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7.2 Changing the injection pump

WARNING!
Fire hazard!

When working on the fuel system do not use open fire,

do not smoke, do not spill any fuel.

WARNING!
Health hazard!

Do not inhale any fuel fumes.

NOTICE!

Ensure strict cleanliness to keep dirt out of the fuel

lines. Dirt particles can destroy the injection system.

ENVIRONMENT!

Catch running out fuel, do not let it seep into the

ground.

Remove the air filter console

Fig. 65.

Remove the valve cover

Fig. 66.

Disassembly

Fig. 65

Trouble shooting

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Содержание BOMAG BPR 25/40 D

Страница 1: ...ting Instruction Maintenance Instruction Original Operating Instructions S N 101 692 51 S N 101 692 70 S N 101 692 53 09 2013 Catalogue No 008 083 21 www discount equipment com G o t o D i s c o u n t...

Страница 2: ...e needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco...

Страница 3: ...e fuel level 53 6 6 4 Filling the water tankOptional equipment 54 6 7 Weekly maintenance 55 6 7 1 Check clean the water separator 55 6 8 Maintenance every month 56 6 8 1 Check clean the air filter rep...

Страница 4: ...uble shooting 73 7 1 General notes 74 7 2 Changing the injection pump 75 7 3 Engine problems 80 8 Disposal 83 8 1 Final shut down of machine 84 Table of contents BPR 25 40 D BPR 25 50 D 4 G o t o D i...

Страница 5: ...1 Foreword Foreword BPR 25 40 D BPR 25 50 D 5 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 6: ...if it is used for purposes other than those mentioned in these instructions No warranty claims can be lodged in case of damage resulting from n operating errors n insufficient maintenance and n wrong...

Страница 7: ...onditions specified in the general terms of business of BOMAG We wish you successful work with your BOMAG machine BOMAG GmbH Copyright by BOMAG Please fill in Machine type Fig 1 Serial No Fig 1 and 2...

Страница 8: ...Fig 2 Fig 3 Foreword BPR 25 40 D BPR 25 50 D 8 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 9: ...2 Technical data Technical data BPR 25 40 D BPR 25 50 D 9 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 10: ...E 140 kg 309 lbs Basic weight 137 kg 302 lbs Water sprinkling system Optional equipment 13 kg 29 lbs Transport wheels Optional equipment 4 kg 9 lbs Travel characteristics Working speed 25 m min 82 ft...

Страница 11: ...rting device Recoil starter Recoil starter Drive system mechanical mechanical Exciter system Frequency 85 Hz 5100 vpm Centrifugal force 25 kN 5620 lbf Filling capacities Fuel diesel 3 0 l 0 8 gal us W...

Страница 12: ...weight 142 kg 313 lbs Water sprinkling system Optional equipment 13 kg 29 lbs Paving plate Optional equipment 14 kg 31 lbs Transport wheels Optional equipment 4 kg 9 lbs Travel characteristics Working...

Страница 13: ...t to technical alterations The following noise and vibration data acc to EC Machine Regulation edition 2006 42 EC the noise regulation 2000 14 EG noise protection guideline 2003 10 EC Vibration Protec...

Страница 14: ...rotection means ear defenders before starting operation Hand arm vibration Vector total of the weighted effective acceleration in three orthog onal directions Weighted total vibration value BPR 25 40...

Страница 15: ...3 Safety regulations Safety regulations BPR 25 40 D BPR 25 50 D 15 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 16: ...ndling work Should the recommendations in these instructions be different from the regulations valid in your country you must comply with the safety regulations valid in your country This machine must...

Страница 17: ...e the responsibilities must be clearly specified and complied with Persons under the influence of alcohol medicine or drugs are not allowed to operate service or repair the machine Maintenance and rep...

Страница 18: ...ly be attached and hoisted by an expert capable person Fasten the lifting gear only at the specified lifting points Check lifting eye for damage before use Do not use a damaged or in any other way imp...

Страница 19: ...adequate supply of fresh air when starting and operating in closed rooms and trenches Operate the machine only with the steering rod folded down Guide the machine only by the steering rod Guide the m...

Страница 20: ...y marked container and dispose of environmentally Working on the fuel system Do not inhale any fuel fumes Avoid open fire do not smoke do not spill any fuel Catch running out fuel do not let it seep i...

Страница 21: ...he battery and cover the fuel tank with insulating material Keep safety stickers in good condition and legible and follow their meaning Replace damaged and illegible safety stickers Safety stickers on...

Страница 22: ...cker Lifting point 4 Information sticker Throttle lever 5 Information sticker Travel lever 6 Information sticker Guaranteed sound capacity level 7 Maintenance sticker 8 Brief operating instructions Sa...

Страница 23: ...Maintenance sticker Engine Fig 7 Safety regulations BPR 25 40 D BPR 25 50 D 23 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 24: ...4 Display and control elements Display and control elements BPR 25 40 D BPR 25 50 D 25 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 25: ...on thoroughly before starting any operation on the machine Here all functions are described in detail The section Operation contains only brief descriptions of the indi vidual control steps Display an...

Страница 26: ...n Recoil starter n Lever for water sprinkling systemOptional equipment Position a Sprinkling system switched off Position b Sprinkling through rear spray bar Position c Sprinkling through front spray...

Страница 27: ...5 Operation Operation BPR 25 40 D BPR 25 50 D 29 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 28: ...s machine you should thoroughly read chapter Indicators and control elements before starting work All indicators and control elements are described in detail in this chapter Operation BPR 25 40 D BPR...

Страница 29: ...he machine on ground as level as possible Cleaning the machine Check condition of engine and machine fuel tank and fuel lines for leaks screw joints for tight fit For a description of the following ta...

Страница 30: ...2 Fig 12 Fold down the steering rod so that it can swing freely Adjust the steering rod with the height adjustment 1 to the height of your body Fig 12 Operation BPR 25 40 D BPR 25 50 D 32 G o t o D i...

Страница 31: ...starting check the starter rope for chafing replace if necessary A damaged rope can break and cause injuries during starting Do not use starting aid sprays or other inflammable fluids for starting Alw...

Страница 32: ...starter handle hit back but guide it back If the engine does not start during the first attempt repeat the starting process Set the throttle lever to position MIN Fig 17 Run the engine warm for appro...

Страница 33: ...ays return the throttle lever to idle speed position this avoids premature wear of the centrifugal clutch Set the throttle lever Fig 18 to position MAX Push the travel lever Fig 19 forward until the v...

Страница 34: ...he travel lever position Move the travel lever Fig 21 to middle position the machine will vibrate on the spot Keep shifting the throttle lever Fig 22 between MIN and MAX positions At the same time pul...

Страница 35: ...emperature equali zation Shift the throttle lever to position MIN Fig 23 and let the engine run with idle speed for a short while Vibration is shut down Set the throttle lever Fig 24 to position STOP...

Страница 36: ...k it Engage the locking pin securely Remove the spring cotter Fig 25 and pull the transport wheels out of the bracket on the steering rod Stand at the side of the machine Tilt the machine forward by t...

Страница 37: ...f the base plate and secure it with the spring cotter Unlock the steering rod and fold it down Fig 29 Lock the steering rod in working position Engage the locking pin securely The machine can now be m...

Страница 38: ...maged or in any other way impaired lifting eye Do not lift or lower the machine jerkily The tension must always be effective in vertical direc tion The machine must not swing about when being lifted D...

Страница 39: ...ehicle Lash the vibratory plate down to the transport vehicle so that it is secured against rolling sliding and turning over Fasten the lashing tackle at the marked lashing points Fig 31 Operation BPR...

Страница 40: ...6 Maintenance Maintenance BPR 25 40 D BPR 25 50 D 43 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 41: ...ters in a separate waste container and dispose of environmentally The lifetime of the diesel engine depends to a great extent on the cleanliness of the fuel Keep fuel free of contaminants and water si...

Страница 42: ...ne manufacturer Operating errors Incorrect inadequate maintenance If you cannot locate the cause of a fault or rectify it yourself by fol lowing the trouble shooting chart you should contact our custo...

Страница 43: ...and ensure strict cleanliness when filling in The fuel provision should always be topped up in due time so that the tank will not run dry The following fuel specifications are permitted n EN 590 n BS...

Страница 44: ...to 45 C 23 F to 113 F SAE 10W 40 0 C to 40 C 32 F to 104 F SAE 30 15 C to 30 C 59 F to 86 F SAE 10W 5 C to 5 C 23 F to 41 F SAE 40 20 C to 35 C 68 F to 95 F Fuel Diesel Winter diesel fuel 3 0 l 0 8 g...

Страница 45: ...l consumption will drop to the normal level after approx 100 to 200 operating hours After 25 operating hours Change the engine oil Check engine and machine for leaks Retighten the fastening screws on...

Страница 46: ...months X 6 8 2 Clean the cooling fins and the cooling air intake openings X 6 9 1 Check the oil level in the exciter housing X 6 9 2 Check the V belt tension if necessary replace the V belt X 6 9 3 C...

Страница 47: ...as required 6 10 6 Check the hydraulic oil level X 6 10 7 Check the rubber buffers X 6 11 1 Tighten all bolted connec tions X 6 11 2 Engine conservation X Maintenance BPR 25 40 D BPR 25 50 D 51 G o t...

Страница 48: ...jet directly into the cooling air openings of the recoil starter into the dry air filter or on electrical equipment Fig 33 After wet cleaning run the engine warm to evaporate all water residues and to...

Страница 49: ...do not use open fire do not smoke do not spill any fuel Do not refuel in closed rooms Shut down the engine WARNING Health hazard Do not inhale any fuel fumes NOTICE For quality and quantity of fuel r...

Страница 50: ...r can block the nozzles Fill only with clean water If there is a risk of frost the water sprinkler system must be emptied or filled with an anti freeze mixture Open the water tank Fig 36 and fill in c...

Страница 51: ...he water separator depends on the water proportion in the fuel and the care that is execised when refuelling Place the transparent container Fig 37 under the drain plug Loosen the screw for approx 3 t...

Страница 52: ...Use a new air filter Incorrectly handled air filters may be ineffective because of damage e g cracks and cause damage to the engine In case of wet or oily dirt replace the filter element Do not run t...

Страница 53: ...8 2 Clean the cooling fins and the cooling air intake openings WARNING Danger of injury Always wear protective clothes goggles gloves when working with compressed air NOTICE Dirty operating condition...

Страница 54: ...nto the air filter and on electrical equipment On a oil contaminated engine use a cold cleansing agent for cleaning After a sufficient soaking time clean off with a water or steam jet and blow out wit...

Страница 55: ...plug 2 and check the oil level The oil level must reach the bottom edge of the drain bore If the oil level is too low top up oil immediately Clean oil drain and bleeding screw and assemble both screw...

Страница 56: ...Reassemble the previously removed spacers Install and fasten the front V belt pulley tightening torque 35 Nm 26 ft lbs Install and fasten the guard tightening torque 15 Nm 11 ft lbs Install the top V...

Страница 57: ...et it seep into the ground and dispose off environmentally Screw the oil dipstick out of the oil filler opening Unscrew the oil drain plug and catch running out old oil Fig 45 Clean the oil drain plug...

Страница 58: ...housing Fig 46 WARNING Danger of injury Always wear goggles when working with compressed air Blow the engine oil filter out with compressed air from inside to outside Check the seal 1 for damage chan...

Страница 59: ...interval to change the fuel filter depends on the cleanliness of the fuel If necessary this service must be performed every six months ENVIRONMENT Catch running out fuel do not let it seep into the g...

Страница 60: ...ng the starter rope Unscrew the fastening screws 1 Fig 48 and pull the recoil starter 2 from the engine housing Pull the starter rope with the starter handle 1 out completely Fig 49 Secure the coil 2...

Страница 61: ...Fig 52 The rope is thereby wound on the coil Test function and light movement of the recoil starter by pulling the starter handle Mount the recoil starter to the engine housing 6 10 5 Change the oil i...

Страница 62: ...y Fill in fresh engine oil through the drain opening Fig 54 Park the machine on level ground Check the oil level The oil level must reach the bottom edge of the drain bore Clean oil drain 2 Fig 55 and...

Страница 63: ...od with height adjustment Fig 56 so that the area with the level inspection plugs is horizontal Unscrew the plug Hold the travel lever in forward position Fig 57 Check whether the hydraulic oil level...

Страница 64: ...crew Fig 60 Wait until all air has escaped then tighten the bleeding screw Fill in hydraulic oil to approx 40 mm 1 6 in below the edge of the filler opening Fig 61 Filling up hydraulic oil Fig 59 Fig...

Страница 65: ...the rubber buffers Check all rubber buffers Fig 63 for tight fit cracks and damage and replace immediately if damaged Fig 62 Fig 63 Maintenance BPR 25 40 D BPR 25 50 D 69 G o t o D i s c o u n t E q u...

Страница 66: ...ine oil and fill in anti corrosion engine oil Drain the fuel from the fuel tank mix it well with 10 anti cor rosion oil and fill it in again Instead of mixing anti corrosion oil with the fuel it is al...

Страница 67: ...e API MIL classification before taking the machine into service Anti corrosion oils are those that comply with the MIL L 21260 or TL 9150 037 2 resp Nato Code C 640 642 Mark a machine with a conserved...

Страница 68: ...7 Trouble shooting Trouble shooting BPR 25 40 D BPR 25 50 D 73 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 69: ...nsufficient maintenance Whenever a fault occurs you should therefore thoroughly read these instruction on correct oper ation and maintenance If you cannot locate the cause of a fault or rectify it you...

Страница 70: ...TICE Ensure strict cleanliness to keep dirt out of the fuel lines Dirt particles can destroy the injection system ENVIRONMENT Catch running out fuel do not let it seep into the ground Remove the air f...

Страница 71: ...out fuel Remove the injection nozzles Fig 68 completely with the nozzle base Disassemble the crankcase ventilation grommet Fig 69 Unscrew the oil shut off valve Fig 70 Fig 66 Fig 67 Fig 68 Fig 69 Fig...

Страница 72: ...injection pump Unscrew the pressure valve holder 1 Fig 73 with O ring 2 Remove filling piece 3 spring 4 seal ring 5 and pressure valve 6 Fig 71 Fig 72 Fig 73 Trouble shooting BPR 25 40 D BPR 25 50 D...

Страница 73: ...ment over the entire control range Replace damaged or worn parts Assemble shim 8 Fig 75 Insert the pump element Fig 76 observe correct posi tioning of the suction hole tapered bore Fig 75 and ele ment...

Страница 74: ...k the position of the starting slot to the suction bore visible through the bore the plug is screwed into The starting slot must be arranged centrally to the suction bore or may be maximum one slot wi...

Страница 75: ...ses power and speed Fuel tank empty Fill in fuel Throttle lever does not stay in selected position Tighten the nuts Fuel filter clogged Change the fuel filter Tank ventilation blocked Check the tank v...

Страница 76: ...he bleeding valve Engine runs with high speed but no vibration Centrifugal clutch defective Change the centrifugal clutch V belt Check tension replace if neces sary Trouble shooting BPR 25 40 D BPR 25...

Страница 77: ...8 Disposal Disposal BPR 25 40 D BPR 25 50 D 83 G o t o D i s c o u n t E q u i p m e n t c o m t o o r d e r y o u r p a r t s...

Страница 78: ...l fuels and lubricants do not let them seep into the ground and dispose of in compliance with legal regulations Empty the fuel tank Drain lubrication oil from engine and exciter housing Drain off hydr...

Страница 79: ...e needs We sell worldwide for the brands Genie Terex JLG MultiQuip Mikasa Essick Whiteman Mayco Toro Stone Diamond Products Generac Magnum Airman Haulotte Barreto Power Blanket Nifty Lift Atlas Copco...

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