Bagela BA 7000F User manual

B
B
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®
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Bagela Baumaschinen GmbH&Co
Gottlieb-Daimler-Str. 5
24568 Kaltenkirchen
Tel: [phone]
Fax:[phone]
e-mail: [email protected]
GERMANY
Gülzer Straße 6
19258 Boizenburg
Tel: [phone]
Fax: [phone]
e-mail: [email protected]
GERMANY
Bagela
Operating instructions
Spare part list
Asphaltrecycler
BA 10000

Bagela
BagelaBagela
Bagela

asphalt recycler
asphalt recyclerasphalt recycler
asphalt recycler
BA 7000F / BA 10000
BA 7000F / BA 10000BA 7000F / BA 10000
BA 7000F / BA 10000



Index
1 Safety Instructions for Asphalt Recyclers 1
2 Operating instruction - short version 2
3 General Description 4
4 Procedure for reprocessing broken-up asphalt slabs 4
4.1 Set-up of recycler for stationary operation 4
4.2 Start-up 5
4.3 Charging 5
4.4 Burner operation 5
4.5 Discharging 6
4.6 Work interruption 6
4.7 Drum cleaning 6
5 Procedure for reprocessing milling asphalt (asphalt fines) 7
5.1 Setting up of the recycler 7
5.2 Charging 7
5.3 Discharging 7
6 Trouble shooting diagram for light oil burner 8
7 Maintenance instructions 10
Attachment

Bagela
BagelaBagela
Bagela

asphalt recycler
asphalt recyclerasphalt recycler
asphalt recycler
BA 7000F / BA 10000
BA 7000F / BA 10000BA 7000F / BA 10000
BA 7000F / BA 10000



1
1 Safety Instructions for Asphalt Recyclers
1. Before putting the recycler into operation, familiarise yourself fully with all parts of the
machine and its functions.
2. Carefully read the operating instructions issued by the manufacturer.
3. Before starting the recycler, check if all protective guards and devices are in place and in
good working order.
4. Before starting the recycler, check if all operating controls and safety devices function
properly.
5. If safety devices are out of order or if there are any other shortcomings, which may
interfere with the safe operation of the recycler, inform your supervisor immediately.
6. If there are any faults, which may interfere with safe operation, shut down the recycler
immediately.
7. Do not leave the recycler at the end of the working day unless you have switched off the
engine and secured the asphalt recycler against accidental movement or unauthorised
use.
8. Before operation, put up the recycler where it does not interfere with the regular road
traffic. If necessary, ensure that the traffic flow is bypassed.
9. Do not undertake any repair or maintenance work with the recycler running unless
specifically required for resettings and/or readjustments.
10. After any repair or maintenance work, make sure all protective guards and devices have
been refitted properly.
11. The recycler should be inspected for good operation by a duly qualified mechanic at least
once a year.

Bagela
BagelaBagela
Bagela

asphalt recycler
asphalt recyclerasphalt recycler
asphalt recycler
BA 7000F / BA 10000
BA 7000F / BA 10000BA 7000F / BA 10000
BA 7000F / BA 10000



2
2 Operating instruction - short version
Setting-up of asphalt recycler:
- Before uncoupling the recycler from the towing vehicle, put chocks against the wheels and
apply the hand brake.
- Let the rear props down to the ground and secure them with pins.
- With the aid of the spirit level at the chassis, level out the recycler into horizontal position by
turning down the forward propping jacks.
- Do not place the unit below overhead power lines, parts of buildings or trees to avoid fires.
Putting recycler into operation:
- Start engine and bring it to full speed.
- Engage the tumbler driving system.
Burner operation:
- Caution! Do not start the burner unless the tumbler is turning.
- Set burner to 1st firing stage (switch position 2).
- After about 2 minutes, when the flame has stabilised, set burner to 2nd firing stage (switch
position 3).
- Set thermostat to the required temperature.
I. first burner stage max. 180°C: red pointer
II. second burner stage max. 150°C: green pointer
Charging:
- Fill asphalt into the recycler until the reading of the hydraulic oil pressure gauge is
- at 80 bar for processing asphalt lumps, or
- at 60 bar for processing asphalt fines.
DO NOT OVERFILL THE TUMBLER TO AVOID EXCESSIVE SMOKE EMISSION!
Discharging:
At the beginning of asphalt reprocessing there may be a delay in true temperature reading
due to the fact that the temperature of the charge is measured via the soak heat.
- Make sure the first batch of reprocessed asphalt is discharged 10 minutes after start-up,
irrespective of the temperature reading.
Warning: Load becomes inflammable, should sojourn duration dwell.
- During continuous operation, keep the contents of the tumbler to a level corresponding to
80 bar (for asphalt lumps) or 60 bar (for asphalt fines) on the hydraulic oil pressure gauge,
keep the burner firing at its maximum rate (second stage) and discharge the reprocessed
asphalt continuously.
Stopping operation:
- Switch off the burner (to stage 1 – burner fan blowing)
- Make sure the tumbler is empty.
- Stop the tumbler drive so that the outlet gate is in low position.
- Leave the engine running and the burner fan blowing (burner switch on 1) until the tumbler
has cooled down to 100 °C.
Type of oil to be used: light fuel oil. Consumption rate: 5 kg/t

Bagela
BagelaBagela
Bagela

asphalt recycler
asphalt recyclerasphalt recycler
asphalt recycler
BA 7000F / BA 10000
BA 7000F / BA 10000BA 7000F / BA 10000
BA 7000F / BA 10000



3
BA 7000F:
BA 10000:
Control lever for self-drive only for recyclers with extra-outfit self-drive.
lever for self-drive
right side
backward ⇐⇒forward
lever for self-drive
left side
backward ⇐⇒forward
lever for discharge
gate lever for charging box
⇑lift
⇓lower
lever for mixing drum
⇑left
⇓right
lever for discharge
gate
lever for self-drive
right side
forward ⇐⇒backward
lever for self-drive
left side
forward ⇐⇒backward
lever for charging box
⇑lower
⇓lift
1. stage 2. stage
lever for mixing drum
⇑right ⇑on
⇓left

Bagela
BagelaBagela
Bagela

asphalt recycler
asphalt recyclerasphalt recycler
asphalt recycler
BA 7000F / BA 10000
BA 7000F / BA 10000BA 7000F / BA 10000
BA 7000F / BA 10000



4
3 General Description
The asphalt recyclers BA 7000F and BA 10000 may be used for reprocessing cold asphalt
mix (fines, milling asphalt) and broken-up asphalt slabs of sizes up to 300 mm by 400 mm by
100 mm (BA 10000: 400x500x100). Thicker slabs should be broken down to lumps of 300
mm side lengths.
Do not fill more than 1100 kg into the tumbler of the BA 7000F (BA 10000: 2000 kg), which
corresponds to 80 bar on the hydraulic oil pressure gauge.
Transport:
- Adjust the drawbar so that the recycler is in horizontal position and the permitted supporting
load will not be exceeded.
4 Procedure for reprocessing broken-up asphalt slabs
4.1 Set-up of recycler for stationary operation
- Before uncoupling from the towing vehicle, secure the recycler against accidental
movement by chocks and applying the hand brake.
- Let the rear props down to the ground and secure them with pins.
- With the aid of the spirit level at the chassis, level out the recycler into horizontal position by
turning down the forward propping jacks.
- Do not place the recycler below overhead power lines, parts of buildings or trees to avoid
fires.
- Top up fuel oil for the burner and diesel for the engine.
- Check the engine oil level and top up if required.
Attention: Use clean fuel only. At temperatures below zero add a suitable fuel flow
improver. Never start the engine and the burner while the recycler is being
moved.

Bagela
BagelaBagela
Bagela

asphalt recycler
asphalt recyclerasphalt recycler
asphalt recycler
BA 7000F / BA 10000
BA 7000F / BA 10000BA 7000F / BA 10000
BA 7000F / BA 10000



5
4.2 Start-up
- For engine start-up see separate operation instruction.
- To attain the voltage required for starting the oil burner, push the accelerator lever up
against its maximum stop.
- Engage the tumbler;
upper position = forward mode
middle position = neutral
lower position = reverse mode, lever must be held down
THE POSITION OF THE OPERATING LEVER CORRESPONDS TO THE TURNING
DIRECTION OF THE TUMBLER.
- Before reversing the tumbler, make sure it is revolving at slow speed.
- To avoid excessive shocks on the structure due to unbalance in the tumbler, never move
the lever abruptly and in a jerky manner. However, any shocks due to rough treatment will
be absorbed by the shock valves.
4.3 Charging
- Fill asphalt lumps into the recycler until the hydraulic oil pressure gauge shows approx. 80
bar.
DO NOT OVERFILL THE RECYCLER TO AVOID EXCESSIVE SMOKE EMISSION.
4.4 Burner operation
Caution: Do not start the burner unless the tumbler is turning.
- Set burner to 1st firing stage (switch position 2).
- After about 2 minutes, when the flame has stabilised, set burner to 2nd firing stage (switch
position 3).
- Set thermostat to the required temperature.
I. first burner stage max. 180°C: red pointer
II. second burner stage max. 150°C: green pointer

Bagela
BagelaBagela
Bagela

asphalt recycler
asphalt recyclerasphalt recycler
asphalt recycler
BA 7000F / BA 10000
BA 7000F / BA 10000BA 7000F / BA 10000
BA 7000F / BA 10000



6
4.5 Discharging
At the beginning of the asphalt reprocessing there may be a delay in true temperature
reading due to the fact that the temperature of the charge is measured via the soak heat.
-Make sure that the first batch of reprocessed asphalt is discharged 10 minutes after start-
up, irrespective of the temperature reading.
Warning: Load becomes inflammable, should sojourn duration dwell.
- During continuous operation, keep the contents of the tumbler to a level corresponding to
80 bar on the hydraulic oil pressure gauge and keep the burner firing at its maximum rate
(second stage) and discharge the reprocessed asphalt continuously
Opening and closing of the discharge gate:
The discharge gate is mechanically opened and closed via the hydraulic tumbler drive by
moving a control rod to either stop.
Open the gate: by pushing the control rod in; the tumbler operates in reverse mode
Close the gate: by pulling the control rod out; the tumbler operates in forward mode
Attention: To open or close the discharging mouth , the drum of the BA 10000 may only
rotate in speed level 1!
4.6 Work interruption
- If the work is to be interrupted for up to thirty minutes, discharge the tumbler to one third or
half of its contents, close the discharge gate, keep the tumbler turning and the burner firing
at low rate (first stage)
- If the work is to be interrupted for more than 30 minutes, discharge the tumbler completely
and switch off burner and engine
- At continuous operation keep the contents of the tumbler at a level corresponding to 80 bar
on the hydraulic oil pressure gauge, keep burner operation at maximum rate and discharge
the reprocessed asphalt continuously.
- Fill asphalt lumps into the recycler until the reading of the hydraulic oil pressure gauge is 80
bar and in case of asphalt fines at 60 bar.
4.7 Drum cleaning
- To make sure that all asphalt lumps in the tumbler are thoroughly heated through, close the
discharge gate and keep the contents tumbling for five minutes at the first burner firing
stage.
- Then open the discharge gate and, with the aid of the forward propping jacks, lower the
discharge end of the recycler to ensure complete discharge
- Remove any stones trapped in the tumbler by fully opening the discharge gate and the
grating (manually)
- Close the grating and the discharge gate, keep engine and burner fan running until the
tumbler has cooled down to 100°C.
- Finally switch of burner and engine and shut down the recycler.

Bagela
BagelaBagela
Bagela

asphalt recycler
asphalt recyclerasphalt recycler
asphalt recycler
BA 7000F / BA 10000
BA 7000F / BA 10000BA 7000F / BA 10000
BA 7000F / BA 10000



7
5 Procedure for reprocessing milling asphalt (asphalt fines)
(differs from procedure for reprocessing broken-up asphalt lumps)
5.1 Setting up of the recycler
With the aid of the spirit level at the chassis, level out the recycler by turning the forward
propping jacks into such a position that the discharge end is slightly raised above the
horizontal (half a bubble in the spirit level).
5.2 Charging
Attention: Charge only asphalt fines which have been stored in a dry place!
- Charge the recycler continually to keep the contents at a constant level corresponding to
about 60 bar on the hydraulic pressure gauge.
DO NOT OVERFILL THE RECYCLER TO AVOID EXCESSIVE SMOKE EMISSION.
5.3 Discharging
- Open discharge gate half-way.
- Discharge the reprocessed asphalt continuously at a ratio equal to the charging rate.
- If the temperature of the tumbler contents rises above normal, open the discharge gate a
little more and lower the discharge end by means of propping jacks.
- If the temperature falls, close the discharge gate further and raise the discharge end.

Bagela
BagelaBagela
Bagela

asphalt recycler
asphalt recyclerasphalt recycler
asphalt recycler
BA 7000F / BA 10000
BA 7000F / BA 10000BA 7000F / BA 10000
BA 7000F / BA 10000



8
6 Trouble shooting diagram for light oil burner
TROUBLE OBSERVED INSTRUMENT READING POSSIBLE CAUSES CORRECTION
General trouble incorrect basic adjustment check basic settings
check power supply
Motor of burner does not turn stage 1 no power supply check power supply
operate overload switch at generator
Burner on, but no flame
malfunction lamp burns vacuum gauge exceeds 0,4 bar filter blocked replace filter cartridge clean filter strainer
vacuum gauge remains below
0,4 bar
pressure gauge does not rise
pump entrains air fill fuel oil tank
replace O-rings
check suction line for leaks
shut vent cock
vacuum gauge remains below
0,4 bar photosensor gets outside light push photosensor into bushing, glass side should be towards tumbler
pressure gauge at: nozzle blocked replace nozzle
13 bar - BA 7 / 16 bar - BA 10 no ignition spark check transformer, cables and ignition
electrodes;
replace ignition electrodes
solenoid valve defective check plug for proper seating; check and,
if necessary, replace solenoid valve
incorrect voltage check generator voltage 230V 50Hz;
tense V-belt
adjust engine speed
oil firing control defective replace oil firing control
Burner on, flame on, but goes
out again vacuum gauge below 0,4 bar pressure gauge at: photosensor defective check connection of photosensor if necessary replace photosensor
malfunction lamp burns 13 bar - BA 7 / 16 bar - BA 10 incorrect burner head
adjustment check basic settings
oil firing control defective replace oil firing control

Bagela
BagelaBagela
Bagela

asphalt recycler
asphalt recyclerasphalt recycler
asphalt recycler
BA 7000F / BA 10000
BA 7000F / BA 10000BA 7000F / BA 10000
BA 7000F / BA 10000



9
TROUBLE OBSERVED INSTRUMENT READING POSSIBLE CAUSES CORRECTION
Burner on, flame on and out at
intervals temp. control setting too low safety thermostat actuates set green pointer to 150 ° C set red pointer to 180° C
charge the tumbler
malfunction light not on vacuum gauge exceeds 0,4 bar fuel starvation replace filter cartridge and clean filter
strainer
screw off pump cover and clean pump
strainer
Burner on, flame on and out at
intervals
malfunction light on
vacuum gauge below 0,4 bar
pressure gauge oscillates below:
13 bar - BA 7 / 16 bar - BA 10
fuel starvation
pump entrains air fill up fuel oil tank replace O-rings
check suction line for tightness
vacuum gauge below 0,4 bar
pressure gauge below: fuel starvation set pump pressure to 13 bar - BA 7 or 16 bar - BA 10
13 bar - BA 7 / 16 bar - BA 10 replace pump
Burner on, flame on but tears incorrect air setting check basic setting
off move jet pipe slightly forward or backward
reduce air intake by turning adj. ring
Burner on, flame on in stage 1,
but goes off in stage 2
after a while, the same
happens again
malfunction light remains off
vacuum gauge below 0,4 bar
pressure gauge:
13 bar - BA 7 / 16 bar - BA 10
air in pressure line unscrew pressure line at control cylinder ,
switch on burner, flame goes on and out
after long intervals; as soon as fuel oil
flows out without air bubbles, close
pressure line
too much air intake close air flap of stage 2 a little
Black smoke comes out of the
burner too little air intake increase air intake
Blue smoke comes out of the
burner too much air intake decrease air intake

Bagela
BagelaBagela
Bagela

asphalt recycler
asphalt recyclerasphalt recycler
asphalt recycler
BA 7000F / BA 10000
BA 7000F / BA 10000BA 7000F / BA 10000
BA 7000F / BA 10000



10
7 Maintenance instructions
- As soon as the pointer of the filter fouling indicator moves into the first red field (-0,3 to –0,4
bar), discard the fouled filter and insert a new one.
- If the filter gets clogged up frequently, clean the fuel tank.
- For engine maintenance see separate operating instructions.
- For burner maintenance see separate operating instructions
- Change the hydraulic oil and filter once a year.
- Relubricate the chain and sprocket drive before each operation.
- Relubricate the four tumbler rollers every 20 operating hours.

Bagela
BagelaBagela
Bagela

asphalt recycler
asphalt recyclerasphalt recycler
asphalt recycler



Attachment
I. EC-Declaration of Conformity
II. Technical Data
III. Two-Stage-Oil-Burner
IV. Hydraulic Diagram
V. Electric diagram
VI. Lighting system

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
asphalt recycler
asphalt recyclerasphalt recycler
asphalt recycler



EC-Declaration of Conformity
acc. 98/37/ EEC
Bagela Baumaschinen GmbH & CO.
Gottlieb-Daimler-Straße 5
D-24568 Kaltenkirchen / Germany
Tel.: [phone]
Name and address of
manufacturer: Bagela Baumaschinen GmbH & CO.
Gottlieb-Daimler-Straße 5
D-24568 Kaltenkirchen / Germany
Tel.: [phone]
Fax.: [phone]
Description: Designation:
Type:
Output:
Ident. No.:
Asphalt Recycler
BA
4 - 10 t/h
W09..2KB13101 to W09..2KB13699
Legal provisions: 98/37/EEC Directive concerning legal regulations of member
states for machines
Harmonised
standards: EN 292 Part 1
EN 292 Part 2
EN 294
EN 349
Safety of machines; basic terminology, general
design principles
Safety of machines; basic terminology, general
design principles
Safety of machines; safety clearances from
dangerous points
Safety of machines; safety clearances to avoid
personal injuries
National standards
and technical
specifications:
UVV-VBG 1 Basic national regulations
Signature:
Kaltenkirchen, 12.Dec.01
D. Marquardt

Bagela
BagelaBagela
Bagela

asphalt recycler
asphalt recyclerasphalt recycler
asphalt recycler



Type: BA 10000
Serial No.: W09A102052KB13201
Drive engine: 4-cyl. diesel engine, electricstart
Power: 20 kW
Heating: Two-Stage-Oil-Burner
Thermostatic control
Effect 400 kW
Fuel light fuel oil
Consumption approx. 5 kg/to
Generator 220 V / 2 kVA
Output up to max. 10 to/h
Drum filling approx. 2000 kg
A-sound level (medium value at a
distance of 7 m and 1 m height)
idle running 61 dB(A)
max. speed 74 dB(A)
Chassis tandem-chassis
electric brake
height adjustable draw bar
ring eye (DIN)
admissible weight 5000 kg
coupling height 650-1250 mm
tyres 215/70 R17,5
Length 5400 mm
Width 2000 mm
Height 2100 mm
Weight: 4400 kg

Two-Stage-Oil-Burner
EO-B 45-Z / H
(Special construction
for BAGELA Asphalt-Recycler)
Technical Information

Content
Burner components
and their function 2
Technical Data 4
General Instructions 5
Maintenance of the Oilburner 6
Instructions Pump Type Suntec 7
2 Technical Information
Burner components and their function
The EO-B 45-Z /H is a special designed 2-stage
oil-burner to heat the BAGELA Asphalt-Recycler
BA 10000.
The burner casing is manufactured from Silumin.
Fuel-pump and E-motor are flanged to the casing.
Both are coupled with an elastic PERBUNAN-
shaft.
The fan sucts the combustion air via the inlet-sy-
stem through the basket-typ design of the pump-
coupling. Under full-load capacity (burner operati-
on position "3" on the switch board) the combusti-
on-air-supply is adjustet via the air inlet-system.
Under part-load (burner operation position "2" on
the switch board) the air-supply is reduced through
a steering cylinder which moves the damper at the
air supply. The opening angle of the damper is pre-
adjusted with the adjusting screw at the steering
cylinder (see Fig. 1). During operation the air flow
is steered automatically from the pressure in the
fuel pipe. The cylinder is de-aerated before supply.
If needed, it can be de-aerated on site with the aim
of the screw connection on the pressure side.
To operate the burner at both stages the fuel
supply to the two nozzles takes place via 3
magnetic valves (see Fig. 1). A safety valve
(MV1a) and the 2 further valves MV1b and MV2,
which releases the fuel flow. Under full-load mode
the release of the magnetic valve MV2 opens
simultaneously the steering cylinder including the
damper, which releases the total air flow to the
combustion head. At the first start-up or at restart
after a refilled storage tank, all fuel tubes can be
de-aerated by opening the magnetic valve MV3
(see Fig. 1). Procedure: Press trouble light switch
till the light shines. MV3 is open. After about 4 min.
press trouble light switch again. Trouble light dims
out. The burner is in full function again.
The high quality precision-draft-tube is manu-
factured from stainless steel. It is fixed with 2
screws to the burner casing. The nozzle holder is
fitted inside co-axally. For individuell adjustment an
axial positioner device is fitted at the passage of
the burner case.
The burner operation is steered and controlled
through the control box, which is connected to the
burner with a plug cable. The proper flame
operation itself is controlled via a foto-cell.
Domestic gas oil or diesel fuel is
recommended as fuel with cloud points ≤- 1°C
to avoid paraffinic crystals.

Description
EO-B 45-Z / H (Bagela) 3
Components
1. Flame cone
2.
3.
4.
5.
Fan housing
Fan weel
Motor
Pump
6.
7.
8.
9.
Shrouded disc
Nozzle
Ignition transformer
Nozzle assembly
10. Air intake 18.
11.
12.
Air damper
Connecting pipe Stage 1
13.
14.
Connecting pipe Stage 2
Solenoid valves
19.
20.
21.
15.
16.
Nozzle assembly adjustment
Connecting pipe, pump -
17.
adjustment device
Adjustment device, Nozzle
assembly adjustment
Photoresistor
Drive coupling
Conical shield plate
Ignition electrodes

Technical Data
4 Technische Information
O
utput range and Nozzles recommended
Burner Oil capacity
kg Output kW Mcal/h Nozzle Monarch mounted Pump pressure bar
EO-B 45-Z /H 8,5 - 45,5 101 - 540 87 - 464 for 1. stage: 5,0 - 60° R
for 2. stage: 2,75 - 60° R 14
Burner head

General Instructions
ADJUSTMENT OF BURNER
The burner is from the factory pre-set to an average
value. A final adjustment on site can be necessary.
To adjust the combustion device, start by increasing
the air volume and the nozzle assembly somewhat.
When the burner starts it is burning with excess air
and smoke number 0. Reduce the nozzle assembly
adjustment until soot occurs, and then increase the
adjustment to make the soot disappear again. Then
the volume of air is reduced until soot occurs and in-
creased again to reach a combustion free of soot.
By this procedure an optimum adjustment is ob-
tained.
A whistling sound maybe heard which can be elimi-
nated or reduced as follows: Increase the nozzle as-
sembly adjustment somewhat. The CO2-content
and consequently the air volume will then be redu-
ced.
ADJUSTMENT OF NOZZLE ASSEMBLY
Adjust the nozzle assembly with the adjustment
screw D to the desired position.
AIR ADJUSTMENT
First stage:
Set the operating switch on low capacity (burner
operation position "2"). Loosen the screw (A) and
turn the damper to the position wanted. Tighten the
screw (A) again.
Second stage:
Set the operating switch on high capacity (burner
operation "3"). Screw the knurled ring (B) in (redu-
ce) or out (increase). The position of the damper
can be read on the damper scale (C).
Check the air adjustment by making a flue gas ana-
lysis.
EO-B 45-Z / H (Bagela) 5
29 mm