Bomag BPR 50 User Manual
Contents
1. With low tem peratures Temperature below starting limit Fuel slurry caused by insufficient low tem perature resistance Starting speed too low oil with too high viscosity insufficiently charged battery Observe cold start instructions Pull the fuel hose off the fuel lift pump and check whether fuel runs out clear and without clouds In case of cloudy fuel you should either warm the engine up or drain the complete fuel supply system Fill with a temperature resistant fuel mix ture Replace engine oil with oil of correct vis cosity Check the battery if necessary consult a specialist workshop BPR 50 52 D3 BPR 55 52 D 3 BOMAG 59 Trouble shooting Fault Possible cause Remedy The starter is not switched on or the engine does not crank Fault in the electric system Battery or other cable connections not correctly connected Cable terminals loose or oxidised Battery defective or not charged Starter defective insufficiently charged battery Check electric equipment and related components or consult the customer serv ice of Bomag Engine ignites but does not continue to run when switching the starter motor off Fuel filter clogged Fuel supply interrupted Stop signal from monitoring elements connected with the oil pressure monitor ing facility no oil pressure Replace the fuel filter check the entire fuel system systematical ly C2. This EU declaration of conformity is only valid together with the appropriate scope of delivery of BOMAG GmbH amp Co OHG and clearly visible CE sign on the machine integrated in the type plate Boppard 11 2000 BOMAG GmbH amp Co OHG VOLS Miele R Steinadler Project Manager BOMAG GmbH amp Co OHG Industriegebiet Hellerwald D 56154 Boppard GB Machines marked with the sign are in accordance with the latest improved safety regulations for the market within the European Union For machines to be used outside this area and where these regulations are not binding BOMAG recommends the application of the same safety standards These BOMAG machines are products from the wide product range of BOMAG compaction equipment BOMAG s vast experience cou pled with the most modern production and testing methods such as lifetime tests of all important components and highest quality de mands ensure highest reliability of your ma chine Using these instructions will e help you to become acquainted with the ma chine e avoid faults caused by unprofessional opera tion Observing the maintenance instructions will e increase the reliability of the machine during use on site e prolong the lifetime of the machine e reduce repair costs and downtime BOMAG does not assume liability for the function of the machine e ifthe machine is handled in a way which does not comply with the use it is intended for e
3. 5 17 Cleaning cooling fins and cooling air intake openings Dirty operating conditions especially oil and fuel deposits on the engine cooling fins and the cooling air intake openings reduce the cooling power con siderably It is therefore mandatory to eliminate any oil and fuel leaks in the area of the cooling blower the cylinder or the cooling air intake and to clean the cooling fins after Dried on dirt e Clean all air guiding parts and the entire cool ing air circulation area like cylinder head cyl inder and flywheel ventilator with a brush and blow out with compressed air Fig 69 Damp and oily dirt Fire hazard Do not use any combustible solvents Do not subject electrical assemblies and con nectors to the direct water jet or dry them im mediately after with compressed air Investigate the cause for the oil leak and call the After Sales Service of BOMAG to seal all leaks BOMAG 49 Maintenance every 6 months Do not guide the water jet directly into the air filter the exhaust tube and the opening for the crankhandle e Disconnect the battery and remove the air guide plates e Spray the entire cooling air circulation area with the solvent e g cold cleansing agent let it soak in for a while and clean it off with a wa ter jet e Run the engine warm to avoid corrosion 50 BOMAG BPR 50 52 D3 BPR 55 52 D 3 5 18 Changing the fuel filter Fire hazard When working on the fuel sys
4. BPR 50 52 D3 BPR 55 52 D 3 We will help you immediately Operating maintenance repair instructions and spare parts catalogues in situ Safe and simple trouble shooting Secure access to required spare parts Easy to understand from experts for users Contact us or your BOMAG distributor 4 f 4 i 4 4 q q 4 k i ie i J Head Office Hauptsitz BOMAG GmbH amp Co OHG Hellerwald 56154 Boppard GERMANY Tel 49 6742 100 0 Fax 49 6742 3090 e mail germany bomag com WebSite www bomag com BOMAG GmbH amp Co OHG Niederlassung Berlin Gewerbestra e 3 15366 Dahlwitz Hoppegarten GERMANY Tel 49 3342 369410 Fax 49 3342 369436 e mail niberlin bomag de WebSite www bomag com BOMAG GmbH amp Co OHG Niederlassung Hannover Dieselstra e 44 30827 Garbsen Berenbostel GERMANY Tel 49 5131 70060 Fax 49 5131 6766 e mail nihannover bomag de WebSite www bomag com BOMAG Maschinenhandelsgesellschaft m b H Postfach 73 Porschestra e 9 1234 Wien Siebenhirten AUSTRIA Tel 43 1 69040 0 Fax 43 1 69040 20 e mail austria bomag com BOMAG GREAT BRITAIN LTD Sheldon Way Larkfield Aylesford Kent ME20 6SE GREAT BRITAIN Tel 44 1622 716611 Fax 44 1622 718385 e mail gb bomag com BOMAG GmbH amp Co OHG Middle East Office P O Box 52 69 Amman 11183 JORDAN Tel 962 6 5827096 Fax 962 6 5827436 e mail jordan b
5. fitting to catch running out fuel e Unscrew the drain fitting 1 Fig 59 from un derneath the fuel tank e After draining the fuel screw the drain fitting back in with a new sealing ring BOMAG 45 Maintenance every 6 months 5 13 Checking the oil level in the vibrator housing Stand the machine on level ground OIL Fig 60 e Unscrew the level plug Fig 60 and check the oil level The oil level must reach the bottom edge of the level bore top up oil if necessary For quality and quantity of oil refer to the table of fuels and lubricants e Screw the level plug back in with a new seal ring 46 BOMAG 5 14 Changing engine oil and en gine oil filter Stand the machine on level ground Drain the engine oil while the engine is warm Catch running out old oil do not let it seep into the ground but dispose of environmentally Danger of scalding There is a danger of scalding when draining hot engine oil CORE Y amp ASN Fig 61 e Pull the dipstick Fig 61 out e Unscrew the drain plug drain and catch the old oil e Screw the plug with a new sealing ring back in BPR 50 52 D3 BPR 55 52 D 3 e Unscrew the filler neck cover 1 Fig 62 e Take the old filter element out and dispose of environmentally e Check the O ring 3 use a new one if neces sary e Install the new filter cartridge with the mark TOP facing upwards and s
6. 0 e Before taking up work run the engine warm for approx 1 to 2 minutes Cold starting At temperatures below 5 C perform the following work Do not use any starting aids like start pilot or ether e Insert the crank handle Fig 14 Stand in correct position to the engine and en sure correct grip of the crank handle e Turn the crank handle slowly until the catch engages e Turn the crank handle with increasing speed until the engine starts Do not interrupt the fric tional connection BPR 50 52 D3 BPR 55 52 D 3 BOMAG 25 Operation EA SS gt ON Q O lt gt fh N Qs SZN RF ATA amp y t QR 2 Fig 16 e Set the throttle lever Fig 16 to position e Insert the crank handle Fig 18 MAX full speed e Crank the engine several times in decom e Shift the travel lever to position 0 pressed condition turn it free until it can be cranked lightly Fig 17 Fig 19 e Pull the decompression lever Fig 17 only a fraction in direction of arrow e Press the hand lever Fig 19 for approx five To turn the engine free you should not pull the de seconds against the spring compression lever all the way to the end stop in starting position 26 BOMAG BPR 50 52 D3 BPR 55 52 D 3 Fig 20 e Pull the protection cover Fig 20 off the dos ing device Fill in engine oil to the top reattach the cover and press it firmly in Max 2 fillings aft
7. extension plates 2 Fig 74 Cover the fastening nuts 1 with OKS 240 copper paste and tighten them with 900 Nm 52 BOMAG 5 20 Check the hydraulic oil level Fig 75 e Adjust the steering rod Fig 75 in upright po sition and lock it in the last locking position of the detent rail 681 119 Fig 76 e Unscrew the plug Fig 76 e Move the travel lever to reverse position and hold it BPR 50 52 D3 BPR 55 52 D 3 Maintenance every year After unscrewing the plug or level control plug the steering rod head must always be depres surized as follows e Place the machine on a rubber mat or rubber tires Adjust the steering rod in upright position and lock it in the last locking position of the detent rail tine J DEE Z227 FIN WAS IR LL EEE LLL e Unscrew the plug start the engine and run it with maximum speed YU GR Vl e Pull the travel lever back and hold it in this po sition ll CLL Fig 77 e Screw the plug back in and release the travel e The hydraulic oil must reach the upper edge of levee the splined shaft top up if necessary Fig 77 e Shut the engine down For quality of oil refer to the table of fuels and lubricants 681 112 Fig 79 e Tighten the plug Fig 79 Fig 78 Tighten the plug with the specified tightening Lay a cloth down before slackening the venting torque screw Hold the travel lever in reverse positi
8. if itis used for purposes other then the ones mentioned in these instructions No warranty claims can be lodged for damage re sulting from e operating errors e insufficient maintenance and e the use of wrong fuels and lubricants Please note This manual was written for operators and mainte nance personnel on construction sites You should only operate the machine after you have been instructed to do so and by following these instructions Please observe strictly the safety regulations Please observe also the guidelines of the civil en gineering liability association safety rules for the operation of road rollers and soil compaction equipment as well as the applicable instructions for the prevention of accidents For your own safety you should only use gen uine BOMAG spare parts BPR 50 52 D3 BPR 55 52 D 3 BOMAG Foreword To comply with the technical development we reserve the right of modifications without prior notification These operating and maintenance instructions are also available in other languages In addition you can obtain a spare parts catalogue from your BOMAG dealer by just stating the serial number of your machine Information for the correct use of our machines in earth and asphalt construction is also available from your BOMAG dealer The notes mentioned above do not constitute an extension of the warranty and liability conditions which are part of the general terms of busines
9. temperature For winter operation below 10 C the oil change intervals must be shortened OIL SAE 1 A m Fig 49 Lubrication oil with a too high viscosity index caus es starting difficulties The temperature when starting the engine is therefore of highest impor tance when choosing the viscosity of engine oil for winter operation Oil viscosity Since lubrication oil changes its viscosity with the temperature the ambient temperature at the oper ating location of the engine is of utmost impor tance when choosing the viscosity class SAE class see diagram Occasionally falling short of the temperature limit will impair the cold starting ability but will not cause any engine damage Regular lubrication oil changes If the following oil change intervals are not reached over a period of 1 year the oil change should be performed at least once per year irrespective of the operating hours reached BPR 50 52 D3 BPR 55 52 D 3 BOMAG Maintenance Oil quality You should preferably use oils of APl quality class CD CE CF CG or SHPD or CCMC D4 D5 PD2 oils When using oils of a lower quality standard the oil change intervals must be reduced to half Lubrication oil change intervals Oil change intervals with oil quality API CD CE CF CG 6 months 250 operating hours CCMC D4 D5 PD2 6 months 250 operating hours Fuels Quality You should only use commercially
10. the valve clearance 5 17 Cleaning cooling fins and cooling air intake openings 5 18 Changing the fuel filter 5 19 Changing the oil in the vibrator housing 5 20 Check the hydraulic oil level 5 21 Checking the rubber buffers 5 22 Checking the condition of the machine and the tight fit of all screws 5 23 Engine conservation Trouble shooting 6 1 General notes 6 2 Engine problems BPR 50 52 D3 BPR 55 52 D 3 BOMAG 13 17 18 18 21 22 22 23 23 29 31 32 34 35 36 37 38 39 40 41 41 42 42 43 44 45 46 46 47 49 49 51 51 52 54 55 55 57 58 59 Table of Contents 8 BOMAG BPR 50 52 D3 BPR 55 52 D 3 1 Technical Data BPR 50 52 D3 BPR 55 52 D 3 BOMAG 9 Technical Data Fig 4 Dimensions in mm BPR 50 52 D 3 BPR 55 52 D 3 Weights Operating weight CECE W Operating weight CECE W1 with extension plates Operating weight CECE W2 with extension plates Drive Engine manufacturer Type Cooling Working cycles Number of cylinders Rated power ISO 9249 Rated speed Starting device Fuel Drive system 10 850 kg kg kg kW rpm BOMAG H1 L L1 1070 1890 900 BPR 50 52 D 3 446 463 473 Hatz 1D 41S Air 4 1 5 8 3400 Crank handle Diesel mechanical V belt 680 058 Ww W Wo 520 660 820 BPR 55 52 D 3 446 463 473 Hatz 1D41S Air 4 1 5 8 3400 Diesel mechanical V belt BPR 50 52 D3 BPR 55 52 D 3 Travel charact
11. to the injec tion pump The engine will stop If the low oil level safety device has responded or if the fuel tank has been driven empty the fuel shut off valve must be opened manually see sec tion initial start up On engines with electric starter switch the ignition on so that the battery is being charged The low oil level safety device does not release the operator from his duty to check the oil level every day Danger of accident Replace a broken handle tube worn cranking pin Slightly lubricate the gliding area between crank handle and guide sleeve Do not use any starting aid spray Before starting make sure that there are no persons in the danger area and that all safety installations are in place and fully functional Remove all loose objects tools from the ma chine Do not run the engine in closed or poorly ven tilated rooms BOMAG 23 Operation Fig 10 e On machines with electric starter turn the igni tion switch Fig 10 to position With the ignition switch in position I the battery is being charged when the engine is running Initial start up Always perform the following work if the low oil level safety device has responded and engine oil has been filled up if the fuel tank has been driven empty the fuel in the supply line has been used up when turning the engine free during cold starting or by starting faults e Check the oil level if necessary fi
12. 141 24500 Fax 49 7141 245025 e mail nistuttgart bomag de WebSite www bomag com BOMAG S A F BP 34 Z A des Cochets 91223 Bretigny sur Orge cedex FRANCE Tel 33 1 69883900 Fax 33 1 60841866 e mail france bomag com WebSite www bomag fr BOMAG Japan Co Ltd 248 Sakama Kitayama Koga City Ibaraki Pref 306 0056 JAPAN Tel 81 280 483411 Fax 81 280 483415 e mail japan bomag com Compaction America Inc 2000 Kentville Road Kewanee Illinois 61443 U S A Tel 1 309 8533571 Fax 1 309 8520350 e mail usa bomag com WebSite www bomag americas com BOMAG
13. 600 244 Fig 28 e Set the fuel valve Fig 28 to STOP closed 28 BOMAG BPR 50 52 D3 BPR 55 52 D 3 Operation 4 5 Starting stopping the en gine electric starter Starting the engine The engine is started electrically instead of turn ing a crank handle The engine is equipped with a low oil level safety pattie device which interrupts the fuel flow to the injec Fig 29 tion pump The engine will stop If the low oil level safety device has responded or if the fuel tank has been driven empty the fuel shut off valve must be opened manually see pre vious section initial start up The low oil level safety device does not release the operator from his duty to check the oil level every day When the engine is running leave the ignition key in position I If the starting attempt takes longer than 10 sec onds wait at least 15 seconds before trying 681 103 again Fig 30 e Set the throttle lever Fig 30 to position MAX full speed Danger of accident Do not use any starting aid spray Before starting make sure that there are no persons in the danger area and that all safety installations are in place and fully functional Remove all loose objects tools from the ma chine as Do not run the engine in closed or poorly ven J IN 600 239 tilated rooms Do not insert the crank handle into the crank shaft Fig 31 e Set the fuel valve Fig 31 to O K open Opti
14. BOMAG Operating instructions Maintenance instructions BPR 50 52 D 3 BPR 55 52 D 3 S N 101 690 27 gt Hatz Vibratory plate Catalogue number 008 157 14 09 2001 If the machine is equipped with a battery CALIFORNIA Proposition 65 Warning _ Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling If the machine is equipped with a diesel engine l CALIFORNIA Proposition 65 Warning The engine exhaust and some of its constituents are known to the state of California to cause cancer birth defects and other reproductive harm BOMAG EC Declaration of Conformity as defined by Machinery Directive 98 37 EEC Annex II A Herewith we declare that this series production machine Designation Vibratory plate Type BPR 30 38 D 3 BPR 35 38 D 3 BPR 40 45D 3 BPR 45 45 D 3 BPR 50 52 D 3 BPR 55 52 D 3 Manufacturer BOMAG GmbH amp Co OHG Boppard Serial number see information on type plate complies with the substantial provisions of EEC Directive Machinery 98 37 EEC EMC 89 336 EEC amended by directive 92 31 ECC 93 68 ECC and the harmonized standards EN 500 1 and 500 4 A specimen of the above mentioned product has been checked and approved by the committee civil engieneering testing and certificated under the number
15. Changing the oil in the vibrator housing 5 20 Checking the hydraulic oil level 5 21 Checking the rubber buffers As required 5 22 Checking the screw joints 5 23 Engine conservation 40 BOMAG BPR 50 52 D3 BPR 55 52 D 3 5 6 Cleaning machine engine Fig 50 Do not guide the water jet directly into the oil bath air filter Fig 50 and into the opening for the crankhandle e After each cleaning run the engine warm to evaporate all water and to avoid corrosion BPR 50 52 D3 BPR 55 52 D 3 Maintenance every day 5 7 Checking the fuel level Fire hazard When working on the fuel system do not use open fire do not smoke Do not refuel in closed rooms Refuel only with the engine shut down Fig 51 e Clean the area around the tank cover screw the tank cover Fig 51 off Dirty fuel can cause engine failures e Fill in fuel through a strainer e Screw the filler neck cover on again For quality of fuel refer to the table of fuels and lubricants BOMAG 41 Maintenance every day 5 8 Checking the engine oil Stand the machine on firm and level ground so that the engine is in horizontal position Fig 52 e Shutthe engine down e Pullthe oil dipstick Fig 52 out wipe it with a clean lint free cloth and reinsert it until it bot toms e Pullthe oil dipstick back out and read the oil level Nominal value The oil level must reach the upper mark Top up oil immed
16. R 50 52 D3 BPR 55 52 D 3 Sections marked like this highlight activities for the safe and environmental disposal of fu els and lubricants as well as replaced parts Safety stickers on the machine Keep safety stickers in good condition and legible and follow their meaning Replace damaged and illegible safety stickers Loading the machine Secure the machine against turning over or slip ping off Persons are highly endangered if they e step under loads being lifted or e stand under loads being lifted Secure the machine on the transport vehicle against rolling off slipping and turning over Starting the machine Before starting Become acquainted with the equipment the con trol elements the working principle of the machine and the working area Wear your personal protective outfit hard hat safety boots etc Wear ear defenders Before starting the machine check whether e the machine shows any obvious faults e all guards and safety elements are in place e the controls are fully functional J the machine is free of oily and combustible material e allgrips are free of grease oils fuel dirt snow and ice Use only machines which are serviced at regular intervals Do not use any starting aids like start pilot or ether For starting move your feet out of the danger zone of the base plate Starting in closed rooms Exhaust gases are highly dangerous Always en sure an adequate supply of fresh ai
17. available brand diesel fuel with a sulphur content below 0 5 and ensure strict cleanliness when filling in The following fuel specifications are permitted DIN 51601 DK BS 2869 A1 and A2 ASTM D 975 1D and 2D Winter fuel For winter operation use only winter diesel fuel to avoid clogging because of paraffin separation At very low temperatures disturbing paraffin separa tion can also be expected when using winter diesel fuel In most cases a sufficient cold resistance can also be achieved by adding flow enhancing fuel addi tives Consult the engine manufacturer 37 Maintenance 5 3 Table of fuels and lubri cants Assembly Fuel or lubricant Quantity approx Summer Winter Attention Observe the level marks Engine Engine oil API CD SE or CD SF approx 1 1 67 cu in SAE 15W 40 20 C to 30 C 20 C to 30 C SAE 15W 40 10 C to 40 C 10 C to 40 C SAE 30 SAE 10W 5 C to 30 C 5 C to 30 C 41 F bis 86 F 5 C to 30 C SAE 40 SAE 20W 20 25 C to 40 C 10 C to 10 C 77 F bis 104 F 10 to 10 C Fuel Diesel Winter diesel fuel 41 1 USgal 12 C 10 4 F Vibrator shaft housing as engine oil 11 38 BOMAG BPR 50 52 D3 BPR 55 52 D 3 BPR 50 52 D3 BPR 55 52 D 3 Maintenance 5 4 Running in instructions For the start up or new machines of over hauled engines the following maintenance work must be performed During the running in per
18. bility only if the battery is dis charged e Remove the cover off the battery Wrong installtion will cause severe damage in the electrical system Fig 38 e Connect the plus pole of the external battery with the plus pole of the starter battery with one of the jump wires Fig 38 e Connect the minus poles of both batteries with the other jump wire e Start the engine as described before e Once the engine is running disconnect the mi nus poles first and the plus poles after This avoids short circuits when touching the plus wire with the minus wire e Reinstall the battery cover and lock the flap BOMAG 31 Operation 4 7 Work operation Operation of the vibratory plate can be started as soon as the engine responds to short throttle com mands Danger of accident Operate the machine only with the steering rod folded down Guide the machine only by the steering rod Wear your personal noise protection ear de fenders Fig 39 e Pull the locking lever Fig 39 up and fold the steering rod down Fig 40 e Adjust the steering rod with the height adjust ment Fig 40 to the height of your body 32 BOMAG 681 102 Fig 41 e Set the throttle lever Fig 41 to position MAX Operate the vibratory plate only with full en gine speed as otherwise the centrifugal clutch will be destroyed For short breaks you should always return the throttle lever to idle speed positi
19. crew the cover on er 15W 40 0 3 US gal e Stand the vibratory plate horizontally and fill in new oil Fig 63 For quality and quantity of oil refer to the table of fuels and lubricants e Insert the oil dipstick and check the oil level again e Check drain plug and oil filler neck cover for leaks after a short test run BPR 50 52 D3 BPR 55 52 D 3 Maintenance every 6 months 5 15 Checking tightening changing the V belt Checking the V belt Fig 64 e Remove the V belt guard e Check the condition and tension of the V belt Fig 64 change the V belt if damaged Compression measurement approx 5 mm 0 2 Tightening the V belt e Unscrew the fastening nuts 1 Fig 65 with washers take the V belt pulley half 2 off e Remove the necessary number of shims 3 from between the pulley halves e Put the V belt pulley half 2 back on and add the removed shims 4 from the outside BOMAG 47 Maintenance every 6 months e Screw the hexagon nuts 1 with the washers back on and tighten them e Crank the V belt drive several times by hand and check the compression measurement ap prox 5 mm again correct the tension if nec essary Changing the V belt e Remove the front V belt pulley half see tight ening the V belt e Slacken the rear fastening screws 3 Fig 66 on both sides for a few turns Danger of injury e Unscrew two front fastening nuts 2 on both
20. d 6 7 m sec for low amplitude 12 BOMAG BPR 50 52 D3 BPR 55 52 D 3 2 Safety regulations BPR 50 52 D3 BPR 55 52 D 3 BOMAG 13 Safety regulations General This BOMAG machine is built in accordance with the latest technical standard and the valid technical rules and regulations However dan gers for persons and property may arise from the machine if it is e put to unintended use e operated by untrained personnel e modified or altered in an unprofessional way J the applicable safety regulations are not ob served Each person involved in operation mainte nance and repair of the machine must there fore read and apply these safety regulations If necessary this should be confirmed by obtain ing the signature of the customer Furthermore the following regulations and instruc tions are obviously also valid e allapplicable instructions for the prevention of accidents e generally acknowledged safety and road traffic regulations e country specific regulations Intended use This machine must only be used for compaction of all types of soil repair work on all types of soil reinforcement of pedestrian walkways work in trenches filling and compaction of hard shoulders The machine should be checked by an expert once every year Unintended use Dangers may however arise from the machine if it is used by untrained personnel in an unprofes sional way or if it is used for purposes other tha
21. el system The lifetime of the diesel engine is decisively de pending on the cleanliness of the fuel e Keep the engine free of dirt and water as this could damage the injection elements of the en gine e Zinc lined drums are not suitable for storing fu el e The fuel drum should rest for a longer period of time before drawing off fuel e Under no circumstances must the drum be rolled to the tapping pint just before drawing off fuel e When choosing the storage place for fuel make sure that spilled fuel will not cause any damage e Do not let the suction hose disturb the sludge on the bottom of the drum 36 BOMAG e Do not draw off fuel from near the bottom of the fuel drum e Fuel left in the fuel drum is not suitable for the engine and should only be used for cleaning purposes Notes on the engine performance Combustion air and fuel injection rates of the die sel engine have been carefully adjusted and deter mine the engine s performance and temperature level as well as the quality of the exhaust gas If your machine has to operate permanently in thin air at high altitudes and with full power you should consult the after sales service of BOMAG or the service department of the engine manufac turer BPR 50 52 D3 BPR 55 52 D 3 5 2 Fuels and lubricants Engine oil In order to assure perfect cold starting it is import to chose the viscosity SAE class of the engine oil according to the ambient
22. er each other Fig 21 e Pull the decompression lever Fig 21 in direc tion of arrow to the end stop BPR 50 52 D3 BPR 55 52 D 3 Operation D Q p N TFT Stand in correct position to the engine and en sure correct grip of the crank handle Fig 22 am Qs e Turn the crank handle slowly until the catch engages e Turn the crank handle with increasing speed until the engine starts Do not interrupt the fric tional connection Hold the crank handle with a tight grip during the starting process 1 2 MINUTEN L O Fig 23 e Setthe throttle lever Fig 23 to position MIN idle speed 681 098 If the engine does not start repeat the starting process BOMAG 27 Operation Y 681 118 e Attach the crank handle Fig 24 e Set the throttle lever Fig 26 to position STOP The engine stops and the warning buzzer sounds Before taking up work let the engine warm up at idle speed for a short while not longer than 5 minutes Shutting the engine down Do not shut the engine down all of the sudden from full speed but let it idle for a while for temperature equalization 1 2 MINUTEN Fig 27 e Turn the ignition key to position 0 Fig 27 and pull it out e The warning buzzer stops to sound Fig 25 e Shift the throttle lever to position Min Fig 25 and let the engine run with idle speed for a short while Vibration is shut down
23. er housing out with compressed air BPR 50 52 D3 BPR 55 52 D 3 Maintenance every month e Wipe the inside of the filter housing out with a clean cloth e Clean the cover with the cyclon pre filter thor oughly LUFT AIR 100 040 Fig 55 Eye injuries Wear protective goggles e Blow the filter cartridge Fig 55 out with dry compressed air max 5 bar from inside to out side e Insert the filter cartridge 3 Fig 56 with the covering disc 2 into the housing e Install the filter cover 1 and ensure correct fit of cover and seal 4 e Check the dry air filter see previous para graph Change the filter cartridge if the maintenance indi cator comes on again BOMAG 43 Maintenance every month 5 11 Checking the condition of the battery greasing the poles Danger of cauticization When working on the battery do not use open fire do not smoke Do not let skin and clothes come in contact with acid Wear protective goggles Do not lay any tools on the battery Fig 57 e Unscrew the fastening screws Fig 57 for the covering flap and fold the cover down e Take the vibration insulation mats off Fig 58 e Take the battery Fig 58 out and clean the battery compartment 44 BOMAG e Clean the outside of the battery e Clean battery poles and pole clamps and grease them with pole grease vaseline e Check the fastening of the battery e Check
24. eristics Working speed max gradability Permissible inclination Vibration system Frequency Amplitude Filling capacities Fuel tank capacity Engine Vibrator system BPR 50 52 D3 BPR 55 52 D 3 The right for technical modifications remains reserved m min Hz BOMAG BPR 50 52 D 3 0 24 30 20 Technical Data BPR 55 52 D 3 0 22 30 20 Technical Data The following noise and vibration values according to the EC machine regulation of revision 93 68 EEC have been measured under typical operating conditions for this machine with vibration and over a specified travel distance DIN 45635 During operation these values may vary because of the existing operating conditions Noise value The sound level according to enclosure 1 paragraph 1 7 4 f of the EC machine regulation is sound pressure level on the operator s stand Loa high amplitude 95 2 dB A low amplitude 98 1 dB A sound capacity level Lwa high amplitude 108 9 dB A low amplitude 111 1 dB A These sound values were determined according to ISO 6081 for the sound pressure level Lpa and ISO 3744 DIN 45635 for sound capacity level Lwa Vibration value The vibration values according to enclosure 1 paragraph 2 2 or 3 6 3 a of the EC machine regulation are Hand arm vibration values The weighted effective acceleration value determined according to ISO 8662 part 1 DIN 45675 part 9 is 6 9 m sec for high amplitude an
25. heck oil level Engine shuts down by itself during operation Tank empty Fuel filter clogged The mechanical oil pressure monitoring shuts the engine down because of a lack off oil Mechanical defects Fill in fuel Replace the fuel filter Check the oil level activate the oil pres sure monitoring system Engine looses power and speed Fuel supply restricted Tank empty Fuel filter clogged Insufficient tank ventilation Pipe connections leaking Throttle lever does not stay in selected position Fill in fuel activate the mechanical oil pressure monitoring system Replace the fuel filter Ensure sufficient ventilation of the tank Check line connections for leaks Block the throttle control Engine looses power and speed black ex haust smoke Air filter dirty Incorrect valve clearance Injection nozzle out of order Clean or replace the air filter Adjust the valve clearance see shop manual 60 BOMAG BPR 50 52 D3 BPR 55 52 D 3 Trouble shooting Fault Possible cause Remedy Engine over Lubrication oil level in engine too high Drain the engine oil down to the top mark heating on the dipstick Insufficient cooling Dirt in the entire area of the cooling air flow Air guide plates not completely closed Clean the cooling air duct Check air guide plates for completeness and good sealing BPR 50 52 D3 BPR 55 52 D 3 BOMAG 61 Trouble shooting 62 BOMAG
26. her oil containing materials in a specially marked container and dispose of en vironmentally Working on electric components Before starting to work on electric components dis connect the battery and cover it with insulating ma terial Working on the battery When working on the battery do not smoke do not use open fire Do not let skin and clothes come in contact with acid In case of injuries caused by acid flush the respec tive parts with clear water and consult a doctor for medical advice Do not place any tools on the battery danger of short circuit When recharging the battery remove all plugs to avoid an accumulation of explosive gases Dispose of old batteries environmentally Working on the fuel system No open fire do not smoke do not spill any fuel Catch running out fuel do not let it seep into the ground and dispose of environmentally Cleaning Do not clean the machine while the engine is run ning Do not use gasoline or other combustible sub stances for cleaning purposes When using steam cleaning equipment do not subject electric parts to the direct water jet or cover it beforehand Do not guide the water jet directly into the air filter and into the air intake opening After maintenance work Reinstall all protective devices after completing the maintenance work Repair Repair work must only be performed by qualified and authorized persons Use our repair instruc tions for this wor
27. iately if the oil level is too low For quality and quantity of oil refer to the table of fuels and lubricants e Check the seals on the oil dipstick change if necessary e Push the oil dipstick in again until it bottoms 42 BOMAG 5 9 Checking the dry air filter Fig 53 e Pull the rubber sleeve Fig 53 up start the engine and run it a max speed If the rubber sleeve is pressed together again when the engine is running clean the air filter see following paragraph BPR 50 52 D3 BPR 55 52 D 3 5 10 Cleaning the dry air filter Do not use gasoline or hot liquids to clean the filter A dry air filter with damaged element or seal must be changed in any case We therefore recommend to keep at least one filter cartridge in stock Change the air filter cartridge after two times cleaning but at the latest after 2 years Mark each cleaning with a cross on the filter cartridge Cleaning is useless if the filter cartridge is cov ered with sooty dirt Use a new filter cartridge Incorrectly handled filter cartridges can be in effective because of damages e g cracks and lead to engine failures Change the filter cartridge if it is covered with damp or oily dirt Fig 54 e Slacken the wing nut 1 Fig 54 and take the cover with the covering disc 2 and the air fil ter insert 3 off No dirt or foreign particles must enter the clean air intake Do not blow the inside of the filt
28. including the cooling system e Run the engine until it is warm and shut it down e Drain the still warm engine oil and fill in anti corrosion engine oil Anti corrosion oils are those that comply with the specification MIL L 21260 B or TL 9150 037 2 re sp Nato Code C 640 642 e Mix the fuel with anti corrosion oil in a mixing ratio of 1 4 0 5 litres for 2 litres of fuel e Run the engine for approx 10 to 15 minutes with this fuel mixture e Take the V belt off and spray the grooves of the V belt pulleys with anti corrosion oil Re move the anticorrosion oil before taking the machine back into service We do not recommend to run the engine during this conservation time as the engine might not warm up properly and it will harm the conserving agent The conserving oil may remain in the engine but has to be changed after 15 operating hours The mixing of anti corrosion oil to the fuel can cause a power drop of 15 When changing the conserving oil against normal engine oil the engine does not have to be flushed BOMAG 55 As required 56 BOMAG BPR 50 52 D3 BPR 55 52 D 3 6 Trouble shooting BPR 50 52 D3 BPR 55 52 D 3 BOMAG 57 Trouble shooting 6 1 General notes The following work must only be carried out by qualified and trained personnel or by the BOMAG sales service Please observe strictly the safety regulations in chapter 2 of these operating and mainte nance instructions Faults occ
29. iod up to approx 200 operating hours check the engine oil level two times every day Depending on the engine load the oil con sumption will drop to its normal level after a running time of approx 100 to 200 operating hours After 25 operating hours e Change the engine oil e Check engine and machine for leaks e Check the valve clearance adjust if neces sary e Retighten the fastening screws for air filter ex haust silencer fuel tank and other attach ments e Tighten the screw connections on the ma chine e Check the vibration drive V belt retighten it if necessary BOMAG 39 Maintenance 5 5 Maintenance chart With all maintenance intervals perform also the work for shorter preceding service inter vals No Designation Note Daily maintenance 5 6 Cleaning machine engine 5 7 Checking the fuel level 5 8 Checking the engine oil level 5 9 Checking the dry air filter Monthly maintenance 5 10 Cleaning the dry air filter 5 11 Checking the battery condition greasing the poles 5 12 Draining the sludge from the fuel tank Maintenance every 6 months 5 13 Checking the oil level in the vibrator housing 5 14 Changing engine oil and oil filter 5 15 Checking tensioning replacing the V belt 5 16 Checking adjusting the valve clearance 5 17 Cleaning the cooling fins and the cooling air intake openings Annual maintenance 5 18 Changing the fuel filter 5 19
30. k 16 BOMAG Exhaust gases are highly dangerous Always en sure an adequate supply of fresh air when starting in closed rooms Mark defective machines by attaching a warning note to the steering handle BPR 50 52 D3 BPR 55 52 D 3 3 Indicators and Controls BPR 50 52 D3 BPR 55 52 D 3 BOMAG 17 Indicators and Controls 3 1 General notes Please read this section thoroughly before operat ing this machine if you are not yet conversant with the indicators and control elements All functions are described in detail hereunder Paragraph 4 Operation contains only concise de scriptions of the individual operating steps 18 BOMAG 3 2 Controls Fig 5 Locking lever Fig 5 Fig 6 Height adjustment Fig 6 of steering rod Pull the locking lever up to fold the steering rod down BPR 50 52 D3 BPR 55 52 D 3 681 120 Fig 7 Controls Fig 7 1 Throttle lever 2 Travel lever Fig 8 Optional equipment Start the engine electrically Fig 8 Turn the ignition key to position 0 warning buzz er Turn the ignition key to position I warning buzzer on Then turn the ignition key further to position Il to start the engine BPR 50 52 D3 BPR 55 52 D 3 BOMAG Indicators and Controls Indicators and Controls 20 BOMAG BPR 50 52 D3 BPR 55 52 D 3 4 Operation BPR 50 52 D3 BPR 55 52 D 3 BOMAG 21 Operation 4 1 General If you are not yet acquainted with the contr
31. ll up to the MAX mark e Check the fuel level if necessary fill in fuel 24 BOMAG Fig 11 e Press the hand lever Fig 11 for approx five seconds against the spring The engine is ready for starting Normal starting Fig 12 e Pull the decompression lever Fig 12 in direc tion of arrow to the end stop The compression lever clicks noticeably into place After engaging the decompression lever another five revolutions with the crank handle are required until the engine can compress and ignite again If less crank handle revolutions are wanted for starting the decompression lever can be push in opposite direction again after it has engaged at the end stop Each noticeable click means one crank handle revolution less BPR 50 52 D3 BPR 55 52 D 3 Operation If the compression lever is not pushed allthe way to the end stop in direction Start the engine When the d onl t to initial might be decompressed but is not ready for start CMTE CECOP SSO OKET EHIN Oua position the highest speed must be reached ing This position is used to turn the engine free at low ambient temperatures e As soon as the engine starts pull the crank handle out of the guide 1 2 MINUTEN a s 681 103 oO 681 098 e Set the throttle lever Fig 13 to position Fig 15 MAX full speed e Setthe throttle lever Fig 15 to position MIN idle speed e Shift the travel lever to position
32. n those mentioned in these instructions 14 BOMAG Who is allowed to work with the ma chine The machine must only be operated by trained and authorized persons who are at least 18 years of age The responsibilities for the operation of the machine must be clearly specified and complied with Persons under the influence of alcohol medica tion or drugs must not operate service or repair the machine Maintenance and repair tasks require specific knowledge and must therefore only be carried out by trained and qualified personnel Conversions and alterations to the ma chine Unauthorized conversions to the machine are pro hibited for safety reasons Original parts and accessories have been special ly designed for this machine We wish to make ex pressly clear that we have not tested or authorized any original parts or special equipment not sup plied by us The installation and or use of such products can impair the active and or passive driv ing safety The manufacturer expressly excludes any liability for damage resulting from the use of non original parts or accessories Safety notes in the operating and main tenance instructions Paragraphs marked like this highlight possible dangers for persons Paragraphs marked this way highlight possi ble dangers for machines or parts of the ma chines Sections marked like this provide technical infor mation concerning the optimal economical use of the machine BP
33. ols and indicating elements on this machine you should thoroughly read chapter 3 Indicators and control elements before starting work All indicators and control elements are de scribed in detail in this chapter 22 4 2 Before starting work Please observe strictly the safety regulations in chapter 2 of these operating and mainte nance instructions Refer also to the detailed description in the chapter Maintenance Top up missing fuels and lubricants according to the respective maintenance instruction e Stand the machine on level ground e Check fuel tank and lines for leaks e Check the engine oil level if necessary top up to the upper mark e Check the fuel level if necessary top up e Check the dry air filter maintenance indicator e Check the condition of the entire machine and check the screw connections for tight fit Loss of hearing Wear your personal noise protection equip ment ear defenders before starting operation BOMAG BPR 50 52 D3 BPR 55 52 D 3 4 3 Folding the steering rod down Danger of injury Shock by spring force The steering rod is resilient in operating posi tion Fig 9 e Pull locking the lever Fig 9 up and fold the rod down so that steering rod can swing free ly BPR 50 52 D3 BPR 55 52 D 3 Operation 4 4 Starting stopping the en gine manual starting The engine is equipped with a low oil level safety device which interrupts the fuel flow
34. omag com BOMAG Light Equipment Division 380 Broome Corporate Parkway Conklin NY 1374 81512 U S A Tel 1 607 762 1500 Fax 1 607 762 1563 e mail info bomagle com WebSite www bomag americas com BOMAG GmbH amp Co OHG Niederlassung Boppard Hellerwald 56154 Boppard GERMANY Tel 49 6742 1000 Fax 49 6742 100392 e mail nlboppard bomag de WebSite www bomag com BOMAG GmbH amp Co OHG Niederlassung M nchen Freisinger Stra e 11 85386 Eching GERMANY Tel 49 8165 6480 Fax 49 8165 61385 e mail nimuenchen bomag de WebSite www bomag com BOMAG CANADA INC 1300 Aerowood Drive Mississauga Ontario L4W 1B7 CANADA Tel 1 905 6256611 Fax 1 905 6254403 e mail canada bomag com WebSite www bomag americas com canada BOMAG Italia Srl Zona Industriale Localit Faustinella 25015 Desenzano del Garda BS ITALY Tel 39 030 9127263 Fax 39 02 70046663 e mail italy bomag com BOMAG GmbH amp Co OHG Representative Office Asia amp Pacific 300 Beach Road The Concourse 32 02 Singapore 199555 SINGAPORE Tel 65 294 1277 Fax 65 294 1377 e mail singapore bomag com BOMAG GmbH amp Co OHG Niederlassung Chemnitz Querstra e 6 09247 R hrsdorf GERMANY Tel 49 3722 51590 Fax 49 3722 515951 e mail nichemnitz bomag de WebSite www bomag com BOMAG GmbH amp Co OHG Niederlassung Stuttgart Kruppstra e 8 71696 M glingen GERMANY Tel 49 7
35. on Slacken the bleeding screw Wait until all air has escaped Fig 78 Tighten the bleeding screw After bleeding check the hydraulic oil level top up if necessary BPR 50 52 D3 BPR 55 52 D 3 BOMAG 53 Maintenance every year 5 21 Checking the rubber buffers Fig 80 e Check the condition and tight fit of the rubber buffers Fig 80 on both sides change if nec essary 54 BOMAG BPR 50 52 D3 BPR 55 52 D 3 5 22 Checking the condition of the machine and the tight fit of all screws i i Tightening torques ft Ib Bolt dimensions EE 2 3 4 4 7 7 Fig 81 Strength classes for screws with untreated non lubricated surfaces The quality designations are stamped on the screw heads The values result in a 90 utilization of the screws yielding point at a coefficient of friction of total 0 14 The tightening torques are not valid when using MOS lubricants e As far as possible check the condition and fas tening of all screws pipes clamps and other attachments and engine fasteners Do not tighten the cylinder head fastening screws e Examine the machine for damage and leaks have repaired if necessary BPR 50 52 D3 BPR 55 52 D 3 As required 5 23 Engine conservation If the engine is to be shut down for a longer period of time e g during winter we recommend the fol lowing conservation measures for the engine to avoid corrosion e Clean the engine
36. on this avoids pre mature wear of the centrifugal clutch 681 104 Fig 42 e Move the travel lever Fig 42 forward as re quired for the desired speed BPR 50 52 D3 BPR 55 52 D 3 Operation 681 106 Fig 43 Fig 45 e Move the travel lever Fig 43 backwards as e Keep moving throttle lever Fig 45 between required for the desired speed MIN and MAX throttle position The machine vibrates forward or backwards with a e Atthe same time pull the vibratory plate by the speed which is in accordance with the chosen steering rod to the right and left until it comes travel lever position free If the machine moves forward with considerably Danger of accident reduced speed pull the travel lever completely back and shift it forward again As a measure to avoid injury the machine must only be guided from the side by the steering handle If the vibratory plate got stuck Fig 44 e Lock the steering rod Fig 44 in the first lock ing position BPR 50 52 D3 BPR 55 52 D 3 BOMAG 33 Operation 4 8 Loading Danger of accident Make sure that persons are not endangered by the machine tipping or sliding off Tie the machine down so that it is secured against rolling sliding and turning over For lifting the machine attach the lifting gear only to the lifting hook The machine must not swing about when be ing lifted Use only safe lifting gear of sufficient load bearing capacity Do not stand
37. onal equipment BPR 50 52 D3 BPR 55 52 D 3 BOMAG 29 Operation Fig 32 e Turn the ignition key Fig 32 to position I The warning buzzer sounds The warning buzzer sounds with the engine at rest and the ignition switched on the battery is not be ing charged in this condition e Turn the ignition key to position II the starter will crank the engine e As soon as the engine ignites return the igni tion key to position I e Once the engine runs correctly reduce the en gine speed 1 2 MINUTEN 3 Fig 33 e Run the engine warm for a short while before starting work Fig 33 e Operation of the vibratory plate can be started once the engine has warmed up for a while 30 BOMAG Shutting the engine down Do not shut the engine down all of the sudden from full speed but let it idle for a while for temperature equalization 1 2 MINUTEN Fig 34 e Shift the throttle lever to position Min Fig 34 and let the engine run with idle speed fora short while Vibration is shut down aD 681 118 e Set the throttle lever to position STOP Fig 35 the warning buzzer sounds BPR 50 52 D3 BPR 55 52 D 3 Fig 36 e Turn the ignition key to position 0 and pull it out The warning buzzer stops to sound 600 244 Fig 37 e Set the fuel valve Fig 37 to STOP closed BPR 50 52 D3 BPR 55 52 D 3 Operation 4 6 Starting with jump wires Use this starting possi
38. or step under loads being lifted Fig 46 e Adjust the steering rod Fig 46 in upright po sition and lock it in the last locking position Fig 47 e Fold the lifting hook Fig 47 up 34 BOMAG Fig 48 e Always attach the lifting gear rope to the lift ing eye to load the vibratory plate on a trans port vehicle Fig 48 Danger of accident Tie the machine down on the transport vehicle so that it is secured against slipping sliding and turning over BPR 50 52 D3 BPR 55 52 D 3 5 Maintenance BPR 50 52 D3 BPR 55 52 D 3 BOMAG 35 Maintenance 5 1 General notes on mainte nance When performing maintenance work observe the applicable safety regulations and especially safety regulations in chapter 2 of these operating main tenance and repair instructions Thorough maintenance of the machine ensures maximum reliability and prolongs the lifetime of im portant components The effort necessary for this purpose is only of minor significance when being compared with the problems which may arise if these instructions are not observed e Clean machine and engine thoroughly before starting maintenance work e For maintenance work park the machine on level ground e Maintenance work must generally be carried out with the engine shut down During maintenance work catch all oils and fu els and do not let them seep into the ground Dispose of oils and fuel environmentally Notes on the fu
39. r when starting in closed rooms BPR 50 52 D3 BPR 55 52 D 3 Safety regulations Operation Operate the machine only with the steering rod folded down Guide the machine so hat your hands do not hit against solid objects danger of injury Watch out for unusual noises and development of smoke Perform trouble shooting and have the fault corrected Operate the machine only with full engine speed as otherwise the centrifugal clutch will be de stroyed Do not let the machine run unattended Parking the machine Park the machine on level firm ground Before leaving the machine e park the machine so that it cannot turn over e shut the engine down Mark machines which could be in the way with a clearly visible sign Filling the fuel tank Refuel only with the engine shut down Do not refuel in closed rooms No open fire do not smoke Do not spill any fuel Catch running out fuel do not let it seep into the ground Maintenance Maintenance work must only be carried out by qualified and authorized personnel Keep unauthorized persons away from the ma chine Do not perform service work while the engine is running If possible park the machine on level and firm ground Working on the engine Drain the engine oil at operating temperature danger of scalding Wipe off spilled oil catch running out oil and dis pose of environmentally BOMAG 15 Safety regulations Store used filters and ot
40. s of BOMAG We wish you much success with your BOMAG machine BOMAG GmbH amp Co OHG Printed in Germany Copyright by BOMAG Foreword Please fill in Engine No Fig 3 Fill in the above listed data when receiving the ma chine Upon receipt of the machine our organization will instruct you about correct operation and mainte nance Please observe strictly all safety regulations and notes on potential dangers 6 BOMAG Fig 2 Fig 3 BPR 50 52 D3 BPR 55 52 D 3 Table of Contents Technical Data Safety regulations Indicators and Controls 3 1 General notes 3 2 Controls Operation 4 1 General 4 2 Before starting work 4 3 Folding the steering rod down 4 4 Starting stopping the engine manual starting 4 5 Starting stopping the engine electric starter 4 6 Starting with jump wires 4 7 Work operation 4 8 Loading Maintenance 5 1 General notes on maintenance 5 2 Fuels and lubricants 5 3 Table of fuels and lubricants 5 4 Running in instructions 5 5 Maintenance chart 5 6 Cleaning machine engine 5 7 Checking the fuel level 5 8 Checking the engine oil 5 9 Checking the dry air filter 5 10 Cleaning the dry air filter 5 11 Checking the condition of the battery greasing the poles 5 12 Draining the fuel tank sludge and water 5 13 Checking the oil level in the vibrator housing 5 14 Changing engine oil and engine oil filter 5 15 Checking tightening changing the V belt 5 16 Checking adjusting
41. sides lift the front of the engine carrier plate up and support it properly 48 BOMAG 681 014 Fig 67 e Unscrew the fastening screws 1 Fig 67 and take the cover 2 off e Fit the new V belt install the cover 2 fasten the engine carrier plate and tighten the V belt as described before e Reinstall the V belt guard Check the V belt tension again after approx 25 operating hours tighten if necessary BPR 50 52 D3 BPR 55 52 D 3 5 16 Checking adjusting the valve clearance Checks and adjustments must only be carried out when the engine is cold 20 10 C The decompression lever must be in initial posi tion The gasket for the cylinder head cover must gen erally be changed Checking the valve clearance e Remove the cylinder head cover e Crank the engine until compression resistance can be felt I _ 010mm E A S 0 004 100 042 Fig 68 e Check the valve clearance with a 0 1 mm feel er gauge on both valves 1 Fig 68 and correct it if necessary Adjusting the valve clearance e Slacken the counter nut 3 e Adjust the setscrew 2 with a screwdriver so that the feeler gauge fits through the gap with only little resistance after tightening the coun ter nut e Reinstall the cylinder head cover with a new gasket 4 and tighten the fastening screws evenly e Check the cover for leaks after a short test run BPR 50 52 D3 BPR 55 52 D 3 Maintenance every 6 months
42. tem do not use open fire do not smoke Do not spill any fuel do not breath in any fuel fumes e Place a suitable container under the filter to catch running out fuel e Disconnect the fuel supply hose and drain the fuel from the fuel tank e Unscrew the hose clamp 1 Fig 70 e Pull the fuel filter 2 out of the upper and lower hoses If necessary flush the tank with clean diesel fuel e Fit the new fuel filter and make surte that the flow direction is correct e Fill the fuel tank BPR 50 52 D3 BPR 55 52 D 3 Maintenance every year 5 19 Changing the oil in the vi brator housing Catch the old oil do not let it seep into the ground and dispose of environmentally Fig 71 e Unscrew the fastening nuts 1 Fig 71 for the extension plates 2 and remove the plates from both sides e Tilt the machine slightly towards the oil drain side and support it properly e Unscrew the drain plug Fig 72 drain and catch all old oil e Screw the drain plug with a new sealing ring back in BOMAG 51 Maintenance every year OIL 15W 40 11 0 26 US gal Fig 73 e Unscrew the level plug Fig 73 e Stand the machine on level ground and fill in approx 1 litre of engine oil For quality and quantity of oil refer to the table of fuels and lubricants The oil level must reach the lower edge of the level bore e Screw the level plug back in with a new sealing ring Fig 74 e Refit the
43. the condition of the vibration insulation mats change if necessary e Lay the vibration insulation mats back in Ensure correct fit of the vibration insulation mats e Close the cover again after servicing is com pleted Non maintenance free batteries Top up missing fluid only with distilled water e Remove all plugs and check the acid level top up with distiled water if necessary With control inserts The acid level must reach the bottom of the control inserts Without control inserts Measure the acid level with a clean wooden stick It must reach up to 10 to 15 mm above the lead plates With transparent battery housing The acid level must reach the mark on the hous ing Maintenance free batteries Perform only the following points e Check the battery for cleanliness e Clean the poles e Tighten the pole clamps Dispose of used batteries environmentally Development of gas BPR 50 52 D3 BPR 55 52 D 3 If possible remove the the plugs when recharg ing the battery to avoid the accumulation of highly explosive gases BPR 50 52 D3 BPR 55 52 D 3 Maintenance every month 5 12 Draining the fuel tank sludge and water Fire hazard When working on the fuel system do not use open fire do not smoke Do not spill any fuel do not breath in any fuel fumes For this work the fuel tank should contain only very little fuel Fig 59 e Place a suitable container under the fuel drain
44. ur frequently due to the fact that the machine has not been properly operated or serv iced Therefore whenever a fault occurs read through these instructions on correct operation and maintenance If you cannot locate the cause of the fault or eliminate it yourself by following the trouble shooting charts you should contact our customer service departments at our branch office or dealers On the following pages you will find a selection of fault remedies It is quite obvious that we were not able to list all possible causes for faults 58 BOMAG BPR 50 52 D3 BPR 55 52 D 3 6 2 Engine problems Trouble shooting Fault Possible cause Remedy Engine does not start or does not start immediate ly but can be cranked with the crank handle Throttle lever in stop or idle speed position no fuel at the injection pump insufficient compression incorrect valve clearance Valves worn Wear on cylinder or piston rings Injection nozzle out of order Shift the lever to Start position Fill in fuel check the entire fuel system systematical ly If no result check supply to engine check fuel filter check function of fuel lift pump Check valve clearance correct if neces sary see shop manual see shop manual see shop manual additionally on engines with mechanical oil pressure moni toring no oil pressure Check oil level Activate mechanical oil pressure monitor ing
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