Fayat BOMAD BPR 50/55 D, Operating Instruction

Page 1: ...plate Operating Instruction Maintenance Instruction Original Operating Instructions S N 101 692 40 1001 09 2018 008 203 24 EN www discount equipment com G o t o D i s c o u n t E q u i p m e n t c o m...

Page 2: ...e needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco...

Page 3: ...to the State of California to cause cancer and birth defects or other reproductive harm WARNING Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause canc...

Page 4: ...eliminary remarks 23 3 4 2 Safety regulations and environmental protection regulations for handling diesel fuel 24 3 4 3 Safety regulations and environmental protection regulations for handling oil 25...

Page 5: ...8 2 Preparations concluding work 63 8 2 1 Opening closing the protection hood 63 8 3 Fuels and lubricants 65 8 3 1 Engine oil 65 8 3 2 Fuel 65 8 3 3 Oil for exciter shaft housing 66 8 3 4 Mineral oil...

Page 6: ...the V belt 93 8 11 4 Checking the oil level in the exciter housing 94 8 11 5 Measures prior to extended shut down period 94 9 Troubleshooting 97 9 1 Preliminary remarks 98 9 2 Starting the engine with...

Page 7: ...1 Introduction Introduction BPR 50 55 D 7 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 8: ...he notes on safety to be followed can be found in chapter Operation Chapter 6 Operation on page 49 Before every start up carry out all required visual inspections and function tests Chapter 5 Checks p...

Page 9: ...you can also order the spare parts catalogue against the serial number of your machine The above notes do not constitute an extension of the warranty and liability conditions specified in the general...

Page 10: ...Made by Designation Type Nominal Power Operating Mass Year of Construction Serial No Patent Protection 56154 Boppard GERMANY Made in Germany 1 2 B DEC 0270 Fig 1 Fig 2 Engine type plate example Introd...

Page 11: ...2 Technical data Technical data BPR 50 55 D 11 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 12: ...illimetres Dimensions in inch Weights Operating weight CECE W 390 860 kg lbs Operating weight CECE W1 405 893 kg lbs Operating weight CECE W2 420 926 kg lbs Basic weight 400 882 kg lbs ECONOMIZER opti...

Page 13: ...m in Filling capacities Fuel diesel 5 0 1 3 l gal us 2 1 Noise and vibration data The following noise and vibration data were determined in accord ance with the following guidelines under equipment sp...

Page 14: ...n data Vector total of the weighted effective acceleration in three orthog onal directions Total vibration value ahv 2 5 m s2 on crushed rock determined acc to ISO 5349 and EN 500 Associated uncertain...

Page 15: ...3 Concerning your safety Concerning your safety BPR 50 55 D 15 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 16: ...fic regulations n country state specific safety regulations It is the duty of the operator to be acquainted with the safety regu lations and to apply these accordingly This also applies for local regu...

Page 17: ...sposal of fuels and lubricants as well as replacement parts 3 1 3 Personal protective equipment Depending on the work to be carried out personal protective equipment is required to be provided by the...

Page 18: ...mpaction of all types of soils n Repair work on all types of soil n Paving of walkways n Work in trenches n Underfilling and compaction of hard shoulders Intended use also includes compliance with the...

Page 19: ...ing tackle must be removed before starting work Starting and operating the machine in explosive environments and in underground mining is prohibited The lifting and lashing points specified in these i...

Page 20: ...lified person An expert qualified person is a person who based on his her pro fessional education and experience has profound knowledge in the field of construction equipment and the machine in questi...

Page 21: ...ence of alcohol medication or drugs are not allowed to operate service or repair the machine Maintenance and repair work requires specific knowledge and must therefore only be performed by trained spe...

Page 22: ...rom the operation of the machine 3 3 2 Regular safety inspections Have the machine inspected by an expert qualified person as required for the conditions the machine is working under but at least once...

Page 23: ...position information on constituents n first aid measures n fire fighting measures n measures in case of accidental release n handling and storage n limitation and monitoring of exposure personal prot...

Page 24: ...nt pro tective gloves protective clothing Do not inhale any fuel fumes Avoid contact CAUTION Danger of slipping on spilled diesel fuel Immediately bind spilled diesel fuel with an oil binding agent EN...

Page 25: ...l protective equipment pro tective gloves protective clothing Do not inhale any oil vapours Avoid contact CAUTION Danger of slipping on spilled oil Immediately bind spilled oil with an oil binding age...

Page 26: ...fire is prohibited Wear your personal protective equipment pro tective gloves protective clothing CAUTION Health hazard caused by contact with hydraulic oil Wear your personal protective equipment pr...

Page 27: ...ion WARNING Danger of injury caused by exploding gas mix ture Remove the plugs before starting to recharge the battery Ensure adequate ventilation Smoking and open fire is prohibited Do not lay any to...

Page 28: ...ion grease Collect and remove excess lubrication grease immediately ENVIRONMENT Lubrication grease is an environmentally haz ardous substance Always keep lubrication grease in proper con tainers Colle...

Page 29: ...nsport vehicle against rolling slip ping and turning over Loads must only be attached and hoisted by an expert capable person Use only lifting gear and lifting tackle with sufficient load bearing capa...

Page 30: ...If the following tests reveal damages or other faults the machine must not be operated until these deficiencies have been corrected Do not operate the machine with defective indicators and control ele...

Page 31: ...sing the steering handle Watch out for unusual noises and development of smoke Perform trouble shooting and have the fault corrected Always keep a safe distance to excavation pit borders embank ments...

Page 32: ...higher sulphur content Apply measures against electrostatic charging Do not spill any fuel Catch running out fuel do not let it seep into the ground Wipe off spilled fuel Keep dirt and water away fro...

Page 33: ...in a sepa rate specially marked container and dispose of environmentally 3 9 3 Maintenance work on electric components and battery Before starting to work on electric parts of the machine disconnect...

Page 34: ...9 5 After maintenance work Reassemble all guards and protections Concerning your safety Maintenance work BPR 50 55 D 34 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 35: ...nt 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 insula...

Page 36: ...erating Mass Year of Construction Serial No Patent Protection Made in Germany before taking into operation vor Inbetriebnahme avant la mise en service anterior a la puesta en servicio weekly w chentli...

Page 37: ...n Before use check the starter rope for chafing n Do not use a defective starter rope Information sticker Lashing point Information sticker Lifting point Fig 10 Fig 11 Fig 12 Fig 13 Concerning your s...

Page 38: ...ticker Ultra low sulphur fuel Information sticker Low ash engine oil Operation sticker Travel lever Fig 14 Fig 15 B DEC 0265 Fig 16 Fig 17 Concerning your safety Signage BPR 50 55 D 38 G o t o D i s c...

Page 39: ...anterior a la puesta en servicio weekly w chentlich hebdomadairement cada semana twice annual halbj hrlich tous les 6 mois cada 6 meses annual 250 h j hrlich 250 h annuellement 250 h anualmente 250 h...

Page 40: ...Concerning your safety Signage BPR 50 55 D 40 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 41: ...4 Indicators and control elements Indicators and control elements BPR 50 55 D 41 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 42: ...ment 2 Recoil starter 3 Operating hour meter 4 Starter switch 5 Handle 6 Throttle lever 7 Locking pawl lever 8 Steering rod height adjustment Indicators and control elements BPR 50 55 D 42 G o t o D i...

Page 43: ...5 Checks prior to start up Checks prior to start up BPR 50 55 D 43 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 44: ...gulations must be followed when han dling fuels and lubricants Chapter 3 4 Han dling fuels and lubricants on page 23 WARNING Danger of injury caused by rotating parts Before starting work on the machi...

Page 45: ...ed connections for tight fit 3 Check machine for contamination and damage 4 Check the hydraulic oil cooler for dirt 5 Check starter rope for chafing Checks prior to start up Visual inspections and fun...

Page 46: ...e it clean with a lint free clean cloth 3 Insert the dipstick and pull it out again to check the oil level The oil level must be between the MIN and MAX marks 4 NOTICE Danger of engine damage Do not f...

Page 47: ...Chapter 8 3 2 Fuel on page 65 Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Clean the area around the filling port 2 Remove the cap and check the filling level visually...

Page 48: ...hine in secured condition on page 55 2 Allow the engine to cool down 3 Check all rubber buffers for tight fit cracks and tear offs 4 Replace damaged rubber buffers immediately B SYM 1073 Fig 27 B 834...

Page 49: ...6 Operation Operation BPR 50 55 D 49 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 50: ...down the steering rod The steering rod can swing freely 2 Adjust the steering rod with the height adjustment 1 to the required height Fig 29 Operation Folding down the steering rod BPR 50 55 D 50 G o...

Page 51: ...uate ventilation when working in trenches WARNING Loss of hearing caused by too high noise bur dens Wear your personal protective equipment ear protection Protective equipment n Hearing protection n W...

Page 52: ...Then allow the starter to cool down to ambient temperature If the engine has not started after these attempts determine the cause Turn the ignition key through position II to position III The starter...

Page 53: ...eye on a running machine Protective equipment n Hearing protection n Working clothes n Safety shoes 1 Make sure that nobody is in the danger zone 2 NOTICE The centrifugal clutch may be damaged Operat...

Page 54: ...ttle lever to MIN position idle speed Vibration is switched off 7 For short work interruptions you should always park the machine in secured condition Chapter 6 4 Parking the machine in secured condit...

Page 55: ...engine all of a sudden from full load speed but let it idle for about two minutes Set the throttle lever to position Stop The engine is shut down The warning buzzer sounds 4 Turn the ignition key to p...

Page 56: ...ays reached Due to fluctuations in the measuring value the dis play value can vary by one digit up down during a pass The average display value during the last pass is decisive The warning display a n...

Page 57: ...7 Loading transporting the machine Loading transporting the machine BPR 50 55 D 57 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 58: ...le must not be damaged by machine parts When lifting the machine make sure the load does not move in an uncontrolled way If necessary hold the load steady with guide ropes Protective equipment n Worki...

Page 59: ...spended loads Do not step or stand under suspended loads Lift the machine carefully and set down again at the intended location 1 B 692 0246 Fig 45 Loading transporting the machine Loading the machine...

Page 60: ...fting tackle must not be damaged by machine parts Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Pull the lashing belts crosswise over the marked lashing point 1 2 Lash th...

Page 61: ...8 Maintenance Maintenance BPR 50 55 D 61 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 62: ...h hot components Park the machine on horizontal level firm ground Perform maintenance work only with the engine shut down Make sure that the engine cannot be accidentally started during maintenance wo...

Page 63: ...tion hood 8 2 1 1 Opening the protection hood Protective equipment n Working clothes n Protective gloves 1 Remove the rear screws 2 on both sides of the machine 2 Put the screws 2 and the matching was...

Page 64: ...nt n Working clothes n Protective gloves 1 Loosen the screw 1 on both sides 2 Close the protection hood 3 Tighten the screw 1 on both sides 4 Screw in screws 2 and washers on both sides and tighten th...

Page 65: ...e oil especially at low ambient temperatures Optimal operating conditions can be achieved by using the oil vis cosity chart as reference 8 3 1 3 Oil change intervals Annually or every 250 operating ho...

Page 66: ...not permitted Copper containing materials copper lines brass items should be avoided because they can cause catalytic reactions in the fuel with subsequent depositing in the injection system 8 3 3 Oil...

Page 67: ...e viscosity index must be at least 150 observe information of manufacturer Maintenance Fuels and lubricants BPR 50 55 D 67 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t...

Page 68: ...30 SAE 30 SAE 10W Fuel Diesel Winter diesel fuel 5 0 l 1 3 gal us Specification Chapter 8 3 2 Fuel on page 65 Exciter shaft housing as engine oil 0 4 l 0 11 gal us Steering rod Hydraulic oil ISO HV 3...

Page 69: ...e on page 77 3 Check engine and machine for leaks 4 Retighten the fastening screws on air filter exhaust and other attachments 5 Retighten the bolted connections on the machine 6 Check the V belt Chap...

Page 70: ...er 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 87 8 9 9 Lubricating the machine 89 Every 2 years every 500 operating...

Page 71: ...bt use a new air filter Protective equipment n Working clothes n Safety shoes n Protective gloves n Safety goggles 1 Park the machine safely Chapter 6 4 Parking the machine in secured condition on pag...

Page 72: ...filter 1 carefully into the filter housing and fasten it with the knurled nut 2 11 NOTICE Danger of engine damage Ensure correct fit of air filter cover and seal Close the cap 3 8 7 2 Checking and cl...

Page 73: ...tainer under the drain plug 3 Loosen the drain plug and collect escaping fluid 4 Drain the fuel off until there is no water left 5 Screw the drain plug tightly back in Ensure leak tightness 6 Dispose...

Page 74: ...y Chapter 6 4 Parking the machine in secured condition on page 55 2 Remove the bracket 1 of the battery 3 Remove the battery 3 and the vibration damping mats 2 4 5 6 4 Check the condition of the vibra...

Page 75: ...gine to cool down 3 Unscrew the V belt guard 1 4 Unscrew the guard 1 5 Unscrew the V belt pulley 1 6 Replace the V belt 3 7 If necessary reassemble the spacers 2 that may have been removed 8 Fasten th...

Page 76: ...the V belt guard 1 8 9 1 1 Checking the frequency of the base plate Keep feet and hands clear of the vibrating base plate CAUTION Danger of injury caused by uncontrolled machine movement Always hold...

Page 77: ...rrect n Check the engine speed n Check the V belt n If necessary contact our customer service 8 9 2 Checking adjusting the valve clearance NOTICE Danger of engine damage We recommend to have this work...

Page 78: ...haust valve EX is fully open 2 Check the valve clearance on the intake valve IN with a feeler gauge 1 adjust if necessary 3 Crank the engine further until the intake valve is fully open 4 Check the va...

Page 79: ...check the valve cover for leaks 8 9 3 Changing the engine oil and cleaning the oil filter NOTICE Danger of engine damage Change the oil only with the engine at oper ating temperature Use only oil of...

Page 80: ...lect any oil running out 6 Clean and screw in the drain plug 7 Assemble the drain hose with the hose clamp 8 Loosen the screw 1 for approx five turns and pull the oil filter 2 out of the housing 9 CAU...

Page 81: ...nmentally friendly way 8 9 4 Replacing the fuel filter NOTICE Danger of engine damage Ensure strict cleanliness Thoroughly clean the area around the fuel tank beforehand Never operate the engine after...

Page 82: ...r filter Protective equipment n Working clothes n Protective gloves 1 Park the machine in secured condition Chapter 6 4 Parking the machine in secured condition on page 55 2 Allow the engine to cool d...

Page 83: ...housing Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Park the machine on level ground 2 Park the machine safely Chapter 6 4 Parking the machine in secured condition on p...

Page 84: ...bore 10 Clean the bleed screw 1 and filling drain plug 2 and screw them in with a low strength sealing agent e g spare parts number 009 700 16 11 Dispose of oil in line with environmental regulations...

Page 85: ...filler screw 4 Press the handle forward against the stop and secure it using suitable means 5 The oil level must reach the mark on the steering rod head if necessary fill in hydraulic oil Mark approx...

Page 86: ...leeding screw 9 Wait until all air has escaped and then tighten the bleeding screw 10 Fill in hydraulic oil up to the mark on the steering rod head 11 Screw in the filler screw Fig 87 Fig 88 Fig 89 Co...

Page 87: ...r 2 4 Pull the starter rope with the starter handle 1 out com pletely 5 Secure the coil 2 against winding up 6 Loosen the knot 3 in the starter rope and remove the old starter rope 7 Carefully turn th...

Page 88: ...Do not let the starter handle hit back Slowly guide the starter handle back to initial position 11 Pull the starter handle to check the function and light move ment of the recoil starter 12 Assemble...

Page 89: ...se damage to components Use only grease of the permitted specifi cation Spare parts number of lubrication grease 009 960 17 Grease the mechanical parts between the fork head 1 lever 2 and bolt 3 4 Fas...

Page 90: ...teering rod with height adjustment so that the area with the filler screw is horizontal 3 Unscrew the filler screw 4 Press the handle forward against the stop and secure it using suitable means 5 Unsc...

Page 91: ...leeding screw 9 Wait until all air has escaped and then tighten the bleeding screw 10 Fill in hydraulic oil up to the mark on the steering rod head 11 Screw in the filler screw 12 Dispose of oil in an...

Page 92: ...e openings How dirty the cooling fins and cooling air intake openings are depends very much on the daily operating conditions clean daily if necessary Protective equipment n Working clothes n Protecti...

Page 93: ...e to cool down 3 Unscrew the V belt guard 1 4 Check condition and tension of V belt Compression measurement 10 25 mm 0 4 1 0 in 5 The V belt cannot be re tightened Replace the V belt if it is damaged...

Page 94: ...tom edge of filling drain bore 7 Clean the bleed screw and filling drain plug and screw them in with a low strength sealing agent e g spare parts number 009 700 16 8 11 5 Measures prior to extended sh...

Page 95: ...rge the battery immediately after an open circuit voltage of 12 25 V or less is reached Do not perform boost charging The open circuit voltage of the battery occurs approx 10 hours after the last char...

Page 96: ...6 Check the oil levels 7 Clean the machine thoroughly Maintenance As required BPR 50 55 D 96 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 97: ...9 Troubleshooting Troubleshooting BPR 50 55 D 97 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 98: ...fore 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 contac...

Page 99: ...es Avoid operation in closed or partly closed rooms or ensure adequate ventilation when working in trenches WARNING Loss of hearing caused by too high noise bur dens Wear your personal protective equi...

Page 100: ...ull the starter rope all the way against the end stop Pull the starter handle quickly and with power 6 Manually guide the starter handle back to initial position 7 If the engine does not start during...

Page 101: ...e of the starter battery using the first jump lead 4 Next connect the second jump lead to the minus pole of the energizing external battery and then to the minus pole of the starter battery 5 Start th...

Page 102: ...with higher ampere ratings and do not bridge fuses Pos Amperage Designation 1 5 A Economizer fuse optional equipment 2 25 A Main fuse B 692 0075 1 2 Fig 118 Troubleshooting Fuse assignment BPR 50 55 D...

Page 103: ...on Recoil starter dirty Clean the recoil starter Insufficient pre tension of the spring Check the pre tension of the spring adjust if necessary Spring broken Replace the recoil starter Engine ignites...

Page 104: ...ut of order Have checked by qualified expert per sonnel Engine overheats Engine oil level too high Check drain off if necessary Lack of cooling air Clean the cooling fins and the cooling air intake op...

Page 105: ...ective gloves 1 Park the machine in secured condition Chapter 6 4 Parking the machine in secured condition on page 55 2 Press the handle forward against the end stop and hold it in this position 3 Car...

Page 106: ...nsor Cable breakage Inform our service department The displayed measuring values are not plausible The acceleration sensor is not fastened correctly Shut down the engine and check the fas tening screw...

Page 107: ...10 Disposal Disposal BPR 50 55 D 107 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 108: ...tion regulations must be followed when han dling fuels and lubricants Chapter 3 4 Han dling fuels and lubricants on page 23 Protective equipment n Working clothes n Safety shoes n Protective gloves n...

Page 109: ...11 List of special tools List of special tools BPR 50 55 D 109 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 110: ...Sirometer Measuring instrument for speed and frequency BOMAG 059 710 02 Fig List of special tools BPR 50 55 D 110 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Page 111: ...e needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco...