Fayat Group BOMAG BRP 35/60 D Operating Instruction, Maintenance Instruction
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Fayat Group BOMAG BRP 35/60 D Operating Instruction, Maintenance Instruction

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Operating Instruction
Maintenance Instruction
Original Operating Instructions
BPR 35/60 D
S/N 101 695 24 1001>
Reversible vibratory plate
www.discount-equipment.com
008 204 48 EN
© 03/2019

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Summary of Contents for Fayat Group BOMAG BRP 35/60 D

  • Page 1 Operating Instruction Maintenance Instruction Original Operating Instructions BPR 35/60 D S/N 101 695 24 1001> Reversible vibratory plate www.discount-equipment.com 008 204 48 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 3.9.5 Measures for longer shut-down periods..................33 3.9.6 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 8.9.5 Replacing the V-belt........................82 8.9.6 Checking, adjusting the valve clearance..................84 8.9.7 Replacing the starter rope......................86 8.9.8 Checking the hydraulic oil level....................88 8.10 Every 2 years/every 500 operating hours................91 8.10.1 Changing the hydraulic oil......................91 8.11 As required..........................

  • Page 7: Introduction

    Introduction Introduction BPR 35/60 D...

  • Page 8: 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 9 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 10: 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 11: Technical Data

    Technical data Technical data BPR 35/60 D...
  • Page 12 Technical data Dimensions B-695-0034 Fig. 3 Dimensions standard 1020 1150 1405 28.3 (40.2) (45.3) (55.3) (30.0) (23.6) Dimensions with "STONEGUARD" (special base plate for paving stones) 1030 1160 1545 (28.7) (40.6) (45.7) (60.8) (32.8) (24.8) Dimensions in millimetres (Dimensions in inch) Weights Operating weight (CECE) (540)
  • Page 13 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” m/min (66) (ft/min) Max. gradeability (depending on soil) Drive Engine manufacturer Hatz...

  • Page 14: Noise And Vibration Data

    Technical data – Noise and vibration data Filling capacities Fuel (diesel) (0.8) (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 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...

  • Page 15: Concerning Your Safety

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

  • Page 16: 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 17: 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 18: 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 19: 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 20: 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 21 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 22: 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 23: 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 24: 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 25: 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 26: 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 27: 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 28: 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 29: 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 30: Working Operation

    Concerning your safety – Working operation 3.7 Working 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. 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 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: 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. It is not necessary to define a maximum storage period if these measures have been performed.

  • Page 34: 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 35: 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 1-2 MINUTEN STOP DIESEL ...
  • Page 36 Concerning your safety – Signage Warning sticker - Follow operating instructions Fig. 9 Information sticker - Lashing point Fig. 10 Information sticker - Lifting point Fig. 11 Information sticker - Guaranteed sound capacity level Fig. 12 BPR 35/60 D...
  • Page 37 Concerning your safety – Signage Operation sticker - Throttle lever Fig. 13 Operation sticker - Travel lever Fig. 14 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...
  • Page 38 Concerning your safety – Signage Machine type plate (example) Made by Designation Type Nominal Power Operating Mass Year of Construction Serial-No. Patent Protection 56154 Boppard;GERMANY Made in Germany B-DEC-0271 Fig. 17 Warning sticker - Starter rope Fig. 18 BPR 35/60 D...

  • Page 39: Safety Components

    Concerning your safety – Safety components 3.12 Safety components B-695-0046 Fig. 19 Protection hood (optional equipment) Heat protection cover Belt guard Protection hood BPR 35/60 D...

  • Page 40: Indicators And Control Elements

    Indicators and control elements Indicators and control elements BPR 35/60 D...
  • Page 41 Indicators and control elements B-695-0022 Fig. 20 Recoil starter Starter switch Operating hour meter Handle Throttle lever Locking pawl lever Steering rod height adjustment BPR 35/60 D...

  • Page 42: Checks Prior To Start Up

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

  • Page 43: 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 44: 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 45: 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 66. B-SYM-1068 Fig. 21 Protective equipment: Working clothes Safety shoes...

  • Page 46: 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 47: Checking The Rubber Buffers

    Checks prior to start up – Checking the rubber buffers 5.5 Checking the rubber buffers B-SYM-1073 Fig. 25 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 48: Operation

    Operation Operation BPR 35/60 D...

  • Page 49: 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 50: 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 51 Operation – Starting the engine Turn the ignition key to position “I”. ð The warning buzzer sounds. B-ELE-0070 Fig. 30 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 52: 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 53 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 54: 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. Fig. 38 NOTICE! Danger of engine damage! –...

  • Page 55: Loading / Transporting The Machine

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

  • Page 56: 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 57 Loading / transporting the machine – Loading the machine Attach the lifting tackle to the dedicated lifting eye. 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 location.

  • Page 58: 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 59: 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 55. Move the steering rod to an upright position and engage the locking pawl lever securely.
  • Page 60 Loading / transporting the machine – Transport wheels Insert the transport wheel into the holding fixture. B-692-0032 Fig. 47 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 61: Maintenance

    Maintenance Maintenance BPR 35/60 D...

  • Page 62: 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 63: 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 64: 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 65: 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 66 Maintenance – Fuels and lubricants The viscosity index must be at least 150 (observe information of manufacturer). BPR 35/60 D...

  • Page 67: 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 0.9 l Ä Chapter 8.3.1 ‘Engine oil’ on page 66 Specification: (0.24 gal us) SAE 15W-40...

  • Page 68: 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 Ä Chapter 8.9.1 ‘Changing the engine Change the engine oil oil and cleaning the oil filter’ on page 77. Ä...

  • Page 69: 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 8.9.1 Changing the engine oil and cleaning the oil filter 8.9.2 Changing the oil in the exciter housing 8.9.3 Replacing the air filter...

  • Page 70: 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 71 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 72: 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 73: 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 74 Maintenance – Semi-annually Assemble the battery box cover. B-692-0038 Fig. 61 BPR 35/60 D...

  • Page 75: Annually

    Maintenance – Annually 8.9 Annually 8.9.1 Changing the engine oil and cleaning the oil filter Change the engine oil at the latest after 250 oper- ating hours. NOTICE! Danger of engine damage! – Change the oil only with the engine at oper- ating temperature.
  • Page 76 Maintenance – Annually Cleaning the oil filter Loosen the screw (1) for approx. five turns and pull the oil filter (2) out of the housing. Fig. 63 CAUTION! Danger of eye injuries caused by particles flying around! – Wear your personal protective equipment (safety gloves, protective working clothes, goggles).

  • Page 77: Changing The Oil In The Exciter Housing

    Maintenance – Annually Filling in engine oil Fill in new engine oil. After a short test run check the oil level on the dipstick; if nec- essary, top up to the top dipstick mark. Fig. 66 Final work Check oil filter and drain plug for leaks. Dispose of oil in an environmentally friendly way.

  • Page 78: Replacing The Air Filter

    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. 68 Stand the machine horizontally and check the oil level. ð...

  • Page 79: Replacing The Fuel Filter

    Maintenance – Annually NOTICE! Danger of engine damage! – Prevent dirt from getting into the air intake opening. – Do not clean the air filter housing with compressed air. Clean the filter housing with a clean, lint-free cloth. Replace the air filter. Insert the air filter (1) carefully into the filter housing and fasten it with the knurled nut (2).

  • Page 80: Replacing The V-Belt

    Maintenance – Annually 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. Plug on the fuel line.
  • Page 81 Maintenance – Annually Check the centre distance (x) between the centrifugal clutch (1) and the V-belt pulley (2). ð Nominal value: 325 ± 1 mm (12.8 ± 0.04 in) If the centre distance is incorrect, contact our customer service. Fasten the guard plate, tightening torque: 15 Nm (11 ft·lbf). B-692-0183 Fig.

  • Page 82: Checking, Adjusting The Valve Clearance

    Maintenance – Annually If frequency incorrect: Check the engine speed. Check the V-belt. If necessary, contact our customer service. 8.9.6 Checking, adjusting the valve clearance NOTICE! Danger of engine damage! We recommend to have this work carried out by trained personnel or our after sales service. –...
  • Page 83 Maintenance – Annually Checking the valve clearance Valve clearance: Intake valve (IN) 0.20 mm (0.008 in) Exhaust valve (EX) 0.20 mm (0.008 in) Crank the engine, until the exhaust valve (EX) is fully open. Check the valve clearance on the intake valve (IN) with a feeler gauge (1), adjust if necessary.

  • Page 84: Replacing The Starter Rope

    Maintenance – Annually Assemble covering (1) and air filter cover (2). After a short test run check the valve cover for leaks. Fig. 82 8.9.7 Replacing the starter rope Protective equipment: Working clothes Protective gloves Park the machine in secured condition Ä...
  • Page 85 Maintenance – Annually Thread in the new starter rope and fix it with knots on both ends . A = 15 mm (0.6 in) Fig. 85 Pre-tension the coil by approx. 4 rotations in direction of arrow. Thereby place the starter rope into the recess in the coil . Fig.

  • Page 86: Checking The Hydraulic Oil Level

    Maintenance – Annually 8.9.8 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 55. 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. 92 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. 95 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 8.10 Every 2 years/every 500 operating hours 8.10.1 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 55. 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. 101 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. 105 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 8.11 As required 8.11.1 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. Protective equipment: Working clothes Protective gloves...

  • Page 93: Servicing The V-Belt

    Maintenance – As required 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’ on page 55. Allow the engine to cool down. Unscrew the V-belt guard (1). B-692-0151 Fig.

  • Page 94: 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 69. Protective equipment: Working clothes Safety shoes Protective gloves Park the machine on level ground.
  • Page 95 Maintenance – As required Change the engine oil and clean the oil filter. Change the fuel filter. 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! –...
  • Page 96 Maintenance – As required 8.11.5.3 Measures before restarting Replace the fuel filter. Replace the air filter. Change the engine oil and clean the oil filter. Check cables, hoses and lines for cracks and leaks. Check the service life of hydraulic hoses and replace if nec- essary.

  • Page 97: Troubleshooting

    Troubleshooting Troubleshooting BPR 35/60 D...

  • Page 98: 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 99: 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 100 Troubleshooting – Starting the engine with the recoil starter Set the handle to position “0”. B-695-0004 Fig. 114 Pull the rope by the starter handle, until resistance can be felt. Guide the starter handle back to initial position. Fig. 115 CAUTION! Danger of injury caused by uncontrolled machine movement!
  • Page 101 Troubleshooting – Starting the engine with the recoil starter 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. Do not operate the engine immediately under full load.

  • 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. Remove the battery box cover. First connect the plus pole of the external battery to the plus pole of the starter battery using the first jump lead.

  • 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 25 A Main fuse Fig. 118 BPR 35/60 D...

  • Page 104: Engine Faults

    Troubleshooting – Engine faults 9.5 Engine faults Fault 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 faults Fault Possible cause Remedy 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 black exhaust smoke Injection nozzle out of order...

  • 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 low...

  • Page 107: Disposal

    Disposal Disposal BPR 35/60 D...

  • 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 D...
  • Page 110 List of special tools Sirometer Measuring instrument for speed and frequency BOMAG 059 710 02 Fig. BPR 35/60 D...
  • 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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