Fayat Group BOMAG BPR 35/60 Operating Instruction, Maintenance Instruction
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Fayat Group BOMAG BPR 35/60 Operating Instruction, Maintenance Instruction

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Operating Instruction

Maintenance Instruction
Original Operating Instructions
BPR 35/60
S/N 101 695 18 1001>
Reversible vibratory plate
www.discount-equipment.com
008 204 59 EN
© 03/2019

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Summary of Contents for Fayat Group BOMAG BPR 35/60

  • Page 1: Operating Instruction

    Operating Instruction Maintenance Instruction Original Operating Instructions BPR 35/60 S/N 101 695 18 1001> Reversible vibratory plate www.discount-equipment.com 008 204 59 EN © 03/2019...
  • 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 3.9.4 Measures for longer shut-down periods..................33 3.9.5 After maintenance work......................33 3.10 Repair............................34 3.11 Signage............................35 3.12 Safety components........................39 Indicators and control elements......................41 Checks prior to start up........................43 5.1 Notes on safety........................... 44 5.2 Visual inspections and function tests..................
  • Page 6 Table of contents 8.8.8 Checking the hydraulic oil level....................88 8.9 Every 2 years/every 500 operating hours................. 91 8.9.1 Changing the hydraulic oil......................91 8.10 As required..........................94 8.10.1 Cleaning the cooling fins and the cooling air intake openings..........94 8.10.2 Cleaning the machine......................

  • Page 7: Introduction

    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 8 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 9: 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 10: Technical Data

    Technical data Technical data BPR 35/60...
  • Page 11 Technical data Dimensions B-695-0034 Fig. 3 Dimensions standard 1020 1150 1405 (26.0) (40.2) (45.3) (55.3) (30.0) (23.6) Dimensions with "STONEGUARD" (special base plate for paving stones) 1030 1160 1545 (26.4) (40.6) (45.7) (60.8) (32.8) (24.8) Dimensions in millimetres (Dimensions in inch) Weights Operating weight (CECE) (452)
  • Page 12 Technical data Weights Full engine protection hood (optional equipment) + 10 (+ 22) (lbs) Transport wheels (optional equipment) (+ 11) (lbs) Travel characteristics Max. working speed m/min (89) (ft/min) Max. working speed with “STONEGUARD” (optional equipment) m/min (66) (ft/min) Max. gradeability (depending on soil) Drive Engine manufacturer Honda...

  • Page 13: 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 14: Concerning Your Safety

    Concerning your safety Concerning your safety BPR 35/60...

  • Page 15: 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 16: 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 17: 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 18: 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 19: 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 20 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 21: 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 22: 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 23: Safety Regulations And Environmental Protection Regulations For Handling Gasoline

    Concerning your safety – Handling fuels and lubricants 3.4.2 Safety regulations and environmental protection regulations for handling gas- oline DANGER! Danger to life caused by explosive gas-air mixes! – Do not allow gasoline to come into contact with hot components. –...

  • Page 24: Safety Regulations And Environmental Protection Regulations For Handling Fuel Stabiliser

    Concerning your safety – Handling fuels and lubricants 3.4.3 Safety regulations and environmental protection regulations for handling fuel stabiliser WARNING! Danger of burning by ignited fuel stabilizer! – Do not allow fuel stabilizer to come into contact with hot components. –...

  • Page 25: Safety Regulations And Environmental Protection Regulations For Handling Oil

    Concerning your safety – Handling fuels and lubricants 3.4.4 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 26: Safety Regulations And Environmental Protection Regulations For Handling Hydraulic Oil

    Concerning your safety – Handling fuels and lubricants 3.4.5 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 27: 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 28: 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 29: Operation In Trenches

    Concerning your safety – Start up procedure 3.6.3 Operation in trenches Applies only to Germany. The vibratory tamper or the vibratory plate were tested outdoors by BG Bau (Germany) regarding CO emissions. The tests were car- ried out in a trench with a width of 1.5 metres, a depth of 3 metres and a length of 10 metres.

  • Page 30: 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 31: 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. Keep away from ignition and heat sources. Apply measures against electrostatic charging. Do not spill any fuel.

  • Page 32: 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 33: 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 34: 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 OPERATION STOP STOP 1-2 MINUTEN GASOLINE BENZIN  before taking into operation weekly vor Inbetriebnahme...
  • Page 35 Concerning your safety – Signage Warning sticker - Follow operating instructions Fig. 8 Warning sticker – California Proposition 65 WARNING California Proposition 65 Warning This product contains chemicals that cause cancer + chemicals that are reproductive toxicants B-DEC-0316 Fig. 9 Information sticker - Lashing point Fig.
  • Page 36 Concerning your safety – Signage Information sticker - Guaranteed sound capacity level Fig. 12 Information sticker - Filler opening for petrol Gasoline/Benzin B-DEC-0216 Fig. 13 Operation sticker - Throttle lever Fig. 14 Operation sticker - Travel lever Fig. 15 BPR 35/60...
  • Page 37 Concerning your safety – Signage Operation sticker - starter switch (optional equipment) B-DEC-0325 Fig. 16 Brief operating instructions with instruction sticker - Wear ear pro- tection Fig. 17 Maintenance sticker GASOLINE BENZIN  before taking into operation weekly vor Inbetriebnahme wöchentlich avant la mise en service hebdomadairement...

  • Page 38: Safety Components

    Concerning your safety – Safety components 3.12 Safety components B-695-0047 Fig. 20 Protection hood (optional equipment) Heat protection cover Belt guard Protection hood BPR 35/60...

  • Page 39: Indicators And Control Elements

    Indicators and control elements Indicators and control elements BPR 35/60...
  • Page 40 Indicators and control elements B-695-0031 Fig. 21 Fuel valve Choke lever Starter switch Handle Throttle lever Operating hour meter (optional equipment) Recoil starter Starter switch (optional equipment) Locking pawl lever 10 Steering rod height adjustment BPR 35/60...

  • Page 41: Checks Prior To Start Up

    Checks prior to start up Checks prior to start up BPR 35/60...

  • Page 42: 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 43: 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 44: 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 8.2.1 ‘Engine oil’ on page 67. B-SYM-1068 Fig. 22 Protective equipment: Working clothes Safety shoes...

  • Page 45: 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 DANGER! Danger to life caused by explosive gas-air mixes! – Do not allow gasoline to come into contact with B-SYM-1069 hot components.

  • Page 46: 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 Check the rubber buffer pairs, left and right, for tight fit, cracks and tear-offs. ð...

  • Page 47: Operation

    Operation Operation BPR 35/60...

  • Page 48: Folding Down The Steering Rod

    Operation – Folding down the steering rod 6.1 Folding down the steering rod Pull the locking pawl lever (2) and fold down the steering rod. ð The steering rod can swing freely. Adjust the steering rod with the height adjustment (1) to the required height.

  • Page 49: 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 50 Operation – Starting the engine Do not operate the choke lever when the engine is warm or at high ambient tempera- tures. Close the choke. B-HON-0037 Fig. 30 Set the throttle lever to “MIN” position. B-692-0022 B-692-0023 B-692-0027 Fig. 31 Set the handle to “0”...
  • Page 51 Operation – Starting the engine Full engine protection hood (optional equipment) Switch starter switch to “Right” position. B-SWI-1698 Fig. 34 Pull the rope by the starter handle, until resistance can be felt. Guide the starter handle back to initial position. Fig.
  • Page 52 Operation – Starting the engine Open the choke bit by bit when the engine is running. Run the engine warm for approx. 1 to 2 minutes in idle speed. NOTICE! Danger of engine damage! – Warm up engine for a short while before starting work.

  • Page 53: Operation

    Operation – Operation 6.3 Operation Operate the machine only with the steering rod folded down. Use only the steering rod to steer the machine. Guide the machine so that your hands do not hit against solid objects. Keep feet clear of the vibrating base plate. CAUTION! Danger of injury caused by uncontrolled machine movement!
  • Page 54 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-695-0006 corresponds with the handle position.

  • Page 55: 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). B-692-0022 B-692-0023 B-692-0027 Fig. 44 NOTICE! Danger of engine damage! –...
  • Page 56 Operation – Parking the machine in secured condition Close the fuel valve completely. B-HON-0036 Fig. 47 BPR 35/60...

  • Page 57: Loading / Transporting The Machine

    Loading / transporting the machine Loading / transporting the machine BPR 35/60...

  • Page 58: 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 way. Only use lifting tackle with sufficient load bearing capacity for the weight to be loaded.
  • Page 59 Loading / transporting the machine – Loading the machine B-695-0032 Fig. 49 Fig. 50 Attach the lifting tackle to the dedicated lifting eye. A Machine with standard protection hood DANGER! B Machine with full engine protec- Danger to life caused by suspended tion hood (optional equipment) loads! –...

  • Page 60: 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 way. Always use appropriate lifting tackle at the lifting points. Use lifting tackle only in the specified loading direction.

  • Page 61: Transport Wheels

    Loading / transporting the machine – Transport wheels 7.3 Transport wheels Optional equipment Protective equipment: Working clothes Safety shoes Protective gloves Ä Chapter 6.4 ‘Parking the machine Park the machine safely in secured condition’ on page 57. Move the steering rod to an upright position and engage the locking pawl lever securely.
  • Page 62 Loading / transporting the machine – Transport wheels Insert the transport wheel into the holding fixture. B-692-0032 Fig. 55 Secure the transport wheel with the split pin. Install the second transport wheel on the opposite side and secure it with the split pin. B-692-0033 Fig.

  • Page 63: Maintenance

    Maintenance Maintenance BPR 35/60...

  • Page 64: 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 65: Fuels And Lubricants

    Maintenance – Fuels and lubricants 8.2 Fuels and lubricants 8.2.1 Engine oil 8.2.1.1 Oil quality The following engine oil specifications are permitted: Engine oils for four-stroke engines acc. to API-classification SJ or higher Avoid mixing of engine oils. 8.2.1.2 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 66: Oil For Exciter Shaft Housing

    Maintenance – Fuels and lubricants 8.2.2.2 Fuel stabilizer If the machine is only occasionally used (if it is out of use for longer than four weeks), mix in the correct amount of fuel stabilizer directly after you have purchased fresh fuel. The fuel stabilizer has a limited shelf life.

  • Page 67: List Of Fuels And Lubricants

    Maintenance – List of fuels and lubricants 8.3 List of fuels and lubricants Assembly group Fuel or lubricant Spare parts Filling quantity number Summer Winter Observe the level mark! Engine oil SAE 10W-30 0.6 l Ä Chapter 8.2.1 ‘Engine oil’ Specification: (0.16 gal us) on page 67...

  • Page 68: Running-In Instructions

    Maintenance – Running-in instructions 8.4 Running-in instructions 8.4.1 General The following maintenance work must be performed when running in new machines or overhauled engines. 8.4.2 After 25 operating hours Change the engine oil. Check the valve clearance, adjust if necessary Ä...

  • Page 69: Maintenance Table

    Maintenance – Maintenance Table 8.5 Maintenance Table Maintenance works Page Weekly 8.6.1 Checking, cleaning the air filter Semi-annually 8.7.1 Changing the engine oil Annually 8.8.1 Replacing the spark plug 8.8.2 Checking, adjusting the valve clearance 8.8.3 Cleaning the slurry filter and fuel strainer 8.8.4 Replacing the air filter 8.8.5...

  • Page 70: Weekly

    Maintenance – Weekly 8.6 Weekly 8.6.1 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 71 Maintenance – Weekly Checking, cleaning the air filter Separate paper element and foam element. Fig. 61 CAUTION! Danger of eye injuries caused by particles flying around! – Wear your personal protective equipment (safety gloves, protective working clothes, goggles). Blow the paper element (4) out with dry compressed air (max.
  • Page 72 Maintenance – Weekly Assembling the air filter NOTICE! Danger of engine damage! – Insert the filter element correctly. Install the rubber seal (5). Insert the filter element (4) correctly and tighten it with the wing nut (3). Tighten the cover (2) with the wing nut (1). Dispose of the filter element (if replaced) in an environmen- tally friendly way.

  • Page 73: Semi-Annually

    Maintenance – Semi-annually 8.7 Semi-annually 8.7.1 Changing the engine oil NOTICE! Danger of engine damage! – Change the oil only with the engine at oper- ating temperature. B-SYM-1078 – Use only oil of the permitted specification Fig. 64 Ä Chapter 8.2.1 ‘Engine oil’ on page 67. Ä...

  • Page 74: Annually

    Maintenance – Annually 8.8 Annually 8.8.1 Replacing the spark plug NOTICE! Danger of engine damage! – Do not use spark plugs with incorrect heat value. Recommended spark plugs: BPR6ES DENSO W20EPR-U Protective equipment: Working clothes Protective gloves Special tool: 13/16 inch spark plug spanner Ä...
  • Page 75 Maintenance – Annually Preparations Protective equipment: Working clothes Protective gloves Ä Chapter 6.4 Park the machine in secured condition ‘Parking the machine in secured condition’ on page 57. Let the engine cool down to 20 °C (68 °F). Unscrew the fastening screws (1). Remove valve cover (2) with seal (3).

  • Page 76: Cleaning The Slurry Filter And Fuel Strainer

    Maintenance – Annually Adjusting the valve clearance Hold the hexagon nut (1) on the rocker arm and loosen counter nut (2). Adjust the hexagon nut, until the feeler gauge can be inserted and pulled out with little resistance after retightening the counter nut.
  • Page 77 Maintenance – Annually Close the fuel valve. B-HON-0036 Fig. 73 Disassemble filter bowl (3), O-ring (2) and filter (1). Clean filter bowl and filter in a non-inflammable solvent, dry them thoroughly afterwards. B-HON-0040 Fig. 74 Open the fuel valve and collect running out fuel. Close the fuel valve.
  • Page 78 Maintenance – Annually Check the O-ring (2) for damage, replace if necessary. Install the filter (1). Observe the alignment (A) of the filter on the housing. Assemble the filter bowl (3) with the O-ring. B-HON-0039 Fig. 76 A View from below: Alignment of filter during installation Unscrew the hexagon nuts (2) and the hexagon screw (1) and take off the fuel tank.

  • Page 79: Replacing The Air Filter

    Maintenance – Annually Assemble the fuel tank with hexagon nuts (2) and hexagon screw (1). Check the fuel system for leaks. Dispose of fuel and replaced components in an environmen- tally friendly way. B-834-0038 Fig. 79 8.8.4 Replacing the air filter NOTICE! Danger of engine damage! –...

  • Page 80: Replacing The V-Belt

    Maintenance – Annually Replace paper element and foam element. NOTICE! Danger of engine damage! – Prevent dirt from getting into the air intake opening. – Do not clean the air filter housing with com- pressed air. Clean the filter housing with a clean, lint-free cloth. Fig.
  • Page 81 Maintenance – Annually Unscrew the V-belt guard (1). B-692-0151 Fig. 83 Unscrew the guard (2). Unscrew the V-belt pulley (1). Replace the V-belt. If necessary, reassemble the spacers that may have been removed. Fasten the V-belt pulley, tightening torque: 35 Nm (26 ft·lbf). B-692-0150 Fig.

  • Page 82: Replacing The Starter Rope

    Maintenance – Annually CAUTION! Danger of injury caused by uncontrolled machine movement! – Always hold on to a running machine. – Always keep an eye on a running machine. Protective equipment: Working clothes Hearing protection Safety shoes Special tool: Sirometer Park the machine on a rubber mat.
  • Page 83 Maintenance – Annually Pull the starter rope with the starter handle out completely. Fig. 88 If the starter rope has been torn or the coil has recoiled com- pletely: Before assembling the rope, turn the coil (2) 5 revolutions in anti-clockwise direction and align the rope openings in coil and housing (5) to one another (A).

  • Page 84: Changing The Oil In The Exciter Housing

    Maintenance – Annually Assemble the recoil starter. Fig. 92 8.8.7 Changing the oil in the exciter housing NOTICE! Components may get damaged! – Use only oil of the permitted specification Ä Chapter 8.3 ‘List of fuels and lubricants’ on page 69. Protective equipment: Working clothes Safety shoes...
  • Page 85 Maintenance – Annually Tilt the machine to the opposite side and secure it properly. NOTICE! Components may get damaged! Do not use low-ash engine oils for the exciter shaft housing. Fill in new oil. B-692-0010 Fig. 94 Stand the machine horizontally and check the oil level. ð...

  • Page 86: Checking The Hydraulic Oil Level

    Maintenance – Annually 8.8.8 Checking the hydraulic oil level Protective equipment: Working clothes Safety shoes Protective gloves Ä Chapter 6.4 ‘Parking the machine Park the machine safely in secured condition’ on page 57. Move the steering rod to an upright position and engage the locking pawl lever securely.
  • Page 87 Maintenance – Annually Check the oil level. ð The oil level must reach the bottom edge of the level bore. B-695-0014 Fig. 99 Topping up hydraulic oil and bleeding the hydraulic system NOTICE! Components may get damaged! – Use only oil of the permitted specification. Clean the area around the filler plug and unscrew the filler plug.
  • Page 88 Maintenance – Annually 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. B-692-0049 Fig. 102 Place a cloth underneath the filler bore to collect leaking oil. Fill in oil through the filler bore, until it starts to run out through the level inspection bore.

  • Page 89: Every 2 Years/Every 500 Operating Hours

    Maintenance – Every 2 years/every 500 operating hours 8.9 Every 2 years/every 500 operating hours 8.9.1 Changing the hydraulic oil Protective equipment: Working clothes Safety shoes Protective gloves Ä Chapter 6.4 ‘Parking the machine Park the machine safely in secured condition’ on page 57. Move the steering rod to an upright position and engage the locking pawl lever securely.
  • Page 90 Maintenance – Every 2 years/every 500 operating hours Unscrew the bleeding screw and collect any oil running out. Screw in the bleeding screw. B-692-0072 Fig. 108 Clean the area around the oil level inspection plug and unscrew the plug. B-695-0013 Fig.
  • Page 91 Maintenance – Every 2 years/every 500 operating hours Fill up hydraulic oil until it comes running out of the inspection bore. Retighten the filler and level inspection plugs. B-695-0017 Fig. 112 Pull the locking pawl lever (1) and fold down the steering rod. Dispose of oil in line with environmental regulations.

  • Page 92: As Required

    Maintenance – As required 8.10 As required 8.10.1 Cleaning the cooling fins and the cooling air intake openings How dirty the cooling fins and cooling air intake openings are depends very much on the daily operating conditions; clean daily if necessary. NOTICE! Danger of engine damage caused by reduced cooling!

  • Page 93: Cleaning The Machine

    Maintenance – As required NOTICE! Components can be damaged by water entering into the system! – Do not direct the water jet directly into the air filter, carburettor, recoil starter, air intake or starter switch. CAUTION! Danger of eye injuries caused by particles flying around! –...

  • Page 94: Checking, Cleaning The Spark Plug

    Maintenance – As required 8.10.3 Checking, cleaning the spark plug NOTICE! Danger of engine damage! – Do not use spark plugs with incorrect heat value. Protective equipment: Working clothes Protective gloves Special tool: 13/16 inch spark plug spanner Ä Chapter 6.4 Park the machine in secured condition ‘Parking the machine in secured condition’...

  • Page 95: Servicing The V-Belt

    Maintenance – As required 8.10.4 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’ on page 57. Allow the engine to cool down. Unscrew the V-belt guard (1). B-692-0151 Fig.

  • Page 96: Checking The Oil Level In The Exciter Housing

    Maintenance – As required 8.10.5 Checking the oil level in the exciter housing NOTICE! Components may get damaged! – Use only oil of the permitted specification Ä Chapter 8.3 ‘List of fuels and lubricants’ on page 69. Protective equipment: Working clothes Safety shoes Protective gloves Park the machine on level ground.
  • Page 97 Maintenance – As required If the machine is shut down for a longer period of time, e.g. winter season, the following work must be carried out. Depending on weather influences these conservation measures will protect the machine for approx. 6 to 12 months. Ä...
  • Page 98 Maintenance – As required Protecting the cylinder Special tool: 13/16 inch spark plug spanner Unscrew the spark plug using a 13/16 inch spark plug spanner. Fill in several drops of fresh engine oil through the ignition plug opening. B-834-0029 Fig. 123 Crank the engine several times with the recoil starter to dis- tribute the oil in the cylinder.
  • Page 99 Maintenance – As required Check the oil levels. If the fuel was drained off before shutting down, you must now fill in fuel. Check cables, hoses and lines for cracks and leaks. Check the service life of hydraulic hoses and replace if nec- essary.

  • Page 100: Troubleshooting

    Troubleshooting Troubleshooting BPR 35/60...

  • Page 101: 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 102: Malfunctions During Operation

    Troubleshooting – Malfunctions during operation 9.2 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 low...

  • Page 103: Engine Malfunctions

    Troubleshooting – Engine malfunctions 9.3 Engine malfunctions Malfunction Possible cause Remedy Engine does not Fuel tank empty Check, fill up if necessary start Fuel valve closed Open the fuel valve Fuel system clogged Clean the fuel screen Check the fuel screen in the carburettor Have checked by qualified expert per- sonnel Set the starter switch to “OFF”...
  • Page 104 Troubleshooting – Engine malfunctions Malfunction Possible cause Remedy Poor fuel quality Check the fuel quality, if necessary change the fuel Engine oil level too low Check the engine oil level, correct if nec- essary Engine runs with Centrifugal clutch defective Have checked by qualified expert per- high speed, but no sonnel...

  • Page 105: What To Do If The Engine Has Flooded

    Troubleshooting – What to do if the engine has flooded 9.4 What to do if the engine has flooded DANGER! Danger to life caused by explosive gas-air mixes! – Do not allow gasoline to come into contact with hot components. –...
  • Page 106 Troubleshooting – What to do if the engine has flooded Open the choke. B-HON-0038 Fig. 128 CAUTION! Danger of eye injuries caused by particles flying around! – Wear your personal protective equipment (safety gloves, protective working clothes, goggles). Crank the engine several times with the recoil starter to remove excessive fuel from the combustion chamber.

  • Page 107: Disposal

    Disposal Disposal BPR 35/60...

  • Page 108: 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 109: List Of Special Tools

    List of special tools List of special tools BPR 35/60...
  • Page 110 List of special tools 13/16 inch spark plug spanner Fig. Sirometer Measuring instrument for speed and frequency BOMAG 059 710 02 Fig. BPR 35/60...
  • Page 111 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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