Fayat Bomag BPR 25/40 Operating Instructions Manual Download Page 6

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8.8.7 Changing the oil in the exciter housing...................................................................................... 87
8.8.8 Checking the hydraulic oil level.................................................................................................. 89

8.9 Every 2 years / every 500 operating hours

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8.9.1 Changing the hydraulic oil.......................................................................................................... 91

8.10 As required

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Troubleshooting

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101

9.1 Preliminary remarks

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102

9.2 Malfunctions during operation

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103

9.3 Engine malfunctions

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104

9.4 What to do if the engine has flooded

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106

Disposal

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109

10.1 Final shut-down of machine

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110

List of special tools

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111

Table of contents

BPR 25/40

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Summary of Contents for Bomag BPR 25/40

Page 1: ...ating Instruction Maintenance Instruction Original Operating Instructions S N 101 692 50 1001 S N 101 692 96 1001 07 2018 008 202 71 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: ...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 and environmental protection regulatio...

Page 5: ...rt vehicle 63 7 3 Transport wheels 64 8 Maintenance 67 8 1 Preliminary remarks and safety notes 68 8 2 Fuels and lubricants 69 8 2 1 Engine oil 69 8 2 2 Fuel 69 8 2 3 Oil for exciter shaft housing 70 8 2 4 Mineral oil based hydraulic oil 70 8 3 List of fuels and lubricants 71 8 4 Running in instructions 72 8 4 1 General 72 8 4 2 After 25 operating hours 72 8 5 Maintenance Table 73 8 6 Weekly 74 8 ...

Page 6: ... the spark plug 95 8 10 4 Servicing the V belt 96 8 10 5 Checking the oil level in the exciter housing 97 8 10 6 Cleaning the machine 97 8 10 7 Measures for longer shut down periods 98 9 Troubleshooting 101 9 1 Preliminary remarks 102 9 2 Malfunctions during operation 103 9 3 Engine malfunctions 104 9 4 What to do if the engine has flooded 106 10 Disposal 109 10 1 Final shut down of machine 110 11...

Page 7: ...1 Introduction Introduction BPR 25 40 7 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 8: ...he notes on safety to be followed can be found in chapter Operation Ä Chapter 6 Operation on page 51 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 9: ...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 25 40 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 10: ...de by Designation Type Nominal Power Operating Mass Year of Construction Serial No Patent Protection 56154 Boppard GERMANY Made in Germany 1 2 B DEC 0270 Fig 1 Engine type and engine number Fig 2 Introduction Machine type plate and engine type plate BPR 25 40 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 11: ...2 Technical data Technical data BPR 25 40 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: ...ensions in inch Weights Operating weight CECE 135 298 kg lbs Basic weight 132 291 kg lbs Water spraying system optional equipment 13 29 kg lbs Transport wheels optional equipment 4 9 kg lbs Dimensions Technical data BPR 25 40 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: ...W hp Rated speed 3600 min 1 Drive system mechanical Exciter system Frequency 85 5100 Hz vpm Centrifugal force 25 5620 kN lbf Amplitude 1 55 0 061 mm in Water sprinkling system optional equipment Type of sprinkling Gravity feed Filling capacities Fuel gasoline 3 1 0 8 l gal us Water 12 0 3 2 l gal us Technical data BPR 25 40 13 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 14: ... 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 2 m s2 on crushed rock determined acc to ISO 5349 and EN 500 Associated uncertainty K 0 3 m s2 det...

Page 15: ...3 Concerning your safety Concerning your safety BPR 25 40 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: ...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 17: ...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 18: ...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 19: ...fting tackle must be removed before starting work Starting and operating the machine in explosive environments and in underground mining is prohibited The lifting and lashing points specified in these instructions must be used It is prohibited to use other lifting and lashing points e g guide handle steering rod Concerning your safety Basic prerequisites BPR 25 40 19 G o t o D i s c o u n t E q u ...

Page 20: ...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 21: ...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 25 40 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 ...

Page 23: ...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 24: ...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 25: ...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 26: ...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 27: ...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 28: ...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 29: ...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 30: ...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 31: ...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 32: ...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 25 40 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 33: ...catch running out oil and dispose of environ mentally When working on the air filter no dirt should fall into the air duct Do not work on the hot exhaust danger of burning Store used filters and other oil contaminated materials in 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 coo...

Page 34: ...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 25 40 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: ...n Serial No Patent Protection 56154 Boppard GERMANY Made in Germany before taking into operation vor Inbetriebnahme avant la mise en service anterior a la puesta en servicio weekly wöchentlich 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...

Page 36: ... sticker Lashing point Information sticker Lifting point Information sticker Guaranteed sound capacity level Fig 8 Fig 9 Fig 10 Fig 11 Concerning your safety Signage BPR 25 40 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: ...pening for water Operation sticker Throttle lever Operation sticker Travel lever B DEC 0216 Gasoline Benzin Fig 12 B DEC 0218 Water Fig 13 Fig 14 Fig 15 Concerning your safety Signage BPR 25 40 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 38: ... 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 17 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 18 Concerning your safety Signage BP...

Page 39: ...4 Indicators and control elements Indicators and control elements BPR 25 40 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: ...ater spraying system 2 Travel lever 3 Handle 4 Steering rod height adjustment 5 Locking bolt 6 Throttle lever Indicators and control elements Machine BPR 25 40 40 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 41: ...ig 20 1 Start switch 2 Throttle lever 3 Choke lever 4 Recoil starter 5 Fuel valve Indicators and control elements Engine BPR 25 40 41 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 42: ...5 Checks prior to start up Checks prior to start up BPR 25 40 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: ... 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 5 Parking the machine in secured con...

Page 44: ...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 25 40 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: ...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 21 B 834 0026 MAX MIN 1 Fig 22 Checks prior to start up...

Page 46: ...l through a screen filter Use only fuel of the permitted specification Ä Chapter 8 2 2 Fuel on page 69 Protective equipment n Working clothes n Safety shoes n Protective gloves 1 Park the machine safely Ä Chapter 6 5 Parking the machine in secured condition on page 60 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 47: ...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 25 B 692 0140 Fig 26 Checks prior to start up Checking the rubber buffers BPR 25 40 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: ...ater supply in the water tank NOTICE Dirty or contaminated water can block the bore holes Fill only with clean water 3 If necessary fill in clean water 4 Close the cap Alternatively the water tank can also be removed and transported for filling 1 Pull the spraying hoses off the valve Water B 692 0230 Fig 27 B 692 0233 Fig 28 Checks prior to start up Checking the water level topping up BPR 25 40 49...

Page 49: ...e tank grip 2 and pull the water tank out in an upwards movement 1 2 B 692 0231 Fig 29 Checks prior to start up Checking the water level topping up BPR 25 40 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: ...6 Operation Operation BPR 25 40 51 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: ...ing rod ð The steering rod can swing freely 3 Adjust the steering rod with the height adjustment 1 to the required height 4 Engage the locking pin securely Fig 30 Operation Folding down the steering rod BPR 25 40 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 52: ... WARNING Loss of hearing caused by too high noise bur dens Wear your personal protective equipment ear protection Operate the machine only with the steering rod folded down and adjusted to height Protective equipment n Hearing protection 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 Fig 31 Operation Startin...

Page 53: ...s Close the choke 4 Set the throttle lever to position MIN 5 Shift the travel lever to position 0 6 Turn the starter switch to position ON Fig 32 Fig 33 Fig 34 Fig 35 Operation Starting the engine BPR 25 40 54 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 54: ...ter handle back to initial position 11 If the engine does not start during the first attempt repeat the starting process 12 Open the choke bit by bit when the engine is running 13 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 14 If the engine stop...

Page 55: ...oke 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 106 Operation Starting the engine BPR 25 40 56 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: ...chine Always keep an eye on a running machine Protective equipment n Hearing protection n Safety shoes 1 NOTICE The centrifugal clutch may be damaged Operate the machine only with full throttle Set the throttle lever to MAX position 2 Shift the travel lever forward ð The machines vibrates forward with a speed which corre sponds with the travel lever position Fig 39 Fig 40 Operation Operation BPR 2...

Page 57: ...you should always return the throttle lever to MIN position idle speed ð Vibration is switched off 6 For short work interruptions you should always park the machine in secured condition Ä Chapter 6 5 Parking the machine in secured condition on page 60 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 c...

Page 58: ... Position 0 Water spraying system off Turn anticlockwise Water spraying system on infinite adjustment of the spraying quantity up to MAX position 0 MAX B 692 0232 Fig 45 Operation Switching the water spraying system on off BPR 25 40 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 59: ...age Do not shut down the engine all of a sudden from full load speed but let it idle for about two minutes Turn the starter switch to position OFF ð The engine is shut down 4 Close the fuel valve completely Fig 46 Fig 47 Fig 48 Operation Parking the machine in secured condition BPR 25 40 60 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: ...7 Loading transporting the machine Loading transporting the machine BPR 25 40 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 61: ...n lifting the machine avoid uncontrolled movements of the load If necessary hold the load with guide ropes Protective equipment n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 5 Parking the machine in secured condition on page 60 2 Allow the engine to cool down 3 Pull and turn the locking bolt 1 4 Move the steering rod to an upright position and engage the locking bolt secu...

Page 62: ...ion of load application Lifting tackle must not be damaged by machine components Protective equipment 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 Fig 51 Loading transporting the machine Lashing the machine to the transport vehicle BPR 25 40 63 G o t o D i s c o u n t E q u i p...

Page 63: ...od to an upright position and engage the locking bolt securely 4 Remove the split pin and pull the transport wheels out of the holding fixture on the steering rod 5 Stand to the side at the front of the machine and tip the machine forward using the steering rod Fig 52 Fig 53 Fig 54 Loading transporting the machine Transport wheels BPR 25 40 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 ...

Page 64: ...sport wheel on the opposite side and secure it with the split pin 9 Fold down the steering rod and engage the locking bolt 1 securely ð The machine can now be moved Fig 55 Fig 56 Fig 57 Loading transporting the machine Transport wheels BPR 25 40 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 65: ...8 Maintenance Maintenance BPR 25 40 67 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 66: ...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 67: ...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 68: ...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 69: ...l stabil izer on page 70 009 940 20 as required Exciter shaft housing SAE 10W 40 Specification Ä Chapter 8 2 3 Oil for exciter shaft housing on page 70 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 70 0 4 l 0 11...

Page 70: ...ce on page 78 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 96 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 97 Maintenance Running in instru...

Page 71: ... oil in the exciter housing 87 8 8 8 Checking the hydraulic oil level 89 Every 2 years every 500 operating hours 8 9 1 Changing the hydraulic oil 91 As required 8 10 1 Cleaning the water spraying system 93 8 10 2 Cleaning the cooling fins and the cooling air intake openings 93 8 10 3 Checking cleaning the spark plug 95 8 10 4 Servicing the V belt 96 8 10 5 Checking the oil level in the exciter hou...

Page 72: ...e or hot fluids to clean the filter element Do not continue to use a damaged air 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 5 Parking the machine in secured condition on page 60 2 Allow the engine to cool down 3 Unscrew wing nut 1 and remove cover 2 4 Clean the cov...

Page 73: ...ine 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 15 Check cyclone housing 3 for dirt remove if necessary 16 Clean the cyclone housing and air duct 2 with water 17 Dry the components thoroughly NOTICE Danger of engine damage Insert the air duct correctly Carefully insert the scree...

Page 74: ...al 4 20 Insert the filter element 5 correctly and tighten it with the wing nut 3 21 Tighten the cover 2 with the wing nut 1 Installing the air filter B 692 0148 1 2 3 4 5 Fig 64 Maintenance Weekly BPR 25 40 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: ...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 76: ...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 77: ... 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 69 Fig 70 Checking the valve clearance Fig 71 Mainte...

Page 78: ...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 Protective gloves 1 Park the machine in secured condition Ä Chapter 6 5 Parking the machine in secured condition on page ...

Page 79: ...nflammable solvent dry them thoroughly afterwards 6 Open the fuel valve and collect running out fuel 7 Close the fuel valve Fig 74 Fig 75 A View from below Alignment of filter during installation Fig 76 Maintenance Annually BPR 25 40 81 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 80: ... 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 17 Assemble the fuel tank with hexagon nuts 2 and hexagon screw 1 18 Check the fuel system for leaks 19 Dispose of fuel and replaced components in an environmen tally friendly way Fig 77 A View from below Alignment of f...

Page 81: ...ition on page 60 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 5 6 Check the rubber seal 4 replace if necessary The rubber seal frequently sticks to the filter element 7 Replace the filter element consisting of paper and foam insert B 692 0148 1 2 3 4 5 Fig 81 Fig 82 Maintenance Annually BPR 25 40 83 G o t o...

Page 82: ... 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 5 Parking the machine in secured condition on page 60 2 Allow the engine to cool down 3 Unscrew the V belt guard 1 B 692 0148 1 2 3 4 5 Fig 83 1 B 692 0151 Fig 84 Maintenance Annually BPR 25 40 84 G o t o D i s c o u n t E q ...

Page 83: ...machine 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 53 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...

Page 84: ...on page 60 2 Allow the engine to cool down 3 Disassembling the recoil starter 4 Pull the starter rope with the starter handle out completely 5 If the starter rope has been torn or the coil has recoiled com pletely n Before assembling the rope turn the coil 2 5 revolutions in anti clockwise direction and align the rope openings in coil and housing 5 to one another A Fig 87 Fig 88 Fig 89 Maintenance...

Page 85: ... 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 the function and light move ment of the recoil starter 11 Assemble the recoil starter 8 8 7 Changing the oil in the exciter housing NOTICE Components may get damaged Use only oil of the permitted specification Ä Chapter 8 3 List of fuels and lubr...

Page 86: ...lt 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 8 Fill in new oil 9 Stand the machine horizontally and check 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 n...

Page 87: ...the filler screw 4 Press the travel lever forward against the end stop and hold it in this position 5 The oil level must reach the mark on the steering rod head if necessary fill in hydraulic oil Mark approx 40 mm 1 6 in below the filler opening NOTICE Components may get damaged Use only oil of the permitted specification Fig 96 Fig 97 Fig 98 Topping up hydraulic oil and bleeding the hydraulic sys...

Page 88: ... 8 Slacken the bleeding screw 9 Wait until all air has escaped and then tighten the bleeding screw 10 Fill in hydraulic oil up to the mark on the steering rod head 11 Screw in the filler plug Fig 99 Fig 100 Fig 101 Concluding work Fig 102 Maintenance Annually BPR 25 40 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 e r y o u r p a r t s ...

Page 89: ...ight adjustment so that the area with the filler screw is horizontal 3 Unscrew the filler screw 4 Press the travel lever forward against the end stop and secure it using suitable means 5 Unscrew the bleeding screw and collect any oil running out 6 Screw in the bleeding screw B 692 0045 Fig 103 B 692 0048 Fig 104 B 692 0072 Fig 105 Maintenance Every 2 years every 500 operating hours BPR 25 40 91 G ...

Page 90: ... has escaped and then tighten the bleeding screw 10 Fill in hydraulic oil up to the mark on the steering rod head 11 Screw in the filler screw 12 Dispose of oil in line with environmental regulations 40 mm HV 32 B 692 0047 Fig 106 B 692 0072 Fig 107 40 mm HV 32 B 692 0047 Fig 108 B 692 0045 Fig 109 Maintenance Every 2 years every 500 operating hours BPR 25 40 92 G o t o D i s c o u n t E q u i p m...

Page 91: ...ff again 9 Fill the water tank with clean water and close the cap 8 10 2 Cleaning the cooling fins and the cooling air intake openings How dirty the cooling fins and cooling air intake openings are depends very much on the daily operating conditions clean daily if necessary NOTICE Danger of engine damage caused by reduced cooling For this reason you should always seal any oil or fuel leaks in the ...

Page 92: ...cleaning NOTICE Components can be damaged by water entering into the system Do not direct the water jet directly into the air filter carburettor recoil starter air intake or starter switch 1 CAUTION Danger of eye injuries caused by particles flying around Wear your personal protective equipment safety gloves protective working clothes goggles Spray the engine with a suitable non inflammable cleans...

Page 93: ...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 78 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 94: ...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 84 6 Fasten the V belt guard 1 1 B 692 0151 Fig 115 Fig 116 1 B 692 0151 Fig 117 Maintenance As required BPR 25 40 96 G o t o D i s c o u n t E q ...

Page 95: ...engine 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 Cleaning the machine NOTICE Danger of engine damage caused by reduced cooling Immediately s...

Page 96: ...eason the following work must be carried out Depending on weather conditions these conservation measures will protect the machine for approx 6 to 12 months 1 Park the machine in secured condition Ä Chapter 6 5 Parking the machine in secured condition on page 60 2 Allow the engine to cool down for at least 30 minutes 3 Clean the machine thoroughly 4 Change the engine oil Ä Chapter 8 7 1 Changing th...

Page 97: ... plug spanner 2 Fill in several drops of fresh engine oil through the ignition plug opening 3 Crank the engine several times with the recoil starter to dis tribute the oil in the cylinder 4 Screw the spark plug back in 5 Slowly pull the starter rope until resistance can be felt and the alignment mark 2 on the starter disc is in line with the upper bore 1 ð Valves will be closed so that no moisture...

Page 98: ... 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 1 Check the oil levels 2 If the fuel was drained off before shutting down you must now fill in fuel 3 Check hoses and lines for cracks and leaks 4 Clean the machine thoroughly 5 Start the engine and run it for 15 to 30 minutes with...

Page 99: ...9 Troubleshooting Troubleshooting BPR 25 40 101 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: ...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 25 40 102 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: ...gloves 1 Park the machine in secured condition Ä Chapter 6 5 Parking the machine in secured condition on page 60 2 Press the travel lever forward against the end stop and hold it in this position 3 Carefully loosen the adjustment screw 1 ð The air makes a slight hissing sound when escaping 4 Wait until all air has escaped and then tighten the adjustment screw Release pressure from the steering rod...

Page 102: ...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 103: ...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 25 40 105 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: ...soline Protective equipment n Working clothes 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 Fig 124 Fig 125 Troubleshooting What to do if the engine has flooded BPR 25 40 1...

Page 105: ...inal value 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...

Page 106: ...10 Disposal Disposal BPR 25 40 109 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 107: ... 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 clothes n Safety shoes n Protective...

Page 108: ...11 List of special tools List of special tools BPR 25 40 111 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 109: ...park plug spanner Fig Sirometer Measuring instrument for speed and frequency BOMAG 059 710 02 Fig List of special tools BPR 25 40 112 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 110: ...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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