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Fayat BOMAG BPR 35/60 D, Operating Instructions Manual

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Summary of Contents for BOMAG BPR 35/60 D

Page 1: ... plate Operating Instruction Maintenance Instruction Original Operating Instructions S N 101 692 80 1007 11 2017 008 203 26 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: ...e defects 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 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 5 Loading transpor...

Page 4: ... 2 Fuel 62 8 3 3 Oil for exciter shaft housing 63 8 3 4 Mineral oil based hydraulic oil 63 8 4 List of fuels and lubricants 65 8 5 Running in instructions 66 8 5 1 General 66 8 5 2 After 25 operating hours 66 8 6 Maintenance Table 67 8 7 Weekly 68 8 7 1 Checking cleaning the air filter 68 8 7 2 Checking cleaning the water separator 69 8 8 Annually 71 8 8 1 Changing the engine oil and cleaning the ...

Page 5: ...shooting 87 9 1 Preliminary remarks 88 9 2 Engine faults 89 9 3 Malfunctions during operation 91 10 Disposal 93 10 1 Final decommissioning of machine 94 Table of contents BPR 35 60 D 5 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 6: ...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 7: ...e notes on safety to be followed can be found in chapter Operation Ä Chapter 6 Operation on page 45 Before every start up carry out all required visual inspections and function tests Ä Chapter 5 Checks prior to start up on page 39 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 8: ...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 9: ... Serial number 2 Please enter here Engine type 1 Engine number 2 Fig 1 Machine type plate example Fig 2 Engine type plate example Introduction Machine type plate and engine type plate BPR 35 60 D 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 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 11: ...cial base plate for paving stones 698 27 5 830 32 7 1230 48 4 1545 60 8 832 32 8 630 24 8 Dimensions in millimetres Dimensions in inch Weights Operating weight CECE 225 496 kg lbs Basic weight 222 489 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 12: ...m min ft min Max gradeability 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...

Page 13: ...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 1 m s2 on crushed rock determined acc to ISO 5349 and EN 500 Associated unc...

Page 14: ...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 15: ...d traffic regulations n country 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 with...

Page 16: ...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 17: ...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 18: ...ting 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 35 60 D 19 G o t o D i s c o u n t E q u...

Page 19: ...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 20: ...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 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 t...

Page 22: ...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 23: ...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 24: ...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 25: ...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 26: ...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 27: ... 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 28: ...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 29: ...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 30 G o t o D i s c o u n t...

Page 30: ...atch 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 cool...

Page 31: ...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 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 r t s ...

Page 32: ... K 0 7 0 8mm 0 03 0 032inch AIR Made by Designation Type Nominal Power Operating Mass Year of Construction Serial No Patent Protection 56154 Boppard GERMANY Made in Germany 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 7 Concerning your safety Signage 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...

Page 33: ...tion sticker Lashing point Information sticker Lifting point Information sticker Ultra low sulphur fuel Fig 8 Fig 9 Fig 10 Fig 11 Concerning your safety Signage 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 34: ...y level Operation sticker Throttle lever Operation sticker Travel lever Maintenance sticker Fig 12 Fig 13 Fig 14 Fig 15 Concerning your safety Signage BPR 35 60 D 35 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: ...g 16 Made by Designation Type Nominal Power Operating Mass Year of Construction Serial No Patent Protection 56154 Boppard GERMANY Made in Germany B DEC 0241 Fig 17 B HAT 0030 Fig 18 Fig 19 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 36: ...4 Indicators and control elements Indicators and control elements BPR 35 60 D 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: ...r 2 Travel lever 3 Handle 4 Throttle lever 5 Locking pawl lever 6 Steering rod height adjustment Indicators and control elements 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 38: ...5 Checks prior to start up Checks prior to start up 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 39: ... 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 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 in secured condition Ä Chapter 6 4 Parking the m...

Page 40: ...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 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: ...ipe it clean with a lint free clean cloth 3 Screw the dipstick back in 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 Screw the oil dipstick in Fig 21 Checks prior to start up Checking the engine oil level BPR 35 60 D 42 G ...

Page 42: ...rmitted specification Ä Chapter 8 3 2 Fuel on page 62 Protective equipment n Working clothes n Protective gloves 1 Clean the area around the filler opening 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 Fig 22 Checks prior to start up Checking the fuel level topping up fuel BPR 35 60 D 43 G o t o D i s c o u n t...

Page 43: ... Parking the machine in secured condition on page 51 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 Fig 23 Checks prior to start up Checking the rubber buffers BPR 35 60 D 44 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: ...6 Operation Operation 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: ...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 24 Operation Folding down the steering rod BPR 35 60 D 46 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 46: ...rking in trenches 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 1 Set the throttle lever to position MIN 2 Shift the travel lever to position 0 Fig 25 Fig 26 Operation Starting the engine BPR 35...

Page 47: ...st the end stop Pull the starter handle quickly and with power 6 Manually guide the starter handle back to initial position 7 If the engine does not start during the first attempt repeat the starting process 8 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 f...

Page 48: ...hine 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 29 Fig 30 Operation Operation BPR 35...

Page 49: ...ou 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 4 Parking the machine in secured condition on page 51 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 co...

Page 50: ...wn 3 NOTICE Danger of engine damage Do not shut down the 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 Fig 35 Fig 36 Operation Parking the machine in secured condition BPR 35 60 D 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: ...7 Loading transporting the machine Loading transporting the machine BPR 35 60 D 53 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: ...ad If necessary hold the load with guide ropes Protective equipment n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 4 Parking the machine in secured condition on page 51 2 Allow the engine to cool down 3 Remove the transport wheels from the base plate 4 Move the steering rod to an upright position and engage the locking pawl lever 5 Attach the lifting tackle to the designat...

Page 53: ...ifting and lashing gear must not be damaged by machine compo nents Protective equipment n Protective gloves 1 Fasten the lashing gear to the marked lashing point 1 2 Lash the machine securely to the transport vehicle Fig 39 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 BPR 35 60 D 55...

Page 54: ...od to an upright position and engage the locking lever 3 Disassemble the split pin and take the wheels out of the holder 4 Stand to the side at the front of the machine and tip the machine forward using the steering rod Fig 40 Fig 41 Fig 42 Loading transporting the machine Transport wheels BPR 35 60 D 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 55: ...n the opposite side and secure it with the split pin 8 Fold down the steering rod and engage the locking pawl lever 1 in working position ð The machine can now be moved Fig 43 Fig 44 Fig 45 Loading transporting the machine Transport wheels 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: ...8 Maintenance Maintenance 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 57: ...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 58: ...tenance flaps and doors again and return all components to their operating condition 8 2 1 Open protection hood Fig 46 A Standard protection hood B Full engine protection hood optional equipment 1 Remove 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 61 G o t o D i s c o u n t ...

Page 59: ...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 60: ... 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 61: ...he viscosity index must be at least 150 observe information of manufacturer Maintenance Fuels and lubricants BPR 35 60 D 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 62: ...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 62 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 63 0 4 l 0 11 gal us Maintenance List of fuels and lubricants BPR 35 60 D 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 ...

Page 63: ...Checking adjusting the valve clearance on page 77 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 8 5 Servicing the V belt on page 76 7 Check the oil level in the exciter shaft housing Maintenance Running in instructions BPR 35 60 D 66 G o t o D i s c o...

Page 64: ...ilter 74 8 8 4 Replacing the fuel filter 75 8 8 5 Servicing the V belt 76 8 8 6 Checking adjusting the valve clearance 77 8 8 7 Replacing the starter rope 79 8 8 8 Checking the hydraulic oil level 82 As required 8 9 1 Cleaning the cooling fins and the cooling air intake openings 84 8 9 2 Cleaning the machine 84 8 9 3 Measures prior to extended shut down period 85 Maintenance Maintenance Table BPR ...

Page 65: ...ele ment If in doubt use a new air filter Protective equipment n Working clothes n Protective gloves n Safety goggles 1 Park the machine in secured condition Ä Chapter 6 4 Parking the machine in secured condition on page 51 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 fro...

Page 66: ... 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 8 7 2 Checking cleaning the water separator The service intervals for the water separator depend on the water content in the fuel and can therefore not be determined precisely After taking the en...

Page 67: ...arent container under the drain plug 3 Loosen the drain plug and collect running out fluid 4 Drain the fuel off until there is no water left 5 Turn the drain plug tightly back in Ensure leak tightness 6 Dispose of collected fluid in an environmentally friendly way Fig 51 Maintenance Weekly BPR 35 60 D 70 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 68: ...ine in secured condition Ä Chapter 6 4 Parking the machine in secured condition on page 51 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 69: ... 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 53 Fig 54 Fig 55 Maintenance Annually BPR 35 ...

Page 70: ... 65 Protective equipment n Working clothes n Protective gloves 1 Park the machine on level ground 2 Park the machine in secured condition Ä Chapter 6 4 Parking the machine in secured condition on page 51 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 filli...

Page 71: ...0 16 11 Dispose of oil in an environmentally friendly way 8 8 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 51 2 Allow the engine to cool down 3 Remove the cap 3 4 Un...

Page 72: ...nd seal Close the cap 3 8 8 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 51 2 ...

Page 73: ...ctive 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 51 2 Allow the engine to cool down 3 Disassemble the V belt guard 1 1 Check condition and tension of V belt ð Compression measurement 5 15 mm 0 2 0 6 in 2 The V belt cannot be re tightened Replace the V belt if it is damaged or if the compress...

Page 74: ...ngine 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 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 51 2 Let the engine to cool down to ambient temperature Replacing the V b...

Page 75: ...e until the exhaust valve EX is fully open 2 Check the valve clearance on the intake valve IN with a feeler gauge 1 adjust if necessary 3 Crank the engine further until the intake valve is fully open 4 Check the valve clearance on the exhaust valve adjust if necessary Fig 67 Fig 68 Checking the valve clearance Fig 69 Maintenance Annually BPR 35 60 D 78 G o t o D i s c o u n t E q u i p m e n t c o...

Page 76: ...1 and air filter cover 2 4 After a short test run check the valve cover for leaks 8 8 7 Replacing the starter rope 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 51 2 Allow the engine to cool down Adjusting the valve clearance Fig 70 Final work Fig 71 Fig 72 Maintenance Annually BPR 3...

Page 77: ...d starter rope 7 Carefully turn the coil back until the recoil spring is relieved 8 Thread in the new starter rope and fix it with knots on both ends A 15 mm 0 6 in 9 Pre tension the coil by approx 4 rotations in direction of arrow Thereby place the starter rope into the recess in the coil Fig 73 Fig 74 Fig 75 Fig 76 Maintenance Annually BPR 35 60 D 80 G o t o D i s c o u n t E q u i p m e n t c o...

Page 78: ...y 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 77 Fig 78 Maintenance Annually BPR 35 60 D 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 79: ...he 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 79 Fig 80 Fig 81 Topping up hydraulic oil and bleeding the hydraulic syst...

Page 80: ...l 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 82 Fig 83 Fig 84 Concluding work Fig 85 Maintenance Annually BPR 35 60 D 83 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 81: ...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 9 2 Cleaning the machine 1 Park the machine in secured condition Ä Chapter 6 4 Parking the machine in secured condition on page 51 2 Allow the engine to cool down for at least 30 min...

Page 82: ...out more than 300 operating hours ago 5 Change the fuel filter 6 After shutting down store the machine under cover in a dry and well ventilated room 7 Protect the cooled down engine against dust and moisture 8 9 3 2 Measures before restarting 1 Replace the fuel filter 2 Replace the air filter 3 Change the engine oil and clean the oil filter 4 Check cables hoses and lines for cracks and leaks 5 Sta...

Page 83: ...9 Troubleshooting Troubleshooting 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 t c o m t o o r d e r y o u r p a r t s ...

Page 84: ...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 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 a r t s ...

Page 85: ... 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 Engine stops Fuel tank empty Check the fuel level top up if necessary Fuel filter clogged Check the fuel filter replace if necessary Tank ventilation blocked Ensure sufficient ventilation of the tank Air in the fuel system Check ...

Page 86: ... 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 Troubleshooting Engine faults 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 e r y o u r p a r t s ...

Page 87: ...gloves 1 Park the machine in secured condition Ä Chapter 6 4 Parking the machine in secured condition on page 51 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 88: ...10 Disposal Disposal 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 89: ...y 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 Empty the fuel tank 2 Drain engine oil from engine and exciter housing 3 Drain off hydraulic oil Disposal Final decommissioning of machine BPR...

Page 90: ...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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