Fayat Group BOMAG BT 65 Instructions for use

BT 65
Vibratory tamper
Operating Instruction
Maintenance Instruction
Original Operating Instructions
S/N 101 541 32 1001> / S/N 101 541 33 1001>
© 02/2016008 201 07 EN
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Table of contents
1 Introduction........................................................................................................................................... 7
1.1 Foreword........................................................................................................................................ 8
1.2 Machine type plate and engine type plate................................................................................ 10
2 Technical data..................................................................................................................................... 11
2.1 Noise and vibration data............................................................................................................ 13
2.1.1 Noise data.................................................................................................................................. 13
2.1.2 Vibration data............................................................................................................................. 14
3 Concerning your safety...................................................................................................................... 15
3.1 General prerequisites................................................................................................................. 16
3.1.1 General...................................................................................................................................... 16
3.1.2 Explanation of warning signs:.................................................................................................... 16
3.1.3 Personal protective equipment................................................................................................... 17
3.1.4 Intended use.............................................................................................................................. 18
3.1.5 Improper use.............................................................................................................................. 18
3.2 Definition of responsible persons............................................................................................. 20
3.2.1 Operating company.................................................................................................................... 20
3.2.2 Expert / qualified person............................................................................................................ 20
3.2.3 Driver / operator......................................................................................................................... 20
3.3 Basic safety regulations for safe operation............................................................................. 22
3.3.1 Remaining dangers, remaining risks.......................................................................................... 22
3.3.2 Regular safety inspections......................................................................................................... 22
3.3.3 Modifications and alterations to the machine............................................................................. 22
3.3.4 Damage, defects, misuse of safety devices............................................................................... 22
3.4 Handling fuels and lubricants.................................................................................................... 23
3.4.1 Preliminary remarks................................................................................................................... 23
3.4.2 Safety regulations and environmental protection regulations for handling oil............................ 24
3.4.3 Safety regulations and environmental protection regulations for handling gasoline.................. 25
3.4.4 Safety regulations and environmental protection regulations for handling fuel stabiliser........... 26
3.5 Loading/transporting the machine............................................................................................ 27
3.6 Start-up procedure...................................................................................................................... 28
3.6.1 Prior to starting up...................................................................................................................... 28
3.6.2 Starting the engine..................................................................................................................... 28
3.7 Operation..................................................................................................................................... 29
3.7.1 Persons in the danger area........................................................................................................ 29
3.7.2 Operation................................................................................................................................... 29
3.7.3 Parking the machine.................................................................................................................. 29
3.8 Refuelling..................................................................................................................................... 30
3.9 Maintenance work....................................................................................................................... 31
3.9.1 Preliminary remarks................................................................................................................... 31
3.9.2 Working on the engine............................................................................................................... 31
3.9.3 Working on the tamper foot........................................................................................................ 31
3.9.4 Cleaning work............................................................................................................................ 31
3.9.5 After maintenance work............................................................................................................. 32
3.10 Repair......................................................................................................................................... 33
Table of contents
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3.11 Signage...................................................................................................................................... 34
4 Display and control elements............................................................................................................ 39
5 Check prior to start up........................................................................................................................ 41
5.1 Notes on safety........................................................................................................................... 42
5.2 Visual inspections and function tests....................................................................................... 43
5.3 Checking the engine oil level..................................................................................................... 44
5.4 Checking the fuel level, topping up fuel................................................................................... 45
6 Operation............................................................................................................................................. 47
6.1 Adjusting the guide handle........................................................................................................ 48
6.2 Start the engine........................................................................................................................... 49
6.3 Operation..................................................................................................................................... 53
6.4 Park the machine in secured condition.................................................................................... 55
6.5 Operating hour meter/engine rpm-meter.................................................................................. 56
6.6 Changing the tamper foot plate................................................................................................. 58
7 Loading/transporting the machine.................................................................................................... 59
7.1 Loading the machine.................................................................................................................. 60
7.2 Lashing the machine to the transport vehicle.......................................................................... 61
8 Maintenance........................................................................................................................................ 63
8.1 Preliminary remarks and safety notes...................................................................................... 64
8.2 Fuels and lubricants................................................................................................................... 65
8.2.1 Engine oil................................................................................................................................... 65
8.2.2 Fuel............................................................................................................................................ 65
8.2.3 Gear oil SAE 75W-90................................................................................................................. 66
8.3 List of fuels and lubricants........................................................................................................ 67
8.4 Running-in instructions.............................................................................................................. 68
8.4.1 General...................................................................................................................................... 68
8.4.2 After 25 operating hours............................................................................................................. 68
8.5 Maintenance table....................................................................................................................... 69
8.6 Monthly........................................................................................................................................ 70
8.6.1 Changing the engine oil............................................................................................................. 70
8.6.2 Cleaning, checking the spark plug, replacing if necessary........................................................ 71
8.6.3 Checking the tamper foot........................................................................................................... 72
8.7 Annually....................................................................................................................................... 74
8.7.1 Checking, adjusting the valve clearance.................................................................................... 74
8.7.2 Replacing the fuel filter............................................................................................................... 79
8.7.3 Cleaning the fuel screen............................................................................................................ 81
8.7.4 Checking, adjusting the engine speed....................................................................................... 84
8.7.5 Replacing the starter rope.......................................................................................................... 86
8.7.6 Changing the oil in the tamper foot............................................................................................ 88
8.8 As required.................................................................................................................................. 90
8.8.1 Air filter maintenance................................................................................................................. 90
8.8.2 Cleaning the machine................................................................................................................ 93
9 Troubleshooting.................................................................................................................................. 95
9.1 Preliminary remarks.................................................................................................................... 96
9.2 Engine faults................................................................................................................................ 97
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9.3 What to do if the engine has flooded........................................................................................ 99
10 Disposal............................................................................................................................................. 103
10.1 Final shut-down of machine................................................................................................... 104
11 List of special tools........................................................................................................................... 105
Table of contents
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1 Introduction
Introduction
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1.1 Foreword
BOMAG manufactures machines for earth, asphalt and refuse
compaction, stabilizers/recyclers as well as milling machines
and pavers.
BOMAG’s vast experience in connection with state-of-the-art
production and testing methods, such as lifetime tests of all
important components and highest quality demands guar-
antee maximum reliability of your machine.
The machine described in this manual complies with the applicable
standards and safety regulations.
If your machine is used in traffic on public roads, it must comply
with all applicable national legal regulations. The driving permit
must be acquired from the responsible authorities.
The machine is equipped with latest technology. Now it's a matter
of handling your machine properly and keeping it in good shape.
These instructions will provide you with all necessary information.
Read and follow these notes before starting to operate your
machine!
In case of operating errors, inadequate maintenance or the use of
unapproved fuels and lubricants all warranty claims will become
null and void.
This manual was written for operators and maintenance personnel.
These operating and maintenance instructions are part of the
machine.
You should only operate the machine in compliance with these
instructions.
Strictly observe the safety regulations.
If you are not yet acquainted with the controls and indicating ele-
ments on this machine, you should thoroughly read the corre-
sponding section
Ä Chapter 4 ‘Display and control elements’
on page 39beforehand.
The description of the individual operating steps, including the
notes on safety to be followed, can be found in chapter "Operation"
Ä Chapter 6 ‘Operation’ on page 47.
Thorough maintenance of the machine guarantees far longer safe
functioning of the machine and prolongs the lifetime of important
components. The effort required for this purpose is by any means
lower than the faults that may occur in case of non-compliance.
The machine must only be serviced by qualified and authorized
personnel. A description of all necessary service work as well as
information on fuels and lubricants can be found in the chapter
"Maintenance"
Ä Chapter 8 ‘Maintenance’ on page 63.
For your own personal safety you should only use original spare
parts from BOMAG.
For your machine we offer service kits to make maintenance
easier.
In the course of technical development we reserve the right for
technical modifications without prior notification.
Introduction – Foreword
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These operating and maintenance instructions are also available in
other languages.
Apart from that, you can also order the spare parts catalogue
against the serial number of your machine.
The above notes do not constitute an extension of the warranty
and liability conditions specified in the general sales and delivery
conditions of BOMAG.
We wish you successful work with your BOMAG machine.
Introduction – Foreword
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1.2 Machine type plate and engine type plate
Please enter here:
Machine type (1):
Serial number (2):
Please enter here:
Engine type (1):
Engine number (2):
Fig. 1: Machine type plate (example)
Fig. 2: Engine type and engine
number
Introduction – Machine type plate and engine type plate
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2 Technical data
Technical data
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Fig. 3
B H L L1W
350
(13.8)
1030
(40.6)
728
(28.7)
335
(13.2)
280
(11.0)
Dimensions in millimetre
(Dimensions in inch)
Weights
Basic weight 67
(148)
kg
(lbs)
Operating weight (CECE) 68
(150)
kg
(lbs)
Travel characteristics
Max. working speed 20
(66)
m/min
(ft/min)
Max. area output (depending on soil) 336
(3616)
m2/h
(ft2/h)
Dimensions
Technical data
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Drive
Engine manufacturer Honda
Type GXR 120
Cooling Air
Number of cylinders 1
Displacement 121 cm3
Rated power SAE J 1349 2.8
(3.8)
kW
(hp)
Rated speed 4200 min-1
Exciter system
Drive system mechanical
Frequency 10 - 11.8
(600 - 708)
Hz
(bpm)
Impact force 17
(3822)
kN
(lbf)
Filling capacities
Fuel (gasoline) 3.0
(0.8)
l
(gal us)
2.1 Noise and vibration data
The following noise and vibration data were determined in accord-
ance with the following guidelines under equipment specific condi-
tions and by using harmonized standards:
nEC Machine Directive edition 2006/42/EC
nNoise Emission Directive 2000/14/EC, Noise Protection Direc-
tive 2003/10/EC
nVibration Protection Directive 2002/44/EC
During operation these values may vary because of the prevailing
operating conditions.
2.1.1 Noise data
LpA = 93 dB(A), determined acc. to ISO 11204 and EN 500.Sound pressure level at the place
of the operator
Technical data – Noise and vibration data
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WARNING!
Loss of hearing caused by too high noise burdens!
– Wear your personal protective equipment (ear pro-
tection).
LWA = 108 dB(A), determined acc. to ISO 3744 and EN 500.
2.1.2 Vibration data
Vector total of the weighted effective acceleration in three orthog-
onal directions:
Weighted total vibration value
ahv = 5.5 m/s2, on crushed rock determined acc. to ISO 5349 and
EN 500.
Observe the daily vibration load (work safety acc. to 2002/44/EC).
Guaranteed sound power level
Hand-arm vibration
Technical data – Noise and vibration data
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3 Concerning your safety
Concerning your safety
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3.1 General prerequisites
3.1.1 General
This BOMAG machine has been built in compliance 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:
nit is used for purposes other than the ones it is intended for,
nit is operated by untrained personnel,
nit is changed or converted in an unprofessional way,
nthe safety instructions are not observed.
Each person involved in the operation, maintenance and repair of
the machine must therefore read and comply with these safety reg-
ulations. If necessary, the customer must obtain the relevant signa-
tures as confirmation.
Furthermore, the following obviously also applies:
napplicable accident prevention instructions,
ngenerally accepted safety and road traffic regulations,
ncountry specific safety regulations.
It is the duty of the operator to be acquainted with the safety regu-
lations and to apply these accordingly. This also applies for local
regulations amnd regulations concerning different types of handling
activities. Should the recommendations in these instructions be dif-
ferent from the regulations valid in your country, you must comply
with the safety regulations valid in your country.
3.1.2 Explanation of warning signs:
DANGER!
Danger to life if failing to comply!
Sections marked accordingly indicate an extremely
dangerous situation that could lead to fatal or severe
injuries, if this warning is disregarded.
WARNING!
Danger to life or danger of severe injuries if failing
to comply!
Sections marked accordingly indicate a dangerous sit-
uation that could lead to fatal or severe injuries, if this
warning is disregarded.
Concerning your safety – General prerequisites
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CAUTION!
Danger of injury if failing to comply!
Sections marked accordingly indicate a dangerous sit-
uation that could lead to fatal or severe injuries, if this
warning is disregarded.
NOTICE!
Danger of material damage if failing to comply!
Sections marked accordingly indicate possible dangers
for machines or components.
Sections marked accordingly indicate technical infor-
mation or notes on using the machine or its compo-
nents.
ENVIRONMENT!
Environmental damage if failing to comply!
Paragraphs marked accordingly indicate practices for
safe and environment-friendly disposal of fuels and
lubricants as well as replacement parts.
3.1.3 Personal protective equipment
Depending on the work to be carried out, personal protective equipment is required (to be provided
by the operating company):
Working clothes Tight fitting working clothes with low tear resistance, tight
sleeves and without any projecting parts protects against
being caught by moving components.
Safety shoes To protect against heavy falling parts and slipping on
slippery ground.
Protective gloves To protect the hands against excoriation, punctures or
deep injuries, against irritating and caustic substances
as well as against burns.
Concerning your safety – General prerequisites
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Safety goggles To protect the eyes against airborne particles and fluid
squirts.
Face protection To protect the face against airborne particles and fluid
squirts.
Hard hat To protect the head against falling parts and to protect
against injuries.
Hearing protection To protect the hearing against too loud noise.
3.1.4 Intended use
This machine must only be used for:
nCompaction of all types of soils
nRepair work on all types of soil
nPaving of walkways
nWork in trenches
nUnderfilling and compaction of hard shoulders
Intended use also includes compliance with the specified oper-
ating, maintenance and repair measures.
3.1.5 Improper 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 improper use is the sole responsibility of the
operating company or driver/operator, the manufacturer cannot be
made liable.
Examples for improper use are:
nWorking in horizontal direction
nRamming of poles
nVibrating of paving blocks
It is not permitted to stand on the machine while working.
Concerning your safety – General prerequisites
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starting and operation of the machine in explosive environments
and in underground mining is prohibited.
Concerning your safety – General prerequisites
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3.2 Definition of responsible persons
3.2.1 Operating company
The operating company is the natural or juridical person who uses
the machine or in who's name the machine is used.
The operating company must make sure that the machine is only
used for the purpose it is intended for and in strict compliance with
the safety regulations mentioned in these operating and mainte-
nance instructions.
The operating company must determine and assess the danger in
his company. It must then take appropriate action to ensure health
and safety at work for his employees and point out any remaining
dangers.
The operating company must determine whether there are special
operation hazards such as a toxic atmosphere or limiting soil con-
ditions. Such conditions requires special, additional measures to
remove or reduce the hazard.
The operating company must make sure that all users read and
understand the information concerning safety.
The operating company is responsible for the planning and profes-
sional execution of regular safety inspections.
3.2.2 Expert / qualified person
An expert / qualified person is a person who, based on his/her pro-
fessional education and experience, has profound knowledge in
the field of construction equipment and the machine in question in
particular.
This person is acquainted with the applicable governmental indus-
trial safety regulations, accident prevention instructions, guidelines
and generally acknowledged technical rules and regulations
(standards, directives, technical rules of other member states of
the European Union or other contractual states concerning the
agreement about the European Economic Area) in as far as is nec-
essary to be able to judge the safe condition of these machines.
3.2.3 Driver / operator
This machine must only be operated by trained, instructed persons
entrusted by the operating company aged 18 or more.
Observe your local laws and regulations.
Rights, obligations and rules of conduct for driver or operator:
The driver or operator must:
nbe instructed about his rights and obligations,
nwear protective equipment as appropriate for the application,
nhave read and understood the operating instructions,
Concerning your safety – Definition of responsible persons
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nhave made himself familiar with the operation of the machine,
nbe physically and psychologically able to drive and operate the
machine.
Persons under the influence of alcohol, medicine or drugs are not
allowed to operate, service or repair the machine.
Maintenance and repair work requires specific knowledge and
must therefore only be performed by trained specialists.
Concerning your safety – Definition of responsible persons
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