Bomag BT 60/4 User manual

Operating instructions
Maintenance instructions
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       
Catalogue No.
008 066 01 02/2010
BT 60/4 / BT 65/4
S/N 101 540 52 2391 > / S/N 101 540 53 4211 >
Vibratory Tampers

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BT 60/4, BT 65/4
F oreword
These BOMAG machines are products from
the wide product range of BOMAG machines
for earth and asphalt construction, refuse
compaction and stabilizing/recycling.
BOMAG’s vast experience in connection with
state-of-the-art production and testing meth-
ods, such as lifetime tests of all important
components and highest quality demands
guarantee maximum reliability of your ma-
chine.
This manual comprises:
●Safety regulations
●Operating instructions
●Maintenance instructions
●Trouble shooting
Using these instructions will
●help you to become familiar with the machine.
●avoid malfunctions caused by unprofessional
operation.
Compliance with the maintenance instructions will
●enhance the reliability of the machine on con-
struction sites,
●prolong the lifetime of the machine,
●reduce repair costs and downtimes.
BOMAG will not assume liability for the function of
the machine
●if it is handled in a way not complying with the
usual modes of use,
●if it is used for purposes other than those men-
tioned in these instructions.
No warranty claims can be lodged in case of dam-
age resulting from
●operating errors,
●insufficient maintenance and
●wrong fuels and lubricants.
Please note!
This manual was written for operators and mainte-
nance personnel on construction sites.
These operating and maintenance instructions are
part of the machine.
You should only operate the machine after you
have been instructed and in compliance with these
instructions.
Strictly observe the safety regulations.
Please observe also the guidelines of the Civil En-
gineering Liability Association ”Safety Rules for
the Operation of Road Rollers and Soil Compac-
tors” and all relevant accident prevention regula-
tions.
For your own personal safety you should only
use original spare parts from BOMAG.
In the course of technical development we re-
serve the right for technical modifications
without prior notification.
These operating and maintenance instructions are
also available in other languages.
Apart from that, the spare parts catalogue is avail-
able from your BOMAG dealer against the serial
number of your machine.
Your BOMAG dealer will also supply you with in-
formation about the correct use of our machines in
soil and asphalt construction.
The above notes do not constitute an extension of
the warranty and liability conditions specified in the
general terms of business of BOMAG.
We wish you successful work with your BOMAG
machine.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG

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BT 60/4, BT 65/4
Please fill in
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine type (Fig. 1)
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Serial-number (Fig. 1 and 2)
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine type (Fig. 3)
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine number (Fig. 3)
i
Note
Supplement the above data together with the com-
missioning protocol.
During commissioning our organisation will in-
struct you in the operation and maintenance of the
machine.
Please observe strictly the safety regulations and
all notes on risks and dangers!
Fig. 1
Fig. 2
Fig. 3

Table of Contents
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Table of Contents
  R
BT 60/4, BT 65/4

  Q
BT 60/4, BT 65/4
1 Technical Data

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BT 60/4, BT 65/4
Fig. 4
Dimensions in mm B H L L1 W
BT 60/4 350 960 735 335 280
BT 65/4 350 1000 735 335 280
*BT 60/4 BT 65/4
Weight
Basic weight kg 61 67
Operating weight (CECE) kg 62 68
Travel characteristics
Max. working speed (depending on soil) m/min 20 20
Max. areal output (depending on soil) m2/h 336 336
Drive
Engine manufacturer Honda Honda
Type GX 100 GX 100
Cooling Air Air
Number of cylinders 1 1
Displacement cm398 98
Rated power ISO 9249 kW 2.2 2.2
Rated speed rpm 4200 4200

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BT 60/4, BT 65/4
Exciter system
Drive system mechanical mechanical
Frequency Hz 10 – 11.8 10 – 11.8
Impact force kN 13.5 16.2
Filling capacities
Fuel tank l 3.0 3.0
Oil in tamper foot l 0.8 1.0
Engine oil l 0.3 0.3
* The right for technical modifications remains reserved
*BT 60/4 BT 65/4

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BT 60/4, BT 65/4
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 Protection Regulation 2002/44/EC
were determined during conditions typical for this type of equipment and by application of harmo-
nized standards.
During operation these values may vary because of the existing operating conditions.
Noise value
Sound pressure level on the place of the operator:
BT 60/4: LpA = 98 dB(A), determined acc. to ISO 11204 and EN 500
BT 65/4: LpA = 95 dB(A), determined acc. to ISO 11204 and EN 500
Guaranteed sound power level:
BT 60/4: LWA = 108 dB(A), determined acc. to ISO 3744 and EN 500
BT 65/4: LWA = 106 dB(A), determined acc. to ISO 3744 and EN 500
n
Danger
Loss of hearing!
Wear your personal noise protection means (ear defenders) before starting operation.
Vibration value
Hand-arm vibration:
Vector total of the weighted effective acceleration in three orthogonal directions:
Weighted total vibration value
BT 60/4 ahv = 9.3 m/sec2on crushed rock determined acc. to ISO 5349 and EN 500
BT 65/4 ahv = 9.0 m/sec2on crushed rock determined acc. to ISO 5349 and EN 500
o
Caution
Observe the daily vibration load (Industrial safety acc. to 2002/44/EEC).

  44
BT 60/4, BT 65/4
2 Safety regulations

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BT 60/4, BT 65/4
General
This BOMAG machine has been built in com-
pliance with the latest technical standard and
complies with the applicable regulations and
technical rules. However, dangers for persons
and property may arise from this machine, if:
●it is used for purposes other than the ones it is
intended for,
●it is operated by untrained personnel,
●it is changed or converted in an unprofessional
way,
●the safety instructions are not observed.
Each person involved in the operation, mainte-
nance and repair of the machine must there-
fore read and comply with these safety
regulations. If necessary, this must be con-
firmed by obtaining the signature of the cus-
tomer.
Furthermore, the following obviously also applies:
●applicable accident prevention instructions,
●generally accepted safety and road traffic reg-
ulations,
●country specific safety regulations. It is the
duty of the operator to be acquainted with
these instructions and to apply these accord-
ingly. This applies also for local regulations
concerning different types of handling work.
Should the recommendations in these instruc-
tions be different from the regulations valid in
your country, you must comply with the safety
regulations valid in your country.
Intended use
This machine must only be used for:
●Compaction of all types of soils
●Repair work in all types of soil
●Reinforcement of walkways
●Work in trenches
●Backfills and compaction of marginal strips
Unintended use
However, dangers may arise from this machine if
it is operated by untrained personnel or if it is sub-
jected of unintended use.
For example:
●Working in horizontal direction
●Ramming of poles
●Vibrating of paving blocks
It is not permitted to stand on the machine while
working.
Starting and operation of the machine in explosive
environments is prohibited.
Remaining dangers, remaining risks
Despite careful work and compliance with stand-
ards and regulations it cannot be ruled out that fur-
ther dangers may arise when working with and
handling the machine.
Both the machine as well as all other system com-
ponents comply with the currently valid safety reg-
ulations. Nevertheless, remaining risks cannot be
ruled out completely, even when using the ma-
chine for the purpose it is intended for and follow-
ing all information given in the operating
instructions.
A remaining risk can also not be excluded beyond
the actual danger zone of the machine. Persons
remaining in this area must pay particular attention
to the machine, so that they can react immediately
in case of a possible malfunction, an incident or
failure etc.
All persons remaining ion the area of the machine
must be informed about the dangers that arise
from the operation of the machine.
Regular safety inspections
Have the machine inspected by an expert (proper-
ly trained person) once every year.
Who is allowed to operate the ma-
chine?
The machine must only be operated by trained
and authorized persons which are at least 18
years of age. The responsibilities for the operation
of the machine are to be clearly specified and
complied with.
Persons under the influence of alcohol, medica-
tion or drugs must not operate, service or repair
the machine.

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BT 60/4, BT 65/4
Maintenance and repairs require very specific
knowledge and must therefore only be carried out
by trained and qualified personnel.
Conversions and alterations to the ma-
chine.
Unauthorized conversions to the machine are pro-
hibited for safety reasons.
Original parts and accessories have been special-
ly designed for this machine. We wish to make ex-
pressly clear that we have not tested or authorized
any original parts or special equipment not sup-
plied by us. The installation and/or use of such
products can impair the active and/or passive driv-
ing safety. The manufacturer expressly excludes
any liability for damage resulting from the use of
non-original parts or accessories.
Damage, deficiencies, misuse of safety
installations
Machines which are not safe to operate must be
immediately taken out of service and shall not be
used, until these deficiencies have been properly
rectified.
Safety installations and switches must neither be
removed nor must they be made ineffective.
Safety notes in the operating and main-
tenance instructions:
n
Danger
Sections marked like this point out possible
dangers for persons.
o
Caution
Sections marked like that point out possible
dangers for the machine or for parts of the ma-
chine.
i
Note
Sections marked like this provide technical infor-
mation concerning the optimal economical utiliza-
tion of the machine.
Loading the machine
Always shut the engine down to transport the
tamper or to lay it on its side.
Secure the machine against tipping over or slip-
ping off.
Persons are highly endangered if they step or
stand under a suspended load.
With the machine suspended be aware that the
machine may swing about.
Secure the machine on the transport vehicle
against rolling, slipping and turning over.
Starting the machine
Before starting
Become acquainted with the equipment, the con-
trol elements, the working principle of the machine
and the working area.
Wear your personal protective outfit (hard hat,
safety boots, etc.). Wear ear defenders.
Before starting the machine check whether:
●the machine shows any obvious faults
●all guards and safety elements are in place
●the controls are fully functional
●the machine is free of oily and combustible
material
●all grips are free of grease, oils, fuel, dirt, snow
and ice.
Use only machines which are serviced at regular
intervals.
Starting and operation of the machine is
closed rooms and trenches
Exhaust gases are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
and operating in closed rooms and trenches!
Operation
●Guide the machine and take care that you do
not hurt your hands on any obstructions, dan-
ger of accident.
●Watch out for unusual noises and the develop-
ment of smoke. Find the cause and have the
fault corrected.
●Do not hold the throttle lever in the area below
I, as this may damage the centrifugal clutch.
●Do not take your hands off the machine while
the engine is running.
●Keep your feet away from the tamper foot

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BT 60/4, BT 65/4
Parking the machine
Stand the machine on ground as level as possible.
Before leaving the machine:
●Secure the machine against tipping over.
Filling in fuel
Refuel only with the engine shut down.
Do not refuel in closed rooms.
No open fire, do not smoke.
Do not spill any fuel. Catch running out fuel, do not
let it seep into the ground.
Do not inhale any fuel fumes.
Avoid contact with skin and eyes.
Do not swallow.
Maintenance
Maintenance work must only be carried out by
qualified and authorized personnel.
Keep unauthorized persons away from the ma-
chine.
Do not perform maintenance work while the en-
gine is running.
Park the machine on level and firm ground.
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.
Do not breath in fuel fumes.
Working on the engine
When working on the fuel filter make sure that no
dirt falls into the air channel.
Do not work on the hot exhaust, risk of burns!
When working on the exhaust channel of the en-
gine make sure that no combustion residues fall
into the cylinder.
Do not touch the piston with the cleaning tools.
Working on the tamper foot
Wipe off spilled oil, catch running out oil and dis-
pose of environmentally.
Store oily material in a specially marked container
and dispose of environmentally.
Cleaning
Do not clean the machine while the engine is run-
ning.
Do not use gasoline or other inflammable sub-
stances to clean the machine.
When using steam cleaning equipment do not
subject electric parts and insulating material to the
direct water jet or cover them beforehand.
Do not guide the water jet directly into the air filter,
into the exhaust or into the air intake opening.
After the maintenance work
Reinstall all protective devices after completing
maintenance.
Repair
Repairs must only be carried out by qualified and
authorized personnel. Always follow our repair in-
structions.
Exhaust gases are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
in closed rooms!
Attach a warning tag to the steering bow if the ma-
chine is defective.
●Do not mix the nozzle in the carburettor up by
mistake.
●Adjust the idling speed regulator screw exact-
ly.
●Do not damage the blower wheel when work-
ing on the magnetic ignition.
●Always replace self locking nuts.
●Do not open the foot cover on the tamper foot,
spring tension. Danger of accident!
●Observe the prescribed tightening torques.
Information and safety stickers/decals
on the machine
Keep safety stickers in good and legible condition
(see parts manual) and comply with their meaning.
Replace damaged and illegible stickers/decals.

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BT 60/4, BT 65/4
Fig. 5
1 Brief operating instructions
2 Information sticker "Oil level" and instruction
sticker "Wear ear defenders"
3 Information sticker "Gasoline"
4 Information sticker "Lifting point"
5 Information sticker "Guaranteed sound capac-
ity level"
6 Warning sticker "Spring"

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BT 60/4, BT 65/4

  4Q
BT 60/4, BT 65/4
3 Indicators and Controls

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BT 60/4, BT 65/4
3.1 General notes
Please read this section thoroughly before operat-
ing this machine if you are not yet conversant with
the indicators and control elements. All functions
are described in detail hereunder.
Paragraph 4 Operation contains only concise de-
scriptions of the individual operating steps.
3.2 Controls
Fig. 6
No. 1 = Throttle lever
Fig. 7
No. 2 = Engine stop button
Fig. 8
No. 3 = Recoil starter

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BT 60/4, BT 65/4
Fig. 9
No. 4 = Fuel cock
Fig. 10
No. 5 = Choke lever

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