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Operating instructions

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Maintenance instructions

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BPR 35/42 D - BPR 35/60 D

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S/N 101 690 41 ....> S/N 101 690 42 ....> S/N 101 690 43 ....> S/N 101 690 44 ....>
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Vibratory plate
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www.discount-equipment.com

Catalogue number
008 041 61 02/2007
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 Foreword

These BOMAG - machines are products from For your own safety you should only use gen-
F oreword

the wide product range of BOMAG compaction uine BOMAG spare parts.
equipment. BOMAG's vast experience, cou-
To comply with the technical development we

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pled with the most modern production and
testing methods, such as lifetime tests of all reserve the right of modifications without prior

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important components and highest quality de- notification.
mands, ensure highest reliability of your ma- These operating and maintenance instructions are

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chine. also available in other languages.
In addition you can obtain a spare parts catalogue

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Using these instructions will
from your BOMAG dealer by just stating the serial
help you to become acquainted with the ma-

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l number of your machine.
chine.
Information for the correct use of our machines in
l avoid faults caused by unprofessional opera- earth and asphalt construction is also available

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tion. from your BOMAG-dealer.

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The notes mentioned above do not constitute an
Observing the maintenance instructions will
extension of the warranty and liability conditions,

or
l increase the reliability of the machine during which are part of the general terms of business of
use on site, BOMAG.

to
l prolong the lifetime of the machine, We wish you much success with your BOMAG
machine.
l reduce repair costs and downtime.
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BOMAG GmbH & Co. OHG
BOMAG does not assume liability for the function
Printed in Germany
of the machine
t.c

Copyright by BOMAG
l if the machine is handled in a way, which does
not comply with the use it is intended for,
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l if it is used for purposes other then the ones

mentioned in these instructions.
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No warranty claims can be lodged for damage re-

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sulting from
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l operating errors,
l insufficient maintenance and
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l the use of wrong fuels and lubricants.

Please note!
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This manual was written for operators and mainte-

nance personnel on construction sites.
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You should only operate the machine after you

have been instructed to do so and by following
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these instructions.
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Please observe strictly the safety regulations.

Please observe also the guidelines of the civil en-
to

gineering liability association "safety rules for the

operation of road rollers and soil compaction
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equipment", as well as the applicable instructions

for the prevention of accidents.
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BPR 35/40 D BPR 35/60 D BOMAG 3

 Foreword

Please fill in
............................
Machine type (Fig. 1)

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............................

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Serial No. (Fig. 1 and 2)

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............................
Engine type (Fig. 3)

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............................

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Engine No. (Fig. 3)

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Fig. 1

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Fill in the above listed data when receiving the ma-
chine.

or
Upon receipt of the machine our organization will
instruct you about correct operation and mainte-

to
nance.
Please observe strictly all safety regulations and
notes on potential dangers!
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Fig. 2
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Fig. 3
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4 BOMAG BPR 35/40 D BPR 35/60 D

 Table of Contents

Technical Data 7
Safety regulations 13

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Indicators and Controls 17

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3.1 General notes 18
3.2 Controls 18

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Operation 21

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4.1 General 22
4.2 Before starting work 22

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4.3 Folding down the steering rod 23
4.4 Starting with recoil starter 23

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4.5 Start the engine electrically. 25

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4.6 Starting with jump leads 26
4.7 Work/operation 26

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4.8 Shutting the engine down 28
4.9 Loading 29

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Maintenance 31
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5.1 General notes on maintenance 32
5.2 Fuels and lubricants 33
5.3 Table of fuels and lubricants 35
t.c

5.4 Running-in instructions 36

5.5 Maintenance chart 37
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5.6 Clean machine/engine 38

5.7 Checking the fuel level 38
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5.8 Checking the engine oil level 39

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5.9 Checking the condition of the battery, greasing the poles 40

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5.10 Check the air filter, replace if necessary. 41

5.11 Checking the oil level in the vibrator housing 43
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5.12 Changing the engine oil 43

5.13 Clean the engine oil filter 44
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5.14 Check, tighten, replace the V-belt 45

5.15 Check, adjust the valve clearance 47
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5.16 Cleaning cooling fins and cooling air intake opening 47

5.17 Cleaning the exhaust screen 48
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5.18 Changing the dry air filter 49

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5.19 Changing the fuel filter 51

5.20 Change the oil in the exciter shaft housing 51
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5.21 Checking the hydraulic oil level and topping up 52

5.22 Checking the rubber buffers 54
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5.23 Drawing the water out of the fuel tank 55

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5.24 Retightening the bolted connections 57

5.25 Tightening the screws 57

BPR 35/40 D BPR 35/60 D BOMAG 5

 Table of Contents

5.26 Engine conservation 58

Trouble shooting 59
6.1 General notes 60

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6.2 Replacing the injection pump 61
6.3 Engine faults 65

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6 BOMAG BPR 35/40 D BPR 35/60 D

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1 Technical Data

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BPR 35/40 D BPR 35/60 D BOMAG 7

 Technical Data

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Fig. 4
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Dimensions in mm Working width W lowest passing height H

BPR 35/42 D BPR 35/42 D (E-Start) 420 687
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*
BPR 35/42 D BPR 35/42D with E-Start
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Weights
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Operating weight (CECE) kg 205 225

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Travel characteristics soil dependent

Working speed m/min 27 27
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Gradability % 32 32

Drive
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Engine manufacturer Hatz Hatz

Type 1B20 1B20
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Cooling Air Air

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Number of cylinders 1 1
Rated power ISO 9249 kW 3,1 3,1
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Rated speed min-1 3000 3000

Starting device Recoil starter Electric starter
Fuel Diesel Diesel
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Drive system mechanical (V-belt) mechanical (V-belt)

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8 BOMAG BPR 35/40 D BPR 35/60 D

 Technical Data

* BPR 35/42 D BPR 35/42D with E-Start

Exciter system
Frequency Hz 80 80

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Centrifugal force kN 35 35

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Filling capacities

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Fuel l 3 3

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* The right for technical modifications remains reserved

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BPR 35/40 D BPR 35/60 D BOMAG 9

 Technical Data

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Fig. 5
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Dimensions in mm Working width W lowest passing height H

BPR 35/60 D BPR 35/60 D with E-Start 600 687
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m

*
BPR 35/60 D BPR 35/60 D
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with E-Start
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Weights
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Operating weight (CECE) kg 220 240

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Travel characteristics soil dependent

Working speed m/min 27 27
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Gradability % 32 32
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Drive
Engine manufacturer Hatz Hatz
D

Type 1B20 1B20

Cooling Air Air
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Number of cylinders 1 1
Rated power ISO 9249 kW 3,1 3,1
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Rated speed rpm 3000 3000

Starting device Recoil starter Electric starter
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Fuel Diesel Diesel

Drive system mechanical (V-belt) mechanical (V-belt)

10 BOMAG BPR 35/40 D BPR 35/60 D

 Technical Data

* BPR 35/60 D BPR 35/60 D

with E-Start

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Exciter system

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Frequency Hz 80 80
Centrifugal force kN 35 35

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Filling capacities
Fuel l 3 3

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* The right for technical modifications remains reserved

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BPR 35/40 D BPR 35/60 D BOMAG 11

 Technical Data

The following noise and vibration data acc. to

- EC Machine Regulation edition 98/37/EC and

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- the noise regulation 2000/14/EG, noise protection guideline 2003/10/EC

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- Vibration Protection Regulation 2002/44/EC

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were determined during conditions typical for this type of equipment and by application of harmo-
nized standards.

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During operation these values may vary because of the existing operating conditions.

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Noise value

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sound pressure level on the operator’s stand:

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LpA = 91 dB(A) BPR 35/42 D with tube frame, determined acc. to ISO 11204 and EN 500
LpA = 92 dB(A) BPR 35/60 D with tube frame, determined acc. to ISO 11204 and EN 500

or
Guaranteed sound power level:

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LWA = 103 dB(A) BPR 35/42 D with tube frame, determined acc. to ISO 3744 and EN 500
LWA = 105 dB(A) BPR 35/60 D with tube frame, determined acc. to ISO 3744 and EN 500
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Danger
!

Loss of hearing!
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Wear your personal noise protection means (ear defenders) before starting operation.
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Vibration value
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Hand-arm vibration:
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Vector total of the weighted effective acceleration in three orthogonal directions:

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Weighted total vibration value

BPR 35/42 D ahw = 6.2 m/sec2 with hood on crushed rock determined acc. to ISO 5349 and EN 500
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BPR 35/42 D ahw = 7.3 m/sec2 with tube frame on crushed rock determined acc. to ISO 5349 and EN 500
BPR 35/60 D ahw = 5.7 m/sec2 with hood on crushed rock determined acc. to ISO 5349 and EN 500
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BPR 35/60 D ahw = 6.7 m/sec2 with tube frame on crushed rock determined acc. to ISO 5349 and EN 500
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Caution
!

Observe the daily vibration load (Industrial safety acc. to 2002/44/EEC).

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12 BOMAG BPR 35/40 D BPR 35/60 D

 ts
2 Safety regulations

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BPR 35/40 D BPR 35/60 D BOMAG 13

 Safety regulations

General Who is allowed to work with the ma-

chine?
This BOMAG machine is built in accordance
with the latest technical standard and the valid The machine must only be operated by trained

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technical rules and regulations. However, dan- and authorized persons who are at least 18 years

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gers for persons and property may arise from of age. The responsibilities for the operation of the
the machine if it is: machine must be clearly specified and complied

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with.
l put to unintended use,
Persons under the influence of alcohol, medica-

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l operated by untrained personnel, tion or drugs must not operate, service or repair
l modified or altered in an unprofessional way, the machine.

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l the applicable safety regulations are not ob- Maintenance and repair tasks require specific
served. knowledge and must therefore only be carried out

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by trained and qualified personnel.

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Each person involved in operation, mainte-
nance and repair of the machine must there-
Conversions and alterations to the ma-
fore read and apply these safety regulations. If

or
necessary this should be confirmed by obtain- chine
ing the signature of the customer. Unauthorized conversions to the machine are pro-

to
Furthermore the following regulations and instruc- hibited for safety reasons.
tions are obviously also valid: Original parts and accessories have been special-
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ly designed for this machine. We wish to make ex-
l all applicable instructions for the prevention of
pressly clear that we have not tested or authorized
accidents,
any original parts or special equipment not sup-
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l generally acknowledged safety and road traffic plied by us. The installation and/or use of such
regulations, products can impair the active and/or passive driv-
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l country specific regulations. ing safety. The manufacturer expressly excludes

any liability for damage resulting from the use of
non-original parts or accessories.
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Intended use
This machine must only be used for: Safety notes in the operating and main-
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l compaction of all types of soil, tenance instructions:

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l repair work on all types of soil,

reinforcement of pedestrian walkways, Danger
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l !

l work in trenches, Paragraphs marked like this highlight possible

dangers for persons.
filling and compaction of hard shoulders.
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l The machine should be checked by an expert !Caution

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once every year.

Paragraphs marked this way highlight possi-
ble dangers for machines or parts of the ma-
Unintended use
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chines.
Dangers may, however, arise from the machine if
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it is used by untrained personnel in an unprofes-

sional way or if it is used for purposes other than
i Note
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those mentioned in these instructions. Sections marked like this provide technical infor-
mation concerning the optimal economical use of
the machine.
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14 BOMAG BPR 35/40 D BPR 35/60 D

 Safety regulations

Environment Operation
Sections marked like this highlight activities Operate the machine only with the steering rod
for the safe and environmental disposal of fu- folded down.

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els and lubricants as well as replaced parts. Guide the machine so hat your hands do not hit

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against solid objects, danger of injury.
Safety stickers on the machine Watch out for unusual noises and development of

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Keep safety stickers in good condition and legible smoke. Perform trouble shooting and have the
and follow their meaning. fault corrected.

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Replace damaged and illegible safety stickers. Operate the machine only with full engine speed,

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as otherwise the centrifugal clutch will be de-
Loading the machine stroyed.
Do not let the machine run unattended.

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Secure the machine against turning over or slip-

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ping off.
Persons are highly endangered if they
Parking the machine

or
Park the machine on level, firm ground.
l step under loads being lifted or
Before leaving the machine:
l stand under loads being lifted

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l park the machine so that it cannot turn over,
Secure the machine on the transport vehicle
against rolling off, slipping and turning over. l shut the engine down.
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Mark machines, which could be in the way, with a
Starting the machine clearly visible sign.
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Before starting
Filling the fuel tank
Become acquainted with the equipment, the con-
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Refuel only with the engine shut down.

trol elements, the working principle of the machine
and the working area. Do not refuel in closed rooms.
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Wear your personal protective outfit (hard hat, No open fire, do not smoke.
safety boots, etc.). Wear ear defenders.
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Do not spill any fuel. Catch running out fuel, do not

Before starting the machine check whether: let it seep into the ground.
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l the machine shows any obvious faults

Maintenance
all guards and safety elements are in place
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Maintenance work must only be carried out by
l the controls are fully functional qualified and authorized personnel.
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l the machine is free of oily and combustible Keep unauthorized persons away from the ma-
material chine.
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l all grips are free of grease, oils, fuel, dirt, snow Do not perform service work while the engine is
and ice. running.
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Use only machines which are serviced at regular If possible, park the machine on level and firm
intervals. ground.
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Do not use any starting aids like start pilot or ether. Working on the engine
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For starting move your feet out of the danger zone Drain the engine oil at operating temperature -
of the base plate. danger of scalding!
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Starting in closed rooms Wipe off spilled oil, catch running out oil and dis-
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Exhaust gases are highly dangerous! Always en- pose of environmentally.

sure an adequate supply of fresh air when starting
in closed rooms!

BPR 35/40 D BPR 35/60 D BOMAG 15

 Safety regulations

Store used filters and other oil containing materials Exhaust gases are highly dangerous! Always en-
in a specially marked container and dispose of en- sure an adequate supply of fresh air when starting
vironmentally. in closed rooms!

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Working on electric components Mark defective machines by attaching a warning
note to the steering handle.

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Before starting to work on electric components dis-
connect the battery and cover it with insulating ma-

p
terial.

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Working on the battery
When working on the battery do not smoke, do not

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use open fire.
Do not let skin and clothes come in contact with

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acid.

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In case of injuries caused by acid flush the respec-
tive parts with clear water and consult a doctor for

or
medical advice.
Do not place any tools on the battery, danger of

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short circuit.
When recharging the battery remove all plugs to
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avoid an accumulation of explosive gases.
Dispose of old batteries environmentally.
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Working on the fuel system

No open fire, do not smoke, do not spill any fuel.
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Catch running out fuel, do not let it seep into the

ground and dispose of environmentally.
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Cleaning
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Do not clean the machine while the engine is run-

ning.
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Do not use gasoline or other combustible sub-

stances for cleaning purposes.
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When using steam cleaning equipment do not

subject electric parts to the direct water jet or cover
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it beforehand.
Do not guide the water jet directly into the air filter
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and into the air intake opening.

After maintenance work

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Reinstall all protective devices after completing

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the maintenance work.

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Repair
Repair work must only be performed by qualified
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and authorized persons. Use our repair instruc-

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tions for this work.

16 BOMAG BPR 35/40 D BPR 35/60 D

 ts
3 Indicators and Controls

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BPR 35/40 D BPR 35/60 D BOMAG 17

 Indicators and Controls

3.1 General notes 3.2 Controls

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Please read this section thoroughly before operat-
ing this machine if you are not yet conversant with

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the indicators and control elements. All functions
are described in detail hereunder.

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Paragraph 4 Operation contains only concise de-

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scriptions of the individual operating steps.

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Fig. 6
Locking lever (Fig. 6)

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Fig. 7
Height adjustment (Fig. 7) of steering rod.
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i Note
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Pull the locking lever up to fold the steering rod

down.
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18 BOMAG BPR 35/40 D BPR 35/60 D

 Indicators and Controls

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Fig. 8

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Controls (Fig. 8).
1 Throttle lever

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2 Steering rod
3 Travel lever

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Fig. 9
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Optional equipment
Start the engine electrically (Fig. 9).
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Ignition key position "0", warning buzzer off.

Ignition key position "I", warning buzzer on.
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Ignition key position "II", the engine will start.

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BPR 35/40 D BPR 35/60 D BOMAG 19

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BPR 35/40 D BPR 35/60 D

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4 Operation

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BOMAG
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21
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 Operation

4.1 General 4.2 Before starting work

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If you are not yet acquainted with the controls Please observe strictly the safety regulations
and indicating elements on this machine you in chapter 2 of these operating and mainte-

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should thoroughly read chapter 3 “Indicators nance instructions.
and control elements” before starting work.

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Refer also to the detailed description in the
All indicators and control elements are de- chapter “Maintenance”.

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scribed in detail in this chapter. Top up missing lubricants according to the mainte-
nance instructions.

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l Park the machine on ground as level as possi-
ble.

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l Check fuel tank and fuel lines for leaks.
l Check the engine oil level, if necessary fill up

or
to the top mark.
l Check the fuel level, fill up if necessary.

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l Check the dry air filter service indicator.
l Check the condition of the complete machine
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and all screw joints for tight fit.
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Danger
!

Loss of hearing!
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Wear your personal noise protection means

(ear defenders) before starting operation.
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22 BOMAG BPR 35/40 D BPR 35/60 D

 Operation

4.3 Folding down the steering 4.4 Starting with recoil starter
rod

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! Danger

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! Danger Danger of explosion!

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Danger of injury! Do not use any starting aid spray.
Shock by spring force! Before starting make sure that there are no

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persons in the danger area of engine or ma-
The steering rod is resilient in operating posi-
chine and that all safety installations are in

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tion.
place.

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Fig. 10
Fig. 11
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l Pull locking lever (Fig. 10) up and fold the rod

l Shift the travel lever (Fig. 11) to position "0".
down, so that steering rod can swing freely.
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Fig. 12

Set the throttle lever (Fig. 12) to position "MIN"

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(idle speed).
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BPR 35/40 D BPR 35/60 D BOMAG 23

 Operation

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Fig. 13 Fig. 15

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l Slightly pull the starter handle (Fig. 13), until l Run the engine warm for approx. 1 to 2 min-
resistance can be felt (compression pressure), utes in idle speed.

or
but do not pull out completely.
l Guide the starter rope back by hand.

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Fig. 14

l Pull the rope by the starter handle quickly and

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powerful as far out as possible (Fig. 14).

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Note
Do not let the starter handle hit back against the
engine.
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l If the engine does not start during the first at-

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tempt, repeat the starting process.

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24 BOMAG BPR 35/40 D BPR 35/60 D

 Operation

4.5 Start the engine electrical-

ly*.

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Fig. 18

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l Then turn the ignition key further to position "II"
(Fig. 18), the engine will start.

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l As soon as the engine runs, guide the ignition
key back to position I.
Fig. 16

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The warning buzzer stops.
l Set the throttle lever (Fig. 16) to position "MIN"
(idle speed).
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! Danger
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Danger of injury!
Before starting make sure that there are no
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persons in the danger area of engine or ma-

chine and that all safety installations are in
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place.
Do not use starting aid sprays or other inflam-
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mable fluids for starting.

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Fig. 19
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l Run the engine warm for a short while before

starting work (Fig. 19).
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l Operation of the vibratory plate can be started

once the engine has warmed up for a while.
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!Caution
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When the engine is running leave the ignition

D

key in position I.
If the starting attempt takes longer than 10 sec-
to

Fig. 17 onds wait at least 15 seconds before trying

again.
l Turn the ignition key to position "I" (Fig. 17),
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the warning buzzer sounds. Excessive running of the starter will discharge
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the battery.

* Optional equipment

BPR 35/40 D BPR 35/60 D BOMAG 25

 Operation

4.6 Starting with jump leads 4.7 Work/operation

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i Note i Note

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Use this starting method if the starter battery is Operation of the vibratory plate can be started as
empty. soon as the engine responds to short throttle com-

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mands.
l Remove the cover from the battery.

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Danger
!

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Caution
!
Danger of accident!
Incorrect connection will cause severe dam-
age in the electric system. Operate the machine only with the steering rod

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folded down.

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The auxiliary battery must have the same volt-
age as the normal starter battery. Guide the machine only by the steering rod.
Wear your personal noise protection (ear de-

or
fenders).

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Fig. 20
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l Connect the plus poles of auxiliary battery and

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starter battery with the jump cable (Fig. 20). Fig. 21

l Connect the minus poles of starter battery and l Pull the locking lever (Fig. 21) up and fold the
steering rod down.
t-E

auxiliary battery with the second jump cable.

l Perform the starting process as described be-
fore.
un

l When the engine is running disconnect the ca-

ble from the minus poles first and then the ca-
co

ble from the plus poles.

is

i Note
D

This method avoids short circuits caused by con-

tact between plus and minus cables.
to

l Reassemble the battery cover.

o
G

Fig. 22

l Adjust the steering rod with the height adjust-

ment (Fig. 22) to the height of your body.

26 BOMAG BPR 35/40 D BPR 35/60 D

 Operation

ts
p ar
ur
r yo
Fig. 23 Fig. 25

de
l Set the throttle lever (Fig. 23) to position l Move the travel lever (Fig. 25) backwards as
"MAX". required for the desired speed.

or
The machine vibrates forward or backwards with a
!Caution speed, which is in accordance with the chosen

to
Operate the vibratory plate only with full en- travel lever position.
gine speed, as otherwise the centrifugal clutch
will be destroyed.
om
i Note
If the machine moves forward with considerably
i Note reduced speed, pull the travel lever completely
t.c

For short breaks you should always return the back and shift it forward again.
throttle lever to idle speed position, this avoids pre-
en

mature wear of the centrifugal clutch. If the vibratory plate got stuck
m
ip
qu
t-E
un
co

Fig. 24 Fig. 26
is

l Move the travel lever (Fig. 24) forward as re- l Lock the steering rod (Fig. 26) in the first lock-
D

quired for the desired speed. ing position.

to
o
G

BPR 35/40 D BPR 35/60 D BOMAG 27

 Operation

4.8 Shutting the engine down

ts
! Caution

ar
Do not shut the engine down all of the sudden
from full speed, but let it idle for a while for

p
temperature equalization.

ur
r yo
Fig. 27

de
l Keep moving throttle lever (Fig. 27) between
"MIN" and "MAX" throttle position.

or
l At the same time pull the vibratory plate by the
steering rod to the right and left, until it comes

to
free. om
Danger
!

Fig. 28
Danger of accident!
l Shift the throttle lever to position "MIN" (Fig.
t.c

As a measure to avoid injury the machine must

28) and let the engine run with idle speed for a
only be guided from the side by the steering
short while.
handle
en

Vibration is shut down.

m
ip
qu
t-E
un
co
is

Fig. 29
D

l Set the throttle lever to position "STOP" (Fig.

29), the warning buzzer sounds.
to
o
G

28 BOMAG BPR 35/40 D BPR 35/60 D

 Operation

4.9 Loading

ts
! Danger

ar
Danger of accident!

p
Make sure that persons are not endangered by
the machine tipping or sliding off.

ur
Tie the machine down, so that it is secured
against rolling, sliding and turning over.

yo
For lifting the machine attach the lifting gear
only to the lifting hook.

r
Fig. 30
The machine must not swing about when be-

de
l Turn the ignition key to position "0" and pull it ing lifted.
out. The warning buzzer stops.
Use only safe lifting gear of sufficient load

or
bearing capacity
Do not stand or step under loads being lifted.

to
om
t.c
en
m
ip
qu

Fig. 31
t-E

l Adjust the steering rod (Fig. 31) in upright po-

sition and lock it in the last locking position.
un
co
is
D
to
o
G

Fig. 32

l Fold the lifting hook (Fig. 32) up.

BPR 35/40 D BPR 35/60 D BOMAG 29

 Operation

ts
p ar
ur
r yo
Fig. 33

de
l Always attach the lifting gear (rope) to the lift-
ing eye to load the vibratory plate on a trans-

or
port vehicle (Fig. 33).

to
! Danger

Danger of accident!
om
Tie the machine down on the transport vehicle, so
that it is secured against slipping, sliding and turn-
t.c

ing over!
en
m
ip
qu
t-E
un
co
is
D
to
o
G

30 BOMAG BPR 35/40 D BPR 35/60 D

 ts
5 Maintenance

p ar
ur
ryo
de
or
to
om
t.c
en
m
ip
qu
t-E
un
co
is
D
to
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G

BPR 35/40 D BPR 35/60 D BOMAG 31

 Maintenance

l Do not draw off fuel from near the bottom of

5.1 General notes on mainte- the fuel drum.
nance l Fuel left in the fuel drum is not suitable for the

ts
engine and should only be used for cleaning
When performing maintenance work observe the purposes.

ar
applicable safety regulations and especially safety
regulations in chapter 2 of these operating, main-

p
Notes on the engine performance
tenance and repair instructions.
Combustion air and fuel injection rates of the die-

ur
Thorough maintenance of the machine ensures sel engine have been carefully adjusted and deter-
maximum reliability and prolongs the lifetime of im- mine the engine's performance and temperature

yo
portant components. The effort necessary for this level as well as the quality of the exhaust gas.
purpose is only of minor significance when being
If your machine has to operate permanently in
compared with the problems, which may arise, if

r
"thin air" (at high altitudes) and with full power, you
these instructions are not observed.

de
should consult the after sales service of BOMAG
l Clean machine and engine thoroughly before or the service department of the engine manufac-
starting maintenance work.

or
turer.
l For maintenance work park the machine on
level ground.

to
l Maintenance work must generally be carried
out with the engine shut down.
om
Environment
t.c

During maintenance work catch all oils and fu-

els and do not let them seep into the ground.
en

Dispose of oils and fuel environmentally.

m

Notes on the fuel system

The lifetime of the diesel engine is decisively de-
ip

pending on the cleanliness of the fuel.

qu

l Keep the engine free of dirt and water as this

could damage the injection elements of the en-
t-E

gine.
l Zinc lined drums are not suitable for storing fu-
el.
un

l The fuel drum should rest for a longer period

of time before drawing off fuel.
co

l Under no circumstances must the drum be

is

rolled to the tapping pint just before drawing off

fuel.
D

l When choosing the storage place for fuel,

make sure that spilled fuel will not cause any
to

damage.
l Do not let the suction hose disturb the sludge
o

on the bottom of the drum.

G

32 BOMAG BPR 35/40 D BPR 35/60 D

 Maintenance

The following oil change intervals apply also for

5.2 Fuels and lubricants multi-purpose oils.

ts
Regular lubrication oil changes
Engine oil

ar
The longest permissible time for an oil filling in the
Use winter engine oil for winter operation!
engine is 1 year.

p
To ensure perfect cold starting it is important to
choose the viscosity (SAE grade) of the engine oil Oil quality

ur
with respect to the ambient temperature.
You should preferably use oils of API-quality class
During winter operation below -10°C the oil

yo
CD-CE-CF-CG, or CCMC-D4/D5/PD2 (SHPD).
change intervals must be shortened. When using oils of lower quality standard the oil
change intervals must be reduced.

r
de
Oil change intervals

Oil change intervals for oil quality

or
API: CD-
CE-CF-

to
CG = 6 months
CCMC-D4/
om
D5/PD2
(SHPD) = 6 months
t.c

!Caution
These intervals apply when using a diesel fuel
en

with a sulphur content of max. 0.5 % by weight

and an ambient temperature higher than -10°C
m

(14°F).
When using fuel with a sulphur content of
ip

l
more than 0,5% to 1% or at ambient tempera-
qu

Fig. 34 tures below -10°C (14°F) the oil change inter-

vals in the table must be halved. For fuels with
Lubrication oil with a too high viscosity index will
a sulphur content higher than 1% to 1,5% the
t-E

cause starting difficulties. The temperature when

engine oil must have a TBN of approx. 12 x
starting the engine is therefore decisive for select-
%S-content when the oil change intervals are
ing the correct viscosity for winter operation.
un

halved.
Oil viscosity
Lubrication oil quality classes
co

Since the viscosity of the lubrication oil changes

The API-classification is used to classify the oil
with the temperature, the ambient temperature at
quality. The lubrication oil manufacturer is respon-
the engine's operating location determines the vis-
is

sible for the correct classification of the product.

cosity class (SAE-grade) to be chosen (see dia-
D

gram).
Although cold stating abilities may be impaired if i Note
to

the temperature occasionally drops below the limit When changing to a higher alloyed oil quality after
(e.g. use of SAE 15W/40 down to -15°C), this will a longer operating period, we recommend the first
oil change of this higher quality oil to be performed
o

not cause any damage to the engine.

after approx. 25 operating hours.
G

Temperature related lubrication oil changes can

be avoided by using multi-purpose engine oils.

BPR 35/40 D BPR 35/60 D BOMAG 33

 Maintenance

Fuels
Quality

ts
You should only use commercial brand diesel fu-
els with a sulphur content below 0,5% and ensure

ar
strict cleanliness when filling in fuel. A higher sul-
phur content has an effect on the oil change inter-

p
vals. Use only winter diesel fuel for lower ambient
temperatures. Top up fuel in time so that the fuel

ur
tank does not run dry.

yo
The following fuel specifications are permitted:
EN 590 DIN 51601; Nato Codes F-54, F-75, F-76;
BS 2869: A1 and A2; ASTM D 975-78:

r
de
1-D and 2-D; VV-F-800 a: DF-A, DF-1 and DF-2.

Winter fuel

or
For winter operation use only winter diesel fuel, to
avoid clogging of the fuel system due to paraffin

to
separation. Under extremely low temperatures
paraffin separation can also be expected with win-
om
ter diesel fuel. .
t.c
en
m
ip
qu
t-E
un
co
is
D
to
o
G

34 BOMAG BPR 35/40 D BPR 35/60 D

 Maintenance

5.3 Table of fuels and lubri-

cants

ts
ar
Assembly Fuel or lubricant Quantity approx.

p
Summer Winter Attention

ur
Observe the level marks

yo
Engine Engine oil API: CD-CE-CF-CG approx. 0.9 l (BPR 35/42
D)

r
approx. 0.9 l (BPR 35/60

de
D)

or
SAE 10W/40

(-20°C to +30°C)

to
(-4°F to +86°F)
om
SAE 15W/40

(-10°C to +40°C)
t.c

(+14°F to +104°F)

SAE 30 SAE 10W

en

(+5°C to +30°C) (-5°C to -30°C)

m

(+41°F to +86°F) (+23°F to -22°F)

ip

SAE 40 SAE 20W/20

qu

(+25°C to +40°C) (+10°C to -10°C)

(+77°F to +104°F) (+50°F to +14°F)

t-E

- Fuel Diesel Winter diesel fuel 3 l (BPR 35/42 D)

un

3 l (BPR 35/60 D)

(-12°C) (+10.4°F)
co

Vibrator shaft as engine oil 0,4 l

is

housing
D

Steering rod Hydraulic oil HV 32 approx. 0,4 l

to
o
G

BPR 35/40 D BPR 35/60 D BOMAG 35

 Maintenance

5.4 Running-in instructions

ts
For the start-up or new machines of over-
hauled engines the following maintenance

ar
work must be performed:

p
! Caution

ur
During the running-in period up to approx. 200
operating hours check the engine oil level two

yo
times every day.
Depending on the engine load the oil con-

r
sumption will drop to its normal level after a

de
running time of approx. 100 to 200 operating
hours.

or
After 25 operating hours
l Change the engine oil.

to
l Check engine and machine for leaks.
om
l Check the valve clearance, adjust if neces-
sary.
l Retighten the fastening screws for air filter, ex-
t.c

haust silencer, fuel tank and other attach-

ments.
en

l Tighten the screw connections on the ma-

chine.
m

l Check the vibration drive V-belt, retighten it if

ip

necessary.
qu
t-E
un
co
is
D
to
o
G

36 BOMAG BPR 35/40 D BPR 35/60 D

 Maintenance

5.5 Maintenance chart

ts
With all maintenance intervals perform also
the work for preceeding shorter intervals.

ar
Pos. Description Note

p
Maintenance every day

ur
5.6 Clean machine/engine

yo
5.7 Check the fuel level
5.8 Check the engine oil level

r
Maintenance every month

de
5.9 Check the condition of the battery, grease the poles

or
5.10 Clean the dry air filter
Maintenance every 6 months

to
5.11 Check the oil level in the vibrator housing
5.12 Change the engine oil
om
5.13 Clean the engine oil filter
5.14 V-belt tension
t.c

5.15 Check, adjust the valve clearance

5.16 Clean cooling fins and cooling air intake opening
en

5.17 Clean the exhaust screen

5.18 Change the dry air filter
m

Dim. mm (inch)
ip

5.19 Change the fuel filter

5.20 Change the oil in the vibrator housing
qu

5.21 Check the rubber buffers

5.22 Draw the water out of the fuel tank
t-E

As required
un

5.23 Retighten the bolted connections Check the machine

visually
co
is
D
to
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G

BPR 35/40 D BPR 35/60 D BOMAG 37

 Maintenance every day

Maintenance every day

5.6 Clean machine/engine 5.7 Checking the fuel level

ts
i Note ! Danger

ar
Dirty operating conditions, particularly lubrication When working on the fuel system do not use
oil and fuel deposits on the cooling fins of the en- open fire, do not smoke, fire hazard!

p
gine and the cooling air intake opening have an
Do not refuel in closed rooms.
adverse effect on the cooling of the engine. You

ur
should therefore immediately seal any oil or fuel Refuel only with the engine shut down.
leaks near fuel tank, cylinder or cooling air intake

yo
and subsequently clean the cooling fins.

r
de
or
to
om
t.c

Fig. 36

l Clean the area around the fuel filler cap, re-

en

Fig. 35 move the filler cap (Fig. 36).

l Do not guide the water jet directly into the cool-
ing air openings of the recoil starter, into the
m

!Caution
dry air filter and on electrical equipment (Fig.
Dirty fuel can cause malfunction or even dam-
ip

35).
age of the engine.
After wet cleaning run the engine warm to
qu

l
evaporate all water residues and to avoid cor- l Fill in fuel through a funnel with screen.
rosion. l Close the tank tightly.
t-E

For quality of fuel refer to the table of fuels and

lubricants.
un
co
is
D
to
o
G

38 BOMAG BPR 35/40 D BPR 35/60 D

 Maintenance every day

5.8 Checking the engine oil lev-

el

ts
Place the machine on level ground, so that the

ar
l
engine is in horizontal position.

p
ur
r yo
de
or
to
Fig. 37
om
l Shut the engine down.
l Pull the oil dipstick (Fig. 37) out, clean it with a
t.c

clean cloth and reinsert it until it bottoms.

l Pull the dipstick back out and read the oil level.
en

Nominal value:
The oil level should reach the top mark. If the oil
m

level is too low top up oil immediately.

ip

For quality and quantity of oil refer to the table

qu

of fuels and lubricants.

l Check the seal on the dipstick, if necessary
t-E

use a new one.

l Push the dipstick in until it bottoms.
un
co
is
D
to
o
G

BPR 35/40 D BPR 35/60 D BOMAG 39

 Maintenance every month

Maintenance every month

5.9 Checking the condition of

the battery*, greasing the

ts
poles

p ar
Danger
!

ur
Danger of injury!
When working on the battery do not smoke, do

yo
not use open fire.
Do not let skin and clothes come in contact

r
with acid. Fig. 39

de
Wear protective goggles. l Take the battery (Fig. 39) out and clean the
Do not place any tools on the battery. battery compartment.

or
l Clean the outside of the battery.
l Clean the battery poles and pole clamps and

to
cover them with acid free grease (vaseline).
l Check the fastening of the battery.
om
l Check the condition of the vibration insulation
mats, replace if necessary.
t.c

l After servicing the battery close the cover

again.
en

Non-maintenance free batteries

m

Caution
ip

!
Fig. 38
Top up missing fluid with distilled water.
qu

l Unscrew the fastening screws (Fig. 38) for the

cover plate and fold the cover up. l Open the plugs and check the acid level, if
necessary top up with distilled water.
t-E

l Take the vibration insulation mats off.

With control inserts:
The acid level must reach the bottom of the control
un

inserts.
co

Without control inserts:

Acid level 10 to 15 mm above the upper edge of
is

the lead plate, measure with a clean wooden stick.

D

With transparent battery housing:

Acid level up to the mark on the housing.
to

Maintenance free batteries

o

Perform only the following points:

G

l Check the battery for cleanliness.

* Option

40 BOMAG BPR 35/40 D BPR 35/60 D

 Maintenance every month

l Clean the poles.

5.10 Check the air filter, replace
l Tighten the terminal clamps.
if necessary.

ts
Caution
!

ar
Dispose of old batteries environmentally. ! Caution

p
Do not use gasoline or hot fluids to clean the
Danger
! filter cartridge.

ur
Development of gas! Dry air filter cartridges with damaged filter ele-
ment or seal ring must be replaced in any case.

yo
If possible remove the plugs when recharging
the battery, to avoid an accumulation of highly It is therefore recommended to keep at least
explosive gases. one filter element in stock.

r
Replace the air filter cartridge after five times

de
cleaning, but at the latest after half a year.
Each cleaning interval must be marked with a

or
cross on the filter element.
Cleaning does not make sense if the filter ele-

to
ment is covered with a sooty deposit. Use a
new filter cartridge.
om
Incorrectly handled filter cartridges may be in-
effective because of damage (e.g. cracks) and
cause damage to the engine.
t.c

In case of wet or oily dirt replace the filter ele-

ment.
en

Do not run the engine without air filter.

m
ip
qu
t-E
un
co
is

Fig. 40
D

l Remove the air filter cover (Fig. 40).

to
o
G

BPR 35/40 D BPR 35/60 D BOMAG 41

 Maintenance every month

ts
p ar
ur
r yo
Fig. 41 Fig. 42

de
l Unscrew the knurled nut and take the air filter l Blow the filter cartridge (Fig. 42) out from in-
cartridge off (Fig. 41). side to outside with dry compressed air (max.

or
5 bar).
Caution
! l Check the filter cartridge for damage, replace

to
The clean air side must be kept clean of dirt if necessary.
and foreign particles.
om
Do not blow the inside of the filter housing out
with compressed air.
t.c

l Wipe the inside of the filter housing only with a

clean cloth.
en

l Clean the cover thoroughly.

m

! Danger
Eye injury!
ip

Wear safety goggles.

qu

Fig. 43
t-E

l Insert the filter cartridge (Fig. 43) into the

housing and fasten it with the knurled nut.
un

l Assemble the filter cover, ensure correct fit of

cover and seal.
co
is
D
to
o
G

42 BOMAG BPR 35/40 D BPR 35/60 D

 Maintenance every 6 months

Maintenance every 6 m onths

5.11 Checking the oil level in the 5.12 Changing the engine oil
vibrator housing

ts
! Caution

ar
i Note Park the machine on level ground.

p
Stand the machine on level ground. Drain the engine oil only when the engine is
warm.

ur
yo
Environment
Catch running out old oil, do not let it seep into
the ground and dispose off environmentally.

r
de
Danger
!

or
Danger of scalding when draining off hot en-
gine oil.

to
om
Fig. 44

l Unscrew the level plug (Fig. 44) and check the

oil level.
t.c

The oil level must reach the bottom edge of the

en

level bore, top up oil if necessary.

For quality and quantity of oil refer to the table

m

of fuels and lubricants.

ip

l Screw the level plug back in with a new seal

ring.
qu

Fig. 45

l Unscrew the oil drain plug and catch running

t-E

out old oil (Fig. 45).

l Clean the oil drain plug and screw it back in
with a new seal ring.
un

Caution
co

Clean the engine oil filter before filling in new

oil, see next section.
is
D
to
o
G

BPR 35/40 D BPR 35/60 D BOMAG 43

 Maintenance every 6 months

5.13 Clean the engine oil filter

ts
! Caution

ar
Remove and clean the engine oil filter only af-
ter draining off the engine oil.

p
ur
r yo
Fig. 46

de
l Fill in new engine oil (Fig. 46).

or
For quality and quantity of oil refer to the table
of fuels and lubricants.
Push the dipstick in again.

to
l

l Perform a test run, inspect drain plug and oil

filter for leaks.
om
Fig. 47

l Loosen the fastening screw and pull the en-

gine oil filter out of the housing (Fig. 47).
t.c

l Blow the engine oil filter out with compressed

air from inside to outside.
en

l Cover the seal slightly with oil.

m

l Push the engine oil filter into the housing and

tighten the fastening screw.
ip

l After filling in engine oil perform a short test

qu

run and check for leaks, if necessary tighten

the fastening screw.
t-E
un
co
is
D
to
o
G

44 BOMAG BPR 35/40 D BPR 35/60 D

 Maintenance every 6 months

5.14 Check, tighten, replace the

V-belt

ts
ar
Check the V-belt

p
ur
r yo
Fig. 50

de
l Take off the front V-belt pulley half (1) (Fig. 50)
with the shims (2) positioned in front.

or
l Take one or two shims (3) from in front of the
rear V-belt pulley half (4) as required to ten-

to
sion the V-belt.
Fig. 48 l Lay the V-belt over the threaded bolts.
om
l Remove the V-belt guard. l Attach the front V-belt pulley half with the re-
l Check the condition and tension of the V-belt moved shims.
t.c

(Fig. 48), replace the V-belt if damaged. l Assemble the washers, turn on and tighten the
Compression measurement, see picture. nuts.
en

Tightening the V-belt. !Caution

m

Do not squash the V-belt, keep turning the

drive while tightening the nuts.
ip

l Check the V-belt tension, if necessary correct

qu

by removing or adding shims.

l Assemble the V-belt guard.
t-E

Caution
!
un

Check the V-belt tension again after a running

time of approx. 25 operating hours, retighten if
necessary.
co

Changing the V-belt

is

Fig. 49
D

l Block the V-belt pulley with a screwdriver (Fig. Caution

!

49).
Take care of differences in V-belt length, see
to

l Unscrew the nuts and remove the washers. spare parts catalogue.
o

l Take the V-belt off the upper V-belt pulley (see

tensioning the V-belt).
G

BPR 35/40 D BPR 35/60 D BOMAG 45

 Maintenance every 6 months

ts
p ar
ur
r yo
Fig. 51 Fig. 53

de
l Loosen the rear nuts (Fig. 51) on both sides for l Unscrew the screws (Fig. 53) and take off the
a few turns. cover.

or
l Unscrew the front nuts on both sides. l Install a new V-belt, assemble the cover, fas-
ten the engine carrier plate and tension the V-

to
belt as described above.
Danger
!

Danger of squashing! l Assemble the V-belt guard.

om
Caution
!
t.c

Check the V-belt tension again after a running

time of approx. 25 operating hours, retighten if
necessary.
en
m
ip
qu
t-E

Fig. 52

Raise the engine carrier plate at the front and

un

l
support it (Fig. 52).
co
is
D
to
o
G

46 BOMAG BPR 35/40 D BPR 35/60 D

 Maintenance every 6 months

5.15 Check, adjust the valve 5.16 Cleaning cooling fins and
clearance cooling air intake opening

ts
ar
! Caution i Note

p
The engines are equipped with an automatic Dirty operating conditions, especially lubrication
valve clearance adjustment, the valve clear- oil and fuel deposits on the cooling fins of the cyl-

ur
ance does therefore not need to be checked inder and in the cooling air intake reduce the cool-
and adjusted. ing power. You should therefore immediately seal

yo
any leaks in the area of the fuel tank, the cylinder
or the cooling air intake and clean the cooling fins
after.

r
de
Dry dirt

or
to
om
t.c
en
m

Fig. 54
ip

l Dry clean the entire cooling air area like cylin-

qu

der head, cylinder flywheel blower and blow it

out with compressed air (Fig. 54).
t-E

Wet or oily dirt

un

Danger
!

Fire hazard!
co

Do not use any inflammable solvents.

is

Caution
D

Do not spray directly on electric assemblies

to

and plug connectors or dry them with com-

pressed air immediately after.
o

Find the cause of oily dirt and have leaks

sealed by the after sales service of BOMAG.
G

BPR 35/40 D BPR 35/60 D BOMAG 47

 Maintenance every 6 months

Do not hold the water jet directly into the air fil-
ter, the exhaust and the electric system (if 5.17 Cleaning the exhaust
present). screen

ts
l Disconnect the battery *.

ar
l Spray the entire cooling air area with cleaning
! Danger
solution (e.g. cold cleansing agent), let it soak

p
in for a while and clean off with a sharp water Danger of burning!
jet. The exhaust is very hot during and after oper-

ur
l Run the engine warm for a short while to avoid ation. Perform this work only after cooling
down.

yo
corrosion.

r
de
or
to
om
t.c

Fig. 55
en

l Unscrew the fastening nut (Fig. 55), remove

the exhaust screen and the fastening bracket.
m
ip
qu
t-E
un
co
is

Fig. 56
D

l Clean deposits on the screen insert with a suit-

able wire brush (Fig. 56).
to

l Examine the exhaust screen for cracks or frac-

tures, replace if necessary.
o
G

* Option

48 BOMAG BPR 35/40 D BPR 35/60 D

 Maintenance every 6 months

5.18 Changing the dry air filter

ts
p ar
ur
r yo
Fig. 57

de
l Insert the fastening bracket into the opening in
the exhaust screen and screw the fastening

or
nut for approx. 1 turn (Fig. 57). Fig. 59

l Remove the air filter cover (Fig. 59).

to
om
t.c
en
m
ip

Fig. 58
qu

l Slide the exhaust screen on with the fastening Fig. 60

bracket (Fig. 58).
l Unscrew the knurled nut and take the air filter
t-E

l Hook the fastening bracket into the bore and cartridge out (Fig. 60).
tighten the fastening nut.
un

! Caution
No dirt or foreign particles must enter the
co

clean air side.

Do not blow the filter housing out with com-
is

pressed air.
D

l Clean the inside of the filter housing only with

a clean cloth.
to

l Clean the cover thoroughly.

o
G

BPR 35/40 D BPR 35/60 D BOMAG 49

 Maintenance every 6 months

ts
p ar
ur
r yo
Fig. 61

de
l Insert the filter cartridge (Fig. 61) into the
housing and fasten it with the knurled nut.

or
l Assemble the filter cover, ensure correct fit of
cover and seal ring.

to
om
t.c
en
m
ip
qu
t-E
un
co
is
D
to
o
G

50 BOMAG BPR 35/40 D BPR 35/60 D

 Maintenance every year

Maintenance every year

5.19 Changing the fuel filter 5.20 Change the oil in the exciter
shaft housing

ts
! Danger

ar
When working on the fuel system do not use Environment
open fire, do not smoke, fire hazard! Do not

p
Environmental damage!
spill any fuel, do not inhale any fuel fumes.
Catch running out old oil, do not let it seep into

ur
the ground and dispose off environmentally.
! Caution

yo
The change interval of the fuel filter depends
on the cleanliness of the fuel. If necessary the
maintenance must be performed every six

r
de
months.

or
to
om
t.c

Fig. 63

l Unscrew plug (Fig. 63), catch old oil.

en

l Turn the screw back in with a new seal ring.

l Stand the machine on a level base.
m

Fig. 62

Open the quick lock on the tank (Fig. 62).

ip

l Pull the fuel filter by the hose out of the tank.

qu

l Pull the fuel hose off the fuel filter and push it
onto the new fuel filter.
t-E

Environment
un

Dispose of the used filter environmentally.

Insert the fuel filter into the tank and attach the
co

l
quick lock.
is

i Note
D

Fig. 64
The fuel system is automatically bled.
l Unscrew plug (Fig. 64) and fill in engine oil.
to
o
G

BPR 35/40 D BPR 35/60 D BOMAG 51

 Maintenance every year

For quality and quantity of oil refer to the table

of fuels and lubricants. 5.21 Checking the hydraulic oil
level and topping up

ts
i Note

ar
The oil level must reach the bottom edge of the
bore .

p
l Turn the screw back in with a new seal ring.

ur
r yo
de
or
Fig. 65

to
l Adjust the steering rod (Fig. 65) in upright po-
sition and lock it in the last locking position of
om
the detent rail.
t.c
en
m
ip
qu
t-E

Fig. 66

Unscrew the plug (Fig. 66).

un

l Move the travel lever to reverse position and

co

hold it.
is
D
to
o
G

52 BOMAG BPR 35/40 D BPR 35/60 D

 Maintenance every year

ts
p ar
ur
r yo
Fig. 67 Fig. 69

de
l Check whether the hydraulic oil level is ap- l Slacken the bleeding screw.
prox. 40 mm below the filler opening (Fig. 67),
Wait until all air has escaped (Fig. 69).

or
l
top up if necessary.
l Tighten the bleeding screw.
For quality of oil refer to the table of fuels and

to
lubricants. om
Filling up hydraulic oil
t.c
en
m
ip
qu

Fig. 70

l Fill in hydraulic oil to approx. 40 mm below the

t-E

edge of the filler opening (Fig. 70).

Fig. 68
i Note
un

After bleeding check the hydraulic oil level, top up

i Note
if necessary.
co

Lay a cloth down before slackening the venting

screw.
is

l Shift the travel lever forward against the stop.

D
to
o
G

BPR 35/40 D BPR 35/60 D BOMAG 53

 Maintenance every year

5.22 Checking the rubber buffers

ts
p ar
ur
r yo
Fig. 71

de
l Tighten the plug (Fig. 71).

or
Caution
!
Fig. 72

Tighten the plug with the specified tightening l Check all rubber buffers (Fig. 72) for cracks

to
torque. and broken out bits and replace if damaged.
l Check the rubber buffers for tight fit.
om
t.c
en
m
ip
qu
t-E
un
co
is
D
to
o
G

54 BOMAG BPR 35/40 D BPR 35/60 D

 Maintenance every year

5.23 Drawing the water out of the

fuel tank

ts
ar
! Danger

p
When working on the fuel system do not use
open fire, do not smoke, fire hazard! Do not

ur
spill any fuel. Fire hazard!

r yo
de
or
to
om
Fig. 73
t.c

l Open the quick lock on the tank (Fig. 73).

en

l Fit an approx. 350 mm long PE-hose to a con-

ventional injection syringe (>20 ml).
m

l Insert the hose down to the bottom of the tank

and draw off the water/fuel mixture.
ip

l Repeat this procedure until only fuel is visible.

qu

Environment
t-E

Catch the fuel/water mixture and dispose of

environmentally.
un
co
is
D
to
o
G

BPR 35/40 D BPR 35/60 D BOMAG 55

 As required

As r equired

5.24 Retightening the bolted 5.25 Tightening the screws

connections

ts
Check all bolted connections for tight fit, i Note

ar
l
retighten if necessary. Self locking nuts must always be replaced by new
ones after they have been unscrewed.

p
l Check the machine for damage and leaks,
have repaired if necessary.

ur
r yo
de
or
to
Fig. 74
*Strength classes for screws with untreated, non-
om
lubricated surfaces. The quality designations are
stamped on the screw heads.
t.c

8.8 = 8 G
10.9 = 10 K
en

12.9 = 12 K
The values result in a 90% utilization of the screw's
m

yielding point at a coefficient of friction of μ total =

0.14.
ip

The compliance with the tightening torques is to be

qu

checked with torque wrenches.

The tightening torques are not applicable when us-
t-E

ing MoS2 lubricants.

un
co
is
D
to
o
G

BPR 35/40 D BPR 35/60 D BOMAG 57

 As required

Caution
5.26 Engine conservation !

Mark a machine with a conserved engine by at-

taching a clearly visible warning tag.

ts
If the engine is to be shut down for a longer pe-
riod of time (e.g. during the winter) we recom-

ar
mend the following conservation measures for
the engine to avoid corrosion:

rp
l Clean the engine including the cooling system:
with cold cleansing agent or, even better, with

u
a steam cleaner.

yo
l Run the engine warm and shut it down.
l Drain the still warm engine oil and fill in anti-

r
corrosion engine oil.

de
l Drain the fuel from the fuel tank, mix it well with
10% anti-corrosion oil and fill it in again. In-

or
stead of mixing anti-corrosion oil with the fuel
it is also possible to fill the tank with injection

to
pump testing oil with anti-corrosive properties
(e.g. Calibration Fluid B).
om
l Run the engine for 10 minutes until all lines, fil-
ters, pump and nozzles are filled with the con-
serving mixture and the new engine oil is
t.c

distributed to all parts.

l After running the engine remove the valve cov-
en

er and spray the rocker chamber with a mix-

ture of diesel fuel and 10% anti-corrosion oil.
After this screw the cover back on.
m

l Crank the engine several times by hand (throt-

ip

tle lever in stop position) to spray the combus-

tion chamber.
qu

l Take the V-belt off and spray the grooves in

the V-belt pulleys with anti-corrosion oil. Re-
-E

move the anti-corrosion oil before taking the

machine back into operation.
nt

l Close the air intake opening on the air filter

ou

and the exhaust tube.

c

i Note
is

Depending on weather conditions these conserv-

ing measures will provide protection for approx. 6
D

- 12 months.
to

The conserving oil must be replaced by engine oil

according to the API- (MIL) classification before
taking the machine into service.
o
G

Anti-corrosion oils are those that comply with the

MIL-L-21260 or TL 9150-037/2 resp. Nato Code
C 640/642.

58 BOMAG BPR 35/40 D BPR 35/60 D

 ts
6 Trouble shooting

ar
rp
u
r yo
de
or
to
om
t.c
en
m
ip
qu
-E
nt
c ou
is
D
to
o
G

BPR 35/40 D BPR 35/60 D BOMAG 59

 Trouble shooting

6.1 General notes

ts
The following work must only be carried out by
qualified and trained personnel or by the

ar
BOMAG sales service.

rp
Please observe strictly the safety regulations
in chapter 2 of these operating and mainte-
nance instructions.

u
Faults occur frequently due to the fact, that the

yo
machine has not been properly operated or serv-
iced. Therefore, whenever a fault occurs, read

r
through these instructions on correct operation

de
and maintenance. If you cannot locate the cause
of the fault or eliminate it yourself by following the
trouble shooting charts, you should contact our

or
customer service departments at our branch office
or dealers.

to
On the following pages you will find a selection of
fault remedies. It is quite obvious that we were not
om
able to list all possible causes for faults.
t.c
en
m
ip
qu
-E
nt
c ou
is
D
to
o
G

60 BOMAG BPR 35/40 D BPR 35/60 D

 Trouble shooting

Catch running out fuel, do not let it seep into

6.2 Replacing the injection the ground.
pump

ts
ar
Disassembly

u rp
r yo
de
Fig. 77

or
l Pull the fuel hose off the leakage socket on the
pump (Fig. 77).

to
Fig. 75 l Place a suitable container under the hose
remove the air filter bracket (Fig. 75). socket to catch running out fuel.
om
l
t.c
en
m
ip
qu
-E

Fig. 76 Fig. 78
nt

l Remove the valve cover (Fig. 76). l Disassemble the injection nozzle (Fig. 78)
completely with the nozzle connection.
ou

Danger
!
c

Fire hazard!
is

When working on the fuel system do not use

D

open fire, do not smoke.

Do not spill any fuel, do not inhale any fuel
to

fumes.
o

Environment
G

Environmental damage!

BPR 35/40 D BPR 35/60 D BOMAG 61

 Trouble shooting

ts
ar
u rp
r yo
Fig. 79 Fig. 82

de
l Remove the crankcase ventilation socket (Fig. l Screw the pressure valve holder 1 (Fig. 82) on
79). with the O-ring (2).

or
l Remove filling piece (3), spring (4), seal ring
(5) and pressure valve (6).

to
!Caution
om
After pressing the pump element out hold the
control sleeve (9) so that it does not drop into
the engine case!
t.c
en
m
ip

Fig. 80

l Unscrew the oil shut-off valve (Fig. 80).

qu
-E
nt
ou

Fig. 83

l Unhook the pump piston (Fig. 83) from the

c

rocker arm to the injection pump.

is
D
to

Fig. 81
o

l Take the locking plate (Fig. 81) off.

G

62 BOMAG BPR 35/40 D BPR 35/60 D

 Trouble shooting

ts
ar
u rp
r yo
Fig. 84 Fig. 86

de
l Press the pump element (Fig. 84) up with your l Insert the pump element (Fig. 86), ensure cor-
finger through the opening on the side and lift rect position of the suction hole (bore with ta-

or
it out with a magnetic rod. per) and of the element flag (the number with
l Take the compensation shim 8 (Fig. 82) out. 400 or 4.. should be on the side opposite the
suction bore).

to
om
t.c
en
m
ip
qu

Fig. 85
Fig. 87
l Insert a screwdriver from the top to secure the
-E

l When inserting the element group make sure

control sleeve (Fig. 85) against falling down.
that the plunger flag is inserted through the
nt

Assembly control sleeve (for easier installation slightly

turn the control sleeve from side to side) and
ou

that the eccentric pin (12) engages in the

! Caution groove of the element cylinder (Fig. 87).
Before inserting the pump element hold the
c

l Attach the pump piston to the injection pump

control sleeve 9 (Fig. 82), so that it cannot fall
is

rocker arm.
into the engine housing!
D

l Assemble parts 6...1, tighten the pressure

l Hold the control sleeve and take the previously
valve holder only lightly (approx. 10 Nm).
inserted screwdriver out.
to

l Turn the throttle lever fully to the right and lock

l Insert the compensation shim 8 (Fig. 82).
it.
o

l Lift the pump piston up for approx. 2 mm.

G

l Now check the position of the starting slot to

the suction bore (through the bore which held
the low oil level shut-off device). The starting

BPR 35/40 D BPR 35/60 D BOMAG 63

 Trouble shooting

slot must be in line with the suction bore or

max. 1 slot width displaced to the left. If this
condition is not met remove the flap (11) with

ts
a marking needle and correct the position by
turning the eccentric (12).

ar
l Tighten the pressure valve holder with
35+/-2Nm.

rp
l Assemble the engine.

u
r yo
de
or
to
om
t.c
en
m
ip
qu
-E
nt
c ou
is
D
to
o
G

64 BOMAG BPR 35/40 D BPR 35/60 D

 Trouble shooting

6.3 Engine faults

ts
Faults Possible cause Remedy

ar
Engine does not Engine start button not pressed and/or too Press the start button and start within 10

rp
start or poor long waiting time seconds.
starting
Fuel supply not correct Fuel tank empty Fill in fuel

u
Incorrect valve clearance Check the valve clearance, adjust it if nec-

yo
essary.

Fuel filter clogged (can be noticed if no Change the fuel filter, fill in fuel

r
fuel runs after pulling the fuel line off).

de
Charge level of battery too low Charge the battery

or
Engine hard to Oil of too high viscosity Drain the oil and fill in oil with lower vis-
crank cosity

to
Engine has no No valve clearance Check and adjust the valve clearance
compression
om
Black exhaust Air filter clogged Clean the air filter
fumes The en-
Valve clearance not correct Adjust the valve clearance
t.c

gine power may

also be low Injection nozzle defective Change the injection nozzle
(speed drops)
en

This is not Too much oil in the crankcase Drain the oil down to the 'Max'-mark on
caused by the the dipstick
m

injection pump
ip

Poor engine The throttle lever does not stay in the cho- Tighten the nuts
power (engine sen position.
qu

speed drops)

No exhaust Air in the injection system Check the function of the bleeding valve
-E

fumes
Fuel filter dirty Change the fuel filter
nt

Engine over- Cooling air flow restricted Clean the cooling air inlet Clean the cool-
ou

heating ing fins

Injection system not working correctly Have the injection system examined
c
is

Too much oil in the crankcase Drain the oil down to the 'Max'-mark on
the dipstick
D
to
o
G

BPR 35/40 D BPR 35/60 D BOMAG 65

 Trouble shooting

Faults Possible cause Remedy

Engine stalls Fuel supply not correct

ts
Fuel tank empty Fill in fuel

ar
Fuel filter clogged (can be noticed if no Change the fuel filter Check the function

rp
fuel runs after pulling the fuel line off). of the bleeding valve

Vacuum in the fuel tank Clear the ventilation bore in the tank filler

u
cap.

yo
The throttle lever returns to "stop"-posi- Tighten the nuts
tion by itself

r
Lack of oil Have the engine repaired, stop work im-

de
mediately (risk of total engine damage!)

or
Engine runs at Centrifugal clutch defective Change the centrifugal clutch
high speed, but
no vibration V-belt Check tension, replace if necessary

to
om
t.c
en
m
ip
qu
-E
nt
c ou
is
D
to
o
G

66 BOMAG BPR 35/40 D BPR 35/60 D

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