Bomag BPR 70-70D Manual

Operating Instruction
Maintenance Instruction
Original Operating Instructions
BPR 70/70 D
S/N 101 695 39 1001>
Reversible vibratory plate
008 206 37 EN © 12/2020

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,
which are known to the State of California to cause cancer and birth
defects or other reproductive harm.
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.
2
Table of contents
Table of contents
1 Introduction........................................................................................................................................... 7
1.1 Foreword........................................................................................................................................ 8
1.2 Machine type plate and engine type plate................................................................................ 10
2 Technical data...................................................................................................................................... 11
2.1 Noise and vibration data............................................................................................................ 14
2.1.1 Noise data.................................................................................................................................. 14
2.1.2 Vibration data............................................................................................................................. 14
3 Concerning your safety...................................................................................................................... 15
3.1 Basic prerequisites..................................................................................................................... 16
3.1.1 General...................................................................................................................................... 16
3.1.2 Explanation of signal words used:.............................................................................................. 16
3.1.3 Personal protective equipment................................................................................................... 17
3.1.4 Intended use.............................................................................................................................. 18
3.1.5 Improper use.............................................................................................................................. 18
3.1.6 Estimated service life of the machine......................................................................................... 19
3.2 Definition of responsible persons............................................................................................. 20
3.2.1 Operating company.................................................................................................................... 20
3.2.2 Expert / qualified person............................................................................................................ 20
3.2.3 Driver / operator......................................................................................................................... 20
3.3 Basic safety regulations for safe operation............................................................................. 22
3.3.1 Remaining dangers, remaining risks.......................................................................................... 22
3.3.2 Regular safety inspections......................................................................................................... 22
3.3.3 Modifications and alterations to the machine............................................................................. 22
3.3.4 Damage, defects, misuse of safety devices............................................................................... 22
3.4 Handling fuels and lubricants.................................................................................................... 23
3.4.1 Preliminary remarks................................................................................................................... 23
3.4.2 Safety regulations and environmental protection regulations for handling diesel fuel............... 24
3.4.3 Safety regulations and environmental protection regulations for handling oil............................ 25
3.4.4 Safety regulations and environmental protection regulations for handling hydraulic oil............. 26
3.4.5 Safety regulations and environmental protection regulations for handling battery acid............. 27
3.4.6 Safety regulations and environmental protection regulations when handling lubrication
grease........................................................................................................................................ 28
3.5 Loading/transporting the machine............................................................................................ 29
3.6 Start-up procedure...................................................................................................................... 30
3.6.1 Prior to starting up...................................................................................................................... 30
3.6.2 Starting the engine..................................................................................................................... 30
3.7 Work mode................................................................................................................................... 31
3.7.1 Persons in the danger area........................................................................................................ 31
3.7.2 Operation................................................................................................................................... 31
3.7.3 Parking the machine.................................................................................................................. 31
3.8 Refuelling..................................................................................................................................... 32
3.9 Maintenance work....................................................................................................................... 33
3.9.1 Preliminary remarks................................................................................................................... 33
3.9.2 Working on the engine............................................................................................................... 33
BPR 70/70 D 3
Table of contents
3.9.3 Maintenance work on electric components and battery............................................................. 33

3.9.4 Cleaning work............................................................................................................................ 33
3.9.5 Measures for longer shut-down periods..................................................................................... 34
3.9.6 After maintenance work............................................................................................................. 34
3.10 Repair......................................................................................................................................... 35
3.11 Signage...................................................................................................................................... 36
3.12 Safety Components.................................................................................................................. 41
4 Indicators and control elements........................................................................................................ 43
4.1 Machine........................................................................................................................................ 44
4.1.1 Decompression lever................................................................................................................. 44
4.1.2 ECONOMIZER display............................................................................................................... 45
4.1.3 Crank handle.............................................................................................................................. 45
4.1.4 Operating hour meter................................................................................................................. 45
4.1.5 Engine control light..................................................................................................................... 46
4.1.6 Oil pressure control light............................................................................................................ 46
4.1.7 Starter switch............................................................................................................................. 47
4.2 Steering rod................................................................................................................................. 48
4.2.1 Height adjustment...................................................................................................................... 48
4.2.2 Locking pawl lever...................................................................................................................... 49
4.2.3 Throttle lever.............................................................................................................................. 49
4.2.4 Handle........................................................................................................................................ 49
5 Checks prior to start up...................................................................................................................... 51
5.1 Notes on safety........................................................................................................................... 52
5.2 Visual inspections and function tests....................................................................................... 53
5.3 Checking the engine oil level..................................................................................................... 54
5.4 Checking the fuel level; topping up fuel................................................................................... 55
5.5 Bleeding the fuel system............................................................................................................ 56
5.6 Checking the rubber buffers...................................................................................................... 57
6 Operation............................................................................................................................................. 59
6.1 Folding down and adjusting the steering rod.......................................................................... 60
6.2 Starting the engine...................................................................................................................... 61
6.3 Work mode................................................................................................................................... 63
6.4 Parking the machine in secured condition............................................................................... 66
6.5 ECONOMIZER.............................................................................................................................. 67
7 Loading / transporting the machine.................................................................................................. 69
7.1 Loading the machine.................................................................................................................. 70
7.2 Lashing the machine to the transport vehicle.......................................................................... 71
8 Maintenance........................................................................................................................................ 73
8.1 Preliminary remarks and safety notes...................................................................................... 74
8.2 Preparations/concluding work................................................................................................... 75
8.2.1 Opening / closing the protection hood........................................................................................ 75
8.3 Fuels and lubricants................................................................................................................... 77
8.3.1 Engine oil................................................................................................................................... 77
8.3.2 Fuel............................................................................................................................................ 77
8.3.3 Oil for exciter shaft housing........................................................................................................ 78
4 BPR 70/70 D
Table of contents
8.3.4 Hydraulic oil................................................................................................................................ 78

8.4 List of fuels and lubricants........................................................................................................ 80
8.5 Maintenance Table...................................................................................................................... 81
8.6 Running-in instructions.............................................................................................................. 82
8.6.1 General...................................................................................................................................... 82
8.6.2 After 25 operating hours............................................................................................................. 82
8.7 Weekly.......................................................................................................................................... 83
8.7.1 Checking, cleaning the air filter.................................................................................................. 83
8.7.2 Checking and cleaning the water separator............................................................................... 85
8.8 Semi-annually.............................................................................................................................. 86
8.8.1 Battery service........................................................................................................................... 86
8.9 Annually / every 250 operating hours....................................................................................... 87
8.9.1 Replacing the V-belt................................................................................................................... 87
8.9.2 Checking, adjusting the valve clearance.................................................................................... 90
8.9.3 Changing engine oil and oil filter element.................................................................................. 92
8.9.4 Replace the fuel filter................................................................................................................. 93
8.9.5 Replacing the air filter................................................................................................................ 95
8.9.6 Changing the oil in the exciter housing...................................................................................... 95
8.9.7 Checking the hydraulic oil level.................................................................................................. 97
8.9.8 Lubricating the machine............................................................................................................. 99
8.10 Every 2 years/every 500 operating hours............................................................................. 100
8.10.1 Changing the hydraulic oil...................................................................................................... 100
8.11 As required.............................................................................................................................. 102
8.11.1 Cleaning the machine............................................................................................................. 102
8.11.2 Cleaning the cooling fins and the cooling air intake openings................................................ 102
8.11.3 Servicing the V-belt................................................................................................................ 103
8.11.4 Checking the oil level in the exciter housing.......................................................................... 104
8.11.5 Measures prior to extended shut-down period....................................................................... 104
9 Troubleshooting................................................................................................................................ 107
9.1 Preliminary remarks.................................................................................................................. 108
9.2 Emergency starting with crank handle................................................................................... 109
9.3 Starting the engine with jump leads........................................................................................ 112
9.4 Fuse assignment....................................................................................................................... 113
9.5 Engine control light................................................................................................................... 114
9.6 Engine malfunctions................................................................................................................. 116
9.7 Malfunctions during operation................................................................................................. 118
9.8 Trouble shooting ECONOMIZER.............................................................................................. 119
10 Disposal............................................................................................................................................. 121
10.1 Final shut-down of machine................................................................................................... 122
11 List of special tools........................................................................................................................... 123
BPR 70/70 D 5
Table of contents
6 BPR 70/70 D
Introduction
1 Introduction
BPR 70/70 D 7
Introduction – Foreword
1.1 Foreword
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 guar-
antee 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.
Please observe the safety regulations strictly and follow all instruc-
tions to ensure safe operation.
If you are not yet acquainted with the controls and indicating ele-
ments on this machine, you should thoroughly read the corre-
sponding chapter Ä Chapter 4 ‘Indicators and control elements’
on page 43.
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 59.
Before every start up, carry out all required visual inspections and
function tests Ä Chapter 5 ‘Checks prior to start up’ on page 51.
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 73.
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 mainte-
nance work or necessary repairs.
In case of operating errors, inadequate maintenance or the use of
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.
BPR 70/70 D 9
Introduction – Machine type plate and engine type plate
1.2 Machine type plate and engine type plate

Please enter here:
Made by Machine type (1):
Designation Type
Serial number (2):
Nominal Power Operating Mass Year of Construction
Serial-No. 1
2
B-DEC-0382
Fig. 1: Machine type plate (example)
Please enter here:

Engine type (1):
Engine number (2):
Fig. 2: Engine type plate (example)
10 BPR 70/70 D
Technical data
2 Technical data
BPR 70/70 D 11
Technical data
Dimensions
Fig. 3
H H1 H2 L L1 W W1 W2
Dimensions standard
910 1180 1540 1860 980 550 700 850
(35.8) (46.5) (60.6) (73.2) (38.6) (21.7) (27.6) (33.5)
Dimensions in millimetres
(Dimensions in inch)
Weights
Operating weight (W) 570 kg
(1257) (lbs)
Operating weight (W1) 592 kg
(1305) (lbs)
Operating weight (W2) 609 kg
(1343) (lbs)
Basic weight 587 kg
(1294) (lbs)
12 BPR 70/70 D
Technical data
Weights
Crank handle (optional equipment) +3 kg
(+ 7) (lbs)
ECONOMIZER (optional equipment) +5 kg
(+ 11) (lbs)
Travel characteristics
Max. working speed 28 m/min
(92) (ft/min)
Max. gradeability (soil and weather dependent) 35 %
Drive
Engine manufacturer Hatz
Type 1D90E
Cooling system Air
Number of cylinders 1
Rated power ISO 3046 9.2 kW
(12.3) (hp)
Rated speed 2700 min-1
Drive system mechanical
Exciter system
Frequency 66 Hz
(3960) (vpm)
Centrifugal force 66 kN
(14837) (lbf)
Amplitude 1.76 mm
(0.07) (in)
Filling capacities
Fuel (diesel) 10.0 l
(2.6) (gal us)
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 accord-
ance with the following guidelines under equipment specific condi-
tions and by using harmonized standards:
n EU Machine Directive edition 2006/42/EU
n Noise Emission Directive 2000/14/EU, Noise Protection Direc-
tive 2003/10/EU
n Vibration Protection Directive 2002/44/EU
During operation these values may vary because of the prevailing
operating conditions.
2.1.1 Noise data

Sound pressure level at the opera- LpA = 94 dB(A), determined acc. to ISO 11201 and EN 500.
tor's stand
WARNING!
Loss of hearing caused by too high noise bur-
dens!
– Wear your personal protective equipment (ear
protection).
Guaranteed sound power level LWA = 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 orthog-
onal directions:
Total vibration value ahv £ 2.5 m/s2 on crushed rock determined
acc. to ISO 5349 and EN 500.
Associated uncertainty K = 0.4 m/s2, determined acc. to EN
12096.
Observe the daily vibration load (work safety acc. to 2002/44/EC).
14 BPR 70/70 D
Concerning your safety
3 Concerning your safety
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 tech-
nical 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,
n it is operated by untrained personnel,
n it is changed or converted in an unprofessional way,
n the safety instructions are not observed.
Each person involved in the operation, maintenance and repair of
the machine must therefore read and comply with these safety reg-
ulations. If necessary, the operating company must obtain the rele-
vant signatures as confirmation.
Furthermore, the following obviously also applies:
n applicable accident prevention instructions,
n generally accepted safety and road traffic regulations,
n country/state specific safety regulations.
It is the duty of the operator to be acquainted with the safety regu-
lations and to apply these accordingly. This also applies for local
regulations and regulations concerning different types of handling
activities. Should the recommendations in these instructions be dif-
ferent from the regulations valid in your country, you must comply
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.
WARNING!
Danger to life or danger of severe injuries if
failing to comply!
Sections marked accordingly indicate a dangerous
situation that could lead to fatal or severe injuries,
if this warning is disregarded.
16 BPR 70/70 D
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.
Sections marked accordingly indicate technical

information or notes on using the machine or its
components.
ENVIRONMENT!
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.
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
Safety goggles To protect the eyes against airborne particles and

squirting fluids.
Face protection To protect the face against airborne particles and

squirting fluids.
Hard hat To protect the head against falling parts and to protect
against injuries.
Hearing protection To protect hearing against excessive noise.
Respiratory protection To protect respiratory tracts against substances or parti-

cles.
3.1.4 Intended use

This machine is intended for commercial use only.
The 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 oper-
ating, maintenance and repair measures.
3.1.5 Improper use

Dangers may arise with the machine if it is used other than for its
intended purpose.
Any hazard caused by improper use is the sole responsibility of the
operating company or driver/operator; the manufacturer cannot be
held liable.
18 BPR 70/70 D
Examples of improper use are:

n Dragging the machine along as a measure of transportation
n Shoving 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.
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).
3.1.6 Estimated service life of the machine

If the following general conditions are met, the service life of the
machine is usually in the range of several thousand operating
hours:
n Regular safety inspections by an expert / qualified person
n Performance of the prescribed maintenance work within the
specified time
n Immediate performance of necessary repair work
n Exclusive use of original spare parts
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 mainte-
nance instructions.
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.
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.
The operating company must make sure that all users read and
understand the information concerning safety.
The operating company is responsible for the planning and profes-
sional execution of regular safety inspections.
3.2.2 Expert / qualified person

An expert / qualified person is a person who, based on his/her pro-
fessional education and experience, has profound knowledge in
the field of construction equipment and the machine in question in
particular.
This person is acquainted with the applicable governmental indus-
trial safety regulations, accident prevention instructions, guidelines
and generally acknowledged technical rules and 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 nec-
essary to be able to judge the safe condition of this machine.
3.2.3 Driver / operator

This machine must only be operated by trained, instructed persons
entrusted by the operating company aged 18 or more.
Observe your local laws and regulations.
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.
BPR 70/70 D 21
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 regula-
tions 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
pay particular attention to the machine, so that they can react
immediately in case of a possible malfunction, an incident or failure
etc.
All persons remaining in the area of the machine must be informed
about the dangers that arise from the operation of the machine.
3.3.2 Regular safety inspections

Have the machine inspected by an expert / qualified person as
required for the conditions the machine is working under, but at
least once every year.
3.3.3 Modifications and alterations to the machine

Unauthorized changes to the machine are prohibited for safety rea-
sons.
Original parts and accessories have been specially designed for
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.
3.3.4 Damage, defects, misuse of safety devices

Machines which are not safe to operate or in traffic must be imme-
diately taken out of service and shall not be used, until these defi-
ciencies 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:
n name of substance
n possible dangers
n composition / information on constituents
n first-aid measures
n fire fighting measures
n measures in case of accidental release
n handling and storage
n limitation and monitoring of exposure / personal protective
equipment
n physical and chemical properties
n stability and reactivity
n toxicological data
n environmental data
n notes on waste disposal
n information on transport
n legislation
n other data
BPR 70/70 D 23
3.4.2 Safety regulations and environmental protection regulations for handling

diesel fuel
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 (pro-
tective gloves, protective clothing).
Fig. 4 CAUTION!
Health hazard caused by contact with diesel
fuel!
– Do not inhale any fuel fumes.
– Avoid contact.
CAUTION!
Danger of slipping on spilled diesel fuel!
– Immediately bind spilled diesel fuel with an oil-
binding agent.
ENVIRONMENT!
Diesel fuel is an environmentally hazardous
substance!
– Always keep diesel fuel in proper containers.
– Immediately bind spilled diesel fuel with an oil-
binding agent and dispose of properly.
– Dispose of diesel fuel and fuel filters according
to regulations.
24 BPR 70/70 D
3.4.3 Safety regulations and environmental protection regulations for handling oil
WARNING!
Danger of burning by ignited oil!
– Do not allow oil to come into contact with hot
components.
Fig. 5 CAUTION!
Health hazard caused by contact with oil!
– Do not inhale any oil vapours.
– Avoid contact.
CAUTION!
Danger of slipping on spilled oil!
– Immediately bind spilled oil with an oil-binding
agent.
ENVIRONMENT!
Oil is an environmentally hazardous substance!
– Always keep oil in proper containers.
agent.
– Dispose of oil and oil filter according to regula-
tions.
BPR 70/70 D 25
3.4.4 Safety regulations and environmental protection regulations for handling

hydraulic oil
WARNING!
Danger of injury caused by escaping pressure
fluid!
– Always depressurize the hydraulic system
before starting work in the hydraulic system.
tective gloves, protective clothing, goggles).
Should pressure fluid penetrate the skin, imme-

Fig. 6 diate medical help is required.
WARNING!
Danger of burning by ignited hydraulic oil!
– Do not allow hydraulic oil to come into contact
with hot components.
CAUTION!
Health hazard caused by contact with hydraulic
oil!
– Do not inhale any oil vapours.
– Avoid contact.
CAUTION!
Danger of slipping on spilled oil!
agent.
ENVIRONMENT!
Oil is an environmentally hazardous substance!
– Always keep oil in proper containers.
agent.
– Dispose of oil and oil filter according to regula-
tions.
26 BPR 70/70 D
3.4.5 Safety regulations and environmental protection regulations for handling bat-
tery acid
WARNING!
Danger of cauterization with acid!
– Do not allow clothes, skin or eyes to come into
contact with acid.
– Rinse off spilled battery acid immediately with
lots of water.
Fig. 7:
Rinse acid off clothes, skin or eyes immediately
with lots of clean water.
Immediately call for medical advice in case of cau-
terization.
WARNING!
Danger of injury caused by exploding gas mix-
ture!
– Remove the plugs before starting to recharge
the battery.
– Ensure adequate ventilation.
– Do not lay any tools or other metal objects on
the battery.
– Do not wear jewellery (watch, bracelets, etc.)
when working on the battery.
ENVIRONMENT!
Battery acid is an environmentally hazardous
substance!
– Dispose of battery and battery acid according
to regulations.
BPR 70/70 D 27
3.4.6 Safety regulations and environmental protection regulations when handling

lubrication grease
CAUTION!
Health hazard caused by contact with lubrica-
tion grease!
tective gloves, safety goggles, protective
clothing).
– Avoid contact.
B-SYM-0210
CAUTION!
Fig. 8
Danger of slipping on lubrication grease!
– Collect and remove excess lubrication grease
immediately.
ENVIRONMENT!
Lubrication grease is an environmentally haz-
ardous substance!
– Always keep lubrication grease in proper con-
tainers.
– Collect excess lubrication grease and dispose
of it according to regulations.
– Dispose of cloths soiled with lubrication grease
according to regulations.
28 BPR 70/70 D
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.
Lifting tackle must not be damaged by machine components.
Secure the machine on the transport vehicle against rolling, slip-
ping and turning over.
Loads must only be attached and hoisted by an expert / capable
person.
Use only lifting gear and lifting tackle with sufficient load bearing
capacity for the weight to be loaded.
Fasten the lifting gear only at the specified lifting points.
Danger to the life of persons if they step or stand under a sus-
pended load.
When lifting the machine avoid uncontrolled movements of the
load. If necessary hold the load with guide ropes.
BPR 70/70 D 29
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).
Do not take any loose objects with you or fasten them to the
machine.
Before start up, check whether:
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.
Before start up, carry out all required visual inspections and func-
tion tests.
If the following tests reveal damages or other faults, the machine
must not be operated, until these deficiencies have been corrected.
Do not operate the machine with defective indicators and control
elements.
3.6.2 Starting the engine

Do not use any starting aids like start pilot or ether.
The machine must not be operated with damaged, missing or non-
functional safety installations.
Before starting and 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 sub-
stances, which could cause damage to health, unconsciousness or
even death.
Avoid operation in closed or partly closed rooms, or ensure ade-
quate ventilation when working in trenches.
30 BPR 70/70 D
Concerning your safety – Work mode
3.7 Work mode

3.7.1 Persons in the danger area
Before taking up work, also after breaks, you should always con-
vince yourself that the danger zone is free of persons or obstruc-
tions.
Give warning signals, if necessary. Stop work immediately if per-
sons remain in the danger zone, despite the warning.
3.7.2 Operation
Operate the machine only with the steering rod folded down and
adjusted to height.
Guide the machine only by means of the steering rod.
Guide the machine so that your hands do not hit against solid
objects.
When reversing, steer the machine using the side of the steering
handle.
Watch out for unusual noises and development of smoke. Perform
trouble shooting and have the fault corrected.
Always keep a safe distance to excavation pit borders, embank-
ments and edges.
Refrain from any work that could adversely affect the stability of the
machine.
3.7.3 Parking the machine

Park the machine on horizontal, level, firm ground.
Before leaving the machine:
n shut 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.
BPR 70/70 D 31
Concerning your safety – Refuelling
3.8 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.
Apply measures against electrostatic charging.
Do not spill any fuel. Collect leaking fuel, do not let it seep into the
ground.
Wipe off spilled fuel. Keep dirt and water away from the fuel.
A leaking fuel tank can cause an explosion. Ensure tight fit of the
cover; if necessary, replace immediately.
32 BPR 70/70 D
Concerning your safety – Maintenance work
3.9 Maintenance work

3.9.1 Preliminary remarks
Always carry out the prescribed maintenance work and mainte-
nance measures on time in order to maintain the safety, opera-
tional readiness and long service life of the machine.
The machine must only be serviced by qualified personnel author-
ised by the operating company.
3.9.2 Working on the engine

Drain the engine oil at operating temperature – danger of scalding!
Wipe off spilled oil, catch running out oil and dispose of environ-
mentally.
When working on the air filter no dirt should fall into the air duct.
Do not work on the hot exhaust - danger of burning!
Store used filters and other oil contaminated materials in a sepa-
rate, specially marked container and dispose of environmentally.
3.9.3 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.
3.9.4 Cleaning work

Do not perform cleaning work while the motor is running.
Allow the engine to cool down before starting cleaning work.
Do not use gasoline or other easily inflammable substances for
cleaning.
BPR 70/70 D 33
Concerning your safety – Maintenance work
3.9.5 Measures for longer shut-down periods

If the machine is taken out of operation for a longer period of time,
various conditions must be met and maintenance work must be
carried out both before and after shut-down Ä Chapter 8.11.5
‘Measures prior to extended shut-down period’ on page 104.
It is not necessary to define a maximum storage period if these
measures have been performed.
3.9.6 After maintenance work

Reassemble all guards and protections.
34 BPR 70/70 D
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.
BPR 70/70 D 35
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.
START
1 2
3 4
OPERATION
1 2
3 4
STOP
1 2
API CJ-4 ASTM D975-09a

ACEA E9/E7 1-D S15 / 2-D S15
DIESEL
before taking into operation weekly

vor Inbetriebnahme wöchentlich
avant la mise en service hebdomadairement
anterior a la puesta en servicio cada semana
twice annual annual / 250 h
halbjährlich jährlich / 250 h
tous les 6 mois annuellement / 250 h
cada 6 meses anualmente / 250 h
WARNING
Made by
Designation Type
Nominal Power Operating Mass Year of Construction California Proposition 65 Warning
Serial-No. This product contains chemicals

that cause cancer + chemicals
that are reproductive toxicants
56154 Boppard;GERMANY Made in Germany
B-695-0104
Fig. 9
36 BPR 70/70 D
Warning sticker - Follow operating instructions
Fig. 10
Warning sticker – California Proposition 65
WARNING
California Proposition 65 Warning
This product contains chemicals

that cause cancer + chemicals
that are reproductive toxicants
B-DEC-0316
Fig. 11
Information sticker - Lashing point
Fig. 12
Information sticker - Lifting point
Fig. 13
BPR 70/70 D 37
Information sticker - Guaranteed sound capacity level
Fig. 14
Information sticker - Ultra-low sulphur fuel
Fig. 15
Information sticker - Low ash engine oil
Fig. 16
Operation sticker - Travel lever
Fig. 17
38 BPR 70/70 D
Operation sticker - Throttle lever
B-DEC-0374
Fig. 18
START
n Brief operating instructions
n Instruction sticker - Wear ear protection
1 2
n Instruction sticker - Observe operating instructions
3 4
OPERATION
1 2
3 4
STOP
1 2
B-DEC-0375
Fig. 19
Maintenance sticker
API CJ-4 ASTM D975-09a

ACEA E9/E7 1-D S15 / 2-D S15
DIESEL
before taking into operation weekly

vor Inbetriebnahme wöchentlich
avant la mise en service hebdomadairement
anterior a la puesta en servicio cada semana
twice annual annual / 250 h
halbjährlich jährlich / 250 h
tous les 6 mois annuellement / 250 h
cada 6 meses anualmente / 250 h
B-DEC-0273
Fig. 20
BPR 70/70 D 39
Machine type plate (example)
Made by
Designation Type
Nominal Power Operating Mass Year of Construction
Serial-No.
B-DEC-0383
Fig. 21
Engine type plate (example)
B-HAT-0030
Fig. 22
40 BPR 70/70 D
Concerning your safety – Safety Components
3.12 Safety Components
B-695-0049
Fig. 23
1 Protection hood
2 Heat protection cover
3 Belt guard
BPR 70/70 D 41
Concerning your safety – Safety Components
42 BPR 70/70 D
Indicators and control elements
4 Indicators and control elements
BPR 70/70 D 43
Indicators and control elements – Machine
4.1 Machine
2
1
3
6 5
7
4
B-695-0105
Fig. 24
1 Decompression lever
2 Economizer display (optional equipment)
3 Crank handle (optional equipment)
4 Operating hour meter
5 Engine control light
6 Oil pressure control light
7 Starter switch
4.1.1 Decompression lever

Position “closed” Engine has compression
Normal operation
Position “open” Engine has no compression
Only for emergency starting with crank
handle (optional equipment) and mainte-
nance
B-695-0079 NOTICE!
Fig. 25 Danger of engine damage!
Opening the decompression lever while the engine
is running leads to engine damage.
– Never use the decompression lever for stop-
ping the engine.
44 BPR 70/70 D
4.1.2 ECONOMIZER display

The ECONOMIZER displays the compaction status of the layer to
be compacted.
Description of display possibilities Ä Chapter 6.5

‘ECONOMIZER’ on page 67.
Optional equipment
Fig. 26
4.1.3 Crank handle

To start the engine when the battery voltage is too low for normal
starting.
Optional equipment
B-692-0220
Fig. 27
4.1.4 Operating hour meter

Maintenance work is to be carried out in accordance with the indi-
cated operating hours.
B-GEN-0114
Fig. 28
BPR 70/70 D 45
4.1.5 Engine control light

Lights up yellow. For commissioning:
n Starter switch is in position "I" (ignition
on).
Goes out after starting the engine.
lights up yellow / During operation:
flashes yellow
n Control unit has detected a fault.
n If a serious fault has occurred, the
engine is shut down.
B-695-0093
n Park the machine safely Ä Chapter 6.4
Fig. 29 ‘Parking the machine in secured condi-
tion’ on page 66.
n Perform troubleshooting Ä Chapter 9.5
‘Engine control light’ on page 114.
n If necessary, contact our Customer
Service.
4.1.6 Oil pressure control light

Lights up red. For commissioning:
n Starter switch is in position "I" (ignition
on).
Goes out after starting the engine.
During operation:
n Control unit has detected low oil pres-
sure.
n The engine is shut down.
B-695-0092
n Park the machine safely Ä Chapter 6.4
Fig. 30 ‘Parking the machine in secured condi-
tion’ on page 66.
n Perform troubleshooting Ä Chapter 9.5
n If necessary, contact our Customer
Service.
46 BPR 70/70 D
4.1.7 Starter switch

Position “0” Switch the ignition off
Ignition key can be removed
Position “I” Ignition on
Position “II” Turn further against spring pressure, the
engine starts
Turn the ignition key back to position “I”
when the engine starts.
Fig. 31 The starter switch is designed with a re-start lock.

The ignition key must first be turned back to posi-
tion “0” before a new starting attempt can be
made.
BPR 70/70 D 47
Indicators and control elements – Steering rod
4.2 Steering rod
1 2 3 4
B-695-0106
Fig. 32
1 Height adjustment
2 Locking pawl lever
3 Throttle lever
4 Handle
4.2.1 Height adjustment

Setting the steering rod height to the operator’s level.
B-695-0097
Fig. 33
48 BPR 70/70 D
4.2.2 Locking pawl lever

For locking and unlocking the steering rod.
B-695-0096
Fig. 34
4.2.3 Throttle lever

Position “MIN” Idle speed
Engine start position
Position “MAX” Maximum speed
B-695-0095
Fig. 35
4.2.4 Handle
Shift forward Forward travel
“Middle” position Neutral position
Pull back Reverse travel
B-695-0094
Fig. 36
BPR 70/70 D 49
50 BPR 70/70 D
Checks prior to start up
5 Checks prior to start up
BPR 70/70 D 51
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.
WARNING!
Health hazard caused by fuels and lubricants!
– Safety regulations and environmental protec-
tion regulations must be followed when han-
dling fuels and lubricants Ä Chapter 3.4 ‘Han-
dling fuels and lubricants’ on page 23.
WARNING!
Danger of injury caused by rotating parts!
– Before starting work on the machine make sure
that the engine can not be started.
1. Park the machine safely Ä Chapter 6.4 ‘Parking the machine

in secured condition’ on page 66.
2. Open and secure the protection hood Ä Chapter 8.2.1.1
‘Opening the protection hood’ on page 75.
3. Close the protection hood again after work is completed
Ä Chapter 8.2.1.2 ‘Closing the protection hood’ on page 76.
52 BPR 70/70 D
Checks prior to start up – Visual inspections and function tests
5.2 Visual inspections and function tests

1. Check the condition of the fuel tank and fuel lines and for
leaks.
2. Check the bolted connections are tight and secure.
3. Check the machine for contamination and damage.
4. Check the hydraulic oil cooler for dirt.
BPR 70/70 D 53
Checks prior to start up – Checking the engine oil level
5.3 Checking the engine oil level
NOTICE!
Danger of engine damage!
– +Use only oil of the permitted specification
B-SYM-1068 Ä Chapter 8.3.1 ‘Engine oil’ on page 77.
Fig. 37
Protective equipment: n Working clothes

n Safety shoes
n Protective gloves
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.
ð The oil level must be between the “MIN” and “MAX”
marks.
4.
NOTICE!
B-695-0112
Fig. 38 – Do not overfill with engine oil.
If the oil level is too low, top up engine oil to the “MAX” mark.
5. Insert the dipstick.
54 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
NOTICE!
– Monitor the entire refuelling process.
B-SYM-1069
– Contaminated fuel can cause malfunction or
even damage of the engine. If necessary, fill in
Fig. 39
fuel through a screen filter.
– Use only fuel of the permitted specification
Ä Chapter 8.3.2 ‘Fuel’ on page 77.

n Safety shoes
n Protective gloves
Diesel
1. Clean the area around the filling port.
2. Remove the cap and check the filling level visually.
3. If necessary, fill with fuel through a funnel with screen filter.
4. Close the cap.
If the fuel tank has been completely emptied or

B-695-0107 when filling the fuel tank for the first time, the fuel
system must be bled before starting Ä Chapter 5.5
Fig. 40 ‘Bleeding the fuel system’ on page 56.
BPR 70/70 D 55
Checks prior to start up – Bleeding the fuel system
5.5 Bleeding the fuel system

Bleeding the fuel system is necessary in the following situations:
n After an engine shut-down due to an empty fuel tank.
n After filling the fuel tank for the first time.
n After several unsuccessful starting attempts.
n After replacing the fuel filter.
n Safety shoes
n Protective gloves
The fuel tank must be full when bleeding.
1. Check the fuel level; top up if necessary.

2. Turn the ignition key to position “I”.
ð Engine control light and oil pressure control light both
light up.
3. Wait approx. 10 seconds until the fuel pump switches off
audibly.
B-ELE-0081
Fig. 41
4. Turn the ignition key to position “0”.

5. Repeat the procedure several times to completely bleed the
fuel system.
ð The engine is ready for starting.
If the engine does not start after

bleeding, contact our customer service
department.
B-ELE-0080
Fig. 42
56 BPR 70/70 D
Checks prior to start up – Checking the rubber buffers
5.6 Checking the rubber buffers
B-SYM-1073
Fig. 43

n Safety shoes
n Protective gloves
2. Allow the engine to cool down.
3. Check all rubber buffers for tight fit, cracks and tear-offs.
4. Replace damaged rubber buffers immediately.
B-692-0160
Fig. 44
BPR 70/70 D 57
Checks prior to start up – Checking the rubber buffers
58 BPR 70/70 D
Operation
6 Operation
BPR 70/70 D 59
Operation – Folding down and adjusting the steering rod
6.1 Folding down and adjusting the steering rod

1. Pull the locking pawl lever and fold the steering rod down.
Do not click the locking pawl lever into posi-

tion again.
The steering rod must be able to swing
freely.
B-695-0100
Fig. 45
2. Use the height adjustment to set the steering rod to the

required height.
B-695-0097
Fig. 46
60 BPR 70/70 D
Operation – Starting the engine
6.2 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.
WARNING!
dens!
protection).
Protective equipment: n Hearing protection

n Working clothes
n Safety shoes
1. Folding down and adjusting the steering rod Ä Chapter 6.1
‘Folding down and adjusting the steering rod’ on page 60.
2. Set the throttle lever to position “MIN”.
Engine start is only possible in position

“MIN”. If the throttle lever is not in this posi-
tion, starting is blocked by the control
system.
B-695-0060
Fig. 47
3. Set the handle to position “0”.
B-695-0056
Fig. 48
BPR 70/70 D 61
Operation – Starting the engine

ð Engine control light and oil pressure control light both
light up.
B-ELE-0081
Fig. 49
5.
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!
B-ELE-0082 – Starting attempts should not exceed 30
seconds uninterrupted or max. 3 times
Fig. 50 for 10 seconds. Then allow the starter to
cool down to ambient temperature.
– If the engine has not started after these
attempts, determine the cause.
Turn the ignition key to position “II”.

ð The starter cranks the engine.
Engine control light and oil pressure control light both go
out. If necessary, perform troubleshooting Ä Chapter 9.5
NOTICE!
– Warm up engine for a short while
before starting work. Do not operate
the engine immediately under full
load.
62 BPR 70/70 D
Operation – Work mode
6.3 Work mode

Operate the machine only with the steering rod folded down and
adjusted to height Ä Chapter 6.1 ‘Folding down and adjusting the
steering rod’ on page 60.
Guide the machine only by means of the steering rod.
Guide the machine so that your hands do not hit against solid
objects.
Keep feet clear of the vibrating base plate.
CAUTION!
Danger of injury caused by uncontrolled
machine movement!
– Always hold on to a running machine.
– Always keep an eye on a running machine.
If the engine control light flashes or lights up in work mode or if the

oil pressure control light lights up, carry out troubleshooting
Ä Chapter 9.5 ‘Engine control light’ on page 114.
B-695-0102
Fig. 51
Protective equipment: n Hearing protection

n Working clothes
n Safety shoes
1. Make sure that nobody is in the danger zone.
2. Set the throttle lever to position “MAX”.
B-695-0059
Fig. 52
BPR 70/70 D 63
3. Shift the handle forwards.

ð The machine vibrates forward with a speed which corre-
sponds to the travel lever position.
B-695-0057
Fig. 53
4.
CAUTION!
Danger of injury caused by the crushing
of body parts!
– When reversing, steer the machine from
the side using the steering handle.
Pull the handle back.

ð The machines vibrates backwards with a speed which
B-695-0058
corresponds with the handle position.
Fig. 54
5. Move the handle back to position “0”.

ð The machine stops and vibrates on the spot.
B-695-0056
Fig. 55
6. For short work interruptions you should always return the

throttle lever to “MIN” position (idle speed).
ð Vibration is switched off.
7. For short work interruptions you should always park the
machine in secured condition Ä Chapter 6.4 ‘Parking the
machine in secured condition’ on page 66.
B-695-0060
Fig. 56
64 BPR 70/70 D
Help if the machine gets stuck

1. Keep shifting the throttle lever between “MIN” and “MAX”
positions.
At the same time use the steering rod to pull the machine
right and left, until it comes free.
B-695-0061
Fig. 57
BPR 70/70 D 65
Operation – Parking the machine in secured condition
6.4 Parking the machine in secured condition

1. Park the machine on level and firm ground.
2. Set the throttle lever to “MIN” position (idle speed).
ð Vibration is shut down.
B-695-0060
Fig. 58
3.
NOTICE!
– Do not shut down the engine all of a
sudden from full load speed, but let it idle
for about two minutes.
Turn the ignition key to position “0”.

ð The engine is shut down.
B-ELE-0080
4. Remove the ignition key.

Fig. 59
66 BPR 70/70 D
Operation – ECONOMIZER
6.5 ECONOMIZER
The ECONOMIZER informs the driver about the compaction status
of the road subbase and enables the detection and selected re-
compaction of weak spots.
An acceleration sensor on the base plate measures the reaction of
the subsoil to the base plate of the machine.
Start process The ECONOMIZER is automatically started by switching the igni-

tion 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.
Measuring operation
With the vibration switched on, the measuring value is displayed by
the LED display (1-10).
If the display value does not increase any further, no further com-
paction 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 dis-

play value can vary by one digit up/down during a
pass.
The average display value during the last pass is
decisive.
The warning display (a):

Fig. 60
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.
Comparability of measuring values In order to achieve the desired compaction condition of the road
subbase, one must always perform a suitable reference measure-
ment before compaction is started.
The reference measurement is used to determine which display
value of the ECONOMIZER corresponds with the measuring value
for soil stiffness.
BPR 70/70 D 67
Operation – ECONOMIZER
68 BPR 70/70 D
Loading / transporting the machine
7 Loading / transporting the machine
BPR 70/70 D 69
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 lashing points that are damaged or impaired in any
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 ‘Tech-
nical data’ on page 11.
Always use appropriate lashing tackle at the lashing points.
Use lashing tackle only in the specified loading direction.
Lashing tackle must not be damaged by machine parts.
When lifting the machine, make sure the load does not move in an
uncontrolled way. If necessary, hold the load steady with guide
ropes.
n Safety shoes
n Protective gloves
3. Make sure that the protection hood is fastened correctly
Ä Chapter 8.2.1.2 ‘Closing the protection hood’ on page 76.
4. Move the steering rod to an upright position and engage the
locking pawl lever.
B-695-0101
Fig. 61
5. Attach the lifting tackle to the dedicated lifting eye.

6.
DANGER!
Danger to life caused by suspended
loads!
– Do not step or stand under suspended
loads.
Lift the machine carefully and set down again at the intended
B-692-0169
location.
Fig. 62
70 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 lashing points that are damaged or impaired in any
way.
Always use appropriate lashing tackle at the lashing points.
Use lashing tackle only in the specified loading direction.
Lashing tackle must not be damaged by machine parts.
n Safety shoes
n Protective gloves
1. Pull at least two suitable lashing belts crosswise across the
marked lashing point.
B-692-0173
Fig. 63
2. Lash the machine securely to the transport vehicle as shown.
B-692-0174
Fig. 64
BPR 70/70 D 71
Loading / transporting the machine – Lashing the machine to the transport vehicle
72 BPR 70/70 D
Maintenance
8 Maintenance
BPR 70/70 D 73
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 quali-
fied and authorized personnel.
– Follow the safety regulations for maintenance
work Ä Chapter 3.9 ‘Maintenance work’
on page 33.
WARNING!
Wear your personal protective equipment.

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 envi-
ronmentally friendly way.
After all maintenance work is completed reinstall all guards and
safety installations.
74 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
n Protective gloves
1. Remove the rear screws (2) on both sides of the machine.
2. Put the screws (2) and the matching washers to the side.
3. Loosen the front screws (1) on both sides.
4. Fold the protection hood forward.
Fig. 65
5. Secure the protection hood against accidental closing.

For this tighten the screw (1) on both sides.
Fig. 66
BPR 70/70 D 75
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.
n Protective gloves
1. Loosen the screw (1) on both sides.
2. Close the protection hood.
Fig. 67
3. Tighten the screw (1) on both sides.

4. Screw in screws (2) and washers on both sides and tighten
them.
Fig. 68
76 BPR 70/70 D
Maintenance – Fuels and lubricants
8.3 Fuels and lubricants

8.3.1 Engine oil
8.3.1.1 Oil quality
Use only low-ash engine oils (Low SAPS) according to the fol-
lowing specifications:
n ACEA E6 / E9
n ACEA C3 / C4 (HTHS ³ 3.5 mPas)
n API CK-4 / CJ-4
Avoid mixing engine oils.
8.3.1.2 Oil viscosity

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.
The engine oil ages during travel operation because of soot and
fuel residues. This adversely affects the properties of the engine
oil, especially at low ambient temperatures.
Optimal operating conditions can be achieved by using the oil vis-
cosity chart as reference.
Fig. 69: 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
The following fuel specifications are permitted:
n EN 590
n ASTM D 975, grade no. 1-D S15 and 2-D S15
n BS 2869 A1/A2
In order to fulfil national emission regulations, the legally required
fuels must be used (e.g. sulphur content).
BPR 70/70 D 77
8.3.2.2 Winter fuel

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!
– The admixture of petroleum and the addition of
“flow enhancing additives” (fuel additives) is
not permitted.
8.3.2.3 Storage
Even traces of zinc, lead and copper can cause deposits in the
injection nozzles, especially in modern Common-Rail injection sys-
tems.
Zinc and lead coatings in refuelling systems and fuel lines are not
permitted.
Copper containing materials (copper lines, brass items) should be
avoided, because they can cause catalytic reactions in the fuel with
subsequent depositing in the injection system.
8.3.3 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!
– Do not use low-ash engine oils for the exciter
shaft housing.
8.3.4 Hydraulic oil

The hydraulic system is operated with hydraulic oil HV 32 (ISO)
with a kinematic viscosity of 32 mm2/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.
78 BPR 70/70 D
The viscosity index must be at least 150 (observe information of

manufacturer).
BPR 70/70 D 79
Maintenance – List of fuels and lubricants
8.4 List of fuels and lubricants

Assembly group Fuel or lubricant Filling quantity
Summer Winter Observe the level
mark!
Engine oil SAE 10W-40 1.9 l
Specification: Ä Chapter 8.3.1 ‘Engine oil’ on page 77 (0.5 gal us)
SAE 15W-40
SAE 10W-30
SAE 30 SAE 10W
Fuel Diesel Winter diesel fuel 10.0 l
Specification: Ä Chapter 8.3.2 ‘Fuel’ on page 77 (2.6 gal us)
Exciter shaft housing SAE 10W-40 0.6 l

Specification: Ä Chapter 8.3.3 ‘Oil for exciter shaft (0.16 gal us)
housing’ on page 78
SAE 15W-40
SAE 10W-30
Steering rod Hydraulic oil (ISO), HV 32 0.4 l
Specification: Ä Chapter 8.3.4 ‘Hydraulic oil’ (0.11 gal us)
on page 78
80 BPR 70/70 D
Maintenance – Maintenance Table
8.5 Maintenance Table

No. Maintenance works Page
Running-in instructions
8.6.1 General 82
8.6.2 After 25 operating hours 82
Weekly
8.7.1 Checking, cleaning the air filter 83
8.7.2 Checking and cleaning the water separator 85
Semi-annually
8.8.1 Battery service 86
Annually / every 250 operating hours
8.9.1 Replacing the V-belt 87
8.9.2 Checking, adjusting the valve clearance 90
8.9.3 Changing engine oil and oil filter element 92
8.9.4 Replace the fuel filter 93
8.9.5 Replacing the air filter 95
8.9.6 Changing the oil in the exciter housing 95
8.9.7 Checking the hydraulic oil level 97
8.9.8 Lubricating the machine 99
Every 2 years/every 500 operating hours
8.10.1 Changing the hydraulic oil 100
As required
8.11.1 Cleaning the machine 102
8.11.2 Cleaning the cooling fins and the cooling air intake openings 102
8.11.3 Servicing the V-belt 103
8.11.4 Checking the oil level in the exciter housing 104
8.11.5 Measures prior to extended shut-down period 104
BPR 70/70 D 81
Maintenance – Running-in instructions
8.6 Running-in instructions

8.6.1 General
The following maintenance work must be performed when running
in new machines or overhauled engines.
8.6.2 After 25 operating hours

1. Change the engine oil Ä Chapter 8.9.3 ‘Changing engine oil
and oil filter element’ on page 92.
2. Check the valve clearance, adjust if necessary Ä Chapter
8.9.2 ‘Checking, adjusting the valve clearance’ on page 90.
3. Check engine and machine for leaks.
4. Retighten the fastening screws on air filter, exhaust and other
attachments.
5. Retighten the bolted connections on the machine.
6. Check the V-belt Ä Chapter 8.11.3 ‘Servicing the V-belt’
on page 103.
7. Check the oil level in the exciter shaft housing Ä Chapter
8.11.4 ‘Checking the oil level in the exciter housing’
on page 104.
82 BPR 70/70 D
Maintenance – Weekly
8.7 Weekly
8.7.1 Checking, cleaning the air filter
NOTICE!
– Do not start the engine after having removed
B-SYM-1074 the air filter.
– If necessary, the air filter may be cleaned up to
Fig. 70
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.
– After cleaning, the air filter must be inspected
for damage using a torch.
– Do not continue to use a damaged air filter ele-
ment. If in doubt use a new air filter.

n Safety shoes
n Protective gloves
n Safety goggles

3. Remove the cover.
4. Pull out the air filter.
5. Clean the cover.
6.
NOTICE!
– Prevent dirt from getting into the air
intake opening.
B-HAT-0046
– Do not clean the air filter housing with
Fig. 71 compressed air.
Clean the filter housing with a clean, lint-free cloth.
BPR 70/70 D 83
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
B-GEN-0042 (73 psi)) from inside to outside by moving the gun up and
down inside the element, until it is free of dust.
Fig. 72
8. Examine the air filter with a torch for cracks and holes.
9. Replace the air filter if it is damaged.
10. Slide the air filter carefully into the filter housing.
11. Check the sealing face on the cover.
12.
NOTICE!
– Ensure correct fit of cover and seal.
Close the cap.

B-HAT-0047
Fig. 73
84 BPR 70/70 D
8.7.2 Checking and cleaning the water separator
The service intervals for the water separator

depend on the water content in the fuel and can
therefore not be determined precisely.
B-SYM-1075 After taking the engine into operation you should
check for signs of water and dirt initially every day.
Fig. 74

n Safety shoes
n Protective gloves
2. Place a suitable container under the drain plug.
3. Loosen the drain plug and drain the fluid until pure diesel fuel
starts to run out.
4. Collect the escaping fluid.
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
B-695-0108
Ä Chapter 5.5 ‘Bleeding the fuel system’
on page 56.
Fig. 75
5. Screw the drain plug back on tightly. Ensure leak tightness.
6. Dispose of collected fluid in line with environmental regula-
tions.
BPR 70/70 D 85
Maintenance – Semi-annually
8.8 Semi-annually
8.8.1 Battery service
Maintenance free batteries also need care. Mainte-

nance free only means that the fluid level does not
need to be checked.
B-SYM-1077 Every battery has a self-discharge, which may, if
not checked occasionally, even cause damage to
Fig. 76 the battery as a result of exhaustive discharge.
Exhausted batteries (batteries with formation of
sulphate on the plates) are not covered under war-
ranty!

n Safety shoes
n Protective gloves
n Safety goggles

2. Remove the bracket (1) of the battery.
1 3. Remove the battery (2) and the vibration damping mats (3).
4. Check the condition of the vibration insulation mats, replace if
2 necessary.
5. Clean the outside of the battery.
3 6. Clean the battery poles and terminals and grease them with
pole grease (Vaseline).
B-692-0123
7. On serviceable batteries check the acid level, if necessary
top up to the filling mark with distilled water.
Fig. 77 8. Install battery and vibration insulation mats.
9. Install the bracket of the battery.
86 BPR 70/70 D
Maintenance – Annually / every 250 operating hours
8.9 Annually / every 250 operating hours

8.9.1 Replacing the V-belt
n Safety shoes
n Protective gloves
Tool: n Locking lever for V-belt pulley
We recommend using the locking lever to unscrew

and screw on the V-belt pulley. The locking lever
prevents the V-belt pulley from turning during work.
The screws and nuts are not included in the scope
of delivery.

3. Unscrew the V-belt guard (1).
1
B-692-0175
Fig. 78
4. Unscrew the guard (1).
1
B-692-0187
Fig. 79
BPR 70/70 D 87
5. Insert two M8 screws according to the required hole spacing

and tighten them with two M8 nuts.
B-695-0146
Fig. 80
6. Insert the locking lever into the V-belt pulley.
B-695-0137
Fig. 81
7. Unscrew the V-belt pulley (1).

8. Replace the V-belt (3).
1 9. If necessary, reassemble the spacers (2) that may have been
removed.
10. Position the V-belt pulley and screw in the screws.
3 11. Insert the locking lever into the V-belt pulley and tighten the
V-belt pulley.
2
B-695-0144
Fig. 82
12. Check the centre distance (x) between the centrifugal clutch
1 (1) and the V-belt pulley (2).
ð Nominal value: 418 ± 1 mm (16.5 ± 0.04 in)
If the centre distance is incorrect, contact

2 our customer service.
x
B-692-0183
Fig. 83
88 BPR 70/70 D
13. Fasten the guard (1), tightening torque: 15 Nm (11 ft·lbf).
1
B-692-0187
Fig. 84
14. Fasten the V-belt guard (1).
1
B-692-0175
Fig. 85
8.9.1.1 Checking the frequency of the base plate

Keep feet and hands clear of the vibrating base plate.
CAUTION!
machine movement!
– Always keep an eye on a running machine.

n Hearing protection
n Safety shoes
Tool: n Sirometer
1. Park the machine on a rubber mat.
2. Start the engine Ä Chapter 6.2 ‘Starting the engine’
on page 61.
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
BPR 70/70 D 89
6. If frequency incorrect:
n Check the engine speed.
n Check the V-belt.
n If necessary, contact our customer service.
8.9.2 Checking, adjusting the valve clearance
NOTICE!
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
2. Let the engine cool down to ambient temperature.
3. Check the position of the decompression lever, if necessary
move it to the initial position.
B-695-0082
Fig. 86
4. Remove the valve cover with the seal.
Fig. 87
90 BPR 70/70 D
Checking the valve clearance Valve clearance:

Intake valve (IN) 0.30 mm (0.012 in)
Exhaust valve (EX) 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. 88
Adjusting the valve clearance

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.
Fig. 89
Concluding work
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.
Fig. 90
BPR 70/70 D 91
8.9.3 Changing engine oil and oil filter element
NOTICE!
– Change the oil only with the engine at oper-
ating temperature.
– Use only oil of the permitted specification
Ä Chapter 8.3.1 ‘Engine oil’ on page 77.
– Filling quantity: Ä Chapter 8.4 ‘List of fuels and
lubricants’ on page 80

n Safety shoes
n Protective gloves
n Safety goggles

Draining off engine oil
2. Clean the area around the dipstick and pull the dipstick out.
B-695-0109
Fig. 91
3. Clean the area around the drain hose.
WARNING!
Danger of burning on hot components!
– Avoid touching hot components.
B-695-0110
4. Unscrew the drain plug and collect any oil running out.
5. Clean the drain plug and screw it in, tightening torque: 20 Nm
Fig. 92 (15 ft·lbf).
92 BPR 70/70 D
Changing the oil filter element

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 a new oil filter element.
When inserting, make sure that the marking

on the oil filter element is pointing upwards.
B-695-0111
10. Check the seal ring on the cover for damage, replace if nec-
Fig. 93
essary.
11. Slightly lubricate the seal ring.
12. Screw the cover back on tightly.
Filling in engine oil
13. Fill in fresh engine oil through the filler opening.
14. Insert the dipstick.
15. After a short test run, check the oil level on the dipstick, top
up oil if necessary.
B-695-0112
Fig. 94
Concluding work 16. Check oil filter and drain plug for leaks.
17. Dispose of oil and oil filter insert in an environmentally
friendly way.
8.9.4 Replace the fuel filter
NOTICE!
– Ensure strict cleanliness! Thoroughly clean the
area around the fuel tank beforehand.
– Never operate the engine after having removed
the fuel filter.
BPR 70/70 D 93

n Safety shoes
n Protective gloves
Replacing the fuel pre-filter
2. Close the fuel line in front of the fuel filter.
3. Clean the area around the fuel filter.
4. Loosen the hose clamps on the fuel filter.
5. Pull the hoses off the fuel filter.
6. Install the new fuel filter and observe the flow direction
(arrow).
7. Reattach hoses and hose clamps.
B-695-0113
Fig. 95
Replacing the main fuel filter

8. Clean the area around the fuel filter.
9. Loosen the hose clamps on the fuel filter.
10. Pull the hoses off the fuel filter.
11. Install the new fuel filter and observe the flow direction
(arrow).
12. Reattach hoses and hose clamps.
13. Open the fuel line again.
B-695-0114
14. Bleed the fuel system Ä Chapter 5.5 ‘Bleeding the fuel
system’ on page 56.
Fig. 96
15. Dispose of fuel and filter in line with environmental regula-
tions.
94 BPR 70/70 D
8.9.5 Replacing the air filter
NOTICE!
– Do not start the engine after having removed
the air filter.

n Safety shoes
n Protective gloves
3. Remove the cover.
4. Pull out the air filter.
5. Clean the cover.
6.
NOTICE!
– Prevent dirt from getting into the air
intake opening.
B-HAT-0046
– Do not clean the air filter housing with
Fig. 97 compressed air.
Clean the filter housing with a clean, lint-free cloth.

7. Replace the air filter.
8. Slide the air filter carefully into the filter housing.
9. Check the sealing face on the cover.
10.
NOTICE!
– Ensure correct fit of cover and seal.
Close the cap.

B-HAT-0047
Fig. 98
8.9.6 Changing the oil in the exciter housing
NOTICE!
Ä Chapter 8.4 ‘List of fuels and lubricants’
on page 80.
shaft housing.
BPR 70/70 D 95

n Protective gloves
1. Park the machine on level ground.
2. Park the machine in secured condition Ä Chapter 6.4
‘Parking the machine in secured condition’ on page 66.
3. Clean the area around the bleeding screw (1) and filling /
drain plug (2).
4. Tilt the machine slightly towards the oil drain side and secure
it properly.
5. Unscrew the bleeding screw.
6. Unscrew the filling/drain plug and collect any oil running out.
2
1
B-692-0196
Fig. 99
7. Tilt the machine to the opposite side and secure it properly.

8. Fill in new oil.
B-692-0198
Fig. 100
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.
1 2
B-692-0197
Fig. 101
96 BPR 70/70 D
8.9.7 Checking the hydraulic oil level

n Safety shoes
n Protective gloves
2. Adjust the steering rod using the height adjustment so that
the area with the filler screw is horizontal.
3. Unscrew the filler screw.
B-695-0143
Fig. 102
4. Press the handle forward against the stop and secure it using
suitable means.
B-692-0070
Fig. 103
5. The oil level must reach the mark on the steering rod head; if
necessary, fill in hydraulic oil.
Mark: approx. 40 mm (1.6 in) below the filler opening
B-695-0141
Fig. 104
Fill in hydraulic oil, bleed the

system NOTICE!
Ä Chapter 8.3.4 ‘Hydraulic oil’ on page 78.
BPR 70/70 D 97
suitable means.
B-692-0070
Fig. 105
7. Place a cloth underneath the bleeding screw to collect

leaking oil.
8. Slacken the bleeding screw.
9. Wait until all air has escaped and then tighten the bleeding
screw.
B-692-0072
Fig. 106
10. Fill in hydraulic oil up to the mark on the steering rod head.
HV 32
B-695-0142
Fig. 107
Concluding work
11. Fasten the filler screw, tightening torque: 45 Nm (33.2 ft·lbf).
B-695-0143
Fig. 108
98 BPR 70/70 D
8.9.8 Lubricating the machine

n Safety shoes
n Protective gloves
2. Unscrew the four fastening screws (1) and remove the cover
2 (2).
1
B-692-0245
Fig. 109
3.
NOTICE!
2
Inadequate lubrication will cause damage
to components!
3 – Use only grease of the permitted specifi-
cation.
(Spare parts number of lubrication
1 grease: 009 960 17)
Grease
B-692-0186 Grease the mechanical parts between the fork head (1), lever
(2) and bolt (3).
Fig. 110
4. Fasten the cover (2) with four fastening screws, tightening

2 torque: 10 Nm (7.5 ft·lbf).
1
B-692-0245
Fig. 111
BPR 70/70 D 99
Maintenance – Every 2 years/every 500 operating hours
8.10 Every 2 years/every 500 operating hours

8.10.1 Changing the hydraulic oil
n Safety shoes
n Protective gloves
2. Adjust the steering rod using the height adjustment so that
the area with the filler screw is horizontal.
3. Unscrew the filler screw.
B-695-0143
Fig. 112
suitable means.
B-692-0070
Fig. 113
5. Unscrew the bleeding screw and collect any oil running out.
6. Screw in the bleeding screw.
B-692-0072
Fig. 114
100 BPR 70/70 D

Maintenance – Every 2 years/every 500 operating hours
7.
NOTICE!
HV 32 Components may get damaged!

Ä Chapter 8.3.4 ‘Hydraulic oil’
on page 78.
Fill in hydraulic oil up to the mark on the steering rod head.

Mark: approx. 40 mm (1.6 in) below the filler opening
B-695-0142
Fig. 115
8. Slacken the bleeding screw.

9. Wait until all air has escaped and then tighten the bleeding
screw.
B-692-0072
Fig. 116
10. Fill in hydraulic oil up to the mark on the steering rod head.
HV 32
B-695-0142
Fig. 117
11. Fasten the filler screw, tightening torque: 45 Nm (33.2 ft·lbf).

12. Dispose of oil in line with environmental regulations.
B-695-0143
Fig. 118
BPR 70/70 D 101

Maintenance – As required
8.11 As required
8.11.1 Cleaning the machine
n Safety shoes
n Protective gloves
2. Allow the engine to cool down for at least 30 minutes.
3.
NOTICE!
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.
Clean the machine from the outside and inside with a water
jet.
Fig. 119: Cleaning the machine 4. Warm up the engine for a while to avoid corrosion.
(example)
8.11.2 Cleaning the cooling fins and the cooling air intake openings
How dirty the cooling fins and cooling air intake

openings are depends very much on the daily
operating conditions; clean daily if necessary.

n Protective gloves
n Safety goggles
3. Remove dried dirt with a suitable brush from all cooling fins
and cooling air intake openings.
4.
CAUTION!
Danger of eye injuries caused by particles
flying around!
– Wear your personal protective equipment
(safety gloves, protective working
clothes, goggles).
Fig. 120 Blow out the cooling fins and cooling air intake openings with
compressed air.
102 BPR 70/70 D

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
3. Unscrew the V-belt guard (1).
Fig. 121
4. Check condition and tension of V-belt.

ð Compression measurement: 10 - 30 mm (0.4 - 1.2 in).
5.
The V-belt cannot be re-tightened.
Replace the V-belt if it is damaged or if the compression

measurement is exceeded Ä Chapter 8.9.1 ‘Replacing the V-
belt’ on page 87.
Fig. 122
6. Fasten the V-belt guard (1).
Fig. 123
BPR 70/70 D 103

8.11.4 Checking the oil level in the exciter housing
NOTICE!
Ä Chapter 8.4 ‘List of fuels and lubricants’
on page 80.
shaft housing.

n Protective gloves
1. Park the machine on level ground.
3. Allow the machine to cool down.
4. Clean the area around the bleeding screw (1) and filling /
drain plug (2).
5. Unscrew the bleeding screw.
6. Unscrew the filling / drain plug and check the oil level, top up
if necessary.
ð Nominal value: Bottom edge of filling / drain bore.
1 2 7. Clean bleeding screw and filling / drain plug and screw them
in with a low-strength sealing agent (e.g. spare parts number:
B-692-0197
009 700 16).
Fig. 124
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. After shutting down store the machine under cover in a dry
and well ventilated room.
3. Spray a thin oil film onto to all lever joints and bearing points
without lubrication.
4. Repair damaged paint; preserve bare areas thoroughly with
anti-corrosive agent.
5. Clean the water separator.
6. Fill the fuel tank with diesel fuel to prevent the formation of
condensation water in the tank.
7. Change engine oil and oil filter.
8. Change the fuel filter.
9. Protect the cooled down engine against dust and moisture.
104 BPR 70/70 D

8.11.5.2 Battery service during prolonged machine downtimes
WARNING!
Danger of injury caused by exploding gas mix-
ture!
– Remove the plugs before starting to recharge
the battery.
– Ensure adequate ventilation.
– Do not lay any tools or other metal objects on
the battery.
– Do not wear jewellery (watch, bracelets, etc.)
when working on the battery.

n Protective gloves
n Safety goggles
1. Switch off all consuming devices (e.g. ignition, light).
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 = dis-
charged 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 reg-
ular open-circuit voltage measurements.
8.11.5.3 Measures before restarting

1. Replace the fuel filter.
2. Replace the air filter.
3. Change the engine oil and clean the oil filter.
4. Check cables, hoses and lines for cracks and leaks.
5. Check the service life of hydraulic hoses and replace if nec-
essary.
BPR 70/70 D 105

6. Start the engine and run it for 15 to 30 minutes with idle

speed.
7. Check the oil levels.
8. Clean the machine thoroughly.
106 BPR 70/70 D

Troubleshooting
9 Troubleshooting
BPR 70/70 D 107

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 fol-
lowing the trouble shooting chart, you should contact our customer
service department.
108 BPR 70/70 D

Troubleshooting – Emergency starting with crank handle
9.2 Emergency starting with crank handle
The engine can only be started with the crank

handle if the battery voltage is still min. 7 V. If nec-
essary, first replace the battery or start the engine
with battery jump leads.
Optional equipment
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.
WARNING!
dens!
protection).

n Hearing protection
n Safety shoes
1. Folding down and adjusting the steering rod Ä Chapter 6.1
‘Folding down and adjusting the steering rod’ on page 60.
2. Set the throttle lever to position “MIN”.
Engine start is only possible in position

“MIN”. If the throttle lever is not in this posi-
tion, starting is blocked by the control
system.
B-695-0060
Fig. 125
BPR 70/70 D 109

3. Set the handle to position “0”.
B-695-0056
Fig. 126
B-ELE-0081
Fig. 127
5. Pull the decompression lever in direction of arrow to the end

stop.
ð The decompression lever clicks noticeably into place.
B-695-0080
Fig. 128
6. Open the cover.

7. Remove the crank handle from the holding fixture and insert
it.
8. Stand in the correct position parallel to the machine.
B-692-0220
Fig. 129
110 BPR 70/70 D

9. Grasp the crank handle with both hands.
5x 10. Turn the crank handle with both hands slowly in the direction
of the arrow until it engages.
CAUTION!
machine movement!
B-695-0081 – Always keep an eye on a running machine.
Fig. 130 11. 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.
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.
12. As soon as the engine starts, pull out the crank handle.
13. If the engine does not start during the first attempt, repeat the
starting process.
ð Always open the decompression lever when repeating
the starting procedure.
NOTICE!
– Warm up engine for a short while
before starting work. Do not operate
the engine immediately under full
load.
14. Hook the crank handle into the holding fixture.

15. Close the cover.
NOTICE!
– Warm up engine for a short while before
starting work. Do not operate the engine imme-
B-692-0220
diately under full load.
Fig. 131
BPR 70/70 D 111

Troubleshooting – Starting the engine with jump leads
9.3 Starting the engine with jump leads
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 unin-

tended 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.
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 61.
6. After starting disconnect the minus poles first and the plus
poles after.
7. Install the bracket of the battery.
Fig. 132
8. Close the protection hood.
112 BPR 70/70 D

Troubleshooting – Fuse assignment
9.4 Fuse assignment
WARNING!
Danger of injury by fire in the machine!
– Do not use fuses with higher ampere ratings
and do not bridge fuses.
4
3
2
1
B-695-0116
Fig. 133
Position Fuse Amperage Designation

1 F67 25 A Potential 30
2 F68 25 A Potential 30 (ECU)
3 F103 15 A Potential 15
4 F275 5A ECONOMIZER (optional equipment)
BPR 70/70 D 113

Troubleshooting – Engine control light
9.5 Engine control light

The engine control light displays existing faults.
If a serious fault occurs, the control system stops the engine.
B-695-0093
Fig. 134
Performance Type of fault Possible cause Remedy

Engine control Engine oil temperature High ambient temperature Shut down the engine and
light flashes. too high allow it to cool down.
(warning level 1).
The engine Lack of cooling air Clean the cooling fins and the
switches to The engine is shut cooling air intake openings.
neutral. down if the engine oil
temperature continues Check air guide plates and
to rise. ducts for completeness and
good sealing.
Temperature switch defective Have cables and temperature
switches checked by qualified
expert personnel; replace if
necessary.
Engine control Engine oil temperature Engine oil level too high Check the engine oil level;
light lights up. too high drain off engine oil if necessary.
(warning level 2)
The engine is Temperature switch defective Have cables and temperature
shut down. switches checked by qualified
necessary.
Internal engine fault Have it checked by qualified
expert personnel; engine diag-
nostics may be necessary.
No engine oil pressure Engine oil level too low Check the engine oil level, top
up if necessary
Oil filter heavily soiled Clean the oil filter; replace if
necessary.
Oil pressure switch defective Have cables and oil pressure
switch checked by qualified
necessary.
Pressure limiting valve is dirty Have the pressure limiting
valve checked by qualified
necessary.
114 BPR 70/70 D

Troubleshooting – Engine control light
Performance Type of fault Possible cause Remedy

Engine speed too high Wrong fuel Check fuel; replace if neces-
(overspeed) sary.
Incorrect valve clearance Check the valve clearance;
adjust if necessary.
Battery voltage > 15 V Have voltage regulator and
generator checked by qualified
necessary.
Engine control Battery voltage too low Battery voltage< 9.5 V Have voltage regulator and
light lights up. generator checked by qualified
The engine is necessary.
not shut
down. Engine speed too high Speed signal fault Have cable and speed actua-
tion checked by qualified
necessary.
Rotary speed sensor defective Have cables and rotary speed
sensor checked by qualified
necessary.
Fault in engine control Internal fault in engine control Have it checked by qualified
unit unit expert personnel; engine diag-
BPR 70/70 D 115

Troubleshooting – Engine malfunctions
9.6 Engine malfunctions

Fault Possible cause Remedy
The engine is hard Start is blocked by throttle lever Set the throttle lever to position “MIN”.
to start or does not
start at all. Fuel tank empty Check the fuel level; top up if necessary.
Fuel filter clogged Check the fuel filter; replace if necessary.
Fuel lines leaking Check the fuel lines.
Incorrect valve clearance Check the valve clearance; adjust if nec-
essary.
Wear on cylinder or piston rings Have it checked by qualified expert per-
sonnel.
Fuel pump defective Have it checked by qualified expert per-
sonnel.
Injection nozzle out of order Have it checked by qualified expert per-
sonnel.
Engine does not Fuel filter clogged by paraffin separation Replace the fuel filter; use winter fuel.
start or starts poorly
at low tempera- Engine oil with wrong SAE viscosity class Changing the engine oil
tures. Insufficiently charged battery Check the battery; charge if necessary.
The starter does Fuse defective Check the fuse; replace if necessary.
not switch on or the
engine does not Battery or other cables not connected Check
crank. correctly
Starter defective Replace the starter.
Starter switch defective Have it checked by qualified expert per-
sonnel; replace if necessary.
Engine stops. Fuel tank empty Check the fuel level; top up if necessary.
Fuel filter clogged Replace the fuel filter
Tank ventilation blocked Ensure sufficient ventilation of the tank.
Air in the fuel system Check the fuel system for air ingress.
Bleed the fuel system.
Control unit has detected a fault. Check engine control light and perform
troubleshooting.
Have checked by qualified expert per-
sonnel.
Mechanical defect / engine blocked Have it checked by qualified expert per-
sonnel.
Engine looses Fuel tank empty Check the fuel level; top up if necessary.
power and speed.
Fuel system clogged Replace the fuel filter
Tank ventilation blocked Ensure sufficient ventilation of the tank.
116 BPR 70/70 D

Troubleshooting – Engine malfunctions

Air in the fuel system Check the fuel system for air ingress.
Bleed the fuel system.
Too much oil in exciter housing. Drain the oil from the exciter housing.
Engine loses power Air filter contaminated Clean the air filter, replace if necessary.
and speed; exhaust
smoke is black. Incorrect valve clearance Check the valve clearance; adjust if nec-
essary.
Injection nozzle out of order Have it checked by qualified expert per-
sonnel.
Motor only runs at Control unit has detected a fault. Check engine control light and perform
low speed, no troubleshooting.
speed increase
Have checked by qualified expert per-
possible
sonnel.
Engine runs with V-belt torn Replacing the V-belt
high speed, but no
vibration.
BPR 70/70 D 117

Troubleshooting – Malfunctions during operation
9.7 Malfunctions during operation

The machines Air in the steering rod hydraulic system Release pressure from the steering rod
vibrates forward
with a strongly The oil level in the exciter shaft housing Check the oil level in the exciter shaft
reduced speed is too high housing
Release pressure from the steering Protective equipment: n Working clothes

rod n Safety shoes
n Protective gloves
2. Press the handle forward against the end stop and hold it in
this position.
3. Carefully loosen the filler screw (1).
ð The air makes a slight hissing sound when escaping.
1 4. Wait until all air has escaped and then tighten the filler screw,
tightening torque: 45 Nm (33.2 ft·lbf).
B-692-0092
Fig. 135
118 BPR 70/70 D

Troubleshooting – Trouble shooting ECONOMIZER
9.8 Trouble shooting ECONOMIZER
Fig. 136: Economizer display

LED (a) flashes Switching on: The LED (a) flashes for
approx 1 - 2 seconds after the vibration
has been switched on.
Vibration frequency too low.
LED (a) lights up No vibration detected. Start the engine, set the throttle lever to
position “MAX” (switch vibration on).
Check the connection of the acceleration
sensor.
Acceleration sensor is not connected. Check the connection of the acceleration
sensor.
Cable breakage. Inform our service department.
The displayed The acceleration sensor is not fastened Shut down the engine and check the fas-
measuring values correctly. tening screws of the acceleration sensor.
are not plausible.
Weak spots in the road subbase. In unfavourable cases, an excessively
varying material composition or moisture
in the road subbase can influence the
measuring results.
On material which is too dry or moist,
lower measuring values will be displayed.
BPR 70/70 D 119

Troubleshooting – Trouble shooting ECONOMIZER
120 BPR 70/70 D

Disposal
10 Disposal
BPR 70/70 D 121

Disposal – Final shut-down of machine
10.1 Final shut-down of machine

After the machine has reached the end of its service life, the indi-
vidual components of the machine must be disposed of properly.
Observe national regulations!
Carry out the following work and have the machine dismantled by a
state-approved recycling company.
WARNING!

n Safety shoes
n Protective gloves
n Safety goggles
1. Remove the batteries.
2. Empty the fuel tank.
3. Drain engine oil from engine and exciter housing.
4. Drain off hydraulic oil.
122 BPR 70/70 D

List of special tools
11 List of special tools
BPR 70/70 D 123

List of special tools
Locking lever for V-belt pulley

BOMAG 690 404 31
TOO-69040431
Fig.
Sirometer
Measuring instrument for speed and frequency
BOMAG 059 710 02
Fig.
124 BPR 70/70 D

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Operating Instruction

S/N 101 695 39 1001>

Reversible vibratory plate

008 206 37 EN © 12/2020

Always start and operate the engine in a well-ventilated area.

For more information go to www.P65warnings.ca.gov/diesel.

WARNING: Crude oil, gasoline, diesel fuel and other petroleum

For more information go to www.P65Warnings.ca.gov/petroleum.

3.9.3 Maintenance work on electric components and battery............................................................. 33

8.3.4 Hydraulic oil................................................................................................................................ 78

In the course of technical development we reserve the right for

1.2 Machine type plate and engine type plate

Fig. 1: Machine type plate (example)

Please enter here:

Fig. 2: Engine type plate (example)

2.1 Noise and vibration data

2.1.1 Noise data

2.1.2 Vibration data

3 Concerning your safety

3.1 Basic prerequisites

3.1.2 Explanation of signal words used:

Sections marked accordingly indicate technical

3.1.3 Personal protective equipment

Safety shoes To protect against heavy falling parts and slipping on

Protective gloves To protect the hands against excoriation, punctures or

Safety goggles To protect the eyes against airborne particles and

Face protection To protect the face against airborne particles and

Hearing protection To protect hearing against excessive noise.

Respiratory protection To protect respiratory tracts against substances or parti-

3.1.4 Intended use

3.1.5 Improper use

Examples of improper use are:

3.1.6 Estimated service life of the machine

3.2 Definition of responsible persons

3.2.2 Expert / qualified person

3.2.3 Driver / operator

n have made himself familiar with the operation of the machine,

3.3 Basic safety regulations for safe operation

3.3.2 Regular safety inspections

3.3.3 Modifications and alterations to the machine

3.3.4 Damage, defects, misuse of safety devices

3.4 Handling fuels and lubricants

3.4.2 Safety regulations and environmental protection regulations for handling

3.4.4 Safety regulations and environmental protection regulations for handling

Should pressure fluid penetrate the skin, imme-

3.4.6 Safety regulations and environmental protection regulations when handling

3.5 Loading/transporting the machine

3.6 Start-up procedure

3.6.2 Starting the engine

3.7 Work mode

3.7.3 Parking the machine

3.9 Maintenance work

3.9.2 Working on the engine

3.9.3 Maintenance work on electric components and battery

3.9.4 Cleaning work

3.9.5 Measures for longer shut-down periods

3.9.6 After maintenance work

API CJ-4 ASTM D975-09a

before taking into operation weekly

Nominal Power Operating Mass Year of Construction California Proposition 65 Warning