BOMAG BPR 50/52 D-3, BPR 55/52 D-3 vibratory plate Operating instructions

Operating instructions
Maintenance instructions
%35'%35'
S/N 101 690 27 ....> Hatz
9LEUDWRU\SODWH
Catalogue number
)RUHZRUG
These BOMAG - machines are products from
the wide product range of BOMAG compaction
equipment. BOMAG’s vast experience, coupled with the most modern production and
testing methods, such as lifetime tests of all
important components and highest quality demands, ensure highest reliability of your machine.
To comply with the technical development we
reserve the right of modifications without prior
notification.
Using these instructions will
Information for the correct use of our machines in
earth and asphalt construction is also available
from your BOMAG-dealer.
F oreword
●
help you to become acquainted with the machine.
●
avoid faults caused by unprofessional operation.
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.
The notes mentioned above do not constitute an
extension of the warranty and liability conditions,
which are part of the general terms of business of
BOMAG.
Observing the maintenance instructions will
●
increase the reliability of the machine during
use on site,
We wish you much success with your BOMAG
machine.
●
prolong the lifetime of the machine,
BOMAG GmbH & Co. OHG
●
reduce repair costs and downtime.
Printed in Germany
Copyright by BOMAG
BOMAG does not assume liability for the function
of the machine
●
if the machine is handled in a way, which does
not comply with the use it is intended for,
●
if it is used for purposes other then the ones
mentioned in these instructions.
No warranty claims can be lodged for damage resulting from
●
operating errors,
●
insufficient maintenance and
●
the use of wrong fuels and lubricants.
Please note!
This manual was written for operators and maintenance 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 engineering 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 genuine BOMAG spare parts.
BPR 50/52 D3 - BPR 55/52 D-3
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Please fill in
............................
Machine type (Fig. 1)
............................
Serial No. (Fig. 1 and 2)
............................
Engine type (Fig. 3)
............................
Engine No. (Fig. 3)
L
Note
Fig. 1
Fill in the above listed data when receiving the machine.
Upon receipt of the machine our organization will
instruct you about correct operation and maintenance.
Please observe strictly all safety regulations and
notes on potential dangers!
Fig. 2
Fig. 3
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Table of Contents
7HFKQLFDO'DWD
6DIHW\UHJXODWLRQV
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3.1 General notes
18
3.2 Controls
18
2SHUDWLRQ
4.1 General
22
4.2 Before starting work
22
4.3 Folding the steering rod down
23
4.4 Starting/stopping the engine, manual starting
23
4.5 Starting/stopping the engine/electric starter
29
4.6 Starting with jump wires
31
4.7 Work/operation
32
4.8 Loading
34
0DLQWHQDQFH
5.1 General notes on maintenance
36
5.2 Fuels and lubricants
37
5.3 Table of fuels and lubricants
38
5.4 Running-in instructions
39
5.5 Maintenance chart
40
5.6 Cleaning machine/engine
41
5.7 Checking the fuel level
41
5.8 Checking the engine oil
42
5.9 Checking the dry air filter
42
5.10 Cleaning the dry air filter
43
5.11 Checking the condition of the battery, greasing the poles
44
5.12 Draining the fuel tank sludge and water
45
5.13 Checking the oil level in the vibrator housing
46
5.14 Changing engine oil and engine oil filter
46
5.15 Checking, tightening, changing the V-belt
47
5.16 Checking, adjusting the valve clearance
49
5.17 Cleaning cooling fins and cooling air intake openings
49
5.18 Changing the fuel filter
51
5.19 Changing the oil in the vibrator housing
51
5.20 Check the hydraulic oil level
52
5.21 Checking the rubber buffers
54
5.22 Checking the condition of the machine and the tight fit of all screws
55
5.23 Engine conservation
55
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6.1 General notes
58
6.2 Engine problems
59
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Table of Contents
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BPR 50/52 D3 - BPR 55/52 D-3
1 Technical Data
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Fig. 4
Dimensions in mm
BPR 50/52 D-3 - BPR 55/52 D-3
H
850
*
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
H1
1070
L
1890
L1
900
W
520
W1
660
W2
820
BPR 50/52 D-3
BPR 55/52 D-3
kg
kg
446
463
446
463
kg
473
473
Hatz
1D 41 S
Air
4
1
5,8
3400
Crank handle
Diesel
mechanical (V-belt)
Hatz
1D 41 S
Air
4
1
5,8
3400
kW
rpm
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Diesel
mechanical (V-belt)
BPR 50/52 D3 - BPR 55/52 D-3
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BPR 50/52 D-3
BPR 55/52 D-3
m/min
%
°
0...24
30
20
0...22
30
20
Vibration system
Frequency
Amplitude
Hz
mm
62
1,8
75
1,2
Filling capacities
Fuel tank capacity
Engine
Vibrator system
l
l
l
4
1,1
1
4
1,1
1
Travel characteristics
Working speed
max. gradability
Permissible inclination
*
The right for technical modifications remains reserved
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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:
LpA = 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 (L WA).
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/sec2 for high amplitude and 6.7 m/sec2 for low amplitude.
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2 Safety regulations
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General
This BOMAG machine is built in accordance
with the latest technical standard and the valid
technical rules and regulations. However, dangers for persons and property may arise from
the machine if it is:
●
put to unintended use,
●
operated by untrained personnel,
●
modified or altered in an unprofessional way,
●
the applicable safety regulations are not observed.
Maintenance and repair tasks require specific
knowledge and must therefore only be carried out
by trained and qualified personnel.
Furthermore the following regulations and instructions are obviously also valid:
all applicable instructions for the prevention of
accidents,
●
generally acknowledged safety and road traffic
regulations,
●
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 unprofessional way or if it is used for purposes other than
those mentioned in these instructions.
14
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, medication or drugs must not operate, service or repair
the machine.
Each person involved in operation, maintenance and repair of the machine must therefore read and apply these safety regulations. If
necessary this should be confirmed by obtaining the signature of the customer.
●
Who is allowed to work with the machine?
Conversions and alterations to the machine
Unauthorized conversions to the machine are prohibited for safety reasons.
Original parts and accessories have been specially designed for this machine. We wish to make expressly clear that we have not tested or authorized
any original parts or special equipment not supplied by us. The installation and/or use of such
products can impair the active and/or passive driving 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 maintenance instructions:
Danger
Paragraphs marked like this highlight possible
dangers for persons.
Caution
Paragraphs marked this way highlight possible dangers for machines or parts of the machines.
L
Note
Sections marked like this provide technical information concerning the optimal economical use of
the machine.
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Environment
Sections marked like this highlight activities
for the safe and environmental disposal of fuels and lubricants as well as replaced parts.
Operation
Safety stickers on the machine
Watch out for unusual noises and development of
smoke. Perform trouble shooting and have the
fault corrected.
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.
Keep safety stickers in good condition and legible
and follow their meaning.
Operate the machine only with full engine speed,
as otherwise the centrifugal clutch will be destroyed.
Replace damaged and illegible safety stickers.
Loading the machine
Do not let the machine run unattended.
Secure the machine against turning over or slipping off.
Parking the machine
Persons are highly endangered if they
●
step under loads being lifted or
●
stand under loads being lifted
Park the machine on level, firm ground.
Before leaving the machine:
Secure the machine on the transport vehicle
against rolling off, slipping and turning over.
●
park the machine so that it cannot turn over,
●
shut the engine down.
Mark machines, which could be in the way, with a
clearly visible sign.
Starting the machine
Before starting
Filling the fuel tank
Become acquainted with the equipment, the control elements, the working principle of the machine
and the working area.
Refuel only with the engine shut down.
Do not refuel in closed rooms.
No open fire, do not smoke.
Wear your personal protective outfit (hard hat,
safety boots, etc.). Wear ear defenders.
Do not spill any fuel. Catch running out fuel, do not
let it seep into the ground.
Before starting the machine check whether:
●
the machine shows any obvious faults
●
all guards and safety elements are in place
●
the controls are fully functional
Maintenance work must only be carried out by
qualified and authorized personnel.
●
the machine is free of oily and combustible
material
Keep unauthorized persons away from the machine.
●
all grips are free of grease, oils, fuel, dirt, snow
and ice.
Do not perform service work while the engine is
running.
Maintenance
Use only machines which are serviced at regular
intervals.
If possible, park the machine on level and firm
ground.
Do not use any starting aids like start pilot or ether.
Working on the engine
For starting move your feet out of the danger zone
of the base plate.
Drain the engine oil at operating temperature danger of scalding!
Starting in closed rooms
Wipe off spilled oil, catch running out oil and dispose of environmentally.
Exhaust gases are highly dangerous! Always ensure an adequate supply of fresh air when starting
in closed rooms!
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Store used filters and other oil containing materials
in a specially marked container and dispose of environmentally.
Exhaust gases are highly dangerous! Always ensure an adequate supply of fresh air when starting
in closed rooms!
Working on electric components
Mark defective machines by attaching a warning
note to the steering handle.
Before starting to work on electric components disconnect the battery and cover it with insulating material.
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 respective 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 running.
Do not use gasoline or other combustible substances 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 instructions for this work.
16
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3 Indicators and Controls
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3.1
General notes
3.2
Controls
Please read this section thoroughly before operating 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 descriptions of the individual operating steps.
Fig. 5
Locking lever (Fig. 5).
Fig. 6
Height adjustment (Fig. 6) of steering rod.
L
Note
Pull the locking lever up to fold the steering rod
down.
18
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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 buzzer.
Turn the ignition key to position "I" warning buzzer
on.
Then turn the ignition key further to position "II" to
start the engine.
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4 Operation
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4.1
General
If you are not yet acquainted with the controls
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 described in detail in this chapter.
4.2
Before starting work
Please observe strictly the safety regulations
in chapter 2 of these operating and maintenance instructions.
Refer also to the detailed description in the
chapter "Maintenance".
Top up missing fuels and lubricants according to
the respective maintenance instruction.
●
Stand the machine on level ground.
●
Check fuel tank and lines for leaks.
●
Check the engine oil level, if necessary top up
to the upper mark.
●
Check the fuel level, if necessary top up.
●
Check the dry air filter maintenance indicator.
●
Check the condition of the entire machine and
check the screw connections for tight fit.
Danger
Loss of hearing!
Wear your personal noise protection equipment (ear defenders) before starting operation.
22
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4.3
Folding the steering rod
down
4.4
Danger
Danger of injury!
L
Starting/stopping the engine, manual starting
Note
The engine is equipped with a low oil level safety
device, which interrupts the fuel flow to the injection pump. The engine will stop.
Shock by spring force!
The steering rod is resilient in operating position.
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 section ”initial start-up”)
On engines with electric starter switch the ignition
on, so that the battery is being charged.
Caution
The low oil level safety device does not release
the operator from his duty to check the oil level
every day!
Danger
Danger of accident!
Fig. 9
●
Pull locking the lever (Fig. 9) up and fold the
rod down, so that steering rod can swing freely.
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 machine.
Do not run the engine in closed or poorly ventilated rooms.
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Fig. 11
Fig. 10
On machines with electric starter turn the ignition switch (Fig. 10) to position "I".
●
Press the hand lever (Fig. 11) for approx. five
seconds against the spring.
●
The engine is ready for starting.
L
Note
With the ignition switch in position "I" the battery is
being charged when the engine is running.
Normal starting
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.
●
Check the oil level, if necessary fill up to the
“MAX”- mark.
●
Check the fuel level, if necessary fill in fuel
Fig. 12
Pull the decompression lever (Fig. 12) in direction of arrow to the end stop.
●
The compression lever clicks noticeably into
place.
L
Note
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.
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If the compression lever is not pushed all the way
to the end stop in direction ”Start”, the engine
might be decompressed, but is not ready for starting. This position is used to turn the engine free at
low ambient temperatures.
L
Note
When the decompression lever returns to initial
position the highest speed must be reached.
As soon as the engine starts pull the crank
handle out of the guide.
●
Fig. 13
Fig. 15
Set the throttle lever (Fig. 13) to position
"MAX" (full speed).
●
●
Set the throttle lever (Fig. 15) to position "MIN"
(idle speed).
●
Before taking up work run the engine warm for
approx. 1 to 2 minutes.
Shift the travel lever to position "0".
●
Cold starting
L
Note
At temperatures below -5 °C perform the following
work.
Danger
Do not use any starting aids like start pilot or
ether.
Fig. 14
Insert the crank handle (Fig. 14).
●
Danger
Stand in correct position to the engine and ensure correct grip of the crank handle.
●
Turn the crank handle slowly, until the catch
engages.
●
Turn the crank handle with increasing speed,
until the engine starts. Do not interrupt the frictional connection.
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Fig. 16
●
Set the throttle lever (Fig. 16) to position
"MAX" (full speed).
●
Shift the travel lever to position "0".
Fig. 18
●
Insert the crank handle (Fig. 18).
●
Crank the engine several times in decompressed condition (turn it free), until it can be
cranked lightly.
Fig. 17
●
Fig. 19
Pull the decompression lever (Fig. 17) only a
fraction in direction of arrow.
●
To turn the engine free you should not pull the decompression lever all the way to the end stop in
starting position.
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Press the hand lever (Fig. 19) for approx. five
seconds against the spring.
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Fig. 20
Fig. 22
Pull the protection cover (Fig. 20) off the dosing device. Fill in engine oil to the top, reattach
the cover and press it firmly in.
●
L
Note
Danger
Stand in correct position to the engine and ensure correct grip of the crank handle (Fig. 22).
●
Turn the crank handle slowly, until the catch
engages.
●
Turn the crank handle with increasing speed,
until the engine starts. Do not interrupt the frictional connection.
Max. 2 fillings after each other.
L
Note
Hold the crank handle with a tight grip during the
starting process.
Fig. 21
●
Pull the decompression lever (Fig. 21) in direction of arrow to the end stop.
Fig. 23
Set the throttle lever (Fig. 23) to position "MIN"
(idle speed).
●
L
Note
If the engine does not start repeat the starting
process.
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Fig. 24
Attach the crank handle (Fig. 24).
●
Caution
Before taking up work let the engine warm up
at idle speed for a short while (not longer than
5 minutes).
Fig. 26
●
Set the throttle lever (Fig. 26) to position
"STOP".
The engine stops and the warning buzzer sounds.
Shutting the engine down
Caution
Do not shut the engine down all of the sudden
from full speed, but let it idle for a while for
temperature equalization.
Fig. 27
●
Turn the ignition key to position "0" (Fig. 27)
and pull it out.
●
The warning buzzer stops to sound.
Fig. 25
●
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.
Fig. 28
●
28
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Set the fuel valve (Fig. 28) to STOP (closed).
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4.5
Starting/stopping the engine/electric starter*
Starting the engine
L
Note
The engine is started electrically, instead of turning a crank handle.
The engine is equipped with a low oil level safety
device, which interrupts the fuel flow to the injection pump. The engine will stop.
Fig. 29
●
Shift the travel lever (Fig. 29) to position "0".
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 previous section ”initial start-up”)
Caution
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 seconds wait at least 15 seconds before trying
again.
Fig. 30
●
Danger
Danger of accident!
Set the throttle lever (Fig. 30) to position
"MAX" (full speed).
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 machine.
Do not run the engine in closed or poorly ventilated rooms.
Do not insert the crank handle into the crankshaft.
Fig. 31
●
*
Set the fuel valve (Fig. 31) to O.K. (open).
Optional equipment
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Shutting the engine down
Caution
Do not shut the engine down all of the sudden
from full speed, but let it idle for a while for
temperature equalization.
Fig. 32
Turn the ignition key (Fig. 32) to position "I".
●
The warning buzzer sounds.
L
Note
The warning buzzer sounds with the engine at rest
and the ignition switched on, the battery is not being charged in this condition!
●
Turn the ignition key to position "II", the starter
will crank the engine.
●
As soon as the engine ignites return the ignition key to position "I".
●
Once the engine runs correctly reduce the engine speed.
Fig. 34
●
Shift the throttle lever to position "Min" (Fig.
34) and let the engine run with idle speed for a
short while.
Vibration is shut down.
Fig. 35
●
Set the throttle lever to position "STOP" (Fig.
35), the warning buzzer sounds.
Fig. 33
●
Run the engine warm for a short while before
starting work (Fig. 33).
●
Operation of the vibratory plate can be started
once the engine has warmed up for a while.
30
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Starting with jump wires
Note
Use this starting possibility only if the battery is discharged.
Remove the cover off the battery.
●
Caution
Wrong installtion will cause severe damage in
the electrical system.
Fig. 36
●
Turn the ignition key to position "0" and pull it
out.
The warning buzzer stops to sound.
Fig. 38
Fig. 37
●
●
Connect the plus pole of the external battery
with the plus pole of the starter battery with
one of the jump wires (Fig. 38).
●
Connect the minus poles of both batteries with
the other jump wire.
●
Start the engine as described before.
●
Once the engine is running disconnect the minus poles first and the plus poles after.
Set the fuel valve (Fig. 37) to STOP (closed).
L
Note
This avoids short circuits when touching the plus
wire with the minus wire.
●
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Reinstall the battery cover and lock the flap.
31
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4.7
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Work/operation
Note
Operation of the vibratory plate can be started as
soon as the engine responds to short throttle commands.
Danger
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 defenders).
Fig. 41
Set the throttle lever (Fig. 41) to position
"MAX".
●
Caution
Operate the vibratory plate only with full engine speed, as otherwise the centrifugal clutch
will be destroyed.
L
Note
For short breaks you should always return the
throttle lever to idle speed position, this avoids premature wear of the centrifugal clutch.
Fig. 39
●
Pull the locking lever (Fig. 39) up and fold the
steering rod down.
Fig. 42
●
Move the travel lever (Fig. 42) forward as required for the desired speed.
Fig. 40
●
32
Adjust the steering rod with the height adjustment (Fig. 40) to the height of your body.
%20$ *
BPR 50/52 D3 - BPR 55/52 D-3
2SHUDWLRQ
Fig. 43
Fig. 45
Move the travel lever (Fig. 43) backwards as
required for the desired speed.
●
The machine vibrates forward or backwards with a
speed, which is in accordance with the chosen
travel lever position.
L
●
Keep moving throttle lever (Fig. 45) between
"MIN" and "MAX" throttle position.
●
At the same time pull the vibratory plate by the
steering rod to the right and left, until it comes
free.
Note
If the machine moves forward with considerably
reduced speed, pull the travel lever completely
back and shift it forward again.
Danger
Danger of accident!
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
●
Lock the steering rod (Fig. 44) in the first locking position.
BPR 50/52 D3 - BPR 55/52 D-3
%20$ *
33
2SHUDWLRQ
4.8
Loading
Danger
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 being lifted.
Fig. 48
Always attach the lifting gear (rope) to the lifting eye to load the vibratory plate on a transport vehicle (Fig. 48).
●
Use only safe lifting gear of sufficient load
bearing capacity
Do not stand or step under loads being lifted.
Danger
Danger of accident!
Tie the machine down on the transport vehicle,
so that it is secured against slipping, sliding
and turning over!
Fig. 46
●
Adjust the steering rod (Fig. 46) in upright position and lock it in the last locking position.
Fig. 47
●
34
Fold the lifting hook (Fig. 47) up.
%20$ *
BPR 50/52 D3 - BPR 55/52 D-3
5 Maintenance
BPR 50/52 D3 - BPR 55/52 D-3
%20$ *
35
0DLQWHQDQFH
5.1
General notes on maintenance
When performing maintenance work observe the
applicable safety regulations and especially safety
regulations in chapter 2 of these operating, maintenance and repair instructions.
Clean machine and engine thoroughly before
starting maintenance work.
●
For maintenance work park the machine on
level ground.
●
Maintenance work must generally be carried
out with the engine shut down.
Do not draw off fuel from near the bottom of
the fuel drum.
●
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
Thorough maintenance of the machine ensures
maximum reliability and prolongs the lifetime of important 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.
●
●
Combustion air and fuel injection rates of the diesel engine have been carefully adjusted and determine 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 manufacturer.
Environment
During maintenance work catch all oils and fuels and do not let them seep into the ground.
Dispose of oils and fuel environmentally.
Notes on the fuel system
The lifetime of the diesel engine is decisively depending on the cleanliness of the fuel.
●
Keep the engine free of dirt and water as this
could damage the injection elements of the engine.
●
Zinc lined drums are not suitable for storing fuel.
●
The fuel drum should rest for a longer period
of time before drawing off fuel.
●
Under no circumstances must the drum be
rolled to the tapping pint just before drawing off
fuel.
●
When choosing the storage place for fuel,
make sure that spilled fuel will not cause any
damage.
●
Do not let the suction hose disturb the sludge
on the bottom of the drum.
36
%20$ *
BPR 50/52 D3 - BPR 55/52 D-3
0DLQWHQDQFH
5.2
Oil quality
Fuels and lubricants
You should preferably use oils of API-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.
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 temperature.
Lubrication oil change intervals
Oil change intervals with oil quality
For winter operation below -10 °C the oil change
intervals must be shortened.
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 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
Fig. 49
Lubrication oil with a too high viscosity index causes starting difficulties. The temperature when
starting the engine is therefore of highest importance when choosing the viscosity of engine oil for
winter operation.
Oil viscosity
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.
In most cases a sufficient cold resistance can also
be achieved by adding flow enhancing fuel additives. Consult the engine manufacturer.
Since lubrication 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 (SAEclass) (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
%20$ *
37
0DLQWHQDQFH
5.3
Table of fuels and lubricants
Assembly
Fuel or lubricant
Summer
Winter
Quantity approx.
Attention
Observe the level marks
Engine
Engine oil API: CD/SE or CD/SF
approx. 1,1 l
(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)
- Fuel
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°C to -10°C)
Diesel
Winter diesel fuel
4 l (1 USgal)
(-12°C) (+10.4°F)*
Vibrator shaft housing
38
as engine oil
%20$ *
1l
BPR 50/52 D3 - BPR 55/52 D-3
0DLQWHQDQFH
5.4
Running-in instructions
For the start-up or new machines of overhauled engines the following maintenance
work must be performed:
Caution
During the running-in period up to approx. 200
operating hours check the engine oil level two
times every day.
Depending on the engine load the oil consumption will drop to its normal level after a
running time of approx. 100 to 200 operating
hours.
After 25 operating hours
BPR 50/52 D3 - BPR 55/52 D-3
●
Change the engine oil.
●
Check engine and machine for leaks.
●
Check the valve clearance, adjust if necessary.
●
Retighten the fastening screws for air filter, exhaust silencer, fuel tank and other attachments.
●
Tighten the screw connections on the machine.
●
Check the vibration drive V-belt, retighten it if
necessary.
%20$ *
39
0DLQWHQDQFH
5.5
Maintenance chart
With all maintenance intervals perform also
the work for shorter preceding service intervals.
No.
Designation
Note
Daily maintenance
5.6
5.7
5.8
5.9
Cleaning machine/engine
Checking the fuel level
Checking the engine oil level
Checking the dry air filter
Monthly maintenance
5.10
5.11
5.12
Cleaning the dry air filter
Checking the battery condition, greasing the poles
Draining the sludge from the fuel tank
Maintenance every 6 months
5.13
5.14
5.15
5.16
5.17
Checking the oil level in the vibrator housing
Changing engine oil and oil filter
Checking, tensioning, replacing the V-belt
Checking, adjusting the valve clearance
Cleaning the cooling fins and the cooling air intake
openings
Annual maintenance
5.18
5.19
5.20
5.21
Changing the fuel filter
Changing the oil in the vibrator housing
Checking the hydraulic oil level
Checking the rubber buffers
As required
5.22
5.23
40
Checking the screw joints
Engine conservation
%20$ *
BPR 50/52 D3 - BPR 55/52 D-3
0DLQWHQDQFHHYHU\GD\
Maintenance every day
5.6
Cleaning machine/engine
5.7
Checking the fuel level
Danger
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. 50
Caution
Do not guide the water jet directly into the oil
bath air filter (Fig. 50) and into the opening for
the crankhandle.
●
After each cleaning run the engine warm to
evaporate all water and to avoid corrosion.
Fig. 51
Clean the area around the tank cover, screw
the tank cover (Fig. 51) off.
●
Caution
Dirty fuel can cause engine failures.
●
Fill in fuel through a strainer.
●
Screw the filler neck cover on again.
For quality of fuel refer to the table of fuels and
lubricants.
BPR 50/52 D3 - BPR 55/52 D-3
%20$ *
41
0DLQWHQDQFHHYHU\GD\
5.8
Checking the engine oil
5.9
Checking the dry air filter
Caution
Stand the machine on firm and level ground,
so that the engine is in horizontal position.
Fig. 53
●
Fig. 52
●
Shut the engine down.
●
Pull the oil dipstick (Fig. 52) out, wipe it with a
clean, lint-free cloth and reinsert it until it bottoms.
●
Pull the oil dipstick back out and read the oil
level.
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).
Nominal value:
The oil level must reach the upper mark. Top up oil
immediately if the oil level is too low.
For quality and quantity of oil refer to the table
of fuels and lubricants.
●
Check the seals on the oil dipstick, change if
necessary.
●
Push the oil dipstick in again until it bottoms.
42
%20$ *
BPR 50/52 D3 - BPR 55/52 D-3
0DLQWHQDQFHHYHU\PRQWK
Maintenance every m onth
5.10 Cleaning the dry air filter
●
Wipe the inside of the filter housing out with a
clean cloth.
●
Clean the cover with the cyclon pre-filter thoroughly.
Caution
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 covered with sooty dirt. Use a new filter cartridge.
Incorrectly handled filter cartridges can be ineffective 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. 55
Danger
Eye injuries!
Wear protective goggles.
●
Blow the filter cartridge (Fig. 55) out with dry
compressed air (max. 5 bar) from inside to outside.
Fig. 54
Slacken the wing nut 1 (Fig. 54) and take the
cover with the covering disc (2) and the air filter insert (3) off.
●
Caution
No dirt or foreign particles must enter the
clean air intake.
Fig. 56
●
Insert the filter cartridge 3 (Fig. 56) with the
covering disc (2) into the housing.
●
Install the filter cover (1) and ensure correct fit
of cover and seal (4).
●
Check the dry air filter (see previous paragraph)
Do not blow the inside of the filter housing out
with compressed air.
Change the filter cartridge if the maintenance indicator comes on again.
BPR 50/52 D3 - BPR 55/52 D-3
%20$ *
43
0DLQWHQDQFHHYHU\PRQWK
5.11 Checking the condition of
the battery, greasing the
poles
Danger
Danger of cauticization!
●
Clean the outside of the battery.
●
Clean battery poles and pole clamps and
grease them with pole grease (vaseline).
●
Check the fastening of the battery.
●
Check the condition of the vibration insulation
mats, change if necessary.
●
Lay the vibration insulation mats back in.
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.
Caution
Ensure correct fit of the vibration insulation
mats.
Close the cover again after servicing is completed.
●
Do not lay any tools on the battery.
Non-maintenance-free batteries
Caution
Top up missing fluid only with distilled water.
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
Fig. 57
●
Unscrew the fastening screws (Fig. 57) for the
covering flap and fold the cover down.
●
Take the vibration insulation mats off.
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 housing.
Maintenance-free batteries
Perform only the following points:
●
Check the battery for cleanliness.
●
Clean the poles.
●
Tighten the pole clamps.
Caution
Dispose of used batteries environmentally.
Fig. 58
●
44
Take the battery (Fig. 58) out and clean the
battery compartment.
Danger
Development of gas!
%20$ *
BPR 50/52 D3 - BPR 55/52 D-3
0DLQWHQDQFHHYHU\PRQWK
If possible remove the the plugs when recharging the battery, to avoid the accumulation of
highly explosive gases.
5.12 Draining the fuel tank
sludge and water
Danger
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.
L
Note
For this work the fuel tank should contain only very
little fuel.
Fig. 59
BPR 50/52 D3 - BPR 55/52 D-3
●
Place a suitable container under the fuel drain
fitting to catch running out fuel.
●
Unscrew the drain fitting 1 (Fig. 59) from underneath the fuel tank.
●
After draining the fuel screw the drain fitting
back in with a new sealing ring.
%20$ *
45
0DLQWHQDQFHHYHU\PRQWKV
Maintenance every 6 months
5.13 Checking the oil level in the
vibrator housing
L
Note
Stand the machine on level ground.
5.14 Changing engine oil and engine oil filter
Caution
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
Danger of scalding!
There is a danger of scalding when draining
hot engine oil.
Fig. 60
●
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.
●
46
Screw the level plug back in with a new seal
ring.
Fig. 61
●
Pull the dipstick (Fig. 61) out.
●
Unscrew the drain plug, drain and catch the
old oil.
●
Screw the plug with a new sealing ring back in.
%20$ *
BPR 50/52 D3 - BPR 55/52 D-3
0DLQWHQDQFHHYHU\PRQWKV
5.15 Checking, tightening,
changing the V-belt
Checking the V-belt
Fig. 62
●
Unscrew the filler neck cover 1 (Fig. 62).
●
Take the old filter element out and dispose of
environmentally,.
●
Check the O-ring (3), use a new one if necessary.
●
Install the new filter cartridge with the mark
"TOP" facing upwards and screw the cover on.
Fig. 64
●
Remove the V-belt guard.
●
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
Fig. 63
●
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.
●
●
Insert the oil dipstick and check the oil level
again.
Check drain plug and oil filler neck cover for
leaks after a short test run.
BPR 50/52 D3 - BPR 55/52 D-3
Fig. 65
●
Unscrew the fastening nuts 1 (Fig. 65) with
washers, take the V-belt pulley half (2) off.
●
Remove the necessary number of shims (3)
from between the pulley halves.
●
Put the V-belt pulley half (2) back on and add
the removed shims (4) from the outside.
%20$ *
47
0DLQWHQDQFHHYHU\PRQWKV
●
Screw the hexagon nuts (1) with the washers
back on and tighten them.
●
Crank the V-belt drive several times by hand
and check the compression measurement (approx. 5 mm) again, correct the tension if necessary.
Changing the V-belt
Remove the front V-belt pulley half (see "tightening the V-belt").
●
Fig. 67
●
Unscrew the fastening screws 1 (Fig. 67) and
take the cover (2) off.
●
Fit the new V-belt, install the cover (2), fasten
the engine carrier plate and tighten the V-belt
as described before.
●
Reinstall the V-belt guard.
Fig. 66
Caution
Check the V-belt tension again after approx. 25
operating hours, tighten if necessary.
Slacken the rear fastening screws 3 (Fig. 66)
on both sides for a few turns.
●
Danger
Danger of injury!
●
48
Unscrew two front fastening nuts (2) on both
sides, lift the front of the engine carrier plate up
and support it properly.
%20$ *
BPR 50/52 D3 - BPR 55/52 D-3
0DLQWHQDQFHHYHU\PRQWKV
5.16 Checking, adjusting the
valve clearance
L
5.17 Cleaning cooling fins and
cooling air intake openings
Note
L
Checks and adjustments must only be carried out
when the engine is cold (20 - 10 °C).
The decompression lever must be in initial position.
The gasket for the cylinder head cover must generally be changed.
Checking the valve clearance
Note
Dirty operating conditions, especially oil and fuel
deposits on the engine cooling fins and the cooling
air intake openings reduce the cooling power considerably. 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
●
Remove the cylinder head cover.
●
Crank the engine until compression resistance
can be felt.
Fig. 69
Clean all air guiding parts and the entire cooling air circulation area like cylinder head, cylinder and flywheel ventilator with a brush and
blow out with compressed air (Fig. 69).
●
Fig. 68
●
Check the valve clearance with a 0.1 mm feeler gauge on both valves 1 (Fig. 68) and correct
it if necessary.
Damp and oily dirt
Adjusting the valve clearance
●
Slacken the counter nut (3).
●
Adjust the setscrew (2) with a screwdriver so
that the feeler gauge fits through the gap with
only little resistance after tightening the counter nut.
Danger
Fire hazard!
Do not use any combustible solvents.
Caution
●
Reinstall the cylinder head cover with a new
gasket (4) and tighten the fastening screws
evenly.
Do not subject electrical assemblies and connectors to the direct water jet or dry them immediately after with compressed air.
●
Check the cover for leaks after a short test run.
Investigate the cause for the oil leak and call
the After Sales Service of BOMAG to seal all
leaks.
BPR 50/52 D3 - BPR 55/52 D-3
%20$ *
49
0DLQWHQDQFHHYHU\PRQWKV
Do not guide the water jet directly into the air
filter, the exhaust tube and the opening for the
crankhandle.
●
Disconnect the battery and remove the air
guide plates.
●
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 water jet.
●
Run the engine warm to avoid corrosion.
50
%20$ *
BPR 50/52 D3 - BPR 55/52 D-3
0DLQWHQDQFHHYHU\\HDU
Maintenance every year
5.18 Changing the fuel filter
5.19 Changing the oil in the vibrator housing
Danger
Fire hazard!
Caution
Catch the old oil, do not let it seep into the
ground and dispose of environmentally.
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.
●
Place a suitable container under the filter to
catch running out fuel.
●
Disconnect the fuel supply hose and drain the
fuel from the fuel tank.
Fig. 71
●
Unscrew the fastening nuts 1 (Fig. 71) for the
extension plates (2) and remove the plates
from both sides.
●
Tilt the machine slightly towards the oil drain
side and support it properly.
Fig. 70
●
Unscrew the hose clamp 1 (Fig. 70).
●
Pull the fuel filter (2) out of the upper and lower
hoses.
L
Note
If necessary flush the tank with clean diesel fuel.
●
Fit the new fuel filter and make surte that the
flow direction is correct.
●
Fill the fuel tank.
Fig. 72
BPR 50/52 D3 - BPR 55/52 D-3
●
Unscrew the drain plug (Fig. 72), drain and
catch all old oil.
●
Screw the drain plug with a new sealing ring
back in.
%20$ *
51
0DLQWHQDQFHHYHU\\HDU
5.20 Check the hydraulic oil level
Fig. 73
●
Unscrew the level plug (Fig. 73).
●
Stand the machine on level ground and fill in
approx. 1 litre of engine oil.
Fig. 75
●
For quality and quantity of oil refer to the table
of fuels and lubricants.
L
Adjust the steering rod (Fig. 75) in upright position and lock it in the last locking position of
the detent rail.
Note
The oil level must reach the lower edge of the level
bore.
●
Screw the level plug back in with a new sealing
ring.
Fig. 76
●
Unscrew the plug (Fig. 76).
●
Move the travel lever to reverse position and
hold it.
Fig. 74
●
52
Refit the extension plates 2 (Fig. 74). Cover
the fastening nuts (1) with OKS 240 copper
paste and tighten them with 900 Nm.
%20$ *
BPR 50/52 D3 - BPR 55/52 D-3
0DLQWHQDQFHHYHU\\HDU
After unscrewing the plug or level control plug
the steering rod head must always be depressurized as follows:
●
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.
●
Unscrew the plug, start the engine and run it
with maximum speed
●
Pull the travel lever back and hold it in this position
●
Screw the plug back in and release the travel
lever
●
Shut the engine down
Fig. 77
The hydraulic oil must reach the upper edge of
the splined shaft, top up if necessary (Fig. 77).
●
For quality of oil refer to the table of fuels and
lubricants.
Fig. 79
L
Caution
Tighten the plug with the specified tightening
torque.
Note
Lay a cloth down before slackening the venting
screw.
●
Hold the travel lever in reverse position.
●
Slacken the bleeding screw.
●
Wait until all air has escaped (Fig. 78).
●
Tighten the bleeding screw.
L
Tighten the plug (Fig. 79).
●
Fig. 78
Note
After bleeding check the hydraulic oil level, top up
if necessary.
BPR 50/52 D3 - BPR 55/52 D-3
%20$ *
53
0DLQWHQDQFHHYHU\\HDU
5.21 Checking the rubber buffers
Fig. 80
●
54
Check the condition and tight fit of the rubber
buffers (Fig. 80) on both sides, change if necessary.
%20$ *
BPR 50/52 D3 - BPR 55/52 D-3
$VUHTXLUHG
As r equired
5.22 Checking the condition of
the machine and the tight fit
of all screws
5.23 Engine conservation
If the engine is to be shut down for a longer period
of time (e.g. during winter) we recommend the following conservation measures for the engine to
avoid corrosion:
●
Clean the engine including the cooling system.
●
Run the engine until it is warm and shut it
down.
●
Drain the still warm engine oil and fill in anticorrosion engine oil.
L
Anti-corrosion oils are those that comply with the
specification MIL-L-21260 B or TL 9150-037/2 resp. Nato Code C 640/642.
Fig. 81
* Strength classes for screws with untreated, nonlubricated surfaces. The quality designations are
stamped on the screw heads.
The values result in a 90% utilization of the screws
yielding point at a coefficient of friction of total =
0.14.
●
Mix the fuel with anti-corrosion oil in a mixing
ratio of 1:4 (0.5 litres for 2 litres of fuel)
●
Run the engine for approx. 10 to 15 minutes
with this fuel mixture.
●
Take the V-belt off and spray the grooves of
the V-belt pulleys with anti-corrosion oil. Remove the anticorrosion oil before taking the
machine back into service.
The tightening torques are not valid when using
MOS2 lubricants.
As far as possible check the condition and fastening of all screws, pipes, clamps and other
attachments and engine fasteners.
●
Caution
Do not tighten the cylinder head fastening
screws.
●
Examine the machine for damage and leaks,
have repaired if necessary.
Note
L
Note
We do not recommend to run the engine during
this conservation time, as the engine might not
warm up properly and it will harm the conserving
agent.
The conserving oil may remain in the engine, but
has to be changed after 15 operating hours.
The mixing of anti-corrosion oil to the fuel can
cause a power drop of 15%.
When changing the conserving oil against normal
engine oil the engine does not have to be flushed.
BPR 50/52 D3 - BPR 55/52 D-3
%20$ *
55
$VUHTXLUHG
56
%20$ *
BPR 50/52 D3 - BPR 55/52 D-3
6 Trouble shooting
BPR 50/52 D3 - BPR 55/52 D-3
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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 maintenance instructions.
Faults occur frequently due to the fact, that the
machine has not been properly operated or serviced. 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.
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6.2
Engine problems
Fault
Possible cause
Remedy
Engine does not
start or does not
start immediately, but can be
cranked with the
crank handle
Throttle lever in stop or idle speed position
Shift the lever to “Start” position
no fuel at the injection pump
Fill in fuel
check the entire fuel system systematically.
If no result:
- check supply to engine
- check fuel filter
- check function of fuel lift pump
insufficient compression:
- incorrect valve clearance
Check valve clearance, correct if necessary
- Valves worn
see shop manual
- Wear on cylinder or piston rings
see shop manual
Injection nozzle out of order
see shop manual
additionally on
engines with
mechanical oil
pressure monitoring
no oil pressure
Check oil level
With low temperatures
Temperature below starting limit
Observe cold start instructions
Fuel slurry caused by insufficient low temperature resistance
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 mixture.
Activate mechanical oil pressure monitoring
Starting speed too low:
- oil with too high viscosity
Replace engine oil with oil of correct viscosity
- insufficiently charged battery
Check the battery, if necessary consult a
specialist workshop
BPR 50/52 D3 - BPR 55/52 D-3
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Fault
Possible cause
Remedy
The starter is not
switched on or
the engine does
not crank
Fault in the electric system:
Check electric equipment and related
components or consult the customer service of Bomag
- Battery or other cable connections not
correctly connected.
- Cable terminals loose or oxidised
- Battery defective or not charged
- Starter defective
- insufficiently charged battery
Engine ignites,
but does not
continue to run
when switching
the starter motor
off.
Engine shuts
down by itself
during operation
Fuel filter clogged
Replace the fuel filter
Fuel supply interrupted
check the entire fuel system systematically
Stop signal from monitoring elements
connected with the oil pressure monitoring facility:
- no oil pressure
Check oil level
Tank empty
Fill in fuel
Fuel filter clogged
Replace the fuel filter
The mechanical oil pressure monitoring
shuts the engine down because of a lack
off oil
Check the oil level, activate the oil pressure monitoring system
Mechanical defects
Engine looses
power and
speed
Engine looses
power and
speed, black exhaust smoke
60
Fuel supply restricted:
- Tank empty
Fill in fuel, activate the mechanical oil
pressure monitoring system
Fuel filter clogged
Replace the fuel filter
Insufficient tank ventilation
Ensure sufficient ventilation of the tank
Pipe connections leaking
Check line connections for leaks
Throttle lever does not stay in selected
position
Block the throttle control
Air filter dirty
Clean or replace the air filter
Incorrect valve clearance
Adjust the valve clearance
Injection nozzle out of order
see shop manual
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BPR 50/52 D3 - BPR 55/52 D-3
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Fault
Possible cause
Remedy
Engine overheating
Lubrication oil level in engine too high
Drain the engine oil down to the top mark
on the dipstick
Insufficient cooling
- Dirt in the entire area of the cooling air
flow
Clean the cooling air duct
- Air guide plates not completely closed
Check air guide plates for completeness
and good sealing
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