 6 Table of Contents BPR 100/80 D...

  • Page 7: Technical Data

    1 Technical Data BPR 100/80 D...
  • Page 8 Fig. 4 Dimensions in 1080 1890 BPR 100/80 D BPR 100/80 D Weights Operating weight (CECE) W Operating weight (CECE) W1 Operating weight (CECE) W2 Basic weight Travel characteristics Working speed max. m/min Max. gradability (depending on soil) Drive Engine manufacturer Hatz Type 1D 90 Z...
  • Page 9 BPR 100/80 D Frequency Centrifugal force Filling capacities Fuel tank (diesel) Engine oil Subject to technical alterations. BPR 100/80 D...
  • Page 10 The following noise and vibration data acc. to - EC Machine Regulation edition 98/37/EC and - the noise regulation 2000/14/EG, noise protection guideline 2003/10/EC - Vibration Protection Regulation 2002/44/EC were determined during conditions typical for this type of equipment and by application of harmo- nized standards.

  • Page 11: Safety Regulations

    2 Safety regulations BPR 100/80 D...
  • Page 12 General For example: Dragging the machine along as a measure of This BOMAG machine has been built in com- transportation pliance with the latest technical standard and complies with the applicable regulations and Throwing the machine off the transport vehicle technical rules.

  • Page 13: Loading The Machine

    Persons under the influence of alcohol, medica- Environment tion or drugs must not operate, service or repair Paragraphs marked like this point out practic- the machine. es for safe and environmental disposal of fuels Maintenance and repair tasks require specific and lubricants as well as replacement parts.

  • Page 14: Parking The Machine

    Starting and operation of the machine is Keep unauthorized persons away from the ma- closed rooms and trenches chine. Exhaust gases are highly dangerous! Always en- Do not perform maintenance work while the motor sure an adequate supply of fresh air when starting is running.
  • Page 15 hoses are mixed up by mistake. Do not guide the water jet directly into air filter and air intake or exhaust muffler. the fitting shows corrosion that impairs both function and strength. After maintenance work fittings are damaged or deformed, whereby After all maintenance work is completed reinstall the function and strength of the hose/hose all guards and safety installations.
  • Page 16 Fig. 5 Stickers and decals BPR 100/80 D Information sticker "Lashing points" Information sticker "Travel lever" Information sticker "Lifting point" Instruction sticker "Wear ear defenders" Information sticker "Fuel" Brief operating instructions Maintenance sticker 10 Information sticker "Hydraulic oil" Information sticker "Guaranteed sound capac- ity level"...
  • Page 17 Fig. 6 Maintenance sticker "Engine" BPR 100/80 D...
  • Page 18 BPR 100/80 D...

  • Page 19: Indicators And Controls

    3 Indicators and Controls BPR 100/80 D...

  • Page 20: General Notes

    3.1 General notes 3.2 Description of indicators and control elements Please read this section thoroughly before operat- ing this machine if you are not yet conversant with the indicators and control elements. All functions are described in detail hereunder. Paragraph 4 Operation contains only concise de- scriptions of the individual operating steps.
  • Page 21 Position "0" = Ignition off, warning buzzer off Position "I" = Ignition on, warning buzzer on Position "II" = Engine starts, warning buzzer Fig. 9 No. 7 = Decompression lever Fig. 12 No. 10 = Fuse (25 A) Note Only machines with electric starter. Caution Always cover the fuse with the protective cov- Fig.

  • Page 22: Function Of The Economizer

    3.3 Function of the Economizer Surface covering compaction control is used to de- termine the dynamic stiffness of the soil. A accel- eration sensor measures the reaction of the soil to the vibrating base plate of the vibratory plate. An LED display shows the soil stiffness measuring value as a non-dimensional value.

  • Page 23: Acceleration Sensor

    Evaluation and display module Fig. 16 The yellow LEDs represent the measuring value from the compaction control in 10 stages. The brightness of the respective last LED varies in order to show intermediate values (example: 4,5: four LEDs are fully on, the fifth LED lights with re- duced brightness).
  • Page 24 BPR 100/80 D...

  • Page 25: Operation

    4 Operation BPR 100/80 D...

  • Page 26: Tests Before Taking Into Op- Eration

    4.1 General 4.2 Tests before taking into op- eration If you are not yet acquainted with the controls and indicating elements on this machine you The following inspections must be carried out be- should thoroughly read chapter 3 “Indicators fore each working day or before a longer working and control elements”...
  • Page 27 4.3 Folding down the steering Operating the low oil level safety device Note The engine is equipped with a low oil level safety device, which interrupts the fuel flow to the injec- tion pump. The engine will stop. If the low oil level safety device has responded or if the fuel tank has been driven empty, the fuel shut-off valve must be opened manually.

  • Page 28: Starting The Engine

    4.5 Starting the engine Danger Exhaust gases are highly dangerous! Always ensure an adequate supply of fresh air when starting and operating in closed rooms and trenches! Danger Danger of accident! Fig. 20 Before starting make sure that there are no Turn the ignition key to position "I"...

  • Page 29: Starting With Jump Wires

    4.6 Starting with jump wires Note Choose this type of starting if the starter battery is exhausted and the machine cannot be started manually with the safety crank handle. Caution A wrong connection will cause severe damage in the electric system. Fig.
  • Page 30 4.7 Emergency starting with safety crank handle Note This starting procedure should only be used in case of a defective, discharged or missing battery. Fig. 26 Set the throttle lever (Fig. 26) to vibration step Fig. 24 Turn the ignition key to position I (Fig. 24), the warning buzzer does not sound.
  • Page 31 Fig. 28 Fig. 29 Take a correct position to the machine (Fig. Hook the safety crank handle 1 (Fig. 29) back 28). Hold the crank handle properly. into the bracket. Turn the crank handle with both hands slowly Close the plastci cover. in direction of arrow until it engages.

  • Page 32: Operation Of Economizer

    Notes on operation 4.8 Operation of Economizer Display values higher during the first pass than during the second pass: the front rounded Meaning of display LEDs/self test shape increases the contact area on loose The display LEDs signalize the measuring value of material, a slightly higher measuring value the system.

  • Page 33: Work/Operation

    Influence of extension bars on the measuring Work/operation value: Assembling or removing extension bars changes the contact area and the vibration amplitude. A generally valid statement about the influence on the measuring result cannot Danger be made. Danger of accident! The measuring values can at present not be Operate the machine only with the steering rod saved and documented.

  • Page 34: Drive Forward

    Drive forward Fig. 35 Press the upper part of the travel lever (tip Fig. 34 switch) (Fig. 35), until the vibratory plate has Press the upper part of the travel lever (tip reached the desired reverse travel speed. switch) (Fig. 34), until the vibratory plate has The machines vibrates backwards with a speed reached the desired forward travel speed.

  • Page 35: Backup Protection

    4.10 Backup protection 4.11 Stopping the vibratory plate, shutting down the en- gine Danger Danger of accident! As a measure to avoid injury during backwards travel, the machine must only be guided from the side by the steering handle. Fig. 38 Operate the travel lever (tip switch) (Fig.
  • Page 36 4.12 Loading Danger Danger of accident! Make sure that persons are not endangered by the machine tipping or sliding off. Lash the machine down, so that it is secured against rolling, sliding and turning over. For lifting the machine attach the lifting gear only to the lifting hook.
  • Page 37 Fig. 43 Fold the lifting hook (Fig. 43) up. Fig. 44 Always attach the lifting gear (rope) to the lift- ing eye to load the vibratory plate (Fig. 44) on a transport vehicle. Danger Danger of accident! Minimum load bearing capacity of lifting gear: see operating weight in chapter "Technical Da- ta".
  • Page 38 BPR 100/80 D...

  • Page 39: Maintenance

    5 Maintenance BPR 100/80 D...

  • Page 40: General Notes On Mainte- Nance

    Notes on the fuel system 5.1 General notes on mainte- The lifetime of the diesel engine depends to a nance great extent on the cleanliness of the fuel. Keep fuel free of contaminants and water, When performing maintenance work ensure strict since this will damage the injection elements compliance with the respective safety instructions of the engine.

  • Page 41: Fuels And Lubricants

    You should preferably use oils of API quality class 5.2 Fuels and lubricants CD/CE/CF/CF-4/CG-4 or higher, or ACEA B2/E2. When using oils of API-quality class CC/SE the oil change intervals must be shortened. Engine oil Lubrication oil change intervals Use winter grade engine oil for winter operation! API: CD/ CE/CF/ In order to assure perfect cold starting it is import CF-4/CG-4...
  • Page 42 according to ISO 6743/3. The viscosity index (VI) must be at least 150. (Observe the information of the manufacturer). BPR 100/80 D...
  • Page 43 5.3 Table of fuels and lubri- cants Assembly Fuel or lubricant Quantity approx. Summer Winter Attention Observe the level marks Engine - Engine oil API CD/CE/CF/CF-4/CG-4 1.9 l SAE 5W/30 (-5 ° C to +35 ° C) SAE 5W/40 (-5 ° C to +45 ° C) SAE 10W/30 (-5 °C to +35 °C) SAE 10W/40 (-5 °C to +45 °C) SAE 10W/40 (0 °C to +40 °C)

  • Page 44: Running-In Instructions

    5.4 Running-in instructions The following maintenance work must be per- formed when running in new machines or overhauled engines: Caution During the running-in period, up to approx. 200 operating 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 45: Maintenance Table

    5.5 Maintenance table Maintenance work Comment Clean the machine Check the engine oil level Dipstick mark Check the fuel level Check the hydraulic oil level Inspection glass 5.10 Check the air filter service indicator Rubber spout 5.11 Clean the cooling fins and the cooling air in- take openings 5.12 Drain the sludge from the fuel tank 5.13 Check condition of battery, grease poles...
  • Page 46 BPR 100/80 D...

  • Page 47: Cleaning The Machine

    Maintenance every day 5.6 Cleaning the machine Check the engine oil level Note Caution Park the machine on level ground so that the en- Perform cleaning work only after the engine gine is in horizontal position. has cooled down and with the engine stopped. Fig.

  • Page 48: Checking The Fuel Level

    5.8 Checking the fuel level 5.9 Check the hydraulic oil level Danger Fire hazard! When working on the fuel system do not use open fire, do not smoke. Do not refuel in closed rooms. Refuel only with the engine stopped. Do not inhale any fuel fumes.
  • Page 49 5.10 Checking the air filter serv- ice indicator Fig. 51 Accelerate the engine for a short while to full speed. Note normal rubber bellows = dry air filter o.k. (Fig. 51). contracted rubber bellows = clean dry air filter. Before cleaning pull the rubber bellows up and start the engine.
  • Page 50 BPR 100/80 D...

  • Page 51: Clean The Cooling Fins And The Cooling Air Intake Open- Ings

    After a sufficient soaking time clean off with a Maintenance every m onth 5.11 Clean the cooling fins and water or steam jet and blow out with com- the cooling air intake open- pressed air. ings Run the engine warm for a while to avoid cor- rosion.
  • Page 52 5.12 Draining the sludge from the fuel tank Danger Fire hazard! When working on the fuel system do not use open fire, do not smoke. Do not inhale any fuel fumes. Do not spill any fuel. Environment Catch running out fuel and dispose of environ- mentally.

  • Page 53: Check The Battery Condition, Grease The Poles

    Maintenance every 6 m onths 5.13 Check the battery condition, grease the poles Danger Danger of burning! When working on the battery do not use open fire, do not smoke! Do not let acid come in contact with skin or clothes! Fig.

  • Page 54: Checking The Valve Clearance

    5.14 Check, adjust the valve clearance Caution Check and adjust only when the engine is cold. The gasket for the cylinder head cover must be generally renewed. Checking the valve clearance Fig. 56 Clean the condition of the vibration insulation mats, replace if ncessary (Fig.

  • Page 55: Adjusting The Valve Clearance

    5.15 Check the oil level in the vi- brator housing Note Park the machine on level ground. Clean the area around the level plug. Unscrew vent plug (2). Fig. 59 Check the valve clearance with a feeler gauge on both valves (Fig. 59). Nominal value: Intake valve (I) 0.10 mm (0.004 inch) Exhaust valve (E) 0.20 mm (0,008 inch)
  • Page 56 BPR 100/80 D...

  • Page 57: Changing The Engine Oil

    Maintenance every year 5.16 Changing the engine oil Danger Danger of scalding! When draining off hot oil. Environment Environmental damage! Catch old oil and dispose of environmentally. Fig. 63 Note Unscrew the drain plug (Fig. 63) and catch running out old oil. Drain the engine oil only when the engine is warm.

  • Page 58: Changing The Engine Oil Fil- Ter

    5.17 Changing the engine oil fil- Danger Danger of scalding! Hot oil when changing the engine oil filter. Environment Catch running out oil and dispose of environ- mentally together with the engine oil filter car- Fig. 65 tridge. After a short test run check the oil level on the dipstick (Fig.

  • Page 59: Changing The Fuel Filter

    5.18 Changing the fuel filter 5.19 Change the oil in the exciter shaft housing Danger Fire hazard! Environment Catch running out old oil, do not let it seep into When working on the fuel system do not use the ground and dispose off environmentally. open fire, do not smoke.

  • Page 60: Check The Rubber Buffers

    Note 5.20 Check the rubber buffers With the machine stopped the oil level must reach the bottom edge of the inspection plug . For quality and quantity of oil refer to the table of fuels and lubricants. Clean level plug (1) and screw in with Omnifit FD 10 BOMAG PIN 00970016.

  • Page 61: Check The V-Belt Tension, If Necessary Replace The V- Belt

    The V-belt cannot be tightened manually. Al- 5.21 Check the V-belt tension, if ways replace the V-belt, if the compression necessary replace the V- measurement is exceeded. belt Changing the V-belt Checking the V-belt Fig. 73 Disassemble the safety cover (1) (Fig. 73). Fig.
  • Page 62 BPR 100/80 D...

  • Page 63: Change The Hydraulic Oil

    Changing the breather filter Maintenance every 2 years 5.22 Changing hydraulic oil, breather filter and hydraulic oil filter Caution Park the machine on level ground. Drain off hydraulic oil at operating tempera- ture. Replace the hydraulic oil filter with every hy- draulic oil change.

  • Page 64: Changing The Hydraulic Oil Filter

    Fig. 77 Fig. 79 Remove the connecting flange (Fig. 77). Fill in new hydraulic oil (Fig. 79). For quality and quantity of oil refer to the table of fuels and lubricants. Check the oil level in the inspection glass, top up if necessary.
  • Page 65 BPR 100/80 D...
  • Page 66 BPR 100/80 D...
  • Page 67 Wear protective clothing (goggles, gloves) As r equired 5.23 Check, clean the dry air fil- Caution Do not use gasoline or hot fluids to clean the filter cartridge. Dry air filter cartridges with damaged filter ele- ment or seal ring must be replaced in any case. It is therefore recommended to keep at least one filter element in stock.

  • Page 68: Tightening The Screws

    Note 5.24 Tightening the screws When tightening the cover do not damage the seal on the filter housing. Note Self locking nuts must always be replaced by new ones after they have been unscrewed. Fig. 84 Check the air filter service indicator (Fig. 84). Fig.

  • Page 69: Engine Conservation

    Caution 5.25 Engine conservation A machine with conserved engine must be clearly marked by attaching a clear warning la- If the engine is to be shut down for a longer period bel. of time (e.g. over winter), we recommend the fol- lowing measures to avoid corrosion: Clean engine and cooling system: With cold cleansing agent and water jet or, even better,...
  • Page 70 BPR 100/80 D...

  • Page 71: Troubleshooting

    6 Trouble shooting BPR 100/80 D...
  • Page 72 General notes The following work must only be carried out by qualified and trained personnel or by the BOMAG sales service. Strictly observe the safety regulations. Malfunctions are frequently caused by incorrect operation of the machine or insufficient mainte- nance. Whenever a fault occurs you should there- fore thoroughly read these instruction on correct operation and maintenance.

  • Page 73: Engine Problems

    6.2 Engine problems Fault Possible cause Remedy Engine does not Throttle lever in stop or idle speed position Shift the lever to “Start” position start or does not no fuel at the injection pump Fill in fuel start immediate- ly, but can be check the entire fuel system systematical- cranked with the crank handle...
  • Page 74 Fault Possible cause Remedy The starter is not Fault in the electric system: Check electric equipment and related switched on or components or consult the customer serv- - Fuse defective the engine does ice of Bomag - Battery or other cable connections not not crank correctly connected.
  • Page 75 Fault Possible cause Remedy Engine over- Lubrication oil level in engine too high Drain the engine oil down to the top mark heating on the dipstick Insufficient cooling - Dirt in the entire area of the cooling air Clean the cooling air duct flow - Air guide plates not completely closed Check air guide plates for completeness...

  • Page 76: Trouble Shooting Econo- Mizer

    6.3 Trouble shooting Econo- mizer Fault Description Possible cause Status-LED off Operation Status-LED on no frequency detected Engine not running Plug-in connector defective Sensor/cable defective Status-LED Frequency detected, but outside permis- Engine speed too low flashing sible range Vibration frequency too low Sensor defective atypical soil V-belt slipping...

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