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Fayat BOMAG BPR 60/65 D, Operating Instruction, Maintenance Instruction

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Summary of Contents for BOMAG BPR 60/65 D

Page 1: ... plate Operating Instruction Maintenance Instruction Original Operating Instructions S N 101 692 98 1001 09 2016 008 202 27 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: ... 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 protection regulations for handling b...

Page 4: ... hood 61 8 3 Fuels and lubricants 62 8 3 1 Engine oil 62 8 3 2 Fuel 62 8 3 3 Mineral oil based hydraulic oil 63 8 4 List of fuels and lubricants 64 8 5 Running in instructions 65 8 5 1 General 65 8 5 2 After 25 operating hours 65 8 6 Maintenance table 66 8 7 Weekly 67 8 7 1 Checking cleaning the water separator 67 8 8 Monthly 68 8 8 1 Air filter maintenance 68 8 8 2 Cleaning the cooling fins and t...

Page 5: ...period 85 9 Troubleshooting 89 9 1 Preliminary remarks 90 9 2 Starting the engine with the recoil starter 91 9 3 Starting the engine with jump leads 94 9 4 Fuse assignment 95 9 5 Engine malfunctions 96 9 6 Malfunctions during operation 98 9 7 Trouble shooting ECONOMIZER 99 10 Disposal 101 10 1 Final shut down of machine 102 Table of contents BPR 60 65 D 5 G o t o D i s c o u n t E q u i p m e n t ...

Page 6: ...1 Introduction Introduction BPR 60 65 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: ... on safety to be followed can be found in chapter Operation Ä Chapter 6 Operation on page 47 Before every start up carry out all required visual inspections and function tests Ä Chapter 5 Tests before taking into opera tion on page 41 Ensure the compliance with the specified operating maintenance and repair measures to maintain the functional safety of your machine A description of all necessary m...

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 60 65 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 60 65 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 60 65 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: ... 29 5 Dimensions in millimetres Dimensions in inch Weights Operating weight CECE W 440 970 kg lbs Operating weight CECE W1 460 1014 kg lbs Operating weight CECE W2 471 1038 kg lbs Basic weight 455 1003 kg lbs Dimensions Technical data BPR 60 65 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: ...gradability depending on soil 35 Drive Engine manufacturer Hatz Type 1B40 Cooling Air Number of cylinders 1 Rated power ISO 3046 6 7 9 0 kW hp Rated speed 3000 min 1 Drive system mechanical Exciter system Frequency 66 3960 Hz vpm Centrifugal force 60 13489 kN lbf Amplitude 1 96 0 077 mm in Filling capacities Fuel diesel 5 0 1 3 l gal us Technical data BPR 60 65 D 13 G o t o D i s c o u n t E q u i...

Page 13: ...500 WARNING Loss of hearing caused by too high noise bur dens Wear your personal protective equipment ear protection LWA 108 dB A determined acc to ISO 3744 and EN 500 2 1 2 Vibration data Vector total of the weighted effective acceleration in three orthog onal directions Total vibration value ahv 2 5 m s2 on crushed rock determined acc to ISO 5349 and EN 500 Associated uncertainty K 0 3 m s2 dete...

Page 14: ...3 Concerning your safety Concerning your safety BPR 60 65 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: ...raffic 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 amnd 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 t...

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 protects against being caught by moving components Safety shoes...

Page 17: ... 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 improper use is the sole responsibility of the operating company or driver operator the manufacturer cannot be made liable Examples for improper use are n dragging the ma...

Page 18: ...ng work Starting and operating the machine in explosive environments and in underground mining is prohibited Concerning your safety Basic prerequisites BPR 60 65 D 19 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 19: ...lified 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 re...

Page 20: ...luence of alcohol medicine 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 60 65 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: ...e from the operation of the machine 3 3 2 Regular safety inspections Have the machine inspected by an expert capable 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: ...ctive equipment 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 Dispose of dies...

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: ...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 27: ...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 28: ... 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 29: ...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 machine n shut d...

Page 30: ...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 60 65 D 31 G o t o D i s c o u n t...

Page 31: ...ore used filters and other oil contaminated materials in a sepa rate specially marked container 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 s...

Page 32: ...3 9 5 After maintenance work Reassemble all guards and protections Concerning your safety Maintenance work BPR 60 65 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 33: ...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 60 65 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: ...good and legible condition and comply with their meaning Replace damaged and illegible stickers or decals immediately Concerning your safety Signage BPR 60 65 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: ...n sticker Lifting point 4 Information sticker Throttle lever 5 Information sticker Handle 6 Information sticker Guaranteed sound capacity level 7 Brief operating instructions Concerning your safety Signage BPR 60 65 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: ...ker Starter rope 1 Maintenance sticker Fig 9 Stickers on engine Fig 10 Maintenance sticker Concerning your safety Signage BPR 60 65 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: ...Concerning your safety Signage BPR 60 65 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: ...4 Display and control elements Display and control elements BPR 60 65 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: ...il starter 3 Operating hour meter 4 Starter switch 5 Handle 6 Throttle lever 7 Locking pawl lever 8 Steering rod height adjustment Display and control elements BPR 60 65 D 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 40: ...5 Tests before taking into operation Tests before taking into operation BPR 60 65 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: ...gulations and environmental protec tion regulations when handling fuels and lubri cants must be followed 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 Park the machine in secured condition on page 53 Tests...

Page 42: ...onnections for tight fit 3 Check machine for contamination and damage 4 Check the hydraulic oil cooler for dirt 5 Check starter rope for chafing Tests before taking into operation Visual inspections and function tests BPR 60 65 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: ...a lint free clean cloth 3 Insert the dipstick and pull it out again to check the oil level ð The oil level must always 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 immedi ately 5 Push the dipstick in Fig 12 Tests before taking into operation Checking the engine oil level BPR 60 65 D 44 G ...

Page 44: ... the permitted 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 tank filler cap 3 Fill in fuel through a funnel with screen filter 4 Close the fuel tank tightly Fig 13 Tests before taking into operation Checking the fuel level topping up fuel BPR 60 65 D 45 G o t o D i s c o u n t E q u ...

Page 45: ...ition on page 53 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 14 Tests before taking into operation Checking the rubber buffers BPR 60 65 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: ...6 Operation Operation BPR 60 65 D 47 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 47: ...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 15 Operation Folding down the steering rod BPR 60 65 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: ... 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 Safety shoes 1 Set the throttle lever to position MIN 2 Set the handle to position 0 Fig 16 Fig 17 Operation Start the engine BPR 60 65 D 49 G o t o D i s c o u n t E q u i p m e n...

Page 49: ...10 seconds 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 Run the engine warm for a short while before starting work Do not operate the engine immediately under full load ...

Page 50: ...achine 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 position MAX 2 Shift the handle forwards ð The machines vibrates forwards with a speed which cor responds with the travel lever position Fig 20 Fig 21 Operation Operation BPR 60 6...

Page 51: ...ith the handle position 4 Move the handle back to position 0 ð Machine stops and vibrates on the spot 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 Fig 22 Fig 23 Help if the machine gets stuck Fig 24 Operation Operation BPR 60 65 D 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...

Page 52: ... engine all of a sudden from full load speed but let it idle for about 2 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 25 Fig 26 Fig 27 Operation Park the machine in secured condition BPR 60 65 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 ...

Page 53: ...he dis played value can vary by one digit up down during a pass The average of the display reading during the last pass is decisive The warning display a n Flashes for 1 2 seconds after the vibration has been switched on The display goes out as soon as the vibration frequency has been reached n Flashes if the vibration frequency is too low n Lights up when at the same time the LED displays 1 10 ha...

Page 54: ...7 Loading transporting the machine Loading transporting the machine BPR 60 65 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 e r y o u r p a r t s ...

Page 55: ...damaged by machine com ponents When 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 4 Park the machine in secured condition on page 53 2 Allow the engine to cool down 3 Move the steering rod to an upright position and engage the locking lever 4 Attac...

Page 56: ...rection of load application Lifting and lashing tackle must not be damaged by machine com ponents Protective equipment n Protective gloves 1 Pull the lashing belts crosswise over the marked lashing point 1 2 Lash the machine securely to the transport vehicle as shown Fig 31 Fig 32 Loading transporting the machine Lashing the machine to the transport vehicle BPR 60 65 D 57 G o t o D i s c o u n t E...

Page 57: ...Loading transporting the machine Lashing the machine to the transport vehicle BPR 60 65 D 58 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 58: ...8 Maintenance Maintenance BPR 60 65 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 59: ...e followed Ä Chapter 3 4 Han dling fuels and lubricants on page 23 1 For all maintenance work park the machine is secured condi tion Ä Chapter 6 4 Park the machine in secured condi tion on page 53 2 Thoroughly clean machine and engine before starting main tenance work 3 Wear your personal protective outfit 4 Do not touch hot engine parts 5 Perform maintenance work only with the engine shut down 6 ...

Page 60: ...nce flaps and doors again and return all components to their operating condition 8 2 1 Open protection hood 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 3 Secure the protection hood against unintended closing by tightening the screws 1 Fig 33 Maintenance Preparations concluding work BPR 60 65 D 61 G o t o D i s c o u n...

Page 61: ...he engine oil especially at low ambient temperatures Optimal operating conditions can be achieved by using the oil vis cosity chart as a 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 ho...

Page 62: ...n sys tems Zinc and lead coatings in refuelling systems and fuel lines are 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 Mineral oil based hydraulic oil The hydraulic system is operated with hydraulic oil HV 32 ISO with a kinematic viscosity of 32 m...

Page 63: ... 30 SAE 30 SAE 10W Fuel Diesel Winter diesel fuel 5 0 l 1 3 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 3 Mineral oil based hydraulic oil on page 63 0 4 l 0 11 gal us Maintenance List of fuels and lubricants BPR 60 65 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...

Page 64: ...Checking adjusting the valve clearance on page 82 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 9 2 Servicing the V belt on page 71 7 Check the oil level in the vibrator housing Ä Chapter 8 9 1 Checking the oil level in the exciter housing on page 71 ...

Page 65: ...ng the screw joints on the diesel engine 72 Annually 8 10 1 Changing the engine oil and cleaning the oil filter 74 8 10 2 Replacing the fuel filter 76 8 10 3 Replacing the starter rope 77 8 10 4 Changing the oil in the exciter housing 78 8 10 5 Checking the hydraulic oil level 80 8 10 6 Checking adjusting the valve clearance 82 As required 8 11 1 Cleaning the machine 85 8 11 2 Measures prior to ex...

Page 66: ...ective gloves 1 Park the machine in secured condition Ä Chapter 6 4 Park the machine in secured condition on page 53 2 Place the transparent container under the drain plug 3 Slacken the drain plug and catch 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 F...

Page 67: ...ir filter must be inspected for damage using a torch 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 Protective gloves n Safety goggles 1 Park the machine in secured condition Ä Chapter 6 4 Park the machine in secured condition on page 53 2 Allow the engine to cool down 3 Remove the air filter cover 3 4 Unscrew the knur...

Page 68: ... 8 2 Cleaning the cooling fins and the cooling air intake openings Protective equipment n Working clothes n Protective gloves n Safety goggles 1 Park the machine in secured condition Ä Chapter 6 4 Park the machine in secured condition on page 53 2 Allow the engine to cool down 3 Loosen dried on dirt with a suitable brush from all cooling fins and cooling air intake openings 4 CAUTION Danger of eye...

Page 69: ...in secured condition Ä Chapter 6 4 Park the machine in secured condition on page 53 2 Remove the bracket 1 of the battery 3 Remove the battery 3 and the vibration damping mats 2 4 5 6 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 On serviceable batterie...

Page 70: ...ound oil breather screw 1 and filling drain plug 2 5 Unscrew the bleeding screw 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 bleeding screw and filler drain plug and install with sealing agent spare parts number 00970016 8 9 2 Servicing the V belt 1 Park the machine in secured condition Ä Chapter 6 4 Park the...

Page 71: ...ve been removed 5 Assemble the V belt pulley tightening torque 35 Nm 26 ft lbf 6 Assemble the guard tightening torque 15 Nm 11 ft lbf 1 Install the V belt guard 1 8 9 3 Checking the screw joints on the diesel engine 1 Park the machine in secured condition Ä Chapter 6 4 Park the machine in secured condition on page 53 2 Allow the engine to cool down Checking the V belt Fig 43 Replacing the V belt F...

Page 72: ...not retighten or adjust the setscrews on throttle control and injection system Check all screw joints on the diesel engine for condition and tight fit retighten if necessary Maintenance Semi annually BPR 60 65 D 73 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 73: ...condition Ä Chapter 6 4 Park the machine in secured condition on page 53 2 Clean the area around the dipstick and pull the dipstick out 3 Clean the area around the drain hose 4 Loosen the hose clamp 1 and route the drain hose to the outside 5 WARNING Danger of burning on hot components Wear your personal protective equipment protective gloves protective clothing Avoid touching hot components Unscr...

Page 74: ...out from inside to outside 10 Check the seal ring 2 for damage change if necessary 11 Slightly oil the seal rings 1 and 2 12 Insert the oil filter 2 into the housing and press it against the end stop 13 Before tightening the screw 1 make sure that the tensioning springs touch the oil filter with both ends 14 Tighten the screw Cleaning the oil filter Fig 47 Fig 48 Fig 49 Maintenance Annually BPR 60...

Page 75: ...hes n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 4 Park the machine in secured condition on page 53 2 Clean the area around the tank filler cap 3 Remove the tank filler cap 4 Pull the fuel filter out of the tank by the string 5 Pull the fuel hose 3 off the fuel filter 2 6 Take the fuel filter out of the bracket 1 and replace it with a new one 7 Plug on the fuel line 8 In...

Page 76: ... 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 8 Thread in the new starter rope and fix it with knots on both ends A 15 mm 0 6 in Fig 52 Fig 53 Fig 54 Maintenance Annually BPR 60 65 D 7...

Page 77: ...arter handle to check the function and light move ment of the recoil starter 12 Assemble the recoil starter 2 with fastening screws 1 8 10 4 Changing the oil in the exciter housing Perform this maintenance work at the latest after 500 operating hours NOTICE Components may get damaged Use only oil of the permitted specification Ä Chapter 8 4 List of fuels and lubri cants on page 64 Fig 55 Fig 56 Fi...

Page 78: ... protective equipment protective gloves protective clothing Avoid touching hot components Unscrew the filling drain plug and catch any oil running out 7 Tilt the machine to the opposite side and secure it properly 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 bleeding screw 1 and filling drain plug 2 and instal...

Page 79: ...l 3 Unscrew the filler plug 4 Press the handle forward against the 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 Risk of damage Use only hydraulic oil of the permitted specifi cation Fig 61 Fig 62 Fig 63 Filling up hydraulic oil Maintenance Annually BPR 60 65...

Page 80: ... 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 Unscrew the filler plug Fig 64 Fig 65 Fig 66 Final work Fig 67 Maintenance Annually BPR 60 65 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 81: ...down Protective equipment n Working clothes n Protective gloves 1 Park the machine in secured condition Ä Chapter 6 4 Park the machine in secured condition on page 53 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 68 Fig 69 Maintenance Annually...

Page 82: ...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 70 Adjusting the valve clearance Fig 71 Final work ...

Page 83: ...covering 1 and air filter cover 2 4 After a short test run check the valve cover for leaks Fig 73 Maintenance Annually BPR 60 65 D 84 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: ... avoid corrosion 8 11 2 Measures prior to extended shutdown period 8 11 2 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 carried out 1 Clean the machine thoroughly 2 Clean the water separator 3 Fill the fuel tank with diesel fuel to prevent the formation of condensation water in the tank 4 Change engine oil if th...

Page 85: ...arge 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 charging process or one hour after the last discharge 4 Switch off the charging current before removing the charging clamps 5 After each charging process allow the battery to rest for one hour before t...

Page 86: ...6 Check the oil levels 7 Clean the machine thoroughly Maintenance As required BPR 60 65 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 87: ...Maintenance As required BPR 60 65 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 88: ...9 Troubleshooting Troubleshooting BPR 60 65 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 89: ...efore thoroughly read these instruction on correct oper ation 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 60 65 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 90: ...hale exhaust gases Avoid operation in 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 Safety shoes 1 Set the throttle lever to position MIN Fig 75 Troubleshooting Starting the engine with the recoil starte...

Page 91: ... not pull the starter rope all the way against 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 NOTICE Danger of engine damage Run the engine warm for a short while before starting work Do not operate the engine immediately under full load Fig ...

Page 92: ...Troubleshooting Starting the engine with the recoil starter BPR 60 65 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 93: ...pole of the starter battery using the first jump lead 4 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 5 Start the engine Ä Chapter 6 2 Start the engine on page 49 6 After starting disconnect the minus poles first and the plus poles after 7 Install the bracket of the battery 8 Close the protection hood Fig 79...

Page 94: ...use fuses with higher ampere ratings and do not bridge fuses Pos Amperage Designation 1 5 A Economizer fuse optional equipment 2 25 A Main fuse Fig 80 Troubleshooting Fuse assignment BPR 60 65 D 95 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 95: ...tion 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 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 conn...

Page 96: ...out of order Have checked by qualified 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...

Page 97: ...otective gloves 1 Park the machine in secured condition Ä Chapter 6 4 Park the machine in secured condition on page 53 2 Press the handle forward against the 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 Fig...

Page 98: ...f the acceleration sensor The displayed measuring values are not plausible The acceleration sensor is not fastened correctly Shut down the engine and check the fas tening screws for the acceleration trans ducer Weak spots in the road subbase In unfavourable cases an excessively varying material composition or moisture can influence the measuring results On considerably dry or excessively moist mat...

Page 99: ...Troubleshooting Trouble shooting ECONOMIZER BPR 60 65 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 100: ...10 Disposal Disposal BPR 60 65 D 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 101: ...tion regulations when handling fuels and lubri cants must be followed 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 and dispose of in compliance with legal regulations 2 Empty the fuel tank 3 Drain engine oil from engine and exciter housing 4 Drain off hydraulic oil Disposal ...

Page 102: ...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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