Bomag BPR 70/70 D Operating And Maintenance Instructions Manual
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Operating Instruction
Maintenance Instruction
Original Operating Instructions
BPR 70/70 D
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Reversible vibratory plate
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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 exhaust system.
Do not idle the engine except as necessary.
For more information go to
www.P65warnings.ca.gov/diesel.
WARNING:
Crude oil, gasoline, diesel fuel and other petroleum products can expose you to chemicals including toluene and benzene, defects or other reproductive harm.
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These exposures can occur in and around oil fields, refineries, chemical plants, transport and storage operations such as pipelines, marine terminals, tank trucks and other facilities and equipment.
For more information go to
www.P65Warnings.ca.gov/petroleum.
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2
Table of contents
Table of contents
3.2 Definition of responsible persons to
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BPR 70/70 D 3
Table of contents
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4 BPR 70/70 D
Table of contents
8.10 Every 2 years / every 500 operating hours to
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BPR 70/70 D 5
1
Introduction
Introduction
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BPR 70/70 D 7
Introduction – Foreword
1.1 Foreword
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BOMAG manufactures machines for earth, asphalt and refuse compaction, stabilizers/recyclers as well as planers and pavers.
BOMAG’s vast experience in connection with state-of-the-art production and testing methods, such as lifetime tests of all important components and highest quality demands guarantee maximum reliability of your machine.
These operating and maintenance instructions are part of your machine.
They provide necessary information to operate your machine safely and properly.
They also contain information on required operating, maintenance and repair measures.
Carefully read the operating and maintenance instructions before taking your machine into operation.
tions to ensure safe operation.
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If you are not yet acquainted with the controls and indicating elements on this machine, you should thoroughly read the corresponding chapter
Ä Chapter 4 „Indicators and control elements“ on page 39 .
The description of the individual operating steps including the 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 45 .
Ensure the compliance with the specified operating, maintenance and repair measures to maintain the functional safety of your machine.
A description of all necessary maintenance work, maintenance intervals as well as information on fuels and lubricants can be
found in the chapter “Maintenance” Ä Chapter 8 „Maintenance“ on page 67 .
Do not service or repair your machine by yourself to avoid harming persons or damaging material or environment.
The machine must only be serviced and repaired by qualified and authorized personnel.
Contact our Customer Service to carry out the required mainteDiscount-Equipment.com unapproved fuels and lubricants all warranty claims will become null and void.
For your own personal safety you should only use original parts from BOMAG.
For your machine we offer service kits to make maintenance easier.
8 BPR 70/70 D
Introduction – Foreword
In the course of technical development we reserve the right for technical modifications without prior notification.
These operating and maintenance instructions are also available in other languages.
Apart from that, 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.
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BPR 70/70 D 9
Introduction – Machine type plate and engine type plate
1.2 Machine type plate and engine type plate
2
Made by
Designation
Nominal Power
Serial-No.
Operating Mass
Patent Protection
56154 Boppard;GERMANY
Type
Year of Construction
Made in Germany
1
Please enter here:
Machine type (1):
Serial number (2):
B-DEC-0270
Fig. 1: Machine type plate (example)
1
2
EMISSION CONTROL INFORMATION
Model:
S/N:
Power:
Displ:
Build:
PV:
Eng.Fam:
Emission Control System:
Power Category:
ULTRA LOW SULFUR DIESEL FUEL ONLY.
FOR MY2018 NONROAD DIESEL ENGINES.
EU-Type:
E 1
Please enter here:
Engine type (1):
Engine number (2): to order your parts
B-HAT-0045
Fig. 2
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10 BPR 70/70 D
2
Technical data
Technical data
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BPR 70/70 D 11
Technical data
Dimensions
Fig. 3
H H
1
H
2
Dimensions standard
870
(34.3)
1030
(40.6)
Dimensions in millimetres
(Dimensions in inch)
1470
(57.9)
L
1860
(73.2)
L
1
980
(38.6)
Weights
Operating weight (CECE) (W)
Operating weight (CECE) (W
1
)
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Basic weight
)
W
550
(21.7) to order your parts
W
1
700
(27.6)
W
2
850
(33.5)
556
(1226)
579
(1277)
595
(1312)
570
(1257) kg
(lbs) kg
(lbs) kg
(lbs) kg
(lbs)
12 BPR 70/70 D
Weights
Crank handle (optional equipment)
ECONOMIZER (optional equipment)
Travel characteristics
Max. working speed
Max. gradeability (depending on soil)
Drive
Engine manufacturer
Type
Cooling
Number of cylinders
Rated power ISO 3046
Rated speed
Drive system
Exciter system
Frequency
Centrifugal force
Amplitude
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Filling capacities
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Fuel (diesel)
Technical data
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Hatz
1D81
Air
1
9.3
(12.5)
2700 mechanical
+ 3
(+ 7) kg
(lbs)
+ 5
(+ 11) kg
(lbs) parts
28
(92) your
35 % kW
(hp) min -1
66
(3960)
70
(15737)
1.80
(0.07)
Hz
(vpm) kN
(lbf) mm
(in)
10.0
(2.6) (gal us) l
BPR 70/70 D 13
Technical data – Noise and vibration data
2.1 Noise and vibration data
The following noise and vibration data were determined in accordance with the following guidelines under equipment specific conditions and by using harmonized standards: n EU Machine Directive edition 2006/42/EU n Noise Emission Directive 2000/14/EU, Noise Protection Directive 2003/10/EU n Vibration Protection Directive 2002/44/EU
During operation these values may vary because of the prevailing operating conditions.
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2.1.1 Noise data
Sound pressure level at the operator's stand
L pA
= 94 dB(A), determined acc. to ISO 11201 and EN 500.
WARNING!
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Loss of hearing caused by too high noise burdens!
– Wear your personal protective equipment (ear protection).
Guaranteed sound power level L
WA
= 109 dB(A), determined acc. to ISO 3744 and EN 500
2.1.2 Vibration data
Hand-arm vibration Vector total of the weighted effective acceleration in three orthogonal directions:
Total vibration value a hv
= 4.5 m/s acc. to ISO 5349 and EN 500.
2 on crushed rock determined
Associated uncertainty K = 0.5 m/s
12096.
2 , determined acc. to EN
Observe the daily vibration load (work safety acc. to 2002/44/EC).
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14 BPR 70/70 D
3
Concerning your safety
Concerning your safety
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BPR 70/70 D 15
Concerning your safety – Basic prerequisites
3.1 Basic prerequisites
3.1.1 General
This machine has been built in compliance with the latest technical standard and complies with the applicable regulations and technical rules.
However, dangers for persons and property may arise from this machine, if: n it is used for purposes other than the ones it is intended for, parts n it is operated by untrained personnel, n it is changed or converted in an unprofessional way, n the safety instructions are not observed.
your
Each person involved in the operation, maintenance and repair of the machine must therefore read and comply with these safety regulations. If necessary, the operating company must obtain the relevant signatures as confirmation.
Furthermore, the following obviously also applies: n n to order n country/state specific safety regulations.
It is the duty of the operator to be acquainted with the safety regulations 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 different from the regulations valid in your country, you must comply with the safety regulations valid in your country.
3.1.2 Explanation of signal words used:
DANGER!
Danger to life if failing to comply!
Sections marked accordingly indicate an extremely dangerous situation that could lead to fatal or severe injuries, if this warning is disregarded.
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WARNING!
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16 BPR 70/70 D
Concerning your safety – Basic prerequisites
CAUTION!
Danger of injury if failing to comply!
Sections marked accordingly indicate a dangerous situation that could lead to fatal or severe injuries, if this warning is disregarded.
NOTICE!
Danger of material damage if failing to comply!
Sections marked accordingly indicate possible dangers for machines or components.
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Sections marked accordingly indicate technical information or notes on using the machine or its components.
ENVIRONMENT!
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Environmental damage if failing to comply!
Paragraphs marked accordingly indicate practices for safe and environment-friendly disposal of fuels and lubricants as well as replacement parts.
3.1.3 Personal protective equipment
Depending on the work to be carried out, personal protective equipment is required (to be provided by the operating company):
Working clothes Tight fitting working clothes with low tear resistance, tight sleeves and without any projecting parts protect against being caught by moving components.
Safety shoes To protect against heavy falling parts and slipping on slippery ground.
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Protective gloves To protect the hands against excoriation, punctures or deep injuries, against irritating and caustic substances as well as against burns.
BPR 70/70 D 17
Concerning your safety – Basic prerequisites
Safety goggles To protect the eyes against airborne particles and squirting fluids.
Face protection
Hard hat
Hearing protection
Respiratory protection
To protect the face against airborne particles and squirting fluids.
To protect the head against falling parts and to protect against injuries.
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To protect hearing against excessive noise.
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To protect respiratory tracts against substances or particles.
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3.1.4 Intended use
This machine must only be used for: n Compaction of all types of soils n Repair work on all types of soil n Paving of walkways n Work in trenches n Underfilling and compaction of hard shoulders
Intended use also includes compliance with the specified operating, maintenance and repair measures.
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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.
18 BPR 70/70 D
Concerning your safety – Basic prerequisites
Examples for improper use are: n dragging the machine along as a measure of transportation n throwing the machine off the transport vehicle n attaching an additional weight to the machine
It is not permitted to stand on the machine while working.
Lifting tackle must be removed before starting work.
Starting and operating the machine in explosive environments and in underground mining is prohibited.
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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).
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BPR 70/70 D 19
Concerning your safety – Definition of responsible persons
3.2 Definition of responsible persons
3.2.1 Operating company
The operating company is the natural or juridical person who uses the machine or in who's name the machine is used.
The operating company must make sure that the machine is only used for the purpose it is intended for and in strict compliance with the safety regulations mentioned in these operating and maintenance instructions.
parts
The operating company must determine and assess the danger in its company. It must then take appropriate action to ensure health and safety at work for its employees and point out any remaining dangers.
your
The operating company must determine whether there are special operational hazards such as a toxic atmosphere or limiting soil conditions. Such conditions require special, additional measures to remove or reduce the hazard.
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The operating company is responsible for the planning and professional execution of regular safety inspections.
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3.2.2 Expert / qualified person
An expert / qualified person is a person who, based on his/her professional 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 industrial safety regulations, accident prevention instructions, guidelines and generally acknowledged technical rules and regulations
(standards, directives, technical rules of other member states of the European Union or other contractual states concerning the agreement about the European Economic Area) in as far as is necessary to be able to judge the safe condition of this machine.
3.2.3 Driver / operator to
This machine must only be operated by trained, instructed persons entrusted by the operating company aged 18 or more.
Rights, obligations and rules of conduct for driver or operator:
The driver or operator must: n be instructed about his rights and obligations, n wear protective equipment as appropriate for the application, n have read and understood the operating instructions,
20 BPR 70/70 D
Concerning your safety – Definition of responsible persons
n have made himself familiar with the operation of the machine, n be physically and psychologically able to drive and operate the machine.
Persons under the influence 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.
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BPR 70/70 D 21
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Concerning your safety – Basic safety regulations for safe operation
3.3 Basic safety regulations for safe operation
3.3.1 Remaining dangers, remaining risks
Despite careful work and compliance with standards and regulations it cannot be ruled out that further dangers may arise when working with and handling the machine.
Both the machine as well as all other system components comply with the currently valid safety regulations. Nevertheless, remaining risks cannot be ruled out completely, even when using the machine for the purpose it is intended for and following all information given in the operating instructions.
A remaining risk can also not be excluded beyond the actual danger zone of the machine. Persons remaining in this area must etc.
your pay particular attention to the machine, so that they can react immediately in case of a possible malfunction, an incident or failure parts
3.3.2 Regular safety inspections
All persons remaining in the area of the machine must be informed about the dangers that arise from the operation of the machine.
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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 reasons.
Original parts and accessories have been specially designed for this machine.
We wish to make explicitly clear that we have not tested or approved any parts or accessories not supplied by us.
The installation and/or use of such products may have an adverse effect on the active and/or passive safety.
to Machines which are not safe to operate or in traffic must be immediately taken out of service and shall not be used, until these deficiencies have been properly rectified.
Safety installations and switches must neither be removed nor must they be made ineffective.
22 BPR 70/70 D
Concerning your safety – Handling fuels and lubricants
3.4 Handling fuels and lubricants
3.4.1 Preliminary remarks
The operating company must ensure that all professional users have read and follow the corresponding safety data sheets for the individual fuels and lubricants.
Safety data sheets provide valuable information about the following characteristics: parts n name of substance n possible dangers n composition / information on constituents n first-aid measures n fire fighting measures your n measures in case of accidental release n handling and storage n limitation and monitoring of exposure / personal protective equipment n n stability and reactivity n toxicological data to n environmental data order n notes on waste disposal n information on transport n legislation n other data
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BPR 70/70 D 23
Concerning your safety – Handling fuels and lubricants
3.4.2 Safety regulations and environmental protection regulations for handling diesel fuel
Fig. 4
WARNING!
Danger of burning by ignited diesel fuel!
– Do not allow diesel fuel to come into contact with hot components.
– Smoking and open fire is prohibited!
– Wear your personal protective equipment (protective gloves, protective clothing).
your
CAUTION!
parts
–
Health hazard caused by contact with diesel fuel!
– order
– Avoid contact.
to
CAUTION!
Danger of slipping on spilled diesel fuel!
– Immediately bind spilled diesel fuel with an oilbinding agent.
ENVIRONMENT!
Diesel fuel is an environmentally hazardous substance!
– Always keep diesel fuel in proper containers.
– Immediately bind spilled diesel fuel with an oilbinding agent and dispose of properly.
– Dispose of diesel fuel and fuel filters according to regulations.
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24 BPR 70/70 D
Concerning your safety – Handling fuels and lubricants
3.4.3 Safety regulations and environmental protection regulations for handling oil
Fig. 5
WARNING!
Danger of burning by ignited oil!
– Do not allow oil to come into contact with hot components.
– Smoking and open fire is prohibited!
– Wear your personal protective equipment (protective gloves, protective clothing).
CAUTION!
Health hazard caused by contact with oil!
your
– Wear your personal protective equipment (protective gloves, protective clothing).
–
– Avoid contact.
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CAUTION!
Danger of slipping on spilled oil!
– Immediately bind spilled oil with an oil-binding agent.
parts
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 regulations.
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BPR 70/70 D 25
Concerning your safety – Handling fuels and lubricants
3.4.4 Safety regulations and environmental protection regulations for handling hydraulic oil
Fig. 6
WARNING!
Danger of injury caused by escaping pressure fluid!
– Always depressurize the hydraulic system before starting work in the hydraulic system.
– Wear your personal protective equipment (protective gloves, protective clothing, goggles).
your
Should pressure fluid penetrate the skin, immediate medical help is required.
parts
WARNING!
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Danger of burning by ignited hydraulic oil!
– Do not allow hydraulic oil to come into contact with hot components.
– Smoking and open fire is prohibited!
– Wear your personal protective equipment (protective gloves, protective clothing).
CAUTION!
Health hazard caused by contact with hydraulic oil!
– Wear your personal protective equipment (protective 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.
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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 regulations.
26 BPR 70/70 D
Concerning your safety – Handling fuels and lubricants
3.4.5 Safety regulations and environmental protection regulations for handling battery acid
Fig. 7:
WARNING!
Danger of cauterization with acid!
– Wear your personal protective equipment (protective gloves, protective clothing, goggles).
– Do not allow clothes, skin or eyes to come into contact with acid.
– Rinse off spilled battery acid immediately with lots of water.
your
Rinse acid off clothes, skin or eyes immediately with lots of clean water.
Immediately call for medical advice in case of cauterization.
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WARNING!
Danger of injury caused by exploding gas mixture!
parts
– 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 (protective gloves, protective clothing, goggles).
ENVIRONMENT!
Battery acid is an environmentally hazardous substance!
– Dispose of battery and battery acid according to regulations.
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BPR 70/70 D 27
Concerning your safety – Loading/transporting the machine
3.5 Loading/transporting the machine
Make sure that persons are not endangered by the machine tipping or sliding off.
Do not use damaged or in any other way impaired lashing points.
Always use appropriate lifting and lashing means on the lifting and lashing points.
Use lifting and lashing gear only in the prescribed direction of load application.
parts
Lifting tackle must not be damaged by machine components.
Secure the machine on the transport vehicle against rolling, slipping and turning over.
your
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.
Danger to the life of persons if they step or stand under a suspended load.
When lifting the machine avoid uncontrolled movements of the load. If necessary hold the load with guide ropes.
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28 BPR 70/70 D
Concerning your safety – Start-up procedure
3.6 Start-up procedure
3.6.1 Prior to starting up
Use only machines which are serviced at regular intervals.
Become acquainted with the equipment, the indicators and control elements, the working principle of the machine and the working area.
Use your personal protective equipment (hard hat, safety boots, if necessary also goggles and ear protection).
parts
Do not take any loose objects with you or fasten them to the machine.
Before start up, check whether: your n persons or obstructions are beside or in front of the machine, n the machine is free of oily and combustible materials, n all safety elements are in place, n all grips are free of grease, oils, fuel, dirt, snow and ice.
tion tests.
order
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 nonfunctional safety installations.
Before starting and moving the machine, make sure that there is nobody in the danger zone.
Always keep an eye on the machine when the engine is running and hold it by the steering bow.
Do not inhale exhaust fumes, because they contain toxic substances, which could cause damage to health, unconsciousness or even death.
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Avoid operation in closed or partly closed rooms, or ensure adequate ventilation when working in trenches.
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BPR 70/70 D 29
Concerning your safety – Operation
3.7 Operation
3.7.1 Persons in the danger area
Before taking up work, also after breaks, you should always convince yourself that the danger zone is free of persons or obstructions.
Give warning signals, if necessary. Stop work immediately if persons remain in the danger zone, despite the warning.
parts
3.7.2 Operation
Only use the steering rod to steer the machine.
Guide the machine so that your hands do not hit against solid objects.
When reversing, steer the machine from the side using the steering handle.
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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, embankments 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 down the engine, pull off the ignition key, n Secure the machine against accidental tipping over, n Secure the machine against unauthorized use.
Mark machines, which could be in the way, with a clearly visible sign.
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30 BPR 70/70 D
3.8 Refuelling
Concerning your safety – Refuelling
Do not inhale any fuel fumes.
Refuel only with the engine shut down.
Do not refuel in closed rooms.
No open fire, do not smoke.
Ultra-low sulphur diesel fuel poses a higher risk of combustion caused by the static charging than diesel fuel with a higher sulphur content.
parts
Apply measures against electrostatic charging.
Do not spill any fuel. Catch running out fuel, do not let it seep into the ground.
your
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.
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BPR 70/70 D 31
Concerning your safety – Maintenance work
3.9 Maintenance work
3.9.1 Preliminary remarks
Adhere to the specified operating, maintenance and repair measures.
The machine must only be serviced by qualified personnel authorised by the operating company.
Keep unauthorised persons away from the machine.
Perform maintenance work only with the engine shut down.
Make sure that the engine cannot be accidentally started during maintenance work.
your parts
3.9.2 Working on hydraulic lines
Relieve hydraulic pressures before working on hydraulic lines.
Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury. Immediately call for medical assistance if injured by hydraulic oil.
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Do not step in front of or behind the machine when performing adjustment work in the hydraulic system.
Do not change the setting of pressure relief valves.
Drain the hydraulic oil at operating temperature – danger of scalding!
Any hydraulic oil must be collected and disposed of in an environmentally friendly way.
Always collect and dispose of hydraulic oils separately.
Do not start the engine after draining off the hydraulic oil. Once all work is completed (with the system still depressurized!) check all connections and fittings for leaks.
Hydraulic hoses must be visually inspected at regular intervals.
Do not mix up hoses by mistake.
Only genuine replacement hydraulic hoses ensure that the correct hose type (pressure range) is used at the right location.
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3.9.3 Working on the engine to
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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 separate, specially marked container and dispose of environmentally.
32 BPR 70/70 D
Concerning your safety – Maintenance work
3.9.4 Maintenance work on electric components and battery
Before starting to work on electric parts of the machine disconnect the battery and cover it with insulating material.
Do not use fuses with higher ampere ratings and do not bridge fuses.
When working on the battery, smoking or open fire is prohibited!
Do not lay any tools or other metal objects on the battery.
Do not wear jewellery (watch, bracelets, etc.) when working on the battery.
The connection cables of the battery must not touch or rub against machine parts.
your parts
3.9.5 Cleaning work
Do not perform cleaning work while the motor is running.
Do not use gasoline or other easily inflammable substances for cleaning.
to
3.9.6 After maintenance work
Reassemble all guards and protections.
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BPR 70/70 D 33
Concerning your safety – Repair
3.10 Repair
Identify a defect machine with a warning sign.
Only operate the machine after it has been repaired.
When replacing safety relevant 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.
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34 BPR 70/70 D
Concerning your safety – Signage
3.11 Signage
Keep stickers and signage in good and legible condition and comply with their meaning.
Replace damaged and illegible stickers or signage immediately.
II
I
L
WA dB your parts
START MIN
1
OPERATION
2
MAX
1
STOP
2
MIN
1-2 MINUTEN
3
3
STOP
1 2 3
START
4
MIN
1-2 MINUTEN
4
4
STOP to order
DIESEL jährlich / 250 h anualmente / 250 h
Made by
Designation
Nominal Power
Serial-No.
Operating Mass
Patent Protection
56154 Boppard;GERMANY
Type
Year of Construction
Made in Germany
Hydraulic Oil
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B-692-0254
BPR 70/70 D 35
Concerning your safety – Signage
Warning sticker - Follow operating instructions
Fig. 9
Fig. 10
Instruction sticker - Wear ear defenders to order your parts
Information sticker - Lashing point
Fig. 11
Information sticker - Lifting point to
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Fig. 12
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36 BPR 70/70 D
Concerning your safety – Signage
Information sticker - Guaranteed sound capacity level
Fig. 13
Hydraulic Oil
B-DEC-0214
Information sticker - Filler opening for hydraulic oil your parts to order
Fig. 14
Operation sticker - Travel lever
Fig. 15
Operation sticker - Throttle lever to
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Fig. 16
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BPR 70/70 D 37
Concerning your safety – Signage
Brief operating instructions
Fig. 17
DIESEL vor Inbetriebnahme avant la mise en service anterior a la puesta en servicio twice annual halbjährlich tous les 6 mois cada 6 meses wöchentlich hebdomadairement cada semana jährlich / 250 h annuellement / 250 h anualmente / 250 h
Maintenance sticker
B-DEC-0287
Fig. 18
Made by
Designation
Nominal Power
Serial-No.
Operating Mass
Patent Protection
56154 Boppard;GERMANY
Type
Year of Construction
Made in Germany
B-DEC-0271
Fig. 19
Machine type plate (example) to order your parts
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38 BPR 70/70 D
4
Indicators and control elements
Indicators and control elements
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BPR 70/70 D 39
Indicators and control elements – Machine
4.1 Machine
4.1.1 Handle
Fig. 20
4.1.2 Travel lever
B-692-0227
Shift upper part forward
Shift lower part forward
Forward travel to order your parts
B-692-0214
Fig. 21
4.1.3 Throttle lever
STOP
II
I
Position “STOP”
Position “MIN”
Position “I”
Position “II”
Engine off
Idle speed position
Medium load position
Full load position
Fig. 22
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B-692-0226
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40 BPR 70/70 D
Indicators and control elements – Machine
4.1.4 Reversing protection
Fig. 23
4.1.5 Starter switch
Fig. 24
B-692-0216 actuated release only forward travel possible
Backward travel and forward travel possible your parts
B-ELE-0069
Position “P”/“0”
Position “I”/“II”
Position “III”
Ignition key can be removed to
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 position “0” before a new starting attempt can be made.
4.1.6 Operating hour meter to
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B-692-0217
BPR 70/70 D 41
Indicators and control elements – Machine
4.1.7 Steering rod height adjustment turn clockwise turn anticlockwise
Fig. 26
4.1.8 Locking pawl lever
B-692-0218 lift the steering rod lower the steering rod to order your parts
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B-692-0219
Fig. 27
4.1.9 ECONOMIZER display
The ECONOMIZER displays the compaction status of the layer to be compacted.
Description of display possibilities Ä Chapter 6.6
Optional equipment
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42 BPR 70/70 D
Indicators and control elements – Engine
4.2 Engine
4.2.1 Ventilation lever
B-692-0157
Fig. 29
4.2.2 Decompression lever
Fig. 30
B-834-0187
Press for approx.
15 seconds
Position “closed”
Position “open”
This will bleed the fuel system your parts
Engine has compression to order
Only for emergency starting with crank handle (optional equipment) and maintenance
NOTICE!
Danger of engine damage!
Opening the decompression lever while the engine is running leads to engine damage.
– Never use the decompression lever for stopping the engine.
4.2.3 Crank handle
Start the engine with the crank handle only if the battery is defective, empty or missing.
to
Go
Fig. 31
B-692-0220
BPR 70/70 D 43
Indicators and control elements – Engine
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44 BPR 70/70 D
5
Checks prior to start up
Checks prior to start up
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BPR 70/70 D 45
Checks prior to start up – Notes on safety
5.1 Notes on safety
If the following tests reveal damages or other defects, the machine must not be operated, until these deficiencies have been corrected.
Do not operate the machine with defective indicators and control elements.
Safety installations must not be removed or made ineffective.
Do not change any fixed settings.
parts
WARNING!
– your tion regulations must be followed when han-
dling fuels and lubricants Ä Chapter 3.4 „Handling fuels and lubricants“ on page 23 .
WARNING!
to order
– Before starting work on the machine make sure that the engine can not be started.
1.
Park the machine safely
Ä Chapter 6.5 „Parking the machine in secured condition“ on page 60
.
2.
Open and secure the protection hood Ä Chapter 8.2.1.1
„Opening the protection hood“ on page 69
.
3.
Close the protection hood again after work is completed
Ä Chapter 8.2.1.2 „Closing the protection hood“ on page 70
.
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46 BPR 70/70 D
Checks prior to start up – Visual inspections and function tests
5.2 Visual inspections and function tests
1.
Check hydraulic oil tank and hydraulic lines for condition and leaks.
2.
Check fuel tank and fuel lines for condition and leaks.
3.
Check the bolted connections are tight and secure.
4.
Check the machine for contamination and damage.
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BPR 70/70 D 47
Checks prior to start up – Checking the engine oil level
5.3 Checking the engine oil level
Fig. 32
Fig. 33
MAX
MIN
B-SYM-1068
B-692-0182
NOTICE!
Danger of engine damage!
– +Use only oil of the permitted specification
Ä Chapter 8.3.1 „Engine oil“ on page 72 .
Protective equipment: n Working clothes n Safety shoes n Protective gloves your
1.
Clean the area around the oil dipstick.
2.
Pull the dipstick out, wipe it off with a lint-free, clean cloth and reinsert it to the end stop.
3.
Pull the dipstick out again.
4.
ð The oil level must be between the “MIN” and “MAX” marks.
NOTICE!
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Danger of engine damage!
– Do not fill in too much engine oil.
parts
If the oil level is too low, top up engine oil to the “MAX” mark.
5.
Push the dipstick in.
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48 BPR 70/70 D
Checks prior to start up – Checking the fuel level; topping up fuel
5.4 Checking the fuel level; topping up fuel
Fig. 34
B-SYM-1069
NOTICE!
Danger of engine damage!
– Monitor the entire refuelling process.
– Contaminated fuel can cause malfunction or even damage of the engine. If necessary, fill in fuel through a screen filter.
–
Use only fuel of the permitted specification
Ä Chapter 8.3.2 „Fuel“ on page 72
.
Protective equipment: n Working clothes your n Safety shoes parts
1.
2.
3.
Remove the cap and check the filling level visually.
4.
Close the cap.
n Protective gloves to order
Fig. 35
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 70.
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BPR 70/70 D 49
Checks prior to start up – Checking the hydraulic oil level
5.5 Checking the hydraulic oil level
Fig. 36
B-SYM-1071
Hydraulic Oil
NOTICE!
Components may get damaged!
– Check the hydraulic oil level at room temperature (approx. 20 °C (68 °F)).
– If, during the daily inspection of the oil level the hydraulic oil level is found to have dropped, check all lines, hoses and components for leaks.
– Use only oil of the permitted specification
Ä Chapter 8.3.4 „Mineral oil based hydraulic oil“ on page 73
.
parts
Protective equipment: n Working clothes
1.
Normal level n Safety shoes n Protective gloves to
1 /
2 order
height of inspection glass
Minimum level approx. 1 /
3
height of inspection glass
2.
For topping up, clean the area around the hydraulic oil tank.
B-692-0255
Fig. 37
3.
Remove the connecting piece and top up oil.
4.
Assemble the connecting piece.
B-692-0006
Fig. 38
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50 BPR 70/70 D
Checks prior to start up – Checking the rubber buffers
5.6 Checking the rubber buffers
Fig. 39
B-SYM-1073
Protective equipment: n Working clothes n Safety shoes n Protective gloves your
1.
Park the machine safely
Ä Chapter 6.5 „Parking the machine in secured condition“ on page 60
.
parts
2.
Allow the engine to cool down.
3.
4.
Check all rubber buffers for tight fit, cracks and tear-offs.
to order
B-692-0160
Fig. 40
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BPR 70/70 D 51
Checks prior to start up – Checking the rubber buffers
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52 BPR 70/70 D
6
Operation
Operation
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BPR 70/70 D 53
Operation – Folding down the steering rod
6.1 Folding down the steering rod
Fig. 41
1.
Pull the locking pawl lever (2) and fold 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.
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54 BPR 70/70 D
6.2 Starting the engine
Operation – Starting the engine
Exhaust fumes contain toxic substances and can damage your health, cause unconsciousness or even death.
WARNING!
Danger of poisoning by exhaust gases!
– Do not inhale exhaust gases.
– Avoid operation in closed or partly closed rooms, or ensure adequate ventilation when working in trenches.
your
WARNING!
parts
Loss of hearing caused by too high noise burdens!
– Wear your personal protective equipment (ear protection).
Protective equipment: n to order n Hearing protection n Safety shoes
1.
Set the throttle lever to position “MIN”.
B-692-0119
Fig. 42
2.
Turn the ignition key to position “I”.
ð The warning buzzer sounds.
to
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B-ELE-0070
BPR 70/70 D 55
Operation – Starting the engine
3.
Fig. 44
B-ELE-0072
The starter switch is designed with a re-start lock. The ignition key must first be turned back to position “0” before a new starting attempt can be made.
NOTICE!
Components may get damaged!
– Starting attempts should not exceed 30 seconds uninterrupted or max. 3 times for 10 seconds. Then allow the starter to cool down to ambient temperature.
your
– If the engine has not started after these attempts, determine the cause.
parts
ð The starter cranks the engine.
to
NOTICE!
Danger of engine damage!
– Warm up engine for a short while before starting work. Do not operate the engine immediately under full load.
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56 BPR 70/70 D
Operation – Operation
6.3 Operation
Operate the machine only with the steering rod folded down.
Use only the steering rod to steer the machine.
Guide the machine so that your hands do not hit against solid objects.
CAUTION!
Danger of injury caused by uncontrolled machine movement!
– Always hold on to a running machine.
– your parts
1.
Protective equipment: n Hearing protection n Safety shoes
NOTICE!
to order
The centrifugal clutch may be damaged!
– Only operate the machine in position “I”,
“II” or “MIN”.
Set the throttle lever to position “I” or “II”.
2.
Always shift the throttle lever to position “MIN” for short work breaks.
ð This prevents premature wear of the centrifugal clutch.
Fig. 45
Driving forward
1.
Shift the upper part of the travel lever forward until the desired speed has been reached.
ð The machine vibrates forward with the adjusted speed.
2.
Release the travel lever.
ð The travel lever moves back to middle position. The machine drives forward with the adjusted speed.
Fig. 46
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BPR 70/70 D 57
Operation – Operation
Driving backwards
Fig. 47
Vibration on the spot
1.
CAUTION!
Danger of injury caused by the crushing of body parts!
– When reversing, steer the machine from the side using the steering handle.
Shift the lower part of the travel lever forward until the desired speed has been reached.
ð The machine vibrates backwards with the adjusted speed.
2.
Release the travel lever.
your parts
ð The travel lever moves back to middle position. The machine drives backwards with the adjusted speed.
to order
1.
Move and hold the travel lever in the opposite direction until the machine vibrates on the spot.
ð The machine stops and vibrates on the spot.
Fig. 48
Help if the machine gets stuck 1.
Park the machine in secured condition
„Parking the machine in secured condition“ on page 60
.
2.
Lift the machine, using suitable lifting and lashing tackle at
the intended lifting points, until it becomes free Ä Chapter 7
„Loading / transporting the machine“ on page 63 .
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58 BPR 70/70 D
Operation – Reversing protection
6.4 Reversing protection
Fig. 49
1.
CAUTION!
Danger of injury caused by the crushing of body parts!
– When reversing, steer the machine from the side using the steering handle.
Operate the reversing protection.
ð The travel lever is switched from backward travel to forward travel.
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BPR 70/70 D 59
Operation – Parking the machine in secured condition
6.5 Parking the machine in secured condition
1.
Drive the machine onto level and firm ground.
2.
Move the travel lever until the machine vibrates on the spot.
Fig. 50
B-692-0002
3.
Set the throttle lever to “MIN” position (idle speed).
ð Vibration is shut down.
to order your parts
Fig. 51
STOP
Fig. 52
B-692-0119
4.
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.
B-692-0120
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.
to
Go
Fig. 53
B-ELE-0069
60 BPR 70/70 D
Operation – ECONOMIZER
6.6 ECONOMIZER
Start process
Measuring operation
Fig. 54
The ECONOMIZER informs the driver about the compaction status of the road subbase and enables the detection and selected recompaction of weak spots.
An acceleration sensor on the base plate measures the reaction of the subsoil to the base plate of the machine.
parts
The ECONOMIZER is automatically started by switching the ignition on.
The ECONOMIZER first of all runs an LED test. The LEDs light up one after the other, starting with LED (1). Once all LEDs are on, the display goes out again in single steps.
your
With the vibration switched on, the measuring value is displayed by the LED display (1-10).
to order
If the display value does not increase any further, no further compaction can be achieved with this machine.
The maximum display value (LED display 1-10 and warning display a) is not always reached.
Due to fluctuations in the measuring value, the display 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, when at the same time the LED displays (1 - 10) have gone out, if no vibration has been detected.
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Comparability of measuring values to
In order to achieve the desired compaction condition of the road subbase, one must always perform a suitable reference measureDiscount-Equipment.com value of the ECONOMIZER corresponds with the measuring value for soil stiffness.
BPR 70/70 D 61
Operation – ECONOMIZER
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62 BPR 70/70 D
7
Loading / transporting the machine
Loading / transporting the machine
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BPR 70/70 D 63
Loading / transporting the machine – Loading the machine
7.1 Loading the machine
Loads may only be attached and hoisted by an expert/qualified person.
Do not use lifting points that are damaged or impaired in any other way.
Only use lifting and lashing tackle with sufficient load bearing capacity for the weight to be loaded. Minimum load bearing
capacity of lifting tackle: see operating weight Ä Chapter 2 „Technical data“ on page 11 .
parts
Always use appropriate lifting and lashing tackle on the lifting and lashing points.
your
Lifting tackle must not be damaged by machine components.
When lifting the machine, avoid uncontrolled movements of the
Protective equipment:
1.
n Protective gloves
Park the machine safely
2.
Allow the engine to cool down.
.
order
3.
Make sure that the protection hood is fastened correctly
Ä Chapter 8.2.1.2 „Closing the protection hood“ on page 70
.
4.
Move the steering rod to an upright position and engage the locking pawl lever.
Fig. 55
5.
Attach the lifting tackle to the designated lifting eye (1).
6.
to
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Fig. 56
DANGER!
Discount-Equipment.com loads.
Lift the machine carefully and lower it again at the intended location.
64 BPR 70/70 D
Loading / transporting the machine – Lashing the machine to the transport vehicle
7.2 Lashing the machine to the transport vehicle
Do not use damaged or in any other way impaired lifting points.
Always use appropriate lifting and lashing tackle on the lifting and lashing points.
Use lifting tackle only in the prescribed direction of load application.
Lifting tackle must not be damaged by machine components.
Protective equipment: n Protective gloves parts
1.
Pull at least two suitable lashing belts crosswise across the marked lashing point (1).
your
Fig. 57 to order
2.
Lash the machine securely to the transport vehicle as shown.
Fig. 58
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BPR 70/70 D 65
Loading / transporting the machine – Lashing the machine to the transport vehicle to order your parts
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66 BPR 70/70 D
8
Maintenance
Maintenance
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BPR 70/70 D 67
Maintenance – Preliminary remarks and safety notes
8.1 Preliminary remarks and safety notes
DANGER!
Danger to life caused by an operationally unsafe machine!
– The machine must only be serviced by qualified and authorized personnel.
– Follow the safety regulations for maintenance work
Ä Chapter 3.9 „Maintenance work“ on page 32
.
your
WARNING!
parts
Health hazard caused by fuels and lubricants!
– Safety regulations and environmental protection regulations must be followed when han-
dling fuels and lubricants Ä Chapter 3.4 „Han-
to
Do not touch 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 completed, dispose of fuels and lubricants, filters, sealing elements and cleaning cloths in an environmentally friendly way.
After all maintenance work is completed reinstall all guards and safety installations.
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68 BPR 70/70 D
Maintenance – Preparations/concluding work
8.2 Preparations/concluding work
Certain maintenance tasks require preparations and concluding activities.
This includes e.g. opening and closing maintenance flaps and maintenance doors as well as securing certain components.
After this work close all maintenance flaps and doors again and return all components to their operating condition.
8.2.1 Opening / closing the protection hood
8.2.1.1 Opening the protection hood your
Protective equipment: n Working clothes n Protective gloves
1.
Remove the rear screws (2) on both sides of the machine.
2.
3.
to
4.
Fold the protection hood forward.
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Fig. 59
5.
Secure the protection hood against accidental closing.
For this tighten the screw (1) on both sides.
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BPR 70/70 D 69
Maintenance – Preparations/concluding work
8.2.1.2 Closing the protection hood
To fasten the protection hood, use only the prescribed original screws.
Always screw in and tighten all screws and their washers.
Protective equipment: n Working clothes n Protective gloves
1.
Loosen the screw (1) on both sides.
2.
Close the protection hood.
your parts
Fig. 61
3.
to order
4.
Screw in screws (2) and washers on both sides and tighten them.
Fig. 62
8.2.2 Bleeding the fuel 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:
Go to n After filling the fuel tank for the first time.
n After using the crank handle without starting, e.g. when temperatures are low.
n After several unsuccessful starting attempts.
n After replacing the fuel filter.
70 BPR 70/70 D
Fig. 63
Maintenance – Preparations/concluding work
Protective equipment: n Working clothes n Safety shoes n Protective gloves
1.
Allow the engine to cool down.
2.
Check the engine oil level, top up if necessary.
The fuel tank must be full when bleeding.
3.
Check the fuel level, top up if necessary.
4.
Press the ventilation lever for approx. 15 seconds against the spring.
your
ð The engine is ready for starting.
If the engine does not start after department.
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BPR 70/70 D 71
Maintenance – Fuels and lubricants
8.3 Fuels and lubricants
8.3.1 Engine oil
8.3.1.1 Oil quality
8.3.1.2 Oil viscosity
The following engine oil specifications are permitted: n API CF/CH-4 or higher quality n ACEA B3/E4 or higher quality
Avoid mixing engine oils.
your
Since engine oil changes its viscosity with the temperature, the ambient temperature at the operating location of the engine is of utmost importance when choosing the viscosity class (SAE-class).
The temperature data of the SAE-class always refer to fresh oils.
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Optimal operating conditions can be achieved by using the oil viscosity chart as reference.
parts
Fig. 64: Oil viscosity diagram
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.
8.3.2 Fuel
8.3.2.1 Fuel quality
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The following fuel specifications are permitted: Discount-Equipment.com n BS 2869 A1/A2
In order to fulfil national emission regulations one must strictly use the legally required fuels (e.g. sulphur content).
72 BPR 70/70 D
8.3.2.2 Winter fuel
8.3.2.3 Storage
Maintenance – Fuels and lubricants
For winter operation use only winter diesel fuel, to avoid clogging because of paraffin separation.
At very low temperatures disturbing paraffin separation can also be expected when using winter diesel fuel.
Diesel fuels suitable for temperatures down to -44 °C (-47 °F) are available for Arctic climates.
NOTICE!
parts
Danger of engine damage!
– The admixture of petroleum and the addition of
“flow enhancing additives” (fuel additives) is not permitted.
your to order
Even traces of zinc, lead and copper can cause deposits in the injection nozzles, especially in modern Common-Rail injection systems.
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.
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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 engine oils for the exciter shaft housing.
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The hydraulic system is operated with hydraulic oil HV 32 (ISO) with a kinematic viscosity of 32 mm 2 /s at 40 °C (104 °F).
When refilling or changing oil, use only hydraulic oil type HVLP according to DIN 51524, part 3, or hydraulic oil type HV according to ISO 6743/4.
BPR 70/70 D 73
Maintenance – Fuels and lubricants
The viscosity index must be at least 150 (observe information of manufacturer).
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74 BPR 70/70 D
Maintenance – List of fuels and lubricants
8.4 List of fuels and lubricants
Assembly group
Engine oil
Fuel
Exciter shaft housing
Hydraulic system
Fuel or lubricant Filling quantity
Summer Winter
SAE 10W-40
Specification:
Ä Chapter 8.3.1 „Engine oil“ on page 72
Observe the level mark!
1.9 l
(0.5 gal us) parts
SAE 15W-40
SAE 30
Diesel
SAE 10W-30
SAE 10W
Winter diesel fuel your
10.0 l
Specification: Ä Chapter 8.3.2 „Fuel“ on page 72
SAE 10W-40
Specification: Ä Chapter 8.3.3 „Oil for exciter shaft housing“ on page 73
to engine oils for the exciter shaft housing.
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(2.6 gal us)
0.6 l
(0.16 gal us)
SAE 15W-40
SAE 10W-30
Hydraulic oil (ISO), HV 32
Specification: Ä Chapter 8.3.4 „Mineral oil based hydraulic oil“ on page 73
2.6 l
(0.7 gal us)
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BPR 70/70 D 75
Maintenance – Running-in instructions
8.5 Running-in instructions
8.5.1 General
8.5.2 After 25 operating hours
The following maintenance work must be performed when running in new machines or overhauled engines.
1.
Change the engine oil
Ä Chapter 8.9.3 „Changing engine oil
2.
and oil filter element“ on page 86
.
Check the valve clearance, adjust if necessary Ä your
3.
Check engine and machine for leaks.
parts
4.
Retighten the fastening screws on air filter, exhaust and other
5.
6.
attachments.
Retighten the bolted connections on the machine.
Check the V-belt
.
order
7.
Check the oil level in the exciter shaft housing
8.11.4 „Checking the oil level in the exciter housing“ on page 97
.
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76 BPR 70/70 D
Maintenance – Maintenance Table
8.6 Maintenance Table
No.
Maintenance works Page
Checking, cleaning the air filter
Checking and cleaning the water separator
Annually / every 250 operating hours
Checking, adjusting the valve clearance
Changing engine oil and oil filter element
Changing the oil in the exciter housing
to
Every 2 years / every 500 operating hours
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your
parts
92 Changing hydraulic oil and hydraulic oil filter
Cleaning the cooling fins and the cooling air intake openings
Checking the oil level in the exciter housing
Measures prior to extended shut-down period
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BPR 70/70 D 77
Maintenance – Weekly
8.7 Weekly
8.7.1 Checking, cleaning the air filter
Fig. 65
B-SYM-1074
NOTICE!
Danger of engine damage!
– Do not start the engine after having removed the air filter.
– If necessary, the air filter may be cleaned up to six times.
– Cleaning does not make sense if the air filter element is covered with a sooty deposit.
– Do not use gasoline or hot fluids to clean the filter element.
parts
– After cleaning, the air filter must be inspected for damage using a torch.
– Do not continue to use a damaged air filter element. If in doubt use a new air filter.
Protective equipment: n to n Safety shoes order n Protective gloves n Safety goggles
1.
Park the machine safely
Ä Chapter 6.5 „Parking the machine in secured condition“ on page 60
.
2.
Allow the engine to cool down.
3.
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.
Fig. 66
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Clean the filter housing with a clean, lint-free cloth.
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78 BPR 70/70 D
Fig. 67
Maintenance – Weekly
7.
CAUTION!
Danger of eye injuries caused by particles flying around!
– Wear your personal protective equipment
(safety gloves, protective working clothes, goggles).
Blow the air filter out with dry compressed air (max. 5 bar
(73 psi)) from inside to outside by moving the gun up and down inside the element, until it is free of dust.
8.
9.
Replace the air filter if it is damaged.
your parts
10.
Slide the air filter (2 ) carefully into the filter housing.
11.
Check the sealing face (3) on the cover.
12.
NOTICE!
to order
Danger of engine damage!
– Ensure correct fit of cover and seal.
Close the cap (1).
Fig. 68
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BPR 70/70 D 79
Maintenance – Weekly
8.7.2 Checking and cleaning the water separator
Fig. 69
Fig. 70
B-SYM-1075
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 engine into operation you should check for signs of water and dirt initially every day.
Protective equipment: n Working clothes n Safety shoes n Protective gloves your
1.
Park the machine safely
Ä Chapter 6.5 „Parking the machine in secured condition“ on page 60
.
parts
2.
Place the transparent container under the drain plug.
3.
4.
to order bleed the fuel system before starting.
Ä Chapter 8.2.2 „Bleeding the fuel system“ on page 70
5.
Screw the drain plug back on tightly. Ensure leak tightness.
6.
Dispose of collected fluid in line with environmental regulations.
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80 BPR 70/70 D
Maintenance – Semi-annually
1
2
3
Fig. 72
8.8 Semi-annually
8.8.1 Battery service
Fig. 71
B-SYM-1077
B-692-0123
Maintenance free batteries also need care. Maintenance free only means that the fluid level does not need to be checked.
Every battery has a self-discharge, which may, if not checked occasionally, even cause damage to the battery as a result of exhaustive discharge.
Exhausted batteries (batteries with formation of sulphate on the plates) are not covered under warranty!
your parts
Protective equipment: n Working clothes
1.
n Safety shoes n n
Protective gloves
Park the machine safely
to
in secured condition“ on page 60
.
order
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 acid level, if necessary top up to the filling mark with distilled water.
8.
Install battery and vibration insulation mats.
9.
Install the bracket of the battery.
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BPR 70/70 D 81
Maintenance – Annually / every 250 operating hours
8.9 Annually / every 250 operating hours
8.9.1 Replacing the V-belt
Protective equipment: n Working clothes n Safety shoes n Protective gloves
1.
Park the machine safely
Ä Chapter 6.5 „Parking the machine in secured condition“ on page 60
.
2.
Allow the engine to cool down.
3.
Unscrew the V-belt guard (1).
your to order
Fig. 73
1
B-692-0175
4.
Unscrew the guard (1).
1
B-692-0187
Fig. 74
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.
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3
2
1
8.
Fasten the V-belt pulley.
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B-692-0188
82 BPR 70/70 D
Fig. 76
Fig. 77 x
1
Maintenance – Annually / every 250 operating hours
9.
Check the centre distance (x) between the centrifugal clutch
(1) and the V-belt pulley (2).
ð Nominal value: 418 ± 1 mm (16.5 ± 0.04 in)
2
B-692-0183
If the centre distance is incorrect, contact our customer service.
10.
your parts to order
11.
Fasten the V-belt guard (1).
Fig. 78
8.9.1.1 Checking the frequency of the base plate
Keep feet and hands clear of the vibrating base plate.
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CAUTION!
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– Always keep an eye on a running machine.
BPR 70/70 D 83
Maintenance – Annually / every 250 operating hours
Protective equipment: n Working clothes n Hearing protection n Safety shoes
Special tool: n Sirometer
1.
Park the machine on a rubber mat.
2.
Start the engine
Ä Chapter 6.2 „Starting the engine“ on page 55 .
3.
Run the machine at maximum speed for one minute.
4.
Check the base plate’s frequency with a suitable measuring instrument (e.g. Sirometer).
ð
Nominal value: Ä Chapter 2 „Technical data“ on page 11
your parts
5.
Park the machine safely
Ä Chapter 6.5 „Parking the machine in secured condition“ on page 60
.
6.
If frequency incorrect: n Check the engine speed.
n Check the V-belt.
n to order
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.
Preparations Protective equipment: n Working clothes n Protective gloves
1.
Park the machine in secured condition
„Parking the machine in secured condition“ on page 60
.
2.
Let the engine cool down to ambient temperature.
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84 BPR 70/70 D
Maintenance – Annually / every 250 operating hours
3.
Check the position of the decompression lever, if necessary move it to the initial position.
Fig. 79
Fig. 80
Checking the valve clearance
4.
Remove the valve cover with the seal.
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Valve clearance:
Intake valve (IN)
Exhaust valve (EX)
0.30 mm (0.012 in)
0.30 mm (0.012 in)
1.
Crank the engine, 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. 81
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BPR 70/70 D 85
Maintenance – Annually / every 250 operating hours
Adjusting the valve clearance
Fig. 82
Final work
1.
Loosen screw (3) on the rocker arm.
2.
Adjust the screw (2), until the feeler gauge (1) can be inserted and pulled out with a barely noticeable resistance after the hexagon nut (3) has been tightened.
your parts
1.
Install the valve cover with a new seal and tighten the screws evenly.
2.
After a short test run check the valve cover for leaks.
to order
Fig. 83
8.9.3 Changing engine oil and oil filter element
NOTICE!
Danger of engine damage!
– Change the oil only with the engine at operating temperature.
– Use only oil of the permitted specification
Ä Chapter 8.3.1 „Engine oil“ on page 72 .
–
Filling quantity: Ä Chapter 8.4 „List of fuels and lubricants“ on page 75
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86 BPR 70/70 D
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Draining off engine oil
Fig. 84
Fig. 85
Changing the oil filter element
Maintenance – Annually / every 250 operating hours
Protective equipment: n Working clothes n Protective gloves n Safety goggles
1.
Park the machine in secured condition
„Parking the machine in secured condition“ on page 60
.
2.
Clean the area around the dipstick and pull the dipstick out.
parts your
3.
to order
WARNING!
Danger of burning on hot components!
– Wear your personal protective equipment (protective gloves, protective clothing).
– Avoid touching hot components.
4.
Unscrew the drain 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 necessary.
12.
Screw the cap on.
BPR 70/70 D 87
Maintenance – Annually / every 250 operating hours
Filling in engine oil
Fig. 87
Concluding work
8.9.4 Replacing the fuel filter
13.
Fill in fresh engine oil through the filler opening.
14.
Push the dipstick in.
15.
After a short test run, check the oil level on the dipstick, top up oil if necessary.
parts your
16.
Check oil filter and drain plug for leaks.
17.
Dispose of oil and oil filter insert in an environmentally friendly way.
to order
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
„Parking the machine in secured condition“ on page 60
.
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.
to
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Fig. 88
6.
Pull the fuel filter with the fuel lines out of the hose clamps.
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9.
Plug on the fuel lines.
Observe the flow direction of the new fuel filter.
10.
Insert the fuel filter with the fuel lines into the hose clamps.
11.
Screw the hose clamps to the holding fixtures.
88 BPR 70/70 D
8.9.5 Replacing the air filter
Maintenance – Annually / every 250 operating hours
12.
Fill the fuel tank.
13.
Bleed the fuel system before starting Ä Chapter 8.2.2
„Bleeding the fuel system“ on page 70
.
14.
After a short test run check fuel filter and fuel lines for leaks.
15.
Dispose of fuel and fuel filter in an environmentally friendly way.
parts
NOTICE!
Danger of engine damage!
your
– Do not start the engine after having removed the air filter.
Protective equipment: n n
Working clothes to order
1.
Park the machine in secured condition
„Parking the machine in secured condition“ on page 60
.
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.
Fig. 89
Clean the filter housing with a clean, lint-free cloth.
7.
Replace the air filter.
8.
Slide the air filter (2 ) carefully into the filter housing.
to
Go
Fig. 90
9.
Check the sealing face (3) on the cover.
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Danger of engine damage!
– Ensure correct fit of cover and seal.
Close the cap (1).
BPR 70/70 D 89
Maintenance – Annually / every 250 operating hours
8.9.6 Changing the oil in the exciter housing
1
2
B-692-0196
NOTICE!
Components may get damaged!
– Use only oil of the permitted specification
Ä Chapter 8.4 „List of fuels and lubricants“ on page 75
.
– Do not use low-ash engine oils for the exciter shaft housing.
Protective equipment: n Working clothes n Protective gloves your
1.
Park the machine on level ground.
2.
Park the machine in secured condition
„Parking the machine in secured condition“ on page 60
.
3.
Clean the area around the bleeding screw (1) and filling / drain plug (2).
to order
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.
parts
Fig. 91
7.
Tilt the machine to the opposite side and secure it properly.
8.
Fill in new oil.
B-692-0198
Fig. 92
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90 BPR 70/70 D
Fig. 93
1 2
Maintenance – Annually / every 250 operating hours
B-692-0197
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 install with low-strength sealing agent (e.g. spare parts number: 009
700 16).
11.
Dispose of oil in an environmentally friendly way.
parts your to order
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BPR 70/70 D 91
Maintenance – Every 2 years / every 500 operating hours
8.10 Every 2 years / every 500 operating hours
8.10.1 Changing hydraulic oil and hydraulic oil filter
Changing the breather filter
NOTICE!
Risk of damage!
– Perform the oil change when the hydraulic oil is warm.
– Use only hydraulic oil of the permitted specification.
–
Filling quantity: Ä Chapter 8.4 „List of fuels and lubricants“ on page 75 .
Protective equipment: n Working clothes your parts n Protective gloves
1.
Park the machine in secured condition
„Parking the machine in secured condition“ on page 60
.
2.
to
3.
Unscrew the plug (1).
4.
Take out the breather filter (3).
5.
Replace and insert the breather filter with seal ring (2).
6.
Replace the plug and screw it in tightly.
Fig. 94
Changing hydraulic oil and filter
7.
Disassemble the connecting piece with the hydraulic lines.
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92 BPR 70/70 D
Fig. 96
Fig. 97
Maintenance – Every 2 years / every 500 operating hours
8.
Disassemble the connecting flange and take it off together with the hydraulic oil filter.
9.
Disassemble the hydraulic oil tank.
10.
Drain the hydraulic oil tank and assemble it again.
your parts to order
11.
Replace the hydraulic oil filter (4) and the seal ring (3) and fasten it to the connecting flange.
12.
Assemble the connecting flange (1) with the new seal ring (2) to the hydraulic oil tank (tightening torque: 13 Nm (9.6 ft.lbs)).
Fig. 98
Filling up hydraulic oil
NOTICE!
Risk of damage!
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– Use only hydraulic oil of the permitted specifi-
cation Ä Chapter 8.3.4 „Mineral oil based
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BPR 70/70 D 93
Maintenance – Every 2 years / every 500 operating hours
Fig. 99
Final work
13.
Fill in new hydraulic oil.
14.
Check the hydraulic oil level in the inspection glass, top up if necessary.
ð Nominal value: Middle of inspection glass your
15.
Assembling the connecting piece with the hydraulic lines.
16.
Check the connections on the hydraulic oil tank and the connecting flange for leaks.
17.
Dispose of hydraulic oil in an environmentally friendly way.
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Fig. 100
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94 BPR 70/70 D
Maintenance – As required
8.11 As required
8.11.1 Cleaning the machine
Protective equipment: n Working clothes n Safety shoes n Protective gloves
1.
Park the machine safely
Ä Chapter 6.5 „Parking the machine in secured condition“ on page 60
.
2.
Allow the engine to cool down for at least 30 minutes.
3.
NOTICE!
your
Electric components can be damaged by water entering into the system!
– Do not guide the water jet directly into the openings of the crank handle, into the air filter or onto electrical equipment.
to order
Clean the machine from the outside and inside with a water jet.
4.
Warm up the engine for a while to avoid corrosion.
Fig. 101: Cleaning the machine
(example)
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8.11.2 Cleaning the cooling fins and the cooling air intake openings to
Fig. 102
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
„Parking the machine in secured condition“ on page 60
.
2.
Allow the engine to cool down.
3.
Remove dried dirt with a suitable brush from all cooling fins and cooling air intake openings.
CAUTION!
Danger of eye injuries caused by particles flying around!
– Wear your personal protective equipment
(safety gloves, protective working clothes, goggles).
Blow out the cooling fins and cooling air intake openings with compressed air.
BPR 70/70 D 95
Maintenance – As required
5.
In case of damp or oily contamination you should consult our customer service department.
8.11.3 Servicing the V-belt
Preparations Protective equipment: n Working clothes n Protective gloves
1.
Park the machine in secured condition
„Parking the machine in secured condition“ on page 60
.
2.
Allow the engine to cool down.
3.
Unscrew the V-belt guard (1).
your parts to order
Fig. 103
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.
Fig. 104
Replace the V-belt if it is damaged or if the compression measurement is exceeded
Ä Chapter 8.9.1 „Replacing the Vbelt“ on page 82
.
6.
Fasten the V-belt guard (1).
to
Go
Fig. 105
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96 BPR 70/70 D
Maintenance – As required
8.11.4 Checking the oil level in the exciter housing
1 2
B-692-0197
NOTICE!
Components may get damaged!
– Use only oil of the permitted specification
Ä Chapter 8.4 „List of fuels and lubricants“ on page 75
.
– Do not use low-ash engine oils for the exciter shaft housing.
Protective equipment: n Working clothes n Protective gloves your
1.
Park the machine on level ground.
2.
Park the machine in secured condition
3.
Allow the machine to cool down.
order
.
4.
Clean the area around the bleeding screw (1) and filling / drain plug (2).
5.
Unscrew the bleeding screw.
to
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 filling / drain plug and screw them in with a low-strength sealing agent (e.g. spare parts number:
009 700 16).
parts
Fig. 106
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.
2.
Clean the water separator.
3.
Fill the fuel tank with diesel fuel to prevent the formation of condensation water in the tank.
Go to 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.
BPR 70/70 D 97
Maintenance – As required
8.11.5.2 Battery service during prolonged machine downtimes
WARNING!
Danger of injury caused by exploding gas mixture!
– 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.
your
– Wear your personal protective equipment (protective gloves, protective clothing, goggles).
Protective equipment: n n
Working clothes to order n Safety goggles
1.
Switch off all consuming devices (e.g. ignition, light).
parts
2.
Measure the open-circuit voltage of the battery at regular intervals (at least 1 x per month).
ð Reference values: 12.6 V = fully charged; 12.3 V = discharged to 50%.
3.
Recharge the battery immediately after an open-circuit voltage of 12.25 V or less is reached. Do not perform boost charging.
ð The open-circuit voltage of the battery occurs approx. 10 hours after the last 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 taking it into service.
6.
For standstill periods of more than one month you should always disconnect the battery. Do not forget to perform regular open-circuit voltage measurements.
Go
8.11.5.3 to
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.
Start the engine and run it for 15 to 30 minutes with idle speed.
98 BPR 70/70 D
Maintenance – As required
6.
Check the oil levels.
7.
Clean the machine thoroughly.
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BPR 70/70 D 99
Maintenance – As required
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100 BPR 70/70 D
9
Troubleshooting
Troubleshooting
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BPR 70/70 D 101
Troubleshooting – Preliminary remarks
9.1 Preliminary remarks
Malfunctions are frequently caused by incorrect operation of the machine or insufficient maintenance. Whenever a fault occurs you should therefore thoroughly read these instructions on correct operation and maintenance.
If you cannot locate the cause of a fault or rectify it yourself by following the trouble shooting chart, you should contact our customer service department.
parts your to order
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102 BPR 70/70 D
Troubleshooting – Emergency starting with crank handle (optional equipment)
9.2 Emergency starting with crank handle (optional equipment)
Start the engine with the crank handle only if the battery is defective, empty or missing.
Exhaust fumes contain toxic substances and can damage your health, cause unconsciousness or even death.
WARNING!
Danger of poisoning by exhaust gases!
your
– Do not inhale exhaust gases.
– Avoid operation in closed or partly closed rooms, or ensure adequate ventilation when working in trenches.
WARNING!
to order
Loss of hearing caused by too high noise burdens!
– Wear your personal protective equipment (ear protection).
parts
Protective equipment: n Working clothes n Hearing protection n Safety shoes
1.
Set the throttle lever to position “MIN”.
B-692-0119
Go
Fig. 107 to
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BPR 70/70 D 103
Troubleshooting – Emergency starting with crank handle (optional equipment)
2.
Turn the ignition key to position “I”.
ð The warning buzzer does not sound.
Fig. 108
B-ELE-0070
With the ignition key in position “I” the battery is charged when the engine is running, as long as the battery voltage is at least 9 V.
3.
Pull the decompression lever in direction of arrow to the end stop.
your
ð The decompression lever clicks noticeably into place.
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Fig. 109
4.
Open the cover.
5.
Remove the crank handle from the bracket and insert it.
6.
Stand in the correct position parallel to the machine.
B-692-0220
Fig. 110
7.
Grip the crank handle with both hands as shown.
8.
Turn the crank handle with both hands slowly in the direction of the arrow until it engages.
to
Go
Fig. 111
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104 BPR 70/70 D
Go
Troubleshooting – Emergency starting with crank handle (optional equipment)
CAUTION!
Danger of injury caused by uncontrolled machine movement!
– Always hold on to a running machine.
– Always keep an eye on a running machine.
9.
Then turn the crank handle with increasing speed, until the engine starts.
Ensure a positive connection between crank handle and engine by turning it quickly.
your
Do not interrupt the starting process under any circumstances.
When the decompression lever closes and engages (after five revolutions), the highest speed must be reached.
10.
to order
11.
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.
parts
NOTICE!
Danger of engine damage!
– Warm up engine for a short while before starting work. Do not operate the engine immediately under full load.
12.
Hook the crank handle into the bracket.
13.
Close the cover.
NOTICE!
Danger of engine damage!
– Warm up engine for a short while before starting work. Do not operate the engine immediately under full load.
BPR 70/70 D 105
Troubleshooting – Starting the engine with jump leads
9.3 Starting the engine with jump leads
Fig. 113
NOTICE!
A wrong connection will cause severe damage in the electric system.
– Bridge the machine only with a 12 Volt auxiliary battery.
1.
Open the protection hood and secure it to prevent unintended closing.
2.
Remove the bracket of the battery.
3.
First connect the plus pole of the external battery to the plus pole of the starter battery using the first jump lead.
your parts
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.
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106 BPR 70/70 D
9.4 Fuse assignment
Fig. 114
Troubleshooting – Fuse assignment
Pos.
1
WARNING!
Danger of injury by fire in the machine!
– Do not use fuses with higher ampere ratings and do not bridge fuses.
Amperage Designation
25 A
5 A
Main fuse
Economizer fuse your parts to order
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BPR 70/70 D 107
Troubleshooting – Engine malfunctions
9.5 Engine malfunctions
Fault
The engine is hard to start or does not start at all
Possible cause
Fuel tank empty
Fuel filter clogged
Fuel lines leaking
The fuel shut-off valve has triggered automatically
Incorrect valve clearance
Wear on cylinder or piston rings
Injection nozzle out of order
Remedy
Check the fuel level, top up if necessary
Check the fuel filter, replace if necessary
Check the fuel lines
Check the engine oil level, top up if necessary.
If necessary, check other causes for triggering.
your
Bleed the fuel system by means of the ventilation lever on the fuel shut-off valve.
Check the valve clearance, adjust if necessary sonnel to order
Have it checked by qualified expert per-
Have it checked by qualified expert personnel parts
Engine does not start or starts poorly 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
Fuel filter clogged
Check the battery, charge if necessary
Check the fuel filter, replace if necessary Engine ignites, but does not run
The starter does not switch on or the engine does not crank.
Main fuse broken
Battery or other cables not connected correctly
Battery defective or not charged
Replace main fuse
Check
Check the battery, charge or replace if necessary
Engine stops
Starter defective
Fuel tank empty
Replace the starter
Check the fuel level, top up if necessary
Fuel filter clogged Replacing the fuel filter
Tank ventilation blocked
Air in the fuel system
Ensure sufficient ventilation of the tank
Check the ventilation valve.
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108 BPR 70/70 D
Troubleshooting – Engine malfunctions
Fault
Engine looses power and speed
Engine looses power and speed, black exhaust smoke
Fuel tank empty
Fuel system clogged
Tank ventilation blocked
Air in the fuel system
Too much oil in exciter housing.
Air filter dirty
Incorrect valve clearance
Engine overheats Engine oil level too high
Engine runs with high speed, but no vibration
Possible cause
The fuel shut-off valve has triggered automatically
Mechanical defect
Injection nozzle out of order
Air filter dirty
Lack of cooling air
Centrifugal clutch defective
V-belt torn
Remedy
Check the engine oil level, top up if necessary.
Check the fuel level, top up if necessary.
If necessary, check other causes for triggering.
Bleed the fuel system by means of the ventilation lever on the fuel shut-off valve.
parts
Have checked by qualified expert personnel.
your
Replacing the fuel filter
Ensure sufficient ventilation of the tank
Check the fuel system for air entry.
to order
Clean the air filter, replace if necessary.
Check the valve clearance, adjust if necessary
Have it checked by qualified expert personnel
Check the engine oil level, drain off engine oil if necessary
Clean the air filter, replace if necessary.
Clean the cooling fins and the cooling air intake openings.
Check air guide plates and ducts for completeness and good sealing.
Have it checked by qualified expert personnel
Replacing the V-belt
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BPR 70/70 D 109
Troubleshooting – Trouble shooting ECONOMIZER
9.6 Trouble shooting ECONOMIZER
your parts
Fig. 115: Economizer display
Fault
LED (a) flashes
LED (a) lights up
Possible cause
Switching on: The LED (a) flashes for approx 1 - 2 seconds after the vibration has been switched on.
Vibration frequency too low.
No vibration detected.
Acceleration sensor is not connected.
Remedy to order
Start the engine, set the throttle lever to position “MAX” (switch vibration on).
Check the connection of the acceleration sensor.
Check the connection of the acceleration sensor.
Inform our service department.
Cable breakage.
The displayed measuring values are not plausible.
The acceleration sensor is not fastened correctly.
Weak spots in the road subbase.
Shut down the engine and check the fastening screws of the acceleration sensor.
In unfavourable cases, an excessively varying material composition or moisture in the road subbase can influence the measuring results.
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On material which is too dry or moist, lower measuring values will be displayed.
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110 BPR 70/70 D
10
Disposal
Disposal
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BPR 70/70 D 111
Disposal – Final shut-down of machine
10.1 Final shut-down of machine
If the machine can no longer be used and needs to be finally shut down you must carry out the following work and have the machine disassembled by an officially recognized specialist workshop.
WARNING!
Health hazard caused by fuels and lubricants!
– Safety regulations and environmental protection regulations must be followed when han-
dling fuels and lubricants Ä Chapter 3.4 „Handling fuels and lubricants“ on page 23 .
your
Protective equipment: n Working clothes parts n Safety shoes
1.
n Protective gloves n order
Remove the batteries and dispose of in compliance with legal regulations.
2.
Empty the fuel tank.
to
3.
Drain engine oil from engine and exciter housing.
4.
Drain off hydraulic oil.
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112 BPR 70/70 D
11
List of special tools
List of special tools
to order your parts
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BPR 70/70 D 113
Fig.
List of special tools
Sirometer
Measuring instrument for speed and frequency
BOMAG 059 710 02 to order your parts
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114 BPR 70/70 D
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