Bomag BT 60/4 Manual

Operating instructions
Maintenance instructions
Catalogue number
008 113 61 06/2005
BT 60/4 - BT 65/4
S/N 101 540 39 ... (EPA II)
S/N 101 540 49 ... (EPA II)
Vibratory Tamper
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Foreword
BOMAG 3BT 60/4, BT 65/4
Foreword
BOMAG machines are products from the wide
range of BOMAG compaction equipment.
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.
Using these instructions will
lhelp you to become familiar with the machine.
lavoid malfunctions caused by unprofessional
operation.
Compliance with the maintenance instructions will
lenhance the reliability of the machine on con-
struction sites,
lprolong the lifetime of the machine,
lreduce repair costs and downtimes.
BOMAG will not assume liability for the function of
the machine
lin case of manipulations which do not comply
with the type of use specified in the safety reg-
ulations,
lif 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
loperating errors,
linadequate maintenance,
lwrong fuels and lubricants.
Please note!
This manual was written for operators and mainte-
nance personnel on construction sites.
You should only operate the machine after you
havebeeninstructedandincompliancewiththese
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.
Theseoperating and maintenanceinstructions are
also available in other languages.
Your BOMAG dealer will also supply you with in-
formation about the correctuse of our machines in
soil and asphalt construction.
The above notes do not constitute an extension of
thewarrantyand liabilityconditionsspecifiedinthe
general terms of business of BOMAG.
We wish you successful work with your BOMAG
machine.
BOMAG GmbH
PrintedinGermany
Copyright by BOMAG
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Foreword
BOMAG4BT 60/4, BT 65/4
Please fill in
............................
Machinetype(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
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Table of Contents
BOMAG 5BT 60/4, BT 65/4
Technical Data 7
Safety regulations 11
Indicators and Controls 15
3.1 General notes 16
3.2 Controls 16
Operation 19
4.1 General notes 20
4.2 Tests before taking into operation 20
4.3 Filling in fuel 21
4.4 Starting the engine 21
4.5 Starting under cold weather conditions 23
4.6 Incorrect starting 24
4.7 Work/operation 24
4.8 Shutting the engine down 26
4.9 Changing the tamper foot plate 27
4.10 Loading and transport 27
Maintenance 29
5.1 General 30
5.2 Fuels and lubricants 30
5.3 Filling capacities 31
5.4 Running-in instructions 32
5.5 Maintenance chart 33
5.6 Cleaning the machine 34
5.7 Checking the bellows on the tamper 34
5.8 Check the engine oil level 35
5.9 Checking the fuel level, topping up fuel 36
5.10 Change the engine oil 37
5.11 Cleaning, checking the spark plug, replacing if necessary 38
5.12 Tamper foot plate 39
5.13 Check the oil level in the tamper foot 39
5.14 Check, adjust the valve clearance 40
5.15 Cleaning the fuel filter inside the tank 42
5.16 Oil change in tamper foot 43
5.17 Clean, change the double dry air filter cartridge 45
Trouble shooting 47
6.1 General notes 48
6.2 Engine problems 49
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BOMAG 7BT 60/4, BT 65/4
1 Technical Data
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Technical Data
BOMAG8BT 60/4, BT 65/4
Fig. 4
Dimensions in
mm H L L1 W
BT 60/4 960 735 335 280
BT 65/4 1000 735 335 280
*BT 60/4 BT 65/4
Weight
Basic weight kg 61 67
Operating weight (CECE) kg 62 68
Engine Honda Honda
Type GX 100 (EPA II) GX 100 (EPA II)
Cooling Air Air
Number of cylinders 1 1
Rated power ISO 9249 kW (PS) 2,5 (3,4) 2,5 (3,4)
Rated speed rpm 4200 4200
Capacities
Fuel tank l 3,0 3,0
Oil in tamper foot l 0,75 1,0
Engine oil l 0,33 0,33
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Technical Data
BOMAG 9BT 60/4, BT 65/4
Vibration
Frequency Hz 9-11,75 9 ... 11,75
Jumping height mm 60 70
Working speed (soil de-
pendent) m/min upto20 upto20
Max. areal output (de-
pending on soil) m2/h 336 336
Max. depth effect (de-
pending on soil) cm up to 55 up to 65
* The right for technical modifications remains reserved
*BT 60/4 BT 65/4
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Technical Data
BOMAG10 BT 60/4, BT 65/4
The following noise and vibration data acc. to
- EC Machine Regulation edition 98/37/EC and
- 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 operator’s stand:
LpA = 95.3 dB(A) BT 60/4, determined acc. to ISO 11204 and EN 500
LpA = 94,9 dB(A) BT 65/4, determined acc. to ISO 11204 and EN 500
Guaranteed sound capacity level:
LWA = 108 dB(A), determined acc. to ISO 3744 and EN 500
!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 ahw =8.1m/sec
2on crushed rock determined acc. to ISO 5349 and EN 500
BT 65/4 ahw =7,9m/sec
2on crushed rock determined acc. to ISO 5349 and EN 500
!
Caution
Observe the daily vibration load (Industrial safety acc. to 2002/44/EEC).
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BOMAG 11BT 60/4, BT 65/4
2 Safety regulations
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Safety regulations
BOMAG12 BT 60/4, BT 65/4
General notes
This BOMAG machine is built in accordance
with the state-of-the-art and the present techni-
cal rules and regulations. However, there is a
risk of danger for persons and property if:
lthe machine is used for purposes other than
those it is intended for
lthe machine is operated by untrained person-
nel
lthe machine is modified or converted in an un-
professional way
lthe applicable safety regulations are not ob-
served.
It is therefore of utmost importance that any
person involved in the operation, maintenance
and repair of the machine reads and applies
these safety regulations. This should be con-
firmed by obtaining the signatures of the cus-
tomer, if necessary.
Furthermore the following regulations and instruc-
tions are obviously also valid:
lapplicable accident prevention instructions
lgenerallyacknowledgedsafetyandroadtraffic
regulations
lcountry specific regulations.
Intended use
This machine must only be used for:
lCompaction of all types of soils
lRepair work in all types of soil
lReinforcement of walkways
lWork in trenches
lBackfills and compaction of marginal strips
Unintended use
Dangers may however arise from the machine if it
is operated by untrained personnel in an unprofes-
sional way or if it is unintentionally used.
Example:
lWorking in horizontal direction
lRamming of poles
lCompaction of interlocking paving stones
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.
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 orauthorized
any original parts or special equipment not sup-
plied by us. The installation and/or use of such
products canimpair the active and/or passive driv-
ing safety. The manufacturer expressly excludes
any liability for damage resulting from the use of
non-original parts or accessories.
Safety notes in the operating and main-
tenance instructions:
!Danger
Sections marked like this point out possible
dangers for persons.
!
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.
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Safety regulations
BOMAG 13BT 60/4, BT 65/4
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
Familiarize yourself with the equipment, the con-
trol elements,the working principle of the machine
and your working area.
Use your protective outfit (hard hat, safety boots
etc.). Wear ear defenders.
Check before starting whether:
lthe machine shows any obvious defects
lall protective devices are properly secured in
their place
lall control elements are fully functional
lthe machine is free of oily and combustible
material
lkeep all grips and handles free of grease, oils,
fuels, dirt, snow and ice.
Use only machines which have been regularly
serviced.
Starting in closed rooms
Exhaust fumes are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
in closed rooms!
Operation
lGuide the machine and take care that you do
not hurt your hands on any obstructions, dan-
ger of accident.
lWatch out forunusual noises and the develop-
ment of smoke. Find the cause and have the
fault corrected.
lDo not hold the throttle lever in the area below
I, as this may damage the centrifugal clutch.
lDo not take your hands off the machine while
the engine is running.
lKeep your feet away from the tamper foot
Parking the machine
Stand the machine on ground as level as possible.
Before leaving the machine:
lSecure 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.
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Safety regulations
BOMAG14 BT 60/4, BT 65/4
Workingonthetamperfoot
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 intothe 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.
lDo not mix the nozzle in the carburettor up by
mistake.
lAdjust the idling speed regulator screw exact-
ly.
lDo not damage the blower wheel when work-
ing on the magnetic ignition.
lAlways replace self locking nuts.
lDo not open the foot cover on the tamper foot,
spring tension. Danger of accident!
lObserve the prescribed tightening torques.
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BOMAG 15BT 60/4, BT 65/4
3 Indicators and Controls
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Indicators and Controls
BOMAG16 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. 5
Throttle lever (Fig. 5).
Fig. 6
Engine stop switch (Fig. 6).
Fig. 7
Recoil starter (Fig. 7).
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Indicators and Controls
BOMAG 17BT 60/4, BT 65/4
Fig. 8
Fuel cock (Fig. 8).
Fig. 9
Choke lever (Fig. 9).
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BOMAG 19BT 60/4, BT 65/4
4Operation
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Operation
BOMAG20 BT 60/4, BT 65/4
4.1 General notes
Please read section 3 Indicators and Control Ele-
ments thoroughly before operating the machine if
you are not yet fully familiar with theindicators and
control elements of the machine.
All indicators and control elements are described
in detail in this chapter.
4.2 Tests before taking into op-
eration
i
Note
During the running in time the idle speed may in-
crease because of the enhanced moveability of
the engine. Idle speed between 1700 and 2000
rpm.
The running in time of the vibratory tamper is 10
operating hours.
Check
lcondition of engine and machine
lengine oil level
lfuel tank and fuel lines for leaks
lfuel level
lconcertina wall for damage and leaks
loil filling of tamper cylinder
lVisual inspection of machine
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Operation
BOMAG 21BT 60/4, BT 65/4
4.3 Filling in fuel
!Danger
Fire hazard!
Only fill in fuel with the engine shut down and
the fuel valve closed. Do not spill any fuel!
Do not inhale any fuel fumes.
No fire, do not smoke!
Fuel:
Unleaded standard grade gasoline.
Fig. 10
lTurn the fuel shut-off valve (Fig. 10) to position
STOP (closed).
Fig. 11
lTank contents max. 3,0 Litres.
lAfter filling close the filler cover tightly (Fig.
11).
4.4 Starting the engine
!Danger
Danger of accident!
Always hold on to the machine.
Keep your feet away from the tamper plate, be-
cause the vibration starts immediately.
Always keep an eye on a running machine.
Wear your personal noise protection means
(ear defenders) before starting operation.
Fig. 12
lOpen the fuel cock (Fig. 12).
Fig. 13
lSet the throttle lever (Fig. 13) to MAX position.
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