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Fayat BOMAG BPR 70, Operating Instruction, Maintenance Instruction

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Summary of Contents for BOMAG BPR 70

Page 1: ... plate Operating Instruction Maintenance Instruction Original Operating Instructions S N 101 695 31 1001 01 2019 008 204 53 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: ...reliminary 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 battery acid 27 3 4 6 S...

Page 5: ... rubber buffers 52 6 Operation 53 6 1 Folding down the steering rod 54 6 2 Starting the engine 55 6 3 Operation 57 6 4 Parking the machine in secured condition 59 6 5 ECONOMIZER 60 7 Loading transporting the machine 61 7 1 Loading the machine 62 7 2 Lashing the machine to the transport vehicle 63 8 Maintenance 65 8 1 Preliminary remarks and safety notes 66 8 2 Preparations concluding work 67 8 2 1...

Page 6: ... every 500 operating hours 93 8 10 1 Changing the hydraulic oil 93 8 11 As required 95 8 11 1 Cleaning the machine 95 8 11 2 Cleaning the cooling fins and the cooling air intake openings 95 8 11 3 Servicing the V belt 96 8 11 4 Checking the oil level in the exciter housing 97 8 11 5 Measures prior to extended shut down period 97 9 Troubleshooting 101 9 1 Preliminary remarks 102 9 2 Emergency start...

Page 7: ...1 Introduction Introduction BPR 70 70 D 7 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 8: ...e notes on safety to be followed can be found in chapter Operation Ä Chapter 6 Operation on page 53 Before every start up carry out all required visual inspections and function tests Ä Chapter 5 Checks prior to start up on page 47 Ensure the compliance with the specified operating maintenance and repair measures to maintain the functional safety of your machine A description of all necessary maint...

Page 9: ...t you can also order the spare parts catalogue against the serial number of your machine The above notes do not constitute an extension of the warranty and liability conditions specified in the general sales and delivery conditions of BOMAG GmbH We wish you successful work with your BOMAG machine Introduction Foreword BPR 70 70 D 9 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o ...

Page 10: ...ermany 1 2 B DEC 0270 Fig 1 Machine type plate example EMISSION CONTROL INFORMATION MOTORENFABRIK HATZ KG D 94099 RUHSTORF GMBH CO Model S N Power Displ Eng Fam Emission Control System Power Category ULTRA LOW SULFUR DIESEL FUEL ONLY FOR MY2018 NONROAD DIESEL ENGINES EU Type www hatz diesel com Build PV E1 1 2 B HAT 0045 Fig 2 Introduction Machine type plate and engine type plate BPR 70 70 D 10 G ...

Page 11: ...2 Technical data Technical data BPR 70 70 D 11 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 12: ...Dimensions in millimetres Dimensions in inch Weights Operating weight CECE W 547 1206 kg lbs Operating weight CECE W1 570 1257 kg lbs Operating weight CECE W2 585 1290 kg lbs Basic weight 560 1235 kg lbs Dimensions Technical data BPR 70 70 D 12 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 13: ... manufacturer Hatz Type 1D81 Cooling Air Number of cylinders 1 Rated power ISO 3046 9 3 12 5 kW hp Rated speed 2700 min 1 Drive system mechanical Exciter system Frequency 66 3960 Hz vpm Centrifugal force 70 15737 kN lbf Amplitude 1 80 0 07 mm in Filling capacities Fuel diesel 10 0 2 6 l gal us Technical data BPR 70 70 D 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 a r...

Page 14: ...500 WARNING Loss of hearing caused by too high noise bur dens Wear your personal protective equipment ear protection LWA 109 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 4 m s2 dete...

Page 15: ...3 Concerning your safety Concerning your safety BPR 70 70 D 15 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 16: ...ffic regulations n country state specific safety regulations It is the duty of the operator to be acquainted with the safety regu lations and to apply these accordingly This also applies for local regulations and regulations concerning different types of handling activities Should the recommendations in these instructions be dif ferent from the regulations valid in your country you must comply wit...

Page 17: ...isposal of fuels and lubricants as well as replacement parts 3 1 3 Personal protective equipment Depending on the work to be carried out personal protective equipment is required to be provided by the operating company Working clothes Tight fitting working clothes with low tear resistance tight sleeves and without any projecting parts protect against being caught by moving components Safety shoes ...

Page 18: ...ompaction of all types of soils n Repair work on all types of soil n Paving of walkways n Work in trenches n Underfilling and compaction of hard shoulders Intended use also includes compliance with the specified oper ating maintenance and repair measures 3 1 5 Improper use Dangers may arise from the machine when it is used for purposes other than the one it is intended for Any danger caused by imp...

Page 19: ...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 70 70 D 19 G o t o D i s c o u n t E q u...

Page 20: ...alified person An expert qualified person is a person who based on his her pro fessional education and experience has profound knowledge in the field of construction equipment and the machine in question in particular This person is acquainted with the applicable governmental indus trial safety regulations accident prevention instructions guidelines and generally acknowledged technical rules and r...

Page 21: ...uence of alcohol medication or drugs are not allowed to operate service or repair the machine Maintenance and repair work requires specific knowledge and must therefore only be performed by trained specialists Concerning your safety Definition of responsible persons BPR 70 70 D 21 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 22: ...from the operation of the machine 3 3 2 Regular safety inspections Have the machine inspected by an expert qualified person as required for the conditions the machine is working under but at least once every year 3 3 3 Modifications and alterations to the machine Unauthorized changes to the machine are prohibited for safety rea sons Original parts and accessories have been specially designed for t...

Page 23: ...mposition information on constituents n first aid measures n fire fighting measures n measures in case of accidental release n handling and storage n limitation and monitoring of exposure personal protective equipment n physical and chemical properties n stability and reactivity n toxicological data n environmental data n notes on waste disposal n information on transport n legislation n other dat...

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

Page 25: ...al protective equipment pro tective gloves protective clothing Do not inhale any oil vapours Avoid contact CAUTION Danger of slipping on spilled oil Immediately bind spilled oil with an oil binding agent ENVIRONMENT Oil is an environmentally hazardous substance Always keep oil in proper containers Immediately bind spilled oil with an oil binding agent Dispose of oil and oil filter according to reg...

Page 26: ...n fire is prohibited Wear your personal protective equipment pro tective gloves protective clothing CAUTION Health hazard caused by contact with hydraulic oil Wear your personal protective equipment pro tective gloves protective clothing Do not inhale any oil vapours Avoid contact CAUTION Danger of slipping on spilled oil Immediately bind spilled oil with an oil binding agent ENVIRONMENT Oil is an...

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

Page 28: ...tion grease Collect and remove excess lubrication grease immediately ENVIRONMENT Lubrication grease is an environmentally haz ardous substance Always keep lubrication grease in proper con tainers Collect excess lubrication grease and dispose of it according to regulations Dispose of cloths soiled with lubrication grease according to regulations B SYM 0210 Fig 8 Concerning your safety Handling fuel...

Page 29: ...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 30: ... 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 31: ...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 32: ...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 70 70 D 32 G o t o D i s c o u n t...

Page 33: ...s 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 smoking or open fire is prohibited Do not lay any too...

Page 34: ...3 9 5 After maintenance work Reassemble all guards and protections Concerning your safety Maintenance work BPR 70 70 D 34 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 35: ...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 70 70 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 36: ...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 DIESEL if available falls vorhanden si existant si está disponible B 692 0248 Fig 9 Concerning your saf...

Page 37: ...formation sticker Lashing point Information sticker Lifting point Operation sticker Travel lever Fig 10 Fig 11 Fig 12 Fig 13 Concerning your safety Signage BPR 70 70 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 38: ...ant 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 DIESEL if available falls vorhanden si existant si está disponible B DEC 0274 Fig 16 Fig 17 Concerning your safety Signage BPR 70 70 D 38 G o t o D i s c o u n t E q u i p m e n...

Page 39: ...inal 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 BPR 70 70 D 39 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 40: ...Concerning your safety Signage BPR 70 70 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 41: ...4 Indicators and control elements Indicators and control elements BPR 70 70 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 42: ...I Ignition on The warning buzzer sounds Position III Turn further against spring pressure the engine starts Turn the ignition key back to position I when the engine starts The starter switch is designed with a re start lock The ignition key must first be turned back to posi tion 0 before a new starting attempt can be made B 692 0224 Fig 19 STOP I II B 692 0225 Fig 20 B ELE 0069 Fig 21 Indicators a...

Page 43: ...e lift the steering rod turn anticlockwise lower the steering rod 4 1 6 Locking pawl lever B 692 0217 Fig 22 B 692 0218 Fig 23 B 692 0219 Fig 24 Indicators and control elements Machine BPR 70 70 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 44: ...atus of the layer to be compacted Description of display possibilities Ä Chapter 6 5 ECONOMIZER on page 60 Optional equipment Fig 25 Indicators and control elements Machine BPR 70 70 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 45: ... nance NOTICE Danger of engine damage Opening the decompression lever while the engine is running leads to engine damage Never use the decompression lever for stop ping the engine 4 2 3 Crank handle Start the engine with the crank handle only if the battery is defective empty or missing Optional equipment B 692 0157 Fig 26 B 834 0187 Fig 27 B 692 0220 Fig 28 Indicators and control elements Engine ...

Page 46: ...Indicators and control elements Engine BPR 70 70 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 47: ...5 Checks prior to start up Checks prior to start up BPR 70 70 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 48: ...n han dling fuels and lubricants Ä Chapter 3 4 Han dling fuels and lubricants on page 23 WARNING Danger of injury caused by rotating parts Before starting work on the machine make sure that the engine can not be started 1 Park the machine safely Ä Chapter 6 4 Parking the machine in secured condition on page 59 2 Open and secure the protection hood Ä Chapter 8 2 1 1 Opening the protection hood on p...

Page 49: ...eaks 2 Check bolted connections for tight fit 3 Check machine for contamination and damage 4 Check the hydraulic oil cooler for dirt Checks prior to start up Visual inspections and function tests BPR 70 70 D 49 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 50: ...off with a lint free clean cloth and reinsert it to the end stop 3 Pull the dipstick out again 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 engine oil to the MAX mark 5 Push the dipstick in B SYM 1068 Fig 29 MIN MAX B 692 0182 Fig 30 Checks prior to start up Checking the engine oil level...

Page 51: ...rotective gloves 1 Clean the area around the filling port 2 Remove the cap and check the filling level visually 3 If necessary fill in fuel through a funnel with screen filter 4 Close the cap If the fuel tank has been completely emptied or when filling the fuel tank for the first time the fuel system must be bled before starting Ä Chapter 8 2 2 Bleeding the fuel system on page 68 B SYM 1069 Fig 31...

Page 52: ...achine in secured condition on page 59 2 Allow the engine to cool down 3 Check all rubber buffers for tight fit cracks and tear offs 4 Replace damaged rubber buffers immediately B SYM 1073 Fig 33 B 692 0160 Fig 34 Checks prior to start up Checking the rubber buffers BPR 70 70 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 r d e r y o u r p a r t s ...

Page 53: ...6 Operation Operation BPR 70 70 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 54: ...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 35 Operation Folding down the steering rod BPR 70 70 D 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 55: ...quate ventilation when working in trenches WARNING Loss of hearing caused by too high noise bur dens Wear your personal protective equipment ear protection Protective equipment n Working clothes n Hearing protection n Safety shoes 1 Set the throttle lever to position MIN 2 Set the handle to position 0 B 692 0178 Fig 36 B 692 0059 Fig 37 Operation Starting the engine BPR 70 70 D 55 G o t o D i s c ...

Page 56: ... Then allow the starter to cool down to ambient temperature If the engine has not started after these attempts determine the cause Turn the ignition key through position II to position III ð The starter cranks the engine The warning buzzer stops NOTICE Danger of engine damage Warm up engine for a short while before starting work Do not operate the engine immediately under full load B ELE 0070 Fig ...

Page 57: ...ng machine Protective equipment n Working clothes n Hearing protection n Safety shoes n Protective gloves 1 Make sure that no persons are in the danger zone 2 NOTICE The centrifugal clutch may be damaged Operate the machine only with full throttle Set the throttle lever to position I or II 3 Shift the handle forwards ð The machine vibrates forward with a speed which corre sponds to the travel leve...

Page 58: ...bration is switched off 7 For short work interruptions you should always park the machine in secured condition Ä Chapter 6 4 Parking the machine in secured condition on page 59 1 Park the machine safely Ä Chapter 6 4 Parking the machine in secured condition on page 59 2 Lift the machine using suitable lifting and lashing tackle at the intended lifting points until it becomes free Ä Chapter 7 Loadi...

Page 59: ...ot 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 The warning buzzer sounds 5 Turn the ignition key to position 0 and pull it out ð The warning buzzer stops B 692 0059 Fig 45 B 692 0180 Fig 46 B 692 0181 Fig 47 B ELE 0069 Fig 48 Operation Parking the machine in secured condition BPR 7...

Page 60: ...ways reached Due to fluctuations in the measuring value the dis play value can vary by one digit up down during a pass The average display value 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 ...

Page 61: ...7 Loading transporting the machine Loading transporting the machine BPR 70 70 D 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 62: ...s of the load If necessary hold the load with guide ropes 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 59 2 Allow the engine to cool down 3 Make sure that the protection hood is fastened correctly Ä Chapter 8 2 1 2 Closing the protection hood on page 68 4 Move the steering rod to an...

Page 63: ...plication Lifting tackle must not be damaged by machine components Protective equipment n Working clothes 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 52 Fig 53 Loading transporting the machine Lashing the machine to the transport vehicle BPR 70 70 D 63 G o t o D i s c o u ...

Page 64: ...Loading transporting the machine Lashing the machine to the transport vehicle BPR 70 70 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 65: ...8 Maintenance Maintenance BPR 70 70 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 t o o r d e r y o u r p a r t s ...

Page 66: ...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 67: ...sing the protection hood 8 2 1 1 Opening the protection hood Protective equipment n Working clothes n Protective gloves 1 Remove the rear screws 2 on both sides of the machine 2 Put the screws 2 and the matching washers to the side 3 Loosen the front screws 1 on both sides 4 Fold the protection hood forward 5 Secure the protection hood against accidental closing For this tighten the screw 1 on bot...

Page 68: ...uel system The fuel shut off valve automatically interrupts the engine s fuel supply if the oil pressure is too low This makes it necessary to bleed the fuel system in the following situations n After an engine shut down due to an empty fuel tank n After filling the fuel tank for the first time n After using the crank handle without starting e g when tem peratures are low n After several unsuccess...

Page 69: ...n bleeding 3 Check the fuel level top up if necessary 4 Press the ventilation lever for approx 15 seconds against the spring ð The engine is ready for starting If the engine does not start after bleeding contact our customer service department Fig 58 Maintenance Preparations concluding work BPR 70 70 D 69 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 70: ...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 71: ... 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 72: ...he viscosity index must be at least 150 observe information of manufacturer Maintenance Fuels and lubricants BPR 70 70 D 72 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: ...fuel 10 0 l 2 6 gal us Specification Ä Chapter 8 3 2 Fuel on page 70 Exciter shaft housing SAE 10W 40 Specification Ä Chapter 8 3 3 Oil for exciter shaft housing on page 71 0 6 l 0 16 gal us SAE 15W 40 SAE 10W 30 Steering rod Hydraulic oil ISO HV 32 Specification Ä Chapter 8 3 4 Mineral oil based hydraulic oil on page 71 0 4 l 0 11 gal us Maintenance List of fuels and lubricants BPR 70 70 D 73 G o...

Page 74: ...cing the fuel filter 86 8 9 5 Replacing the air filter 87 8 9 6 Changing the oil in the exciter housing 88 8 9 7 Checking the hydraulic oil level 90 8 9 8 Lubricating the machine 92 Every 2 years every 500 operating hours 8 10 1 Changing the hydraulic oil 93 As required 8 11 1 Cleaning the machine 95 8 11 2 Cleaning the cooling fins and the cooling air intake openings 95 8 11 3 Servicing the V bel...

Page 75: ...ecking 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 11 3 Servicing the V belt on page 96 7 Check the oil level in the exciter shaft housing Ä Chapter 8 11 4 Checking the oil level in the exciter housing on pag...

Page 76: ...ilter ele ment If in doubt use a new air filter Protective equipment n Working clothes n Safety shoes n Protective gloves n Safety goggles 1 Park the machine safely Ä Chapter 6 4 Parking the machine in secured condition on page 59 2 Allow the engine to cool down 3 Remove the cap 1 4 Pull out the air filter 5 Clean the cover 6 NOTICE Danger of engine damage Prevent dirt from getting into the air in...

Page 77: ...nd down inside the element until it is free of dust 8 Examine the air filter with a torch for cracks and holes 9 Replace the air filter if it is damaged 10 Slide the air filter 2 carefully into the filter housing 11 Check the sealing face 3 on the cover 12 NOTICE Danger of engine damage Ensure correct fit of cover and seal Close the cap 1 Fig 62 Fig 63 Maintenance Weekly BPR 70 70 D 77 G o t o D i...

Page 78: ...g the machine in secured condition on page 59 2 Place the transparent container under the drain plug 3 Loosen the drain plug and collect escaping fluid 4 Drain the fuel off until there is no water left If the fuel tank has been completely emptied bleed the fuel system before starting Ä Chapter 8 2 2 Bleeding the fuel system on page 68 5 Screw the drain plug back on tightly Ensure leak tightness 6 ...

Page 79: ...safely Ä Chapter 6 4 Parking the machine in secured condition on page 59 2 Remove the bracket 1 of the battery 3 Remove the battery 2 and the vibration damping mats 3 4 Check the condition of the vibration insulation mats replace if necessary 5 Clean the outside of the battery 6 Clean the battery poles and terminals and grease them with pole grease Vaseline 7 On serviceable batteries check the aci...

Page 80: ... Allow the engine to cool down 3 Unscrew the V belt guard 1 4 Unscrew the guard 1 5 Unscrew the V belt pulley 1 6 Replace the V belt 3 7 If necessary reassemble the spacers 2 that may have been removed 8 Fasten the V belt pulley B 692 0175 1 Fig 68 B 692 0187 1 Fig 69 B 692 0188 1 2 3 Fig 70 Maintenance Annually every 250 operating hours BPR 70 70 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 81: ... Fasten the V belt guard 1 8 9 1 1 Checking the frequency of the base plate Keep feet and hands clear of the vibrating base plate CAUTION Danger of injury caused by uncontrolled machine movement Always hold on to a running machine Always keep an eye on a running machine B 692 0183 x 1 2 Fig 71 Fig 72 Fig 73 Maintenance Annually every 250 operating hours BPR 70 70 D 81 G o t o D i s c o u n t E q u...

Page 82: ... incorrect n Check the engine speed n Check the V belt n If necessary contact our customer service 8 9 2 Checking adjusting the valve clearance NOTICE Danger of engine damage We recommend to have this work carried out by trained personnel or our after sales service Before checking the valve clearance let the engine cool down Protective equipment n Working clothes n Protective gloves 1 Park the mac...

Page 83: ...xhaust 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 74 Fig 75 Checking the valve clearance Fig 76 Maintenance Annually every 250 operating hours BPR 70 70 D 83 G o t o D i s c o u n t E q u i ...

Page 84: ...over for leaks 8 9 3 Changing engine oil and oil filter element NOTICE Danger of engine damage Change the oil only with the engine at oper ating temperature Use only oil of the permitted specification Ä Chapter 8 3 1 Engine oil on page 70 Filling quantity Ä Chapter 8 4 List of fuels and lubricants on page 73 Adjusting the valve clearance Fig 77 Final work Fig 78 Maintenance Annually every 250 oper...

Page 85: ... plug and collect any oil running out 5 Clean the drain plug and screw it in tightening torque 20 Nm 15 ft lbf 6 Clean the area around the cover 7 Unscrew the cover and change the oil filter element 8 Clean the sealing face on the engine 9 Insert the new filter oil filter element with the recess facing downwards 10 Check the seal ring on the cover for damage replace if nec essary 11 Slightly lubri...

Page 86: ...ine in secured condition Ä Chapter 6 4 Parking the machine in secured condition on page 59 2 Use a suitable vessel to collect running out fuel 3 Drain the fuel 4 Clean the area around the fuel filter 5 Unscrew the hose clamp from the holding fixtures 6 Pull the fuel filter with the fuel lines out of the hose clamps 7 Pull the fuel lines off the fuel filter 8 Replace the fuel filter 9 Plug on the f...

Page 87: ...e machine in secured condition on page 59 2 Allow the engine to cool down 3 Remove the cap 1 4 Pull out the air filter 5 Clean the cover 6 NOTICE Danger of engine damage Prevent dirt from getting into the air intake opening Do not clean the air filter housing with compressed air Clean the filter housing with a clean lint free cloth 7 Replace the air filter 8 Slide the air filter 2 carefully into t...

Page 88: ...on Ä Chapter 6 4 Parking the machine in secured condition on page 59 3 Clean the area around the bleeding screw 1 and filling drain plug 2 4 Tilt the machine slightly towards the oil drain side and secure it properly 5 Unscrew the bleeding screw 6 Unscrew the filling drain plug and collect any oil running out 7 Tilt the machine to the opposite side and secure it properly 8 Fill in new oil 2 1 B 69...

Page 89: ...screw 1 and filling drain plug 2 and install with low strength sealing agent e g spare parts number 009 700 16 11 Dispose of oil in an environmentally friendly way 2 1 B 692 0197 Fig 88 Maintenance Annually every 250 operating hours BPR 70 70 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 90: ...e filler screw 4 Press the handle forward against the stop and secure it using suitable means 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 89 Fig 90 Fig 91 Fill in hydraulic oil bleed the system Maintenance Annually e...

Page 91: ...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 screw Fig 92 Fig 93 Fig 94 Concluding work Fig 95 Maintenance Annually every 250 operating hours BPR 70 70 D 91 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 92: ...ause damage to components Use only grease of the permitted specifi cation Spare parts number of lubrication grease 009 960 17 Grease the mechanical parts between the fork head 1 lever 2 and bolt 3 4 Fasten the cover 2 with four fastening screws tightening torque 10 Nm 7 5 ft lbf 2 1 B 692 0245 Fig 96 B 692 0186 2 1 Grease 3 Fig 97 2 1 B 692 0245 Fig 98 Maintenance Annually every 250 operating hour...

Page 93: ...e steering rod with height adjustment so that the area with the filler screw is horizontal 3 Unscrew the filler screw 4 Press the handle forward against the stop and secure it using suitable means 5 Unscrew the bleeding screw and collect any oil running out 6 Screw in the bleeding screw Fig 99 Fig 100 Fig 101 Maintenance Every 2 years every 500 operating hours BPR 70 70 D 93 G o t o D i s c o u n ...

Page 94: ...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 screw 12 Dispose of oil in an environmentally friendly way Fig 102 Fig 103 Fig 104 Fig 105 Maintenance Every 2 years every 500 operating hours BPR 70 70 D 94 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r ...

Page 95: ...gs How dirty the cooling fins and cooling air intake openings are depends very much on the daily operating conditions clean daily if necessary 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 59 2 Allow the engine to cool down 3 Remove dried dirt with a suitable brush f...

Page 96: ...ow the engine to cool down 3 Unscrew the V belt guard 1 4 Check condition and tension of V belt ð Compression measurement 10 30 mm 0 4 1 2 in 5 The V belt cannot be re tightened Replace the V belt if it is damaged or if the compression measurement is exceeded Ä Chapter 8 9 1 Replacing the V belt on page 80 6 Fasten the V belt guard 1 Preparations Fig 108 Fig 109 Fig 110 Maintenance As required BPR...

Page 97: ... Bottom edge of filling drain bore 7 Clean bleeding screw and filling drain plug and screw them in with a low strength sealing agent e g spare parts number 009 700 16 8 11 5 Measures prior to extended shut down period 8 11 5 1 Measures before shutting down If the machine is shut down for a longer period of time e g winter season the following work must be carried out 1 Clean the machine thoroughly...

Page 98: ...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 99: ...6 Check the oil levels 7 Clean the machine thoroughly Maintenance As required BPR 70 70 D 99 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 100: ...Maintenance As required BPR 70 70 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 101: ...9 Troubleshooting Troubleshooting BPR 70 70 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 102: ...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 70 70 D 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 103: ...haust 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 Working clothes n Hearing protection n Safety shoes 1 Set the throttle lever to position MIN B 692 0178 Fig 112 Troubleshooting Emergency starting ...

Page 104: ...ompression lever in direction of arrow to the end stop ð The decompression lever clicks noticeably into place 5 Open the cover 6 Remove the crank handle from the bracket and insert it 7 Stand in the correct position parallel to the machine B 692 0059 Fig 113 B ELE 0070 Fig 114 Fig 115 B 692 0220 Fig 116 Troubleshooting Emergency starting with crank handle BPR 70 70 D 104 G o t o D i s c o u n t E ...

Page 105: ...ions the highest speed must be reached 11 As soon as the engine starts pull out the crank handle 12 If the engine does not start during the first attempt repeat the starting process ð Always open the decompression lever when repeating the starting procedure NOTICE Danger of engine damage Warm up engine for a short while before starting work Do not operate the engine immediately under full load 13 ...

Page 106: ...e 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 Starting the engine on page 55 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 11...

Page 107: ...use fuses with higher ampere ratings and do not bridge fuses Pos Amperage Designation 1 25 A Main fuse 5 A Economizer fuse optional equipment Fig 120 Troubleshooting Fuse assignment BPR 70 70 D 107 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 108: ...ly at low temperatures Fuel filter clogged by paraffin separation Change the fuel filter use winter fuel Engine oil with wrong SAE viscosity class Changing the engine oil Insufficiently charged battery Check the battery charge if necessary 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 Main ...

Page 109: ... the oil from the exciter housing Engine looses power and speed black exhaust smoke Air filter dirty Clean the air filter replace if necessary Incorrect valve clearance Check the valve clearance adjust if nec essary Injection nozzle out of order Have it checked by qualified expert per sonnel Engine overheats Engine oil level too high Check the engine oil level drain off engine oil if necessary Air...

Page 110: ...ctive gloves 1 Park the machine in secured condition Ä Chapter 6 4 Parking the machine in secured condition on page 59 2 Press the handle forward against the end stop and hold it in this position 3 Carefully loosen the filler screw 1 ð The air makes a slight hissing sound when escaping 4 Wait until all air has escaped and then tighten the filler screw Release pressure from the steering rod Fig 121...

Page 111: ...ensor Cable breakage Inform our service department The displayed measuring values are not plausible The acceleration sensor is not fastened correctly Shut down the engine and check the fas tening screws of the acceleration sensor Weak spots in the road subbase In unfavourable cases an excessively varying material composition or moisture in the road subbase can influence the measuring results On ma...

Page 112: ...Troubleshooting Trouble shooting ECONOMIZER BPR 70 70 D 112 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 113: ...10 Disposal Disposal BPR 70 70 D 113 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s ...

Page 114: ...tion regulations must be followed when han dling fuels and lubricants Ä Chapter 3 4 Han dling fuels and lubricants on page 23 Protective equipment n Working clothes n Safety shoes n Protective gloves n Safety goggles 1 Remove the batteries 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 115: ...11 List of special tools List of special tools BPR 70 70 D 115 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 116: ...Sirometer Measuring instrument for speed and frequency BOMAG 059 710 02 Fig List of special tools BPR 70 70 D 116 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 117: ...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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