Ingersoll-Rand BXR-60 User manual

CPN 13164496 February 16, 2001
OPERATION / MAINTENANCE
AND PARTS MANUAL
BXR-60
REVERSIBLE PLATE COMPACTOR
Read this instruction manual before operating this equipment
021601AB
Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of
either.
Revised (01-13)

BXR-60 REVERSIBLEPLATECONPACTOR
OPERATIONANDMAINTENANCE MANUAL
COMMUNICATIONNO.13464496
This manual should be used with all related supplemental books, engine and transmission manuals, and part books.
Related Service Bulletins should be reviewed to provide information regarding some of the recent changes.
If any questions arise concerning this publication or others, contact your local distributor for the latest available
information.
Contents of this manual are based on information in effect at the time of publication and are subject to change without
notice.
CONTENTS SECTION
SAFETY PRECAUTIONS AND GUIDELINES 1
INTRODUCTION 2
SYMBOL IDENTIFICATION AND METRIC
CONVERSION 3
OPERATING INSTRUCTIONS 4
FUEL AND LUBRICATION SPECIFICATIONS 5
INITIAL BREAK-IN MAINTENANCE 6
TROUBLE SHOOTING AND GENERAL MAINTENANCE 7
10 HOUR OR DAILY ROUTINE MAINTENANCE 8
50 HOURS OR WEEKLY ROUTINE MAINTENANCE 9
100 HOURS OR MONTHLY MAINTENANCE 10
250 HOURS OR QUARTERLY ROUTINE MAINTENANCE 11
500 HOURS OR SEMI-ANNUAL ROUTINE MAINTENANCE 12
1000 HOURS OR ANNUAL ROUTINE MAINTENANCE 13
ROUTINE ADJUSTMENTS 14
MISCELLANEOUS AND OPTIONAL EQUIPMENT 15
SCHEMATICS 16
PARTS MANUAL 17
i,ii

1-1
SECTION 1 -
SAFETYPRECAUTIONSANDGUIDELINES
Contents ............................................................................................................................................................................................... Page
OVERVIEW ..........................................................................................................................................................................1
PRE-START INSPECTION..................................................................................................................................................1
OPERATING........................................................................................................................................................................ 1
MAINTENANCE ..................................................................................................................................................................2
OERATINGPROCEDURES...............................................................................................................................................................2
OVERVIEW
Before you operate, maintain, or in any other way, use this machine, read and study this manual. Know how to safety use the
compactor’s controls and what you must do for safe maintenance.
BEFORE YOU OPERATE, MAINTAIN OR IN ANY OTHER WAY, OPERATE THIS MACHINE:
READ and STUDY this manual. KNOW how to safely use the unit’s controls and what you must do for safe maintenance.
The machine has been built in accordance with state-of-the-art standards and the recognized safety rules. Nevertheless, its
use may constitute a risk to life and limb of the user or of third parties, or cause damage to the machine and to other material
property. •
ALWAYS wear or use the proper safety items required for your personal protection.
For reasons of security, long hair must be tied back or otherwise secured, garments must be close-fitting and no jewellery -
such as rings - may be worn. Injury may result from being caught up in the machinery or from rings catching on moving parts.
•
If you have ANY QUESTIONS about the safe use or maintenance of this unit, ASK YOUR SUPERVISOR OR CONTACT ANY
INGERSOLL-RAND DISTRIBUTOR. NEVER GUESS - ALWAYS CHECK.
Never make any modifications, additions or conversions which might affect safety without the supplier’s approval. This also
applies to the installation and adjustment of safety devices and valves as well as to welding work on load-bearing elements.
•
Observe all fire-warning and fire-fighting procedures. •
PRE-STARTINSPECTION
INSPECT your machine. Have any malfunctioning, broken or missing parts corrected or replaced before use.
Check the machine at least once per working shift for obvious damage and defects. Report any changes (incl. changes in the
machine’s working behaviour) to the competent organisation/person immediately. If necessary, stop the machine immediately
and lock it. •
Take the necessary precautions to ensure that the machine is used only when in a safe and reliable state.
Operate the machine only if all protective and safety oriented devices, such as removable safety devices, emergency shut-off
equipment, sound-proofing elements and exhausts, are in place and fully functional. •

SECTION 1 -
SAFETYPRECAUTIONSANDGUIDELINES
1-2
The electrical equipment of machines is to be inspected and checked at regular intervals. Defects such as loose connections
or scorched cables must be rectified immediately. •
VERIFY that all the instruction and safety labels are in place and readable. These are as important as any other equipment
on the compactor.
NEVER fill the fuel tank, with the engine running, while near an open flame, or when smoking. ALWAYS wipe up any spilled
fuel immediately.
CHECK for WARNING tags placed on the machine. DO NOT operate the equipment until repairs have been made and the
WARNING tags are removed by authorized personnel.
KNOW the location of the Emergency Shut-Down Control if the machine is so equipped.
OPERATING
In the event of safety-relevant modifications or changes in the behaviour of the machine during operation, stop the machine
immediately and report the malfunction to the competent authority/person. •
Always wear the prescribed ear protectors. •
Always make sure that no person or obstruction is in your line of travel. Watch your step to avoid tripping.
USE extreme caution and be observant when working in close quarters or congested areas.
Before beginning work, familiarize yourself with the surroundings and circumstances of the site, such as obstacles in the working
and travelling area, the soil bearing capacity and any barriers separating the construction site from public roads. •
When travelling on public roads, ways and places always observe the valid traffic regulations and, if necessary, make sure
beforehand that the machine is in a condition compatible with these regulations •
Always keep at a distance from the edges of building pits and slopes. •
DO NOT run the engine in a closed building for an extended length of time. EXHAUST FUMES CAN KILL.
DO NOT operate the compactor on non-compactable material, such as concrete or hardened asphalt.
MAINTENANCE
Observe the adjusting, maintenance and inspection activities and intervals set out in the operating instructions, including
information on the replacement of parts and equipment. These activities may be executed by skilled personnel only. •
Ensure that the maintenance area is adequately secured. •
Observe the adjusting, maintenance and inspection activities and intervals set out in the operating instructions, including
information on the replacement of parts and equipment. These activities may be executed by skilled personnel only. •
After cleaning, examine all fuel, lubricant, and hydraulic fluid lines for leaks, loose connections, chafe marks and damage. Any
defects found must be rectified without delay. •
Always tighten any screwed connections that have been loosened during maintenance and repair. •

1-3
SECTION 1 -
SAFETYPRECAUTIONSANDGUIDELINES
Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immediately upon
completion of the maintenance and repair work. •
Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental impact. •
AVOID, whenever possible, servicing, cleaning or examining the unit with the engine running.
NEVER fill the fuel tank, with the engine running, while near an open flame, or when smoking. ALWAYS wipe up any spilled
fuel immediately.
ALWAYS disconnect the spark plug before performing any work on the unit.
DO NOT alter the engine governor settings from that indicated in the engine manual.
ALWAYS replace damaged or lost decals. Refer to the Parts Manual for the proper location and part number of all decals.
Carry out welding, flame-cutting and grinding work on the machine only if this has been expressly authorized, as there may
be a risk of explosion and fire. •
Before carrying out welding, flame-cutting and grinding operations, clean the machine and its surroundings from dust and other
inflammable substances and make sure that the premises are adequately ventilated (risk of explosion). •
1-3,1-4

SECTION2-INTRODUCTION
2-1
EXCELLENT CHOICE! The Ingersoll-Rand Reversible Plate
Compactor you have chosen will give you many hours of
maintenance free operation resulting in a faster return of your
investment.
Safe operation depends on reliable equipment and the use
of proper operating procedures. Performing the checks and
servicesdescribed inthis manual willhelp keepyour machine
in good condition. These recommended operation
procedures will help you to avoid unsafe practices.
Safety notes have been included throughout this manual to
help you avoid injury and prevent damage to the equipment.
These notes are not intended to cover all eventualities; it is
impossible to anticipate and evaluate all possible methods
of operation. Therefore, you are the only person who can
guarantee safe operation and maintenance.
It is important that any procedure not specifically
recommended in this manual be thoroughly evaluated from
the standpoint of safety before it is implemented.
Continuing improvement and advancement of product design
may cause changes to your machine which may not be
included in this publication. Each publication is reviewed
andrevised, as required,toupdate and include thesechanges
in later editions. Ingersoll-Rand reserves the right to modify
or make changes within a specific model group without notice
and without incurring any liability to retrofit units previously
shipped from the factory. Contact your Ingersoll-Rand
Distributor for non-routine maintenance information that is
not covered in this publication.
2-1,2-2

SECTION3- SYMBOLIDENTIFICATIONANDMETRICCONVERSION
3-1
Contents Page
INTERNATIONAL MACHINE SYMBOLS ______________________________________________________________1
INTERNATIONAL HIGHWAY SYMBOLS ______________________________________________________________2
METRIC CONVERSIONS __________________________________________________________________________4
INTERNATIONALMACHINESYMBOLS
The following explains the meaning of international symbols that may appear on your machine
OIL PRESSURE
WATER
TEMPERATURE
ON / OFF
LIGHTS
WATER
BATTERY
AMMETER OR
VOLTMETER
AIR PRESSURE
- LOW AIR PRESSURE
ENGINE RPM
BRAKE
HORN
CAUTION
DIESEL FUEL
SLOW
FAST
TRANSMISSION
GREASE
OIL
HYDRAULIC
OIL
HOURS
NEUTRAL
LOW ENGINE RPM.
BRAKE - PARK
VIBRATION
AMPLITUDE
FREQUENCY
CAUTION - PRESSURIZED

3-2
SECTION3- SYMBOLIDENTIFICATIONANDMETRICCONVERSION
INTERNATIONALHIGHWAYSYMBOLS
The following symbols may also appear in a yellow square instead of a red triangle.


road bends
dangerous bend
double bend
dangerous descent
steep ascent
carriageway narrows
carriageway narrows
"end of priority" sign
oncomig traffic has priority
priority over oncoming traffic
swing bridge
road leads onto quay or river bank
uneven road
ridge
dip
slippery road
loose gravel
no entry for power driven vehicles
no entry for vehicles exceeding width
no entry for vehicles exceeding length
falling rocks
pedestrian crossing
road work
light signals

SECTION3- SYMBOLIDENTIFICATIONANDMETRICCONVERSION
3-3
two-way traffic
other dangers
level crossing
level crossing
no entry
closed to all vehicles in
both directions
Intersection, user must give way
intersection user must give way
Intersection user must give way
"give way" sign
stop sign (new)
stop sign (old)
"priority road" sign
no entry for vehicles exceeding weight
no entry for vehicle axle weight exceeding
no u-turn
no turn direction shown
no entry for power driven vehicles

3-4
SECTION3- SYMBOLIDENTIFICATIONANDMETRICCONVERSION
TO CONVERT INTO MULTIPLY BY
OMREGNET FRA TIL MULTIPLICERES MED
bar pound/sq.in 14.50
bar kilopascals 100.
centigrade fahrenheit (C° x 9/5) + 32
centimeters inches 0.3937
centimeters millimeters 10.0
circumference radians 6.283
cubic centimeters cu.inches 0.06102
degrees (angle) radians 0.01745
degrees/sec. revolutions/min 0.1667
feet meters 0.3048
feet/min meters/min. 0.3048
foot-pounds kg-meters 0.1383
gallons liters 3.785
Hertz vibrations/min. 60.
horsepower kilowatts 0.7457
inches centimeters 2.540
inches millimeters 25.40
kilograms pounds .250
kilogram meters -pounds 7.233
kilopascal pounds/sq.in 0.1450
kilopascal bars 0.01
kilowatts horsepower 1.341
liters gallons (U.S. liq) 0.2642
liters pints (U.S. liq) 2.113
liters quarts (U.S. liq) 1.057
meters feet 3.281
meters inches 39.37
meters/min feet/sec 0.05468
miles/hr kms/hr 1.609
millimeters inches 0.03937
Newtons pounds 4.448
Newton-meter pound-feet 0.737
pints (liq) liters 0.4732
pounds kilograms 0.4536
pounds Newtons 0.225
pound feet Newton-meter 1.356
pounds/ft. kgs/meter 1.488
pounds/sq in bars 0.06895
pounds/sq in kilopascals 6.895
quarts (liq) liters 0.9463
radians degrees 57.30
radians/sec revolutions/min 9.549
revolutions/min degrees/sec 6.0
revolutions/min radians/sec 0.1047
temperature (°C) + 17.78 temperature (°F) 1.8
temperature (°F) - 32 temperature (°C) 5/9
tons (short) tons (metric) 0.9078
vibrations/min Hertz 0.0167

SECTION4-OPERATINGINSTRUCTIONS
4-1
Contents Page
SAFETY CHECKS - PRE-STARTING _________________________________________________________________1
INSPECTION PRIOR TO OPERATION ________________________________________________________________2
OPERATION _____________________________________________________________________________________2
STORAGE ______________________________________________________________________________________6
Improper maintenance can be hazardous.
Read and understand SECTION 1 - SAFETY PRECAUTIONS AND GUIDELINES before you perform any maintenance,
service or repairs.
SAFETYCHECKS-PRE-STARTING
Before starting each day, in addition to the 10 hour daily routine maintenance, check or inspect the following items to ensure
trouble free performance.
1. Check fluid lines, hoses, fittings, filler openings, drain plugs, pressure cap, muffler, safety shrouds and the area underneath
the unit for signs of leakage or damage. Fix any leaks and correct any damage before operating.
2. Inspect the entire unit for damaged or missing parts and repair or replace them as needed.
3. Check the fuel level. If necessary, fill the fuel tank with the proper fuel.
4. Check all fastening hardware to ensure it is adequately tightened and that none is missing or broken.
5. Do not operate faulty equipment.
6. Be observant of people and obstructions within the work area.
Please read “INSTRUCTIONS FOR USE” for ROBIN engine EY15D and this instruction manual for correct use and care.
Please check if the unit is correctly maintained in good operating conditions.

SECTION4-OPERATINGINSTRUCTIONS
4-2
INSPECTIONPRIORTOOPERATION
CHECK ENGINE OIL
Before checking or refilling engine oil, be sure the rammer is located on a stable level surface.
Do not thread the gauge into oil filler to check oil level. If the oil level is below the lower level line on the dipstick, refill with the
proper oil to the upper level (to the neck of oil filler). See section 9.
CHECKENGINEFUEL
Do not refuel while smoking, near an open flame or other potential hazards.
CLEANING AIR CLEANER
Check Air Cleaner to be sure it is clean and not comtaminated. If it needs cleaning perform the follwing steps:
Remove the outer urethane foam and inner element. Wash the element in kerosene or diesel fuel. Saturate it in a mixture
of 3 parts kerosene or diesel fuel and 1 part engine oil. Shake off excessive oil and reinstall. Wash the air cleaner case
using kerosene. After cleaning it up, apply engine oil on the inner part of the case.
If the air cleaner element is seriously contaminated engine start up may fail or poor output and malfunction of the engine
may result.
CHECK EACH PART FOR LOSE OR BROKEN BOLTS AND NUTS
Tighten loose bolts and nuts, if any. Check each part for fuel or oil leak. Replace broken or damaged parts, if any, with
new ones.
OPERATION
STARTING
1. Turn the STOP SWITCH (1, Figure 4-1) clockwise to the position “I” (ON).
Figure4-1
1

SECTION4-OPERATINGINSTRUCTIONS
4-3
2. Open the FUEL COCK (1, Figure 4-2) located under the fuel tan.
Figure4-2
3. Close the CHOKE LEVER (1, Figure 4-3). If the engine is cold or the ambient temperature is low, close the Choke Lever
(1, Figure 4-2) fully. If the engine is warm or the ambient temperature is high, open the Choke Lever half-way, or keep it fully
open.
Figure4-3
4. Position THROTTLE LEVER (Figure 4-5) to “LOW” speed position.
Avoid fully pulling out the rope. Return the Handle to its original position.
5.Pull the STARTER HANDLE (1, Figure 4-4) of RECOIL STARTER slowly until resistance is felt. This is the “COMPRESSION”
point. Return the Handle to its original position and pull swiftly. After starting the engine, allow the Starter Handle to return
to its original position while still holding the Handle.
1
1

SECTION4-OPERATINGINSTRUCTIONS
4-4
Figure4-4
After the engine starts, set the Throttle Lever (Figure 4-5) at the low speed position “LOW” and warm it up without load for a few
minutes. Fully open CHOKE LEVER (1, Figure 4-3) gradually.
RUNNING
1. Shift the Throttle Lever (Figure 4-5) to “HIGH” speed position quickly. The rammer starts to vibration and move forward.
Figure4-5
STOPPING
1. Shift the throttle lever (Figure 4-5) to “LOW” speed position.
2. Allow the engine to run at low speed for 2-3 minutes before stopping.
3. Turn the STOP SWITCH (1, Figure 4-6) counterclockwise to the position “O”(OFF).
1

SECTION4-OPERATINGINSTRUCTIONS
4-5
Figure4-6
4.Close the fuel cock (1, Figure 4-7).
Figure4-7
Do not stop engine suddenly while running at high speed
1
1

SECTION4-OPERATINGINSTRUCTIONS
4-6
LONGSTORAGE
Discharge fuel (No Smoking !)
1. Remove the strainer cup of the fuel cock, place the strainer over a container and open the fuel cock to discharge fuel from
the fuel tank. Remove the carburetor float chamber bolt from the bottom and discharge fuel from the carburetor
2. Close the fuel cock.
3. Change the engine oil with fresh oil.
4. Remove the spark plug, pour about 5 cc of the engine oil into the cylinder, slowly pull the starter handle of the recoil starter
2 or 3 times, and re-install the spark plug.
5. Slowly pull the recoil starter handle until resistance is felt and leave it in that position.
6. Clean the unit and engine.
7. Store the unit and engine indoors in a well-ventilated, low humidity area. Use the cover to avoid dirt, etc. if storage will be
for a long time.
Always stop the engine and allow to cool down before covering the unit.

SECTION5- FUEL AND LUBRICATION SPECIFICATIONS
5-1
Contents Page
GENERAL INFORMATION ________________________________________________________________________ 1
FLUID CAPACITIES______________________________________________________________________________ 1
GENERALINFORMATION
Lubrication is an essential part of preventive maintenance, affecting to a great extent the useful life of the unit. Different lubricants
are needed and some components in the unit require more frequent lubrication than others.
Specific recommendations of brand and grade of lubricants are not made here due to regional availability, operating conditions,
and the continual development of improved products. Where questions arise, refer to the requirements and specifications in
the engine manufacturer's manual.
All oil levels are to be checked with the machine parked on a level surface, and while the oil is cold, unless otherwise specified.
TABLE 5-1 FLUID CAPACITIES
FUEL/OIL APPROXIMATE CAPACITY
ENGINE FUEL (Unleaded Gasoline) ______________________________________________________ 2.96 QUARTS
ENGINE OIL (SAE 10W30)______________________________________________________________ 0.63 QUARTS
CHECKFUEL
1. Stop the engine and open the fuek tank cap.
2. Use the automobile unleaded gasoline only.
3. Close the fuel cock before filling the fuel tank.
4. When filling the fuel tank, always use the fuel filter.
5. Wipe off any spilled fuel before starting the engine.
Fuel is flammable. May cause injury and property damage.
Shut down the engine, extinguish all open flames and do not smoke while filling the fuel tank.
Always wipe up any spilled fuel.
5-1,5-2

SECTION 6-INITIALBREAK-INMAINTENANCE
6-1
Contents Page
ENGINEOIL ____________________________________________________________________________________1
GENERAL INFORMATION ________________________________________________________________________ 1
Improper maintenance can be hazardous.
ReadandunderstandSECTION1-SAFETYPRECAUTIONSANDGUIDELINESbeforeyouperformanymaintenance,
service or repairs.
ENGINEOIL
Drain the engine oil after the first 20 hours of operation. Fill with the correct amount of the recommended oil. Check the oil
level with the oil filler cap/dip stick. See Section 9.
Hot oil and/or components can burn.
Oil must be at normal operating temperature when draining.
Avoid contact with hot oil or components.

6-2
SECTION 6-INITIALBREAK-INMAINTENANCE
GENERALMAINTENANCE
Perform the following maintenance checks after the initial break in peroid.
1. Engine RPM is adjusted to: 3,600 - 3,700 min-1 (3,600 - 3,700 rpm ) (With load ).
2. Check Bolts and Nuts for looseness. Tighten it if necessary.
3. Check for fuel and oil leak.
4. Keep the RUBBER BUFFER away from oil and fuel.
5. Check the V-Belt and Timing Belt for wear, damage and cracks. If necessary, replace the belt with new one.
6. Please refer to “INSTRUCTION FOR USE” for ROBIN engine EY15D regarding the how-to maintenance for engine.

SECTION 7 - TOUBLE SHOOTING - GENERAL MAINTENANCE
7-1
Contents Page
TROUBLESHOOTING _____________________________________________________________________________1
GENERAL MAINTENANCE ________________________________________________________________________2
TIMING BELT REPLACEMENT ______________________________________________________________________3
TROUBLESHOOTING
1) Engine fails to start.
a) Spark plug is defective Clean or replace.
b) Air in the fuel system. Bleed air completely.
c) Fuel tank is empty. Fill Tank
d) Carburetor is clogged. Clean or replace, if necessary.
e) Excessive fuel. Open fuel drain cock and excess fuel.
Clean spark plug.
2) Engine runs irregularly.
a) Fuel line sucks air. Retighten the fuel pipe joints and bleed air.
b) Air cleaner is clogged. Clean air cleaner or replace element.
c) Engine stalls during operation. Clean fuel system and retighten the fuel
pipe joints.
d) Low compression. Replace head gasket or retighten spark plug.
3) Machine fails to vibrate.
a) Incorrect setting RPM of engine. Adjust.
b) Throttle cable is slacked. Adjust.
c) Centrifugal clutch is slipped. Overhaul or replace, If necessary.
d) Belt is slipped. Adjust or replace, If necessary.
4) The travelling is bad or the vibration is diffuse.
a) Incorrect setting RPM of engine. Adjust.
b) Air cleaner is clogged. Clean air cleaner or replace element.
c) Centrifugal clutch is slipped. Overhaul or replace, If necessary.
d) Belt is slipped. Adjust or replace, If necessary.