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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 Download Page 98

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.

Troubleshooting – Preliminary remarks

 

BPR 35/60 D

 

100

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Summary of Contents for BOMAG BRP 35/60 D

Page 1: ... plate Operating Instruction Maintenance Instruction Original Operating Instructions S N 101 695 24 1001 03 2019 008 204 48 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: ...ety 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 diesel fuel 24 3 4 3 Safety regulations and environmental protection regulations for handling oil 25 3 4 4 Safety regulations and environmental protection regulations for handling hydraulic oil 26 3 4 5 Safety regulations and environmental ...

Page 5: ... Maintenance 63 8 1 Preliminary remarks and safety notes 64 8 2 Preparations concluding work 65 8 2 1 Opening the protection hood 65 8 3 Fuels and lubricants 66 8 3 1 Engine oil 66 8 3 2 Fuel 66 8 3 3 Oil for exciter shaft housing 67 8 3 4 Mineral oil based hydraulic oil 67 8 4 List of fuels and lubricants 69 8 5 Running in instructions 70 8 5 1 General 70 8 5 2 After 25 operating hours 70 8 6 Mai...

Page 6: ...4 8 11 3 Servicing the V belt 95 8 11 4 Checking the oil level in the exciter housing 96 8 11 5 Measures prior to extended shut down period 96 9 Troubleshooting 99 9 1 Preliminary remarks 100 9 2 Starting the engine with the recoil starter 101 9 3 Starting the engine with jump leads 104 9 4 Fuse assignment 105 9 5 Engine faults 106 9 6 Malfunctions during operation 108 10 Disposal 109 10 1 Final s...

Page 7: ...1 Introduction Introduction BPR 35 60 D 7 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 8: ...e 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 maint...

Page 9: ...t 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 D 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 ...

Page 10: ...ermany 1 2 B DEC 0270 Fig 1 Machine type plate example EMISSION CONTROL INFORMATION MOTORENFABRIK HATZ KG D 94099 RUHSTORF GMBH CO Model S N Power Displ Eng Fam Emission Control System Power Category ULTRA LOW SULFUR DIESEL FUEL ONLY FOR MY2018 NONROAD DIESEL ENGINES EU Type www hatz diesel com Build PV E1 1 2 B HAT 0045 Fig 2 Introduction Machine type plate and engine type plate BPR 35 60 D 10 G ...

Page 11: ...2 Technical data Technical data BPR 35 60 D 11 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 12: ...for paving stones 730 28 7 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 245 540 kg lbs Basic weight 242 534 kg lbs STONEGUARD optional equipment 23 51 kg lbs Dimensions Technical data BPR 35 60 D 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 13: ...eability depending on soil 32 Drive Engine manufacturer Hatz Type 1B20 Cooling Air Number of cylinders 1 Rated power ISO 3046 3 1 4 2 kW hp Rated speed 3000 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 Amplitude with STONEGUARD 1 16 0 046 mm in Technical data BPR 35 60 D 13 G o t o D i s c o u n t E q u i p m e n ...

Page 14: ...acc to ISO 11201 and EN 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 4 0 m s2 on crushed rock determined acc to ISO 5349 and EN 500 Associated unc...

Page 15: ...3 Concerning your safety Concerning your safety BPR 35 60 D 15 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 16: ...ffic 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 wit...

Page 17: ...isposal 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 18: ...ompaction 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 imp...

Page 19: ...tions 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 20: ...alified 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 r...

Page 21: ...uence 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 D 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 22: ...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 t...

Page 23: ...mposition 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 dat...

Page 24: ...ent pro tective gloves protective clothing Do not inhale any fuel fumes Avoid contact CAUTION Danger of slipping on spilled diesel fuel Immediately bind spilled diesel fuel with an oil binding agent ENVIRONMENT Diesel fuel is an environmentally hazardous substance Always keep diesel fuel in proper containers Immediately bind spilled diesel fuel with an oil binding agent and dispose of properly Dis...

Page 25: ...al 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 reg...

Page 26: ...n 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 an...

Page 27: ...tion WARNING Danger of injury caused by exploding gas mix ture Remove the plugs before starting to recharge the battery Ensure adequate ventilation Smoking and open fire is prohibited Do not lay any tools or other metal objects on the battery Do not wear jewellery watch bracelets etc when working on the battery Wear your personal protective equipment pro tective gloves protective clothing goggles ...

Page 28: ...ansport 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 avoi...

Page 29: ... 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 and...

Page 30: ...rom 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 mac...

Page 31: ...a higher sulphur content Apply measures against electrostatic charging Do not spill any fuel Catch running out fuel do not let it seep into the ground Wipe off spilled fuel Keep dirt and water away 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 D 31 G o t o D i s c o u n t...

Page 32: ...ainer and dispose of environmentally 3 9 3 Maintenance work on electric components and battery Before starting to work on electric parts of the machine disconnect the battery and cover it with insulating material Do not use fuses with higher ampere ratings and do not bridge fuses When working on the battery smoking or open fire is prohibited Do not lay any tools or other metal objects on the batte...

Page 33: ...ance 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 3 9 6 After maintenance work Reassemble all guards and protections Concerning your safety Maintenance work BPR 35 60 D 33 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: ...ant 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 D 34 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 35: ...us les 6 mois cada 6 meses annual 250 h jährlich 250 h annuellement 250 h anualmente 250 h DIESEL 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 1 4 4 4 1 2 2 2 3 3 3 1 OPERATION START STOP 0 1 2 MINUTEN 1 2 MINUTEN STOP STOP MIN MIN MAX MAX STAR...

Page 36: ...sticker Lashing point Information sticker Lifting point Information sticker Guaranteed sound capacity level Fig 9 Fig 10 Fig 11 Fig 12 Concerning your safety Signage BPR 35 60 D 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 37: ...ada semana twice annual halbjährlich tous les 6 mois cada 6 meses annual 250 h jährlich 250 h annuellement 250 h anualmente 250 h DIESEL if available falls vorhanden si existant si está disponible B DEC 0274 Fig 15 B DEC 0242 008 307 65 1 4 4 4 1 2 2 2 3 3 3 1 OPERATION START STOP 0 1 2 MINUTEN 1 2 MINUTEN STOP STOP MIN MIN MAX MAX START Fig 16 Concerning your safety Signage BPR 35 60 D 37 G o t o...

Page 38: ...on Type Nominal Power Operating Mass Year of Construction Serial No Patent Protection 56154 Boppard GERMANY Made in Germany B DEC 0271 Fig 17 Fig 18 Concerning your safety Signage BPR 35 60 D 38 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: ...0046 Fig 19 1 Protection hood optional equipment 2 Heat protection cover 3 Belt guard 4 Protection hood Concerning your safety Safety components BPR 35 60 D 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 40: ...4 Indicators and control elements Indicators and control elements BPR 35 60 D 41 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 41: ...r 2 Starter switch 3 Operating hour meter 4 Handle 5 Throttle lever 6 Locking pawl lever 7 Steering rod height adjustment Indicators and control elements BPR 35 60 D 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 42: ...5 Checks prior to start up Checks prior to start up BPR 35 60 D 43 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 43: ...ulations 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 condition on page 55 2 Open and secure the protection hood Ä Chapter 8 2 1 Openi...

Page 44: ...ted 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 D 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 45: ...pe it clean with a lint free clean cloth 3 Insert the dipstick and 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 Push the dipstick in B SYM 1068 Fig 21 B HAT 0003 Fig 22 Checks prior to start up Checking the engine oil level B...

Page 46: ... Ä Chapter 8 3 2 Fuel on page 66 Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Clean the area around the filling port 2 Remove the cap and check the filling level visually 3 If necessary fill in fuel through a funnel with screen filter 4 Close the cap B SYM 1069 Fig 23 B 692 0019 Fig 24 Checks prior to start up Checking the fuel level topping up fuel BPR 35 60 D 47 G ...

Page 47: ...achine in secured condition on page 55 2 Allow the engine to cool down 3 Check all rubber buffers for tight fit cracks and tear offs 4 Replace damaged rubber buffers immediately B SYM 1073 Fig 25 B 695 0023 Fig 26 Checks prior to start up Checking the rubber buffers BPR 35 60 D 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 48: ...6 Operation Operation BPR 35 60 D 49 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 49: ...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 27 Operation Folding down the steering rod BPR 35 60 D 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 50: ...quate ventilation when working in trenches WARNING Loss of hearing caused by too high noise bur dens Wear your personal protective equipment ear protection Protective equipment n Hearing protection n Working clothes n Safety shoes 1 Set the throttle lever to position MIN 2 Set the handle to position 0 B 692 0023 Fig 28 B 695 0004 Fig 29 Operation Starting the engine BPR 35 60 D 51 G o t o D i s c ...

Page 51: ... Then allow the starter to cool down to ambient temperature If the engine has not started after these attempts determine the cause Turn the ignition key through position II to position III ð The starter cranks the engine The warning buzzer stops NOTICE Danger of engine damage Warm up engine for a short while before starting work Do not operate the engine immediately under full load B ELE 0070 Fig ...

Page 52: ...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 B...

Page 53: ...ottle 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 55 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 34 B 69...

Page 54: ...engine all of a sudden from full load speed but let it idle for about two minutes Set the throttle lever to position Stop ð The engine is shut down The warning buzzer sounds 4 Turn the ignition key to position 0 and pull it out ð The warning buzzer stops Fig 38 Fig 39 Fig 40 Operation Parking the machine in secured condition BPR 35 60 D 55 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 ...

Page 55: ...7 Loading transporting the machine Loading transporting the machine BPR 35 60 D 57 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 56: ...le must not be damaged by machine parts When lifting the machine make sure the load does not move in an uncontrolled way If necessary hold the load steady with guide ropes Protective equipment n 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 55 2 Allow the engine to cool down 3 If necessary remove the tran...

Page 57: ...ads Lift the machine carefully and set down again at the intended location A B B 695 0024 Fig 42 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 D 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: ...tive 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 0026 Fig 43 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 B...

Page 59: ...sition 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 44 B 692 0030 Fig 45 B 695 0012 Fig 46 Loading transporting the machine Transport wheels BPR 35 60 D 61 G o t o D i s c o u n t E q u i ...

Page 60: ...posite 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 47 B 692 0033 Fig 48 1 B 692 0037 Fig 49 Loading transporting the machine Transport wheels BPR 35 60 D 62 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 61: ...8 Maintenance Maintenance BPR 35 60 D 63 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

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

Page 63: ... doors again and return all components to their operating condition 8 2 1 Opening the protection hood 1 2 1 2 2 A B B 692 0035 Fig 50 A Standard protection hood B Full engine protection hood optional equipment 1 Unscrew the screws 2 on both sides of the machine 2 Loosen the screws 1 on both sides and fold the protection hood forwards Maintenance Preparations concluding work BPR 35 60 D 65 G o t o ...

Page 64: ...gine oil especially at low ambient temperatures Optimal operating conditions can be achieved by using the oil vis cosity chart as reference 8 3 1 3 Oil change intervals Annually or every 250 operating hours When changing to a higher alloyed oil quality after a longer period of operation it is recommended to perform the first oil change of the higher quality oil already after 25 operating hours 8 3...

Page 65: ... not permitted Copper containing materials copper lines brass items should be avoided because they can cause catalytic reactions in the fuel with subsequent depositing in the injection system 8 3 3 Oil for exciter shaft housing Use only engine oils according to the following specifications n API CI 4 or higher quality Avoid mixing engine oils NOTICE Components may get damaged Do not use low ash en...

Page 66: ...he viscosity index must be at least 150 observe information of manufacturer Maintenance Fuels and lubricants BPR 35 60 D 68 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 67: ...W 30 SAE 30 SAE 10W Fuel Diesel Winter diesel fuel 3 0 l 0 8 gal us Specification Ä Chapter 8 3 2 Fuel on page 66 Exciter shaft housing as engine oil 0 4 l 0 11 gal us Steering rod Hydraulic oil ISO HV 32 Specification Ä Chapter 8 3 4 Mineral oil based hydraulic oil on page 67 0 4 l 0 11 gal us Maintenance List of fuels and lubricants BPR 35 60 D 69 G o t o D i s c o u n t E q u i p m e n t c o m ...

Page 68: ...Checking adjusting the valve clearance on page 84 3 Check engine and machine for leaks 4 Retighten the fastening screws on air filter exhaust and other attachment parts 5 Retighten the bolted connections on the machine 6 Check the V belt Ä Chapter 8 11 3 Servicing the V belt on page 95 7 Check the oil level in the exciter shaft housing Ä Chapter 8 11 4 Checking the oil level in the exciter housing...

Page 69: ...e 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 Every 2 years every 500 operating hours 8 10 1 Changing the hydraulic oil 91 As required 8 11 1 Cleaning the cooling fins and the cooling air intake openings 94 8 11 2 Cleaning the machine 94 8 11 3 Servicing the V belt 95 8 11 4 Checking the oil level in the ex...

Page 70: ...bt use a new air filter Protective equipment n Working clothes n Safety shoes n Protective gloves n Safety goggles 1 Park the machine safely Ä Chapter 6 4 Parking the machine in secured condition on page 55 2 Allow the engine to cool down 3 Remove the cap 3 4 Unscrew the knurled nut 2 and pull out the air filter 1 5 Clean the cover 6 NOTICE Danger of engine damage Prevent dirt from getting into th...

Page 71: ... element until it is free of dust 8 Examine the air filter with a torch for cracks and holes 9 Replace the air filter if it is damaged 10 Insert the air filter 1 carefully into the filter housing and fasten it with the knurled nut 2 11 NOTICE Danger of engine damage Ensure correct fit of air filter cover and seal Close the cap 3 B GEN 0042 Fig 54 B HAT 0006 1 2 3 Fig 55 Maintenance Weekly BPR 35 6...

Page 72: ...otective gloves 1 Park the machine safely Ä Chapter 6 4 Parking the machine in secured condition on page 55 2 Place the transparent container under the drain plug 3 Loosen the drain plug and collect escaping fluid 4 Drain the fuel off until there is no water left 5 Screw the drain plug back in tightly Ensure leak tightness 6 Dispose of collected fluid in line with environmental regula tions B SYM ...

Page 73: ...Ä Chapter 6 4 Parking the machine in secured condition on page 55 2 Remove the battery box cover 3 Remove the battery 2 and the vibration damping mats 1 3 4 5 4 Check the condition of the vibration insulation mats replace if necessary 5 Clean the outside of the battery 6 Clean battery poles and pole clamps and grease them with pole grease Vaseline 7 Install the battery and vibration damping mats a...

Page 74: ...9 Assemble the battery box cover B 692 0038 Fig 61 Maintenance Semi annually BPR 35 60 D 76 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 75: ...ine in secured condition Ä Chapter 6 4 Parking the machine in secured condition on page 55 2 Clean the area around the dipstick and pull the dipstick out 3 Clean the area around the drain plug 4 WARNING Danger of burning on hot components Wear your personal protective equipment protective gloves protective clothing Avoid touching hot components Unscrew the oil drain plug 2 with the seal ring 1 and...

Page 76: ... out from inside to outside 8 Check the seal ring 2 for damage change if necessary 9 Slightly oil the seal rings 1 and 2 10 Insert the oil filter 2 into the housing and press it against the end stop 11 Before tightening the screw 1 make sure that the tensioning springs touch the oil filter with both ends 12 Tighten the screw Cleaning the oil filter Fig 63 Fig 64 Fig 65 Maintenance Annually BPR 35 ...

Page 77: ...ective equipment n Working clothes n Safety shoes n Protective gloves 1 Park the machine on level ground 2 Park the machine safely Ä Chapter 6 4 Parking the machine in secured condition on page 55 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 drai...

Page 78: ...spose of oil in line with environmental regulations 8 9 3 Replacing the air filter NOTICE Danger of engine damage Do not start the engine after having removed the air filter Protective equipment n Working clothes n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 4 Parking the machine in secured condition on page 55 2 Allow the engine to cool down 3 Remove the cap 3 4 Unscrew ...

Page 79: ...nd seal Close the cap 3 8 9 4 Replacing the fuel filter NOTICE Danger of engine damage Ensure strict cleanliness Thoroughly clean the area around the fuel tank beforehand Never operate the engine after having removed the fuel filter Protective equipment n Working clothes n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 4 Parking the machine in secured condition on page 55 2 ...

Page 80: ... 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 55 2 Allow the engine to cool down 3 Unscrew the V belt guard 1 4 Unscrew the guard 2 5 Unscrew the V belt pulley 1 6 Replace the V belt 7 If necessary reassemble the spacers that may have been removed 8 Fasten the V belt pulley tighten...

Page 81: ...e Always keep an eye on a running machine Protective equipment n Working clothes n Hearing protection n Safety shoes Special tool n Sirometer 1 Park the machine on a rubber mat 2 Start the engine Ä Chapter 6 2 Starting the engine on page 51 3 Run the machine at maximum speed for one minute 4 Check the base plate s frequency with a suitable measuring instrument e g Sirometer ð Nominal value Ä Chapt...

Page 82: ...let the engine cool down Protective equipment n Working clothes n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 4 Parking the machine in secured condition on page 55 2 Let the engine to cool down to ambient temperature 3 Remove the air filter cover 2 4 Disassemble the covering 1 5 Unscrew the fastening screws 1 6 Remove the valve cover 2 with gasket Preparations Fig 77 Fig ...

Page 83: ...arance on the exhaust valve adjust if necessary 1 Loosen screw 3 on the rocker arm 2 Adjust the hexagon nut 2 until the feeler gauge 1 can be inserted and pulled out with noticeable resistance after the screw 3 has been tightened 1 Install the valve cover 2 with a new gasket 2 Tighten the fastening screws 1 evenly Checking the valve clearance Fig 79 Adjusting the valve clearance Fig 80 Final work ...

Page 84: ...n page 55 2 Allow the engine to cool down 3 Unscrew the fastening screws 1 and disassemble the recoil starter 2 4 Pull the starter rope with the starter handle 1 out com pletely 5 Secure the coil 2 against winding up 6 Loosen the knot 3 in the starter rope and remove the old starter rope 7 Carefully turn the coil back until the recoil spring is relieved Fig 82 Fig 83 Fig 84 Maintenance Annually BP...

Page 85: ...used by the starter handle hitting against your body Do not let the starter handle hit back Slowly guide the starter handle back to initial position 11 Pull the starter handle to check the function and light move ment of the recoil starter 12 Assemble the recoil starter 2 with fastening screws 1 Fig 85 Fig 86 Fig 87 Fig 88 Maintenance Annually BPR 35 60 D 87 G o t o D i s c o u n t E q u i p m e n...

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 89 B 695 0013 Fig 90 B 695 0016 Fig 91 Maintenance Annually BPR 35 60 D 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 ...

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 92 Topping up hydraulic oil and bleeding the hydraulic system B 695 0015 Fig 93 B 695 0016 Fig 94 Maintenance Annually BPR 35 60 D 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 95 HV 32 B 695 0017 Fig 96 Concluding work 1 B 692 0037 Fig 97 Maintenance Annually BPR 35 60 D 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 d...

Page 89: ...ve 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 98 B 695 0015 Fig 99 B 695 0016 Fig 100 Maintenance Every 2 years every 500 operating hours BPR 35 60 D 91 G o t o D i s c o u n t E q ...

Page 90: ...e 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 101 B 695 0013 Fig 102 HV 32 B 695 0017 Fig 103 B 692 0072 Fig 104 Maintenance Every 2 years every 500 operating hours BPR 35 60 D 92 G o t o D ...

Page 91: ... 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 105 1 B 692 0037 Fig 106 Maintenance Every 2 years every 500 operating hours BPR 35 60 D 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: ...fety gloves protective working clothes goggles Blow out the cooling fins and cooling air intake openings with compressed air 5 In case of damp or oily contamination you should consult our customer service department 8 11 2 Cleaning the machine 1 Park the machine in secured condition Ä Chapter 6 4 Parking the machine in secured condition on page 55 2 Allow the engine to cool down for at least 30 mi...

Page 93: ...rd 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 9 5 Replacing the V belt on page 82 6 Fasten the V belt guard 1 1 B 692 0151 Fig 109 Fig 110 1 B 692 0151 Fig 111 Maintenance As required BPR 35 60 D 95 G o t o D i s c o u n t E q...

Page 94: ... 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 11 5 Measures prior to extended shut down period 8 11 5 1 Measures before shutting down If the machine is shut down for a longer period of time e g winter season the following work must be carri...

Page 95: ...g devices e g ignition light 2 Measure the open circuit voltage of the battery at regular intervals at least 1 x per month ð Reference values 12 6 V fully charged 12 3 V dis charged to 50 3 Recharge the battery immediately after an open circuit voltage of 12 25 V or less is reached Do not perform boost charging ð The open circuit voltage of the battery occurs approx 10 hours after the last chargin...

Page 96: ...es hoses and lines for cracks and leaks 5 Check the service life of hydraulic hoses and replace if nec essary 6 Start the engine and run it for 15 to 30 minutes with idle speed 7 Check the oil levels 8 Clean the machine thoroughly Maintenance As required BPR 35 60 D 98 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 97: ...9 Troubleshooting Troubleshooting BPR 35 60 D 99 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 98: ...efore 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 D 100 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 99: ... closed or partly closed rooms or ensure adequate ventilation when working in trenches WARNING Loss of hearing caused by too high noise bur dens Wear your personal protective equipment ear protection Protective equipment n Hearing protection n Working clothes n Safety shoes 1 Fold down the steering rod and adjust it 2 Set the throttle lever to position MIN B 692 0023 Fig 113 Troubleshooting Starti...

Page 100: ...achine 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 7 Manually guide the starter handle back to initial position 8 If the engine does not start during the first attempt repeat the starting process B 695 0004 Fig 114 Fig 115 Fig 116 Troubleshooting Starting the engine with the recoil starter BPR 35 ...

Page 101: ...f engine damage Warm up engine for a short while before starting work Do not operate the engine immediately under full load Troubleshooting Starting the engine with the recoil starter BPR 35 60 D 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 102: ...ry using the first jump lead 3 Next connect the second jump lead to the minus pole of the energizing external battery and then to the minus pole of the starter battery 4 Start the engine Ä Chapter 6 2 Starting the engine on page 51 5 After starting disconnect the minus poles first and the plus poles after 6 Assemble the battery box cover Fig 117 Troubleshooting Starting the engine with jump leads ...

Page 103: ...the machine Do not use fuses with higher ampere ratings and do not bridge fuses Pos Amperage Designation 1 25 A Main fuse Fig 118 Troubleshooting Fuse assignment BPR 35 60 D 105 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 104: ...ing Check the pre tension of the spring adjust if necessary Spring broken Replace the recoil starter Engine ignites but does not run Fuel filter clogged Check the fuel filter replace if necessary The starter does not switch on or the engine does not crank Fault in the electric system n Battery or other cable connections not correctly connected n Cable terminals loose or oxidised n Battery defectiv...

Page 105: ...ified expert per sonnel Engine overheats Engine oil level too high Check drain off if necessary Lack of cooling air Clean the cooling fins and the cooling air intake openings Check air guide plates and ducts for com pleteness and good sealing Engine runs with high speed but no vibration Centrifugal clutch defective Have checked by qualified expert per sonnel V belt broken Replace the V belt Troubl...

Page 106: ...ety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 4 Parking the machine in secured condition on page 55 2 Press the handle forward against the end stop and hold it in this position 3 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 107: ...10 Disposal Disposal BPR 35 60 D 109 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 108: ...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 clothes n Safety shoes n Protective gloves n Safety goggles 1 Remove the batteries 2 Empty the fuel tank 3 Drain engine oil from engine and exciter housing 4 Drain off hydraulic oil Di...

Page 109: ...11 List of special tools List of special tools BPR 35 60 D 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 110: ...Sirometer Measuring instrument for speed and frequency BOMAG 059 710 02 Fig List of special tools BPR 35 60 D 112 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 111: ...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...

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