Fayat Group BOMAG BT 60 User manual

Operating instructions
Maintenance instructions
Original operating instructions
Catalogue No.
008 071 41 04/2011
BT 60 / BT 65
S/N 101 541 10 .... > / S/N 101 541 30 .... >
Vibratory Tampers
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Foreword
BOMAG 3 BT 60 / BT 65
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:
lSafety regulations
lOperating instructions
lMaintenance instructions
lTrouble shooting
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
lif it is handled in a way not complying with the
usual modes of use,
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,
linsufficient maintenance and
lwrong 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
PrintedinGermany
Copyright by BOMAG
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Foreword
BOMAG 4 BT 60 / BT 65
Please fill in
............................
Machinetype(Fig.1)
............................
Serial number (Fig. 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
541002
008 330 20
Made by
FAYAT GR OUP
Hellerwald, 56154 Boppard
Made in Germany
kW kg
Patent Protection
Type
Serial Number
Year of Construction
Nominal Power Operating Mass
Designation
541003
008 330 20
Made by
FAYAT GR OUP
Hellerwald, 56154 Boppard
Made in Germany
kW kg
Patent Protection
Type
Serial Number
Year of Construction
Nominal Power Operating Mass
Designation
541004
000 00 0000
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Table of Contents
BOMAG 5 BT 60 / BT 65
Technical Data 7
Safety regulations 11
Indicators and Controls 17
3.1 General notes 18
3.2 Description of indicators and control elements 18
Operation 21
4.1 General 22
4.2 Tests before taking into operation 22
4.3 Starting the engine 23
4.4 Work/operation 26
4.5 Shutting down the engine 27
4.6 Changing the tamper foot plate 28
4.7 Loading/transport 29
4.8 Final shut-down of machine 30
Maintenance 31
5.1 General notes on maintenance 32
5.2 Fuels and lubricants 33
5.3 Table of fuels and lubricants 34
5.4 Running-in instructions 35
5.5 Maintenance table 36
5.6 Clean the machine 37
5.7 Check the engine oil level 37
5.8 Checking the fuel level 38
5.9 Change the engine oil 39
5.10 Cleaning, checking the spark plug, replacing if necessary 40
5.11 Check the tamper foot 41
5.12 Checking, adjusting the valve clearance 43
5.13 Changing the fuel filter 45
5.14 Clean the fuel screen 46
5.15 Oil change in tamper foot 47
5.16 Check, clean the air filter, replace if necessary 49
Trouble shooting 51
6.1 General notes 52
6.2 Engine problems 53
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BOMAG 7 BT 60 / BT 65
1 Technical Data
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Technical Data
BOMAG 8 BT 60 / BT 65
Fig. 4
Dimensions in mm B H L L1 W
BT 60 350 1000 735 335 230
BT 65 350 1000 735 335 280
*BT 60 BT 65
Weight
Basic weight kg 59 64
Operating weight (CECE) kg 60 65
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
541005
L
W
H
B
L1
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Technical Data
BOMAG 9 BT 60 / BT 65
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 0.75 1.0
Engine oil l 0.3 0.3
* The right for technical modifications remains reserved
*BT 60 BT 65
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Technical Data
BOMAG 10 BT 60 / BT 65
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: LpA = 94 dB(A), determined acc. to ISO 11204 and EN 500
BT 65: LpA = 93 dB(A), determined acc. to ISO 11204 and EN 500
Guaranteed sound power level:
BT 60: LWA = 108 dB(A), determined acc. to ISO 3744 and EN 500
BT 65: 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: ahv =9.4m/sec
2on crushed rock determined acc. to ISO 5349 and EN 500
BT 65: ahv =8.6m/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 11 BT 60 / BT 65
2 Safety regulations
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Safety regulations
BOMAG 12 BT 60 / BT 65
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:
lit is used for purposes other than the ones it is
intended for,
lit is operated by untrained personnel,
lit is changed or converted in an unprofessional
way,
lthe 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:
lapplicable accident prevention instructions,
lgenerally accepted safety and road traffic reg-
ulations,
lcountry 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:
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 arise from the machine when it is
used for purposes other than the one it is intended
for.
Any danger caused by intended use is the sole re-
sponsibility of the customer or driver/operator, the
manufacturer cannot be made liable.
Examples for unintended use are:
lWorking in horizontal direction
lRamming of poles
lVibrating of paving blocks
It is not permitted to stand on the machine while
working.
Starting and operation of the machine in explosive
environments and in underground mining is pro-
hibited.
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 (capa-
ble person) as required for the conditiosn the ma-
chine is working under, but at least 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
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Safety regulations
BOMAG 13 BT 60 / BT 65
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 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:
! 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.
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:
lthe machine shows any obvious faults
lall guards and safety elements are in place
lthe controls are fully functional
lthe machine is free of oily and combustible
material
lall 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
lGuide the machine and take care that you do
not hurt your hands on any obstructions, dan-
ger of accident.
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Safety regulations
BOMAG 14 BT 60 / BT 65
lWatch out for unusual 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 work
Maintenance work must only be performed by
qualified and authorized persons.
Keep unauthorized persons away from the ma-
chine.
Do not perform maintenance work while the motor
is running.
Park the machine on level, firm ground.
Working on the fuel system
Avoid open fire, do not smoke, do not spill any fuel.
Catch running out fuel, do not let it seep into the
ground and dispose off environmentally.
Do not inhale any fuel fumes.
Avoid contact with skin and eyes.
Do not swallow.
Working on the engine
When working on the air filter no dirt should fall
into the air duct.
Do not work on the hot exhaust, danger of burning!
When working on the engine exhaust duct no com-
bustion residues should fall into the cylinder.
Do not touch the piston with the cleaning tools.
Workingonthetamperfoot
Wipe off spilled oil, catch running out oil and dis-
pose of environmentally.
Store oil contaminated materials in a separate,
specially marked container and dispose of envi-
ronmentally.
Cleaning work
Do not perform cleaning work while the motor is
running.
Do not use gasoline or other easily inflammable
substances for cleaning.
When using a steam cleaner for cleaning do not
subject electrical parts and insulation material to
the direct jet or cover these items beforehand.
Do not guide the water jet directly into air filter, ex-
haust pipe and air intake opening.
After maintenance work
After all maintenance work is completed reinstall
all guards and safety installations.
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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Safety regulations
BOMAG 15 BT 60 / BT 65
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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BOMAG 17 BT 60 / BT 65
3 Indicators and Controls
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Indicators and Controls
BOMAG 18 BT 60 / BT 65
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 Description of indicators
and control elements
Fig. 5
No. 1 = Engine oil level warning lamp
!
Caution
If the engine oil level warning lamp (1) (Fig. 5)
lights when starting the engine, you must
check the oil level.
No. 2 = Engine stop button
No. 3 = Throttle lever
No.4= Recoilstarter
No.5= Fuelcock
Fig. 6
No. 6 = Choke lever
541018
1
2
3
4
5
541019
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Indicators and Controls
BOMAG 19 BT 60 / BT 65
Fig. 7
No. 7 = Operating hour meter/engine speed
meter*
Engine off = Indication of operating hours
Engine on = RPM-meter
i
Note
After the first 25 operating hours "SERVICE" flash-
es for about 2 hours to remind you that the initial
service is due.
After the first 100 operating hours "SERVICE"
flashes for about 2 hours again to remind you that
service is due.
* Optional equipment
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BOMAG 21 BT 60 / BT 65
4Operation
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Operation
BOMAG 22 BT 60 / BT 65
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 de-
scribed 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 1850 and 2000
rpm.
The running in time of the vibratory tamper is 10
operating hours.
The following inspections must be carried out be-
fore each working day or before a longer working
period.
!
Danger
Danger of accident!
Please observe strictly the safety regulations
in chapter 2 of this instruction manual!
lPark the machine on ground as level as possi-
ble.
Check:
lcondition of engine and machine
lfuel tank and fuel lines for leaks
lscrew joints for tight fit
i
Note
For a description of the following tasks refer to the
chapter "Daily maintenance".
lEngine oil level, top up if necessary
lFuel level, top up if necessary.
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