Fayat BOMAG BT 60/4, BOMAG BT 65/4 Operating And Maintenance Instructions Manual

Operating instructions

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Maintenance instructions

Original operating instructions

BT 60/4 / BT 65/4

S/N 101 540 57 .... / S/N 101 540 58 1177 >

Vibratory Tampers

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Catalogue No.

008 076 21

01/2013

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Foreword

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1 Foreword

BOMAG manufactures machine for earth, as­phalt and refuse compaction, stabilizers/recy­clers as well as milling machine and finishers.

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
guarantee maximum reliability of your ma­chine.

This manual comprises:

l Safety regulations

l Operating instructions

l maintenance instructions

l Trouble shooting

Using these instructions will

l help you to become familiar with the machine.

l avoid malfunctions caused by unprofessional

operation.

Compliance with the maintenance instructions will

l enhance the reliability of the machine on con-

struction sites,

l prolong the lifetime of the machine,

l reduce repair costs and downtimes.

BOMAG will not assume liability for the function of
the machine

l if it is handled in a way not complying with the

usual modes of use,

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 En­gineering Liability Association ”Safety Rules for
the Operation of Road Rollers and Soil Compac­tors” and all relevant accident prevention regula­tions.

For your own personal safety you should only
use original spare parts from BOMAG.

For your machine BOMAG offers service kits
to make maintenance easier.

In the course of technical development we re­serve 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 avail­able from your BOMAG dealer against the serial
number of your machine.

Your BOMAG dealer will also supply you with in­formation 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

Copyright by BOMAG

l if it is used for purposes other than those men-

tioned in these instructions.

No warranty claims can be lodged in case of dam­age resulting from

l operating errors,

l insufficient maintenance and

l wrong fuels and lubricants.

Please note!

This manual was written for operators and mainte­nance personnel on construction sites.

BOMAG 3BT 60/4, BT 65/4

Foreword

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Please fill in

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine type(Fig. 1)

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Serial number (Fig. 2)

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine type (Fig. 3)

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine number (Fig. 3)

Note

i

Supplement the above data together with the com­missioning protocol.

During commissioning our organisation will in­struct you in the operation and maintenance of the
machine.

Please observe strictly the safety regulations and
all notes on risks and dangers!

Made by

Designation

Type

Serial Number

Nominal Power Operating Mass

Patent Protection

Hellerwald, 56154 Boppard

Made in Germany

Fig. 1

Made by

Designation

Type

Serial Number

Nominal Power Operating Mass

Patent Protection

Hellerwald, 56154 Boppard

Made in Germany

Year of Construction

kW kg

540231

Year of Construction

kW kg

Fig. 2

Fig. 3

540232

000 00 0000

540233

BOMAG4 BT 60/4, BT 65/4

Table of Contents

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1Foreword 3

2 Technical Data 7

3 Safety regulations 13

4 Indicators and Controls 19

4.1 General notes 20

4.2 Description of indicators and control elements 20

5 Operation 23

5.1 General 24

5.2 Tests before taking into operation 24

5.3 Adjusting the steering bow 25

5.4 Starting the engine 25

5.5 Work/operation 28

5.6 Shutting down the engine 30

5.7 Changing the tamper foot plate 31

5.8 Loading/transport 31

6 Maintenance 33

6.1 General notes on maintenance 34

6.2 Fuels and lubricants 35

6.3 Table of fuels and lubricants 36

6.4 Running-in instructions 37

6.5 Maintenance table 38

Maintenance every day 39

6.6 Clean the machine 39

6.7 Check the engine oil level 39

6.8 Check the fuel level 40

Maintenance every month 41

6.9 Change the engine oil 41

6.10 Cleaning, checking the spark plug, replacing if necessary 42

6.11 Check the tamper foot 43

Maintenance every year 45

6.12 Check, adjust the valve clearance 45

6.13 Replace the fuel filter 47

6.14 Cleaning the fuel screen 48

6.15 Check, adjust the engine speed 50

6.16 Replacing the starter rope 52

6.17 Oil change in tamper foot 54

As required 55

BOMAG 5BT 60/4, BT 65/4

Table of Contents

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6.18 Check, clean the air filter, replace if necessary 55

7 Trouble shooting 57

7.1 General notes 58

7.2 Engine problems 59

8Disposal 61

8.1 Final shut-down of machine 62

BOMAG6 BT 60/4, BT 65/4

2 Technical Data

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BOMAG 7BT 60/4, BT 65/4

Technical Data

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H1L1H

W

L

Fig. 4

Dimensions in mm
(in)

BT 60/4

1

Weight

Basic weight kg (lbs) 61 (134)
Operating weight (CECE) kg (lbs) 62 (137)

Travel characteristics

Max. working speed (depending on soil) m/min (ft/min) 20 (66)
Max. areal output (depending on soil) m

Drive

Engine manufacturer Honda
Type GX 100
Cooling Air
Number of cylinders 1
Displacement cm

B H L L1 W

350 (13.8) 960 (37.8) 735 (28.9) 335 (13.2) 280 (11.0)

2

/h (ft2/h) 336 (3616)

B

540234

BT 60/4

3

98

BOMAG8 BT 60/4, BT 65/4

Technical Data

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1

Rated power ISO 9249 kW (hp) 2,3 (3.1)
Rated speed min

Exciter system

Drive system mechanical
Frequency Hz 10 – 11.8
Impact force kN (lbf) 13,5 (3035)

Filling capacities

Fuel tank l (gal us) 3,0 (0.80)
Oil in tamper foot l (gal us) 0,75 (0.20)
Engine oil l (gal us) 0,3 (0.08)

1 The right for technical modifications remains reserved

-1

BT 60/4

4200

BOMAG 9BT 60/4, BT 65/4

Technical Data

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H1L1H

W

L

Fig. 5

Dimensions in mm
(in)

BT 65/4

1

Weight

Basic weight kg (lbs) 67 (148)
Operating weight (CECE) kg (lbs) 68 (150)

Travel characteristics

Max. working speed (depending on soil) m/min (ft/min) 20 (66)
Max. areal output (depending on soil) m

Drive

Engine manufacturer Honda
Type GX 100
Cooling Air
Number of cylinders 1
Displacement cm

B H L L1 W

350 (13.8) 1000 (39.4) 735 (28.9) 335 (13.2) 280 (11.0)

2

/h (ft2/h) 336 (3616)

B

540234

BT 65/4

3

98

BOMAG10 BT 60/4, BT 65/4

Technical Data

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1

Rated power ISO 9249 kW (hp) 2,3 (3.1)
Rated speed min

Exciter system

Drive system mechanical
Frequency Hz 10 – 11.8
Impact force kN (lbf) 16,2 (3642)

Filling capacities

Fuel tank l (gal us) 3,0 (0.80)
Oil in tamper foot l (gal us) 1,0 (0.26)
Engine oil l (gal us) 0,3 (0.08)

1 The right for technical modifications remains reserved

-1

BT 65/4

4200

BOMAG 11BT 60/4, BT 65/4

Technical Data

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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 harmo­nized 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: L

BT 65/4: L

Guaranteed sound power level:

BT 60/4: L

BT 65/4: L

= 94 dB(A), determined acc. to ISO 11204 and EN 500

pA

= 93 dB(A), determined acc. to ISO 11204 and EN 500

pA

= 108 dB(A), determined acc. to ISO 3744 and EN 500

WA

= 108 dB(A), determined acc. to ISO 3744 and EN 500

WA

!

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 a

BT 65/4 a

Caution

!

Observe the daily vibration load (Industrial safety acc. to 2002/44/EEC).

= 9.4 m/s2 on crushed rock determined acc. to ISO 5349 and EN 500

hv

= 8.6 m/s2 on crushed rock determined acc. to ISO 5349 and EN 500

hv

BOMAG12 BT 60/4, BT 65/4

3 Safety regulations

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BOMAG 13BT 60/4, BT 65/4

Safety regulations

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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:

l it is used for purposes other than the ones it is

intended for,

l it is operated by untrained personnel,

l it is changed or converted in an unprofessional

way,

l the 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
regulations. If necessary, this must be con­firmed by obtaining the signature of the cus­tomer.

Furthermore, the following obviously also applies:

l applicable accident prevention instructions,

l generally accepted safety and road traffic reg-

ulations,

l country specific safety regulations. It is the

duty of the operator to be acquainted with
these instructions and to apply these accord­ingly. This applies also for local regulations
concerning different types of handling work.
Should the recommendations in these instruc­tions 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:

l Compaction of all types of soils

l Repair work in all types of soil

l Reinforcement of walkways

l Work in trenches

Any danger caused by intended use is the sole re­sponsibility of the customer or driver/operator, the
manufacturer cannot be made liable.

Examples for unintended use are:

l Working in horizontal direction

l Ramming of poles

l Vibrating 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 pro­hibited.

Remaining dangers, remaining risks

Despite careful work and compliance with stand­ards and regulations it cannot be ruled out that fur­ther dangers may arise when working with and
handling the machine.

Both the machine as well as all other system com­ponents comply with the currently valid safety reg­ulations. Nevertheless, remaining risks cannot be
ruled out completely, even when using the ma­chine for the purpose it is intended for and follow­ing 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 (capa­ble person) as required for the conditiosn the ma­chine is working under, but at least once every
year.

l Backfills and compaction of marginal strips

Who is allowed to operate the ma­chine?

Unintended use

Dangers may arise from the machine when it is
used for purposes other than the one it is intended
for.

BOMAG14 BT 60/4, BT 65/4

Only trained, instructed and authorized persons of
at least 18 years of age are permitted to drive and
operate this machine. For operation of the ma-

Safety regulations

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chine the responsibilities must be clearly specified
and complied with.

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.

Changes and conversions to the ma­chine

Unauthorized changes to the machine are prohib­ited for safety reasons.

Original parts and accessories have been special­ly designed for this machine.

We wish to make explicitly clear that we have not
tested or approved any parts or accessories not
supplied by us.

The installation and/or use of such products may
have an adverse effect on the active and/or pas­sive safety.

The manufacturer explicitly excludes any liability
for damage caused by 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.

Notes on safety in the operating and
maintenance instructions

Danger!

Paragraphs marked like this highlight possible
dangers for persons.

Caution

!

Paragraphs marked like this highlight possible
dangers for machines or parts of the machine.

Note

i

Paragraphs marked like this contain technical in­formation for the optimal economical use of the
machine.

Environment

Paragraphs marked like this point out practic­es for safe and environmental disposal of fuels
and lubricants as well as replacement parts.

Observe the regulations for the protection of
the environment.

Loading/transporting the machine

Always shut the engine down to transport the
tamper or to lay it on its side.

Make sure that persons are not endangered by the
machine tipping or sliding off.

Lifting tackle must only be attached to loads by ex­pert personnel (qualified person).

Use only safe lifting gear of sufficient load bearing
capacity Minimum lifting capacity of lifting gear:
see operating weight in chapter "Technical Data".

Fasten the lifting gear only at the specified lifting
points.

Check all lifting and lashing points for damage be­fore lifting or lashing down the machine. Do not
use a damaged or in any other way impaired lifting
and lashing eyes.

Do not lift or lower the machine jerkily.

The tension must always be effective in vertical di­rection.

The machine must not swing about when being lift­ed.

Do not step or stand under suspended loads.

Always use suitable lashing gear on the lifting
points to lash down the machine.

Lash the machine down, so that it is secured
against rolling, sliding and turning over.

Starting the machine

Before starting

Become acquainted with the equipment, the con­trol elements, the working principle of the machine
and the working area.

BOMAG 15BT 60/4, BT 65/4

Safety regulations

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Wear your personal protective outfit (hard hat,
safety boots, etc.). Wear ear defenders.

Before starting the machine check whether:

l the machine shows any obvious faults

l all guards and safety elements are in place

l the controls are fully functional

l the machine is free of oily and combustible

material

l all grips are free of grease, oils, fuel, dirt, snow

and ice.

Examine the starter rope of the recoil starter for
chafing before starting, replace if necessary. A
damaged rope can break and cause injuries dur­ing starting.

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 en­sure an adequate supply of fresh air when starting
and operating in closed rooms and trenches!

Operation

l Always keep an eye on the machine when the

engine is running.

l Always hold on to the machine.

l Steer the machine only be the steering handle.

l Guide the machine so hat your hands do not

hit against solid objects, danger of injury.

l Keep your feet clear of the tamper foot plate.

l Wear your personal noise protection (ear de-

fenders).

l Watch out for unusual noises and develop-

ment of smoke. Perform trouble shooting and
have the fault corrected.

l Do not hold the throttle lever in the area below

-1

3600 min

, since this would destroy the cen-

trifugal clutch.

Parking the machine

Stand the machine on ground as level as possible.

Before leaving the machine:

l Secure the machine against tipping over.

Refuelling

Do not inhale any fuel fumes.

Do not swallow fuel.

Avoid contact with skin and eyes.

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.

Keep dirt and water away from the fuel.

A leaking fuel tank can cause an explosion. En­sure tight fit of the fuel tank cover, if necessary re­place immediately.

Fuel stabilizer

Fuel stabilizer is inflammable. No open fire, do not
smoke. Do not spill any fuel stabilizer.

Do not inhale any fuel stabilizer fumes.

Do not swallow fuel stabilizer.

Avoid contact with skin and eyes.

Maintenance work

Comply with the maintenance work described in
the operating and maintenance instructions, in­cluding the information concerning the replace­ment of parts.

Maintenance work must only be performed by
qualified and authorized persons.

Keep unauthorized persons away from the ma­chine.

Do not touch hot engine parts.

Generally perform maintenance work only with the
engine shut down and the spark plug socket dis­connected.

Park the machine on level and solid ground and
secure it against tipping over.

Working on the fuel system

Do not inhale any fuel fumes.

Do not swallow fuel.

Avoid contact with skin and eyes.

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.

BOMAG16 BT 60/4, BT 65/4

Safety regulations

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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 com­bustion residues should 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 dis­pose of environmentally.

Store oil contaminated materials in a separate,
specially marked container and dispose of envi­ronmentally.

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, ex­haust pipe and air intake opening.

l Do not open the foot cover on the tamper foot,

spring tension. Danger of accident!

l 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.

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 in­structions.

Exhaust gases are highly dangerous! Always en­sure an adequate supply of fresh air when starting
in closed rooms!

Attach a warning tag to the steering bow if the ma­chine is defective.

l Do not mix the nozzle in the carburettor up by

mistake.

l Adjust the idling speed regulator screw exact-

ly.

l Do not damage the blower wheel when work-

ing on the magnetic ignition.

l Always replace self locking nuts.

BOMAG 17BT 60/4, BT 65/4

Safety regulations

STOP

O

N

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3

1

2

3

Fig. 6

2

4

5

6

1

OPERATION

PERATIO

-1

3600 - 4200 min 1-2 MINUTEN

OFF

4

3-6 Sec.

5

MAX

1-2 MINUTEN

6

1

2

=

MIN

Low Oil Level = No Start

STOP

MIN

1

ON

OFF

2

Max: 0,3 l

=

18.3 in

MIN

1850 - 2000 min

MAXMAX

3850 - 4200 min

3

-1

-1

RUN

7

540235

Stickers and decals

1 Brief operating instructions

2 Information sticker - Lifting point

3 Information sticker - Guaranteed sound capac-

ity level

4 Instruction sticker - Wear ear defenders

5 Information sticker - Lashing point

6 Information sticker - Choke lever

7 Warning sticker - Spring

BOMAG18 BT 60/4, BT 65/4