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

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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:

NGK

BPR6ES

DENSO

W20EPR-U

Protective equipment:

Working clothes

Protective gloves

Special tool:

13/16 inch spark plug spanner

Park the machine in secured condition

Chapter 6.4

‘Parking the machine in secured condition’ on page 57

Allow the engine to cool down for at least 15 minutes.

Clean the area around the spark plug.

Unscrew the spark plug using a 13/16 inch spark plug

spanner.

Check the electrode gap of the new spark plug with a feeler

gauge, if necessary, adjust the gap.

Nominal value:

0.7 - 0.8 mm (0.028 - 0.032 in)

Screw in the new spark plug carefully by hand.

Once the sealing surface of the new spark plug is in contact,

tighten for another 1/2 turn with the spark plug spanner.

8.8.2 Checking, adjusting the valve clearance

Perform this maintenance work at the latest after

250 operating hours

NOTICE!
Danger of engine damage!

We recommend to have this work carried out by

trained personnel or our after sales service.

–

Before checking the valve clearance let the

engine cool down.

Fig. 67

Maintenance – Annually

BPR 35/60

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your

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Summary of Contents for BOMAG BPR 35/60

Page 1: ...plate Operating Instruction Maintenance Instruction Original Operating Instructions S N 101 695 18 1001 03 2019 008 204 59 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 t o o r d e r y o u r p a r t s ...

Page 2: ...ne 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 Chicago Pneumatic Allmand Miller Curber Skyjack Lull Skytrak Tsurumi Husquvarna Target Stow Wacker Sakai Mi T M Sullair Basic Dynapac MBW Weber Bartell Bennar Newman Haulotte Ditch Runner Menegotti M...

Page 3: ...n 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 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 e...

Page 4: ...efects misuse of safety devices 22 3 4 Handling fuels and lubricants 23 3 4 1 Preliminary remarks 23 3 4 2 Safety regulations and environmental protection regulations for handling gasoline 24 3 4 3 Safety regulations and environmental protection regulations for handling fuel stabiliser 25 3 4 4 Safety regulations and environmental protection regulations for handling oil 26 3 4 5 Safety regulations...

Page 5: ...s 63 8 Maintenance 65 8 1 Preliminary remarks and safety notes 66 8 2 Fuels and lubricants 67 8 2 1 Engine oil 67 8 2 2 Fuel 67 8 2 3 Oil for exciter shaft housing 68 8 2 4 Mineral oil based hydraulic oil 68 8 3 List of fuels and lubricants 69 8 4 Running in instructions 70 8 4 1 General 70 8 4 2 After 25 operating hours 70 8 5 Maintenance Table 71 8 6 Weekly 72 8 6 1 Checking cleaning the air fil...

Page 6: ...8 10 4 Servicing the V belt 97 8 10 5 Checking the oil level in the exciter housing 98 8 10 6 Measures prior to extended shut down period 98 9 Troubleshooting 103 9 1 Preliminary remarks 104 9 2 Malfunctions during operation 105 9 3 Engine malfunctions 106 9 4 What to do if the engine has flooded 108 10 Disposal 111 10 1 Final shut down of machine 112 11 List of special tools 113 Table of contents...

Page 7: ...he notes on safety to be followed can be found in chapter Operation Ä Chapter 6 Operation on page 49 Before every start up carry out all required visual inspections and function tests Ä Chapter 5 Checks prior to start up on page 43 Ensure the compliance with the specified operating maintenance and repair measures to maintain the functional safety of your machine A description of all necessary main...

Page 8: ...at 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 sales and delivery conditions of BOMAG GmbH We wish you successful work with your BOMAG machine Introduction Foreword BPR 35 60 9 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...

Page 9: ...ion 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 Machine type plate example Engine type and engine number Fig 2 Introduction Machine type plate and engine type plate BPR 35 60 10 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 10: ...2 Technical data Technical data BPR 35 60 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 11: ... for paving stones 670 26 4 1030 40 6 1160 45 7 1545 60 8 832 32 8 630 24 8 Dimensions in millimetres Dimensions in inch Weights Operating weight CECE 205 452 kg lbs Basic weight 202 445 kg lbs STONEGUARD optional equipment 23 51 kg lbs Dimensions Technical data BPR 35 60 12 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: ...gradeability depending on soil 32 Drive Engine manufacturer Honda Type GX 160 Cooling Air Number of cylinders 1 Rated power SAE J 1349 3 6 4 8 kW hp Rated speed 3600 min 1 Drive system mechanical Exciter system Frequency 80 4800 Hz vpm Centrifugal force 35 7868 kN lbf Amplitude 1 30 0 051 mm in Filling capacities Fuel gasoline 3 1 0 8 l gal us Technical data BPR 35 60 13 G o t o D i s c o u n t E ...

Page 13: ... 500 WARNING Loss of hearing caused by too high noise bur dens Wear your personal protective equipment ear protection LWA 108 dB A determined acc to ISO 3744 and EN 500 2 1 2 Vibration data Vector total of the weighted effective acceleration in three orthog onal directions Total vibration value ahv 3 7 m s2 on crushed rock determined acc to ISO 5349 and EN 500 Associated uncertainty K 0 3 m s2 det...

Page 14: ...3 Concerning your safety Concerning your safety BPR 35 60 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 15: ...affic 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 regulations and regulations concerning different types of handling activities Should the recommendations in these instructions be dif ferent from the regulations valid in your country you must comply wi...

Page 16: ...disposal 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 operating company Working clothes Tight fitting working clothes with low tear resistance tight sleeves and without any projecting parts protect against being caught by moving components Safety shoes...

Page 17: ...Compaction 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 specified oper ating maintenance and repair measures 3 1 5 Improper use Dangers may arise from the machine when it is used for purposes other than the one it is intended for Any danger caused by im...

Page 18: ...ctions must be used It is prohibited to use other lifting and lashing points e g guide handle steering rod 3 1 6 Estimated service life of the machine If the following general conditions are met the estimated service life of the machine is usually in the range of several thousand oper ating hours n Regular safety inspections by an expert qualified person n Performance of the prescribed maintenance...

Page 19: ...ualified 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 question in particular This person is acquainted with the applicable governmental indus trial safety regulations accident prevention instructions guidelines and generally acknowledged technical rules and ...

Page 20: ...luence 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 specialists Concerning your safety Definition of responsible persons BPR 35 60 21 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 21: ... from 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 every year 3 3 3 Modifications and alterations to the machine Unauthorized changes to the machine are prohibited for safety rea sons Original parts and accessories have been specially designed for ...

Page 22: ...omposition 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 protective equipment n physical and chemical properties n stability and reactivity n toxicological data n environmental data n notes on waste disposal n information on transport n legislation n other da...

Page 23: ...line Wear your personal protective outfit protective gloves protective clothing Do not inhale any fuel fumes Do not swallow gasoline Avoid contact with gasoline ENVIRONMENT Gasoline is an environmentally hazardous sub stance Always keep gasoline in proper containers Immediately bind spilled gasoline with an oil binding agent and dispose of in accordance with regulations Dispose of gasoline and fue...

Page 24: ...protective outfit protective gloves protective clothing Do not inhale any fuel stabilizer fumes Do not swallow fuel stabilizer Avoid contact with fuel stabilizer ENVIRONMENT Fuel stabilizer is an environmentally hazardous substance Immediately bind spilled fuel stabilizer with an oil binding agent and dispose of according to regulations Dispose of fuel stabilizer according to regula tions Concerni...

Page 25: ...nal 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 agent ENVIRONMENT Oil is an environmentally hazardous substance Always keep oil in proper containers Immediately bind spilled oil with an oil binding agent Dispose of oil and oil filter according to re...

Page 26: ...en 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 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 agent ENVIRONMENT Oil is a...

Page 27: ...ransport 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 capacity for the weight to be loaded Fasten the lifting gear only at the specified lifting points Danger to the life of persons if they step or stand under a sus pended load When lifting the machine avo...

Page 28: ...s 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 elements 3 6 2 Starting the engine Do not use any starting aids like start pilot or ether The machine must not be operated with damaged missing or non functional safety installations Before starting an...

Page 29: ...ional exposure limit OEL according to TRGS 900 when operating a maximum of 4 times 15 minutes per shift 8 hours For this reason take care to ensure sufficient ventilation when operating the vibratory tamper or vibratory plate in more than shoulder deep trenches which have a width of less than 1 5 metres a maximum depth of less than 3 metres or a maximum length of less than 10 metres Concerning you...

Page 30: ...from the side using 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 and edges Refrain from any work that could adversely affect the stability of the machine 3 7 3 Parking the machine Park the machine on horizontal level firm ground Before leaving the ma...

Page 31: ...lectrostatic 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 from the fuel A leaking fuel tank can cause an explosion Ensure tight fit of the fuel tank cover if necessary replace immediately Concerning your safety Refuelling BPR 35 60 32 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 ...

Page 32: ...n a sepa rate specially marked container and dispose of environmentally 3 9 3 Cleaning work Do not perform cleaning work while the motor is running Allow the engine to cool down before starting cleaning work Do not use gasoline or other easily inflammable substances for cleaning 3 9 4 Measures for longer shut down periods If the machine is taken out of operation for a longer period of time various...

Page 33: ...vant 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 Concerning your safety Repair BPR 35 60 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 34: ...mana twice annual halbjährlich tous les 6 mois cada 6 meses annual 250 h jährlich 250 h annuellement 250 h anualmente 250 h BENZIN GASOLINE if available falls vorhanden si existant si está disponible Made by Designation Type Nominal Power Operating Mass Year of Construction Serial No Patent Protection 56154 Boppard GERMANY Made in Germany WARNING California Proposition 65 Warning This product cont...

Page 35: ...formation sticker Lifting point Fig 8 WARNING California Proposition 65 Warning This product contains chemicals that cause cancer chemicals that are reproductive toxicants B DEC 0316 Fig 9 Fig 10 Fig 11 Concerning your safety Signage BPR 35 60 36 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 36: ...er Filler opening for petrol Operation sticker Throttle lever Operation sticker Travel lever Fig 12 B DEC 0216 Gasoline Benzin Fig 13 Fig 14 Fig 15 Concerning your safety Signage BPR 35 60 37 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 37: ... hebdomadairement cada semana twice annual halbjährlich tous les 6 mois cada 6 meses annual 250 h jährlich 250 h annuellement 250 h anualmente 250 h BENZIN GASOLINE if available falls vorhanden si existant si está disponible B DEC 0285 Fig 18 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 1...

Page 38: ... 0047 Fig 20 1 Protection hood optional equipment 2 Heat protection cover 3 Belt guard 4 Protection hood Concerning your safety Safety components BPR 35 60 39 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 39: ...4 Indicators and control elements Indicators and control elements BPR 35 60 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 40: ... 5 Throttle lever 6 Operating hour meter optional equipment 7 Recoil starter 8 Starter switch optional equipment 9 Locking pawl lever 10 Steering rod height adjustment Indicators and control elements BPR 35 60 42 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: ...5 Checks prior to start up Checks prior to start up BPR 35 60 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 42: ... by fuels and lubricants Safety regulations and environmental protec tion regulations must be followed when han dling fuels and lubricants Ä Chapter 3 4 Han dling fuels and lubricants on page 23 WARNING Danger of injury caused by rotating parts Before starting work on the machine make sure that the engine can not be started 1 Park the machine safely Ä Chapter 6 4 Parking the machine in secured con...

Page 43: ...lted 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 function tests BPR 35 60 45 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: ...clean cloth 3 Insert the dipstick into the oil filler socket do not screw it in but pull it out again to check the oil level ð The oil level must be between the MIN and MAX marks 4 NOTICE Danger of engine damage Do not fill in too much engine oil If the oil level is too low top up oil to the MAX mark 5 Screw the oil dipstick in B SYM 1068 Fig 22 B 834 0026 MAX MIN 1 Fig 23 Checks prior to start up...

Page 45: ...l through a screen filter Use only fuel of the permitted specification Ä Chapter 8 2 2 Fuel on page 67 Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 4 Parking the machine in secured condition on page 57 2 Clean the area around the filling port 3 Remove the cap and check the filling level visually 4 If necessary fill in fuel through ...

Page 46: ...1 Check the rubber buffer pairs left and right for tight fit cracks and tear offs ð Replace damaged rubber buffers immediately B SYM 1073 Fig 26 B 692 0140 Fig 27 Checks prior to start up Checking the rubber buffers BPR 35 60 48 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 47: ...6 Operation Operation BPR 35 60 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 48: ... down the steering rod ð The steering rod can swing freely 2 Adjust the steering rod with the height adjustment 1 to the required height Fig 28 Operation Folding down the steering rod BPR 35 60 50 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 49: ...n 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 Working clothes n Safety shoes The engine does not start if the oil level is too low 1 Fold down the steering rod and adjust it 2 Fully open the fuel tap B HON 0035 Fig 29 Operation Starting the engine BPR 35 60 51 G...

Page 50: ... the throttle lever to MIN position 5 Set the handle to 0 position 6 Turn the starter switch to ON position B HON 0037 Fig 30 B 692 0023 Fig 31 B 695 0004 Fig 32 B 834 0079 ON OFF I 0 Fig 33 Operation Starting the engine BPR 35 60 52 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 51: ...chine NOTICE The starter rope may tear off Do not pull the starter rope all the way against the end stop Pull the starter handle quickly and with power 11 Manually guide the starter handle back to initial position 12 If the engine does not start during the first attempt repeat the starting process Full engine protection hood optional equipment B SWI 1698 Fig 34 Fig 35 Fig 36 Operation Starting the...

Page 52: ...ll load 15 If the engine stops again after approx 3 to 5 seconds n Close the choke again n Repeat the starting procedure If the recoil starter is frequently operated with the choke closed the engine will draw in too much fuel and is unable to start Ä Chapter 9 4 What to do if the engine has flooded on page 108 B HON 0038 Fig 37 Operation Starting the engine BPR 35 60 54 G o t o D i s c o u n t E q...

Page 53: ... an 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 Operate the machine only with full throttle Set the throttle lever to MAX position 3 Shift the handle forwards ð The machine vibrates forward with a speed which corre sponds to the travel lever position ...

Page 54: ...rottle lever to MIN position idle speed ð Vibration is switched off 7 For short work interruptions you should always park the machine in secured condition Ä Chapter 6 4 Parking the machine in secured condition on page 57 1 Keep shifting the throttle lever between MIN and MAX positions At the same time use the steering rod to pull the machine right and left until it comes free B 695 0006 Fig 40 B 6...

Page 55: ... speed but let it idle for about two minutes Turn the starter switch to OFF position ð The engine is shut down 4 Switch starter switch to Left position ð The engine is shut down B 692 0023 Fig 44 B 834 0080 OFF 0 ON I Fig 45 Full engine protection hood optional equipment B SWI 1699 Fig 46 Operation Parking the machine in secured condition BPR 35 60 57 G o t o D i s c o u n t E q u i p m e n t c o ...

Page 56: ...5 Close the fuel valve completely B HON 0036 Fig 47 Operation Parking the machine in secured condition BPR 35 60 58 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 57: ...7 Loading transporting the machine Loading transporting the machine BPR 35 60 59 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: ...kle 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 Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 4 Parking the machine in secured condition on page 57 2 Allow the engine to cool down 3 If necessary remove the tra...

Page 59: ...s Lift the machine carefully and set down again at the intended location A B B 695 0032 Fig 49 Fig 50 A Machine with standard protection hood B Machine with full engine protec tion hood optional equipment Loading transporting the machine Loading the machine BPR 35 60 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 60: ...ctive equipment n Working clothes n Safety shoes n Protective gloves 1 Pull at least two suitable lashing belts crosswise across the marked lashing point 2 Lash the machine securely to the transport vehicle as shown A B B 695 0033 Fig 51 A Machine with standard protection hood B Machine with full engine protec tion hood Loading transporting the machine Lashing the machine to the transport vehicle ...

Page 61: ...osition and engage the locking pawl lever securely 3 Remove the split pin and pull the transport wheels out of the holding fixture on the steering rod 4 Stand to the side at the front of the machine and tip the machine forward using the steering rod B 692 0029 Fig 52 B 692 0030 Fig 53 B 695 0012 Fig 54 Loading transporting the machine Transport wheels BPR 35 60 63 G o t o D i s c o u n t E q u i p...

Page 62: ...pposite side and secure it with the split pin 8 Fold down the steering rod and engage the locking pawl lever 1 securely ð The machine can now be moved B 692 0032 Fig 55 B 692 0033 Fig 56 1 B 692 0037 Fig 57 Loading transporting the machine Transport wheels BPR 35 60 64 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 63: ...8 Maintenance Maintenance BPR 35 60 65 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 64: ...Park the machine on horizontal level firm ground Perform maintenance work only with the engine shut down and the spark plug connector disconnected Make sure that the engine cannot be accidentally started during maintenance work Thoroughly clean machine and engine before starting maintenance work Do not leave any tools or other objects that could cause damage in or on the machine After maintenance ...

Page 65: ...ratures SAE 10W 30 is recommended for general use You may alternatively use 15W 40 except under low tempera tures 8 2 1 3 Oil change intervals Oil change interval semi annually or every 100 operating hours 8 2 2 Fuel 8 2 2 1 Fuel quality Use unleaded gasoline with a research octane number of 91 or higher or octane number 86 or higher Use unleaded standard grade gasoline with maximum 10 percent by ...

Page 66: ...the following specifications n API CI 4 or higher quality Avoid mixing engine oils NOTICE Components may get damaged Do not use low ash engine oils for the exciter shaft housing 8 2 4 Mineral oil based hydraulic oil The hydraulic system is operated with hydraulic oil HV 32 ISO with a kinematic viscosity of 32 mm2 s at 40 C 104 F When refilling or changing oil use only hydraulic oil type HVLP accor...

Page 67: ...hapter 8 2 2 2 Fuel stabil izer on page 68 009 940 20 as required Exciter shaft housing SAE 10W 40 Specification Ä Chapter 8 2 3 Oil for exciter shaft housing on page 68 Components may get damaged Do not use low ash engine oils for the exciter shaft housing 0 4 l 0 11 gal us SAE 15W 40 SAE 10W 30 Steering rod Hydraulic oil ISO HV 32 Specification Ä Chapter 8 2 4 Mineral oil based hydraulic oil on ...

Page 68: ...ce on page 76 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 Ä Chapter 8 10 4 Servicing the V belt on page 97 7 Check the oil level in the exciter shaft housing Ä Chapter 8 10 5 Checking the oil level in the exciter housing on page 98 Maintenance Running in instru...

Page 69: ... 8 8 7 Changing the oil in the exciter housing 86 8 8 8 Checking the hydraulic oil level 88 Every 2 years every 500 operating hours 8 9 1 Changing the hydraulic oil 91 As required 8 10 1 Cleaning the cooling fins and the cooling air intake openings 94 8 10 2 Cleaning the machine 95 8 10 3 Checking cleaning the spark plug 96 8 10 4 Servicing the V belt 97 8 10 5 Checking the oil level in the excite...

Page 70: ...filter ele ment If in doubt use a new air filter Protective equipment n Working clothes n Safety shoes n Protective gloves n Safety goggles 1 Park the machine safely Ä Chapter 6 4 Parking the machine in secured condition on page 57 2 Allow the engine to cool down 3 Unscrew wing nut 1 and remove cover 2 4 Clean the cover 5 Unscrew wing nut 3 and remove filter element 4 6 Check the rubber seal 5 rep...

Page 71: ...element until it is free of dust 9 In case of excessive dirt replace the paper element 10 Clean the foam element 5 in warm soapy water rinse it and let it dry thoroughly 11 Soak the foam element in clean engine oil and press exces sive oil out 12 Check both elements thoroughly for holes and cracks 13 Replace if damaged 14 Pull the foam rubber element over the paper element Checking cleaning the ai...

Page 72: ...rectly and tighten it with the wing nut 3 17 Tighten the cover 2 with the wing nut 1 18 Dispose of the filter element if replaced in an environmen tally friendly way Assembling the air filter B HON 0033 1 2 3 4 5 Fig 63 Maintenance Weekly BPR 35 60 74 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 73: ...ective equipment protective gloves protective clothing Avoid touching hot components Clean the area around oil dipstick 1 and drain plug 2 3 Unscrew the oil dipstick 4 Unscrew the drain plug and collect any oil running out 5 Clean the drain plug and screw it back in tightening torque 15 Nm 11 ft lbf 6 Fill in fresh oil up to the bottom edge of the filler bore 7 Screw the oil dipstick in 8 Check fo...

Page 74: ...g spanner 5 Check the electrode gap of the new spark plug with a feeler gauge if necessary adjust the gap ð Nominal value 0 7 0 8 mm 0 028 0 032 in 6 Screw in the new spark plug carefully by hand 7 Once the sealing surface of the new spark plug is in contact tighten for another 1 2 turn with the spark plug spanner 8 8 2 Checking adjusting the valve clearance Perform this maintenance work at the la...

Page 75: ... centre position of the compres sion stroke For this purpose align the alignment mark 2 on the starter disc to the top bore 1 Valve clearance Intake valve IN 0 08 mm 0 003 in Exhaust valve EX 0 10 mm 0 004 in 1 Check the valve clearance with a feeler gauge between rocker arm 2 and valve shaft 1 on both valves adjust if necessary Preparations Fig 68 Fig 69 Checking the valve clearance Fig 70 Mainte...

Page 76: ...anger to life caused by explosive gas air mixes Do not allow gasoline to come into contact with hot components Smoking and open fire is prohibited Keep away from heat sources sparks and other sources of ignition Do not spill any gasoline Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 4 Parking the machine in secured condition on page...

Page 77: ...n a non inflammable solvent dry them thoroughly afterwards 6 Open the fuel valve and collect running out fuel 7 Close the fuel valve B HON 0036 Fig 73 1 2 3 B HON 0040 Fig 74 B HON 0035 Fig 75 Maintenance Annually BPR 35 60 79 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 78: ...off the fuel hose 13 Unscrew the fuel strainer 3 with the seal 2 14 Clean the fuel strainer check the condition of the screen replace if necessary 15 Turn the fuel strainer tightly in with the new seal 16 Assemble the fuel hose with the hose clamp 1 2 3 A 1 B HON 0039 Fig 76 A View from below Alignment of filter during installation 1 2 B 834 0038 Fig 77 2 1 B 834 0039 3 Fig 78 Maintenance Annually...

Page 79: ...thes n Safety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 4 Parking the machine in secured condition on page 57 2 Allow the engine to cool down 3 Unscrew wing nut 1 and remove cover 2 4 Clean the cover 5 Unscrew wing nut 3 and remove filter element 4 6 Check the rubber seal 5 replace if necessary The rubber seal frequently sticks to the filter element 1 2 B 834 0038 Fig 79 B HO...

Page 80: ...rubber seal 5 11 Insert the filter element 4 correctly and fasten it with the wing nut 3 12 Fasten the cover 2 with the wing nut 1 13 Dispose of the old filter element in an environmentally friendly way 8 8 5 Replacing the V belt Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 4 Parking the machine in secured condition on page 57 2 Al...

Page 81: ...t pulley 2 ð Nominal value 327 1 mm 12 9 0 04 in If the centre distance is incorrect contact our customer service 10 Fasten the guard plate tightening torque 15 Nm 11 ft lbf 11 Fasten the V belt guard 1 8 8 5 1 Checking the frequency of the base plate Keep feet and hands clear of the vibrating base plate 1 B 692 0151 Fig 83 B 692 0150 2 1 Fig 84 B 692 0183 x 1 2 Fig 85 1 B 692 0151 Fig 86 Maintena...

Page 82: ...nt e g Sirometer ð Nominal value Ä Chapter 2 Technical data on page 11 5 Park the machine safely Ä Chapter 6 4 Parking the machine in secured condition on page 57 6 If frequency incorrect n Check the engine speed n Check the V belt n If necessary contact our customer service 8 8 6 Replacing the starter rope Protective equipment n Working clothes n Protective gloves 1 Park the machine in secured co...

Page 83: ...1 7 Untie the knots of the starter rope at both ends and remove the old starter rope 8 Thread in the new starter rope 3 and fix it with knots on both ends 9 CAUTION Danger of injury caused by the starter handle hitting against your body Do not let the starter handle hit back Remove the fixing of the coil and run the starter handle slowly back to initial position 10 Pull the starter handle to check...

Page 84: ...chine on level ground 2 Park the machine safely Ä Chapter 6 4 Parking the machine in secured condition on page 57 3 Clean the area around the bleeding screw 1 and filling drain plug 2 4 Tilt the machine slightly towards the oil drain side and secure it properly 5 Unscrew the bleeding screw 6 Unscrew the filling drain plug and collect any oil running out Fig 92 1 2 B 692 0009 Fig 93 Maintenance Ann...

Page 85: ...eck the oil level ð Nominal value Bottom edge of filling drain 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 B 692 0010 Fig 94 1 2 B 692 0011 Fig 95 Maintenance Annually BPR 35 60 87 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...

Page 86: ... Move the steering rod to an upright position and engage the locking pawl lever securely 3 Clean the area around the oil level inspection plug and unscrew the plug 4 Press the handle forward against the end stop and hold it in this position B 692 0029 Fig 96 B 695 0013 Fig 97 B 695 0016 Fig 98 Maintenance Annually BPR 35 60 88 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...

Page 87: ...a around the filler plug and unscrew the filler plug 7 Press the handle forward against the stop and secure it in this position using suitable means B 695 0014 Fig 99 Topping up hydraulic oil and bleeding the hydraulic system B 695 0015 Fig 100 B 695 0016 Fig 101 Maintenance Annually BPR 35 60 89 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 88: ...t leaking oil 12 Fill in oil through the filler bore until it starts to run out through the level inspection bore 13 Retighten the filler and level inspection plugs 14 Pull the locking pawl lever 1 and fold down the steering rod B 692 0049 Fig 102 HV 32 B 695 0017 Fig 103 Concluding work 1 B 692 0037 Fig 104 Maintenance Annually BPR 35 60 90 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 ...

Page 89: ...e the steering rod to an upright position and engage the locking pawl lever securely 3 Clean the area around the filler plug and unscrew the filler plug 4 Press the handle forward against the stop and secure it in this position using suitable means B 692 0029 Fig 105 B 695 0015 Fig 106 B 695 0016 Fig 107 Maintenance Every 2 years every 500 operating hours BPR 35 60 91 G o t o D i s c o u n t E q u...

Page 90: ...se only oil of the permitted specification 9 Fill in oil through the filler bore until it starts to run out through the level inspection bore 10 Slacken the bleeding screw 11 Wait until all air has escaped and then tighten the bleeding screw B 692 0072 Fig 108 B 695 0013 Fig 109 HV 32 B 695 0017 Fig 110 B 692 0072 Fig 111 Maintenance Every 2 years every 500 operating hours BPR 35 60 92 G o t o D i...

Page 91: ...n plugs 14 Pull the locking pawl lever 1 and fold down the steering rod 15 Dispose of oil in line with environmental regulations HV 32 B 695 0017 Fig 112 1 B 692 0037 Fig 113 Maintenance Every 2 years every 500 operating hours BPR 35 60 93 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 92: ...goggles 1 Park the machine in secured condition Ä Chapter 6 4 Parking the machine in secured condition on page 57 2 Allow the engine to cool down 3 Remove dried dirt with a suitable brush from all cooling fins and cooling air intake openings 4 CAUTION Danger of eye injuries caused by particles flying around Wear your personal protective equipment safety gloves protective working clothes goggles Bl...

Page 93: ...nation and have any leaks sealed by our customer service 8 10 2 Cleaning the machine NOTICE Danger of engine damage caused by reduced cooling Immediately seal any oil or fuel leaks near fuel tank cylinder or cooling air intake 1 Park the machine in secured condition Ä Chapter 6 4 Parking the machine in secured condition on page 57 2 Allow the engine to cool down for at least 30 minutes NOTICE Comp...

Page 94: ...he spark plug clean if necessary 6 In case of excessive combustion residues or burned off elec trodes replace the spark plug Ä Chapter 8 8 1 Replacing the spark plug on page 76 7 Check the electrode gap of the spark plug with a feeler gauge if necessary adjust the gap ð Nominal value 0 7 0 8 mm 0 028 0 032 in 8 Carefully screw in the spark plug by hand 9 Once the sealing surface of the used spark ...

Page 95: ...ard 1 4 Check condition and tension of V belt ð Compression measurement 5 15 mm 0 2 0 6 in 5 The V belt cannot be re tightened Replace the V belt if it is damaged or if the compression measurement is exceeded Ä Chapter 8 8 5 Replacing the V belt on page 82 6 Fasten the V belt guard 1 1 B 692 0151 Fig 117 Fig 118 1 B 692 0151 Fig 119 Maintenance As required BPR 35 60 97 G o t o D i s c o u n t E q ...

Page 96: ...gine oils for the exciter shaft housing 6 Unscrew the filling drain plug and check the oil level top up if necessary ð Nominal value Bottom 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 10 6 Measures prior to extended shut down period 8 10 6 1 Measures before shutting down DANGER Dan...

Page 97: ...of the manufacturer 2 Empty the fuel tank and fill it with the prepared fuel mix 3 Start the engine and run the machine for approx 10 minutes in the open 4 Park the machine in secured condition 1 Close the fuel valve 2 Disassemble the drain plug 3 and the seal 4 from the car burettor and collect leaking fuel 3 Disassemble the filter bowl 2 and the O ring 1 4 Open the fuel valve and collect running...

Page 98: ... store the machine under cover in a dry and well ventilated room 2 Repair damaged paint preserve bare areas thoroughly with anti corrosive agent 3 Cover the engine to protect it against dust and moisture 4 A machine with conserved engine must be clearly marked by attaching an information sign 8 10 6 2 Measures before restarting DANGER Danger to life caused by explosive gas air mixes Do not allow g...

Page 99: ...es and lines for cracks and leaks 4 Check the service life of hydraulic hoses and replace if nec essary 5 Clean the machine thoroughly 6 Start the engine and run it for 15 to 30 minutes with idle speed Maintenance As required BPR 35 60 101 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 100: ...9 Troubleshooting Troubleshooting BPR 35 60 103 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 101: ...refore 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 Troubleshooting Preliminary remarks BPR 35 60 104 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 102: ...fety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 4 Parking the machine in secured condition on page 57 2 Press the handle forward against the end stop and hold it in this position 3 Carefully loosen the filler screw 1 ð The air makes a slight hissing sound when escaping 4 Wait until all air has escaped and then tighten the filler screw Release pressure from the steering rod 1 B...

Page 103: ...e recoil starter Starter rope of recoil starter does not return to initial position 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 Low engine power Air filter clogged Clean the air filter replace if necessary Throttle cable defective Have checked by qualified exper...

Page 104: ...Check the engine oil level correct if nec essary Engine runs with high speed but no vibration Centrifugal clutch defective Have checked by qualified expert per sonnel V belt broken Replacing the V belt Troubleshooting Engine malfunctions BPR 35 60 107 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 105: ...quipment n Working clothes n Safety shoes n Protective gloves n Safety goggles Special tool n 13 16 inch spark plug spanner 1 Allow the engine to cool down 2 Close the fuel valve 3 Pull off the spark plug socket 4 Unscrew the spark plug using a 13 16 inch spark plug spanner 5 Have a cloth ready to soak up the fuel B HON 0036 Fig 126 B 834 0029 Fig 127 Troubleshooting What to do if the engine has f...

Page 106: ...0 7 0 8 mm 0 028 0 032 in 12 Screw the used spark plug carefully in by hand and once the sealing surface of the used spark plug is in contact tighten it for another 1 8 to 1 4 turn with the spark plug spanner 13 Once the sealing surface of the new spark plug is in contact tighten for another 1 2 turn with the spark plug spanner NOTICE Danger of engine damage caused by a loose spark plug Always scr...

Page 107: ...10 Disposal Disposal BPR 35 60 111 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: ...rks and other sources of ignition Do not spill any gasoline Components that previously contained gaso line must not be cut with a cutting torch WARNING Health hazard caused by fuels and lubricants Safety regulations and environmental protec tion regulations must be followed when han dling fuels and lubricants Ä Chapter 3 4 Han dling fuels and lubricants on page 23 Protective equipment n Working cl...

Page 109: ...11 List of special tools List of special tools BPR 35 60 113 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: ...park plug spanner Fig Sirometer Measuring instrument for speed and frequency BOMAG 059 710 02 Fig List of special tools BPR 35 60 114 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 ...

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

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