Bomag BT 60 - 4 Operating Instructions Manual
Bomag BT 60 - 4 Operating Instructions Manual
Bomag BT 60 - 4 Operating Instructions Manual
com/
Operating instructions
Maintenance instructions
BT 60/4 / BT 65/4
S/N 101 540 52 2391 > / S/N 101 540 53 4211 >
Vibratory Tampers
Catalogue No.
008 066 01 02/2010
These BOMAG machines are products from You should only operate the machine after you
F oreword
the wide product range of BOMAG machines have been instructed and in compliance with these
for earth and asphalt construction, refuse instructions.
compaction and stabilizing/recycling. Strictly observe the safety regulations.
BOMAG’s vast experience in connection with Please observe also the guidelines of the Civil En-
state-of-the-art production and testing meth- gineering Liability Association ”Safety Rules for
ods, such as lifetime tests of all important the Operation of Road Rollers and Soil Compac-
components and highest quality demands tors” and all relevant accident prevention regula-
guarantee maximum reliability of your ma- tions.
chine.
For your own personal safety you should only
This manual comprises: use original spare parts from BOMAG.
● Safety regulations In the course of technical development we re-
● Operating instructions serve the right for technical modifications
without prior notification.
● Maintenance instructions
These operating and maintenance instructions are
● Trouble shooting also available in other languages.
Using these instructions will Apart from that, the spare parts catalogue is avail-
able from your BOMAG dealer against the serial
● help you to become familiar with the machine. number of your machine.
● avoid malfunctions caused by unprofessional Your BOMAG dealer will also supply you with in-
operation. formation about the correct use of our machines in
soil and asphalt construction.
Compliance with the maintenance instructions will
The above notes do not constitute an extension of
● enhance the reliability of the machine on con- the warranty and liability conditions specified in the
struction sites, general terms of business of BOMAG.
● prolong the lifetime of the machine, We wish you successful work with your BOMAG
● reduce repair costs and downtimes. machine.
BOMAG GmbH
BOMAG will not assume liability for the function of
the machine Printed in Germany
Copyright by BOMAG
● if it is handled in a way not complying with the
usual modes of use,
● if it is used for purposes other than those men-
tioned in these instructions.
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.
BT 60/4, BT 65/4
Please fill in
............................
Machine type (Fig. 1)
............................
Serial-number (Fig. 1 and 2)
............................
Engine type (Fig. 3)
............................
Engine number (Fig. 3)
i Note Fig. 1
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. 2
Fig. 3
Table of Contents
BT 60/4, BT 65/4
Table of Contents
1 Technical Data
BT 60/4, BT 65/4
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Fig. 4
Dimensions in mm B H L L1 W
BT 60/4 350 960 735 335 280
BT 65/4 350 1000 735 335 280
*
BT 60/4 BT 65/4
Weight
Basic weight kg 61 67
Operating weight (CECE) kg 62 68
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 cm3 98 98
Rated power ISO 9249 kW 2.2 2.2
Rated speed rpm 4200 4200
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* BT 60/4 BT 65/4
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 0.8 1.0
Engine oil l 0.3 0.3
* The right for technical modifications remains reserved
BT 60/4, BT 65/4
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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 60/4: LpA = 98 dB(A), determined acc. to ISO 11204 and EN 500
BT 65/4: LpA = 95 dB(A), determined acc. to ISO 11204 and EN 500
nDanger
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:
oCaution
Observe the daily vibration load (Industrial safety acc. to 2002/44/EEC).
2 Safety regulations
BT 60/4, BT 65/4
44
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This BOMAG machine has been built in com- ● Working in horizontal direction
pliance with the latest technical standard and ● Ramming of poles
complies with the applicable regulations and
● Vibrating of paving blocks
technical rules. However, dangers for persons
and property may arise from this machine, if: It is not permitted to stand on the machine while
working.
● it is used for purposes other than the ones it is
intended for, Starting and operation of the machine in explosive
environments is prohibited.
● it is operated by untrained personnel,
● it is changed or converted in an unprofessional Remaining dangers, remaining risks
way,
Despite careful work and compliance with stand-
● the safety instructions are not observed. ards and regulations it cannot be ruled out that fur-
ther dangers may arise when working with and
Each person involved in the operation, mainte-
handling the machine.
nance and repair of the machine must there-
fore read and comply with these safety Both the machine as well as all other system com-
regulations. If necessary, this must be con- ponents comply with the currently valid safety reg-
firmed by obtaining the signature of the cus- ulations. Nevertheless, remaining risks cannot be
tomer. ruled out completely, even when using the ma-
chine for the purpose it is intended for and follow-
Furthermore, the following obviously also applies:
ing all information given in the operating
● applicable accident prevention instructions, instructions.
● generally accepted safety and road traffic reg- A remaining risk can also not be excluded beyond
ulations, the actual danger zone of the machine. Persons
● country specific safety regulations. It is the remaining in this area must pay particular attention
duty of the operator to be acquainted with to the machine, so that they can react immediately
these instructions and to apply these accord- in case of a possible malfunction, an incident or
ingly. This applies also for local regulations failure etc.
concerning different types of handling work. All persons remaining ion the area of the machine
Should the recommendations in these instruc- must be informed about the dangers that arise
tions be different from the regulations valid in from the operation of the machine.
your country, you must comply with the safety
regulations valid in your country. Regular safety inspections
Have the machine inspected by an expert (proper-
Intended use ly trained person) once every year.
This machine must only be used for:
● Compaction of all types of soils Who is allowed to operate the ma-
● Repair work in all types of soil
chine?
The machine must only be operated by trained
● Reinforcement of walkways
and authorized persons which are at least 18
● Work in trenches years of age. The responsibilities for the operation
● Backfills and compaction of marginal strips of the machine are to be clearly specified and
complied with.
Unintended use Persons under the influence of alcohol, medica-
tion or drugs must not operate, service or repair
However, dangers may arise from this machine if the machine.
it is operated by untrained personnel or if it is sub-
jected of unintended use.
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Maintenance and repairs require very specific Secure the machine against tipping over or slip-
knowledge and must therefore only be carried out ping off.
by trained and qualified personnel. Persons are highly endangered if they step or
stand under a suspended load.
Conversions and alterations to the ma- With the machine suspended be aware that the
chine. machine may swing about.
Unauthorized conversions to the machine are pro- Secure the machine on the transport vehicle
hibited for safety reasons. against rolling, slipping and turning over.
Original parts and accessories have been special-
ly designed for this machine. We wish to make ex- Starting the machine
pressly clear that we have not tested or authorized
any original parts or special equipment not sup- Before starting
plied by us. The installation and/or use of such Become acquainted with the equipment, the con-
products can impair the active and/or passive driv- trol elements, the working principle of the machine
ing safety. The manufacturer expressly excludes and the working area.
any liability for damage resulting from the use of
Wear your personal protective outfit (hard hat,
non-original parts or accessories.
safety boots, etc.). Wear ear defenders.
Before starting the machine check whether:
Damage, deficiencies, misuse of safety
installations ● the machine shows any obvious faults
Machines which are not safe to operate must be ● all guards and safety elements are in place
immediately taken out of service and shall not be ● the controls are fully functional
used, until these deficiencies have been properly
rectified. ● the machine is free of oily and combustible
material
Safety installations and switches must neither be
removed nor must they be made ineffective. ● all grips are free of grease, oils, fuel, dirt, snow
and ice.
Safety notes in the operating and main- Use only machines which are serviced at regular
tenance instructions: intervals.
nDanger
Starting and operation of the machine is
closed rooms and trenches
Sections marked like this point out possible Exhaust gases are highly dangerous! Always en-
dangers for persons. sure an adequate supply of fresh air when starting
and operating in closed rooms and trenches!
o Caution
Operation
Sections marked like that point out possible
dangers for the machine or for parts of the ma- ● Guide the machine and take care that you do
chine. not hurt your hands on any obstructions, dan-
ger of accident.
BT 60/4, BT 65/4
4
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Fig. 5
BT 60/4, BT 65/4
4
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BT 60/4, BT 65/4
4Q
Fig. 6
No. 1 = Throttle lever
Fig. 7
No. 2 = Engine stop button
Fig. 8
No. 3 = Recoil starter
Fig. 9
No. 4 = Fuel cock
Fig. 10
No. 5 = Choke lever
BT 60/4, BT 65/4
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4 Operation
BT 60/4, BT 65/4
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Danger
Danger of accident!
Please observe strictly the safety regulations
in chapter 2 of this instruction manual!
● Park the machine on ground as level as possi-
ble.
Check:
● condition of engine and machine
● fuel tank and fuel lines for leaks
● screw joints for tight fit
i Note
For a description of the following tasks refer to the
chapter "Daily maintenance".
● concertina wall for damage and leaks
i Note
Important! The engine cannot be started if the en-
gine oil level is too low.
● Engine oil level
● Fuel level
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n Danger
Exhaust gases are highly dangerous!
Always ensure an adequate supply of fresh air
when starting and operating in closed rooms
and trenches!
n Danger
Danger of accident!
Fig. 12
Always hold on to the machine.
● Set the throttle lever (Fig. 12) to position
Keep your feet away from the tamper plate, be- "MAX".
cause the vibration starts immediately.
Always keep an eye on a running machine.
n Danger
Loss of hearing!
Wear your personal noise protection means
(ear defenders) before starting operation.
Fig. 13
i Note
Always close the choke to start a cold and warm
engine.
Fig. 11
BT 60/4, BT 65/4
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Fig. 14 Fig. 16
● Pull the rope by the starter handle (Fig. 14) un- ● Open the choke (Fig. 16) 3 to 6 seconds after
til resistance can be felt. the engine has started running.
● Let the starter handle run back to initial posi-
tion.
Fig. 17
o
Once the engine has warmed up you can start to
Caution work with the tamper.
Do not let the starter handle hit back.
Starting under cold weather conditions
● Guide the starter handle back to initial position
by hand. ● If the engine stops again after approx. 3 to 5
seconds, close the choke again and repeat the
● If the engine does not start during the first at- starting process.
tempt, repeat the starting process.
Engine oil level too low
The engine does not start if the oil level is too low.
● Check the engine oil level, fill up if necessary.
● Repeat the starting procedure.
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Engine "drowned"
4.4 Work/operation
i Note
When the choke is closed and the starter rope is n Danger
pulled several times, the engine draws in too much
Danger of accident!
fuel and will probably not start.
Guide the machine only with the handle.
Remedy
Do not let the machine run unattended.
● Close the fuel cock.
Use your personal noise protection means (ear
● Open the choke. defenders).
● Set the throttle lever to full speed position.
● Operate the recoil starter until the engine
starts.
i Note
If the engine does not start after 10 to 20 attempts
● pull off the spark plug socket.
● unscrew the spark plug.
● operate the starter several times.
● Dry the spark plug with a clean cloth or blow it
dry with compressed air. If necessary clean
with a wire brush. Fig. 18
● Screw the spark plug back in and plug the ● Set the throttle lever (Fig. 18) to "MAX"-posi-
spark plug socket back on. tion.
● Repeat the starting procedure. ● The machine works at max. frequency.
Fig. 19
BT 60/4, BT 65/4
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Fig. 20 Fig. 22
● The travel speed can be influenced by altering ● During short breaks you should always set the
the load on the steering handle (Fig. 20). throttle lever to "MIN"-position (Fig. 22).
No load = slowly forward
i Note
This avoids premature wear of the centrifugal
clutch and reduces the fuel consumption
Fig. 21
i Note
The lift height of the material to be compacted
should not be higher, than the tamper can man-
age.
If the tamper should get out of rhythm on highly
compacted ground, smooth running can be
achieved by slightly changing the engine speed
and/or the inclination of the tamper.
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Caution
Do not shut the engine down all of the sudden
from full speed, but let it idle for a while for
temperature equalization.
Fig. 25
Fig. 23
Fig. 26
i Note
This procedure protects against moisture deposits
inside the engine.
Fig. 24
n Danger
Danger of burning!
Immediately after shutting down the engine is
still hot, do not touch the exhaust.
Park the machine so that it cannot turn over.
BT 60/4, BT 65/4
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Fig. 28
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Fig. 29
BT 60/4, BT 65/4
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5 Maintenance
BT 60/4, BT 65/4
4
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Environment
During maintenance work catch all oils and fu-
els and do not let them seep into the ground or
into the sewage system. Dispose of oils and fu-
els environmentally.
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Fuel
5.2 Fuels and lubricants
Quality
The engine has been approved for operation with
Engine oil unleaded gasoline with a octane number of 86 or
higher (research octane number of 91).
Quality
Use only commercially available brand fuel.
The oil is an essential factor for the performance
and lifetime of the engine. You can use unleaded standard grade petrol with
maximum 10 percent by volume of ethanol (E10)
Use engine oil for four-stroke engines which meets
or maximum 5 percent by volume of methanol.
or even exceeds the requirements for API-service
class SJ or higher (or equivalent). Methanol must also contain co-solvents and corro-
sion inhibitors.
Using fuels with higher ethanol or methanol con-
tents exceeding the values specified above may
cause starting difficulties and/or performance
problems. Damage may also occur to metal, rub-
ber or plastic parts in the fuel system.
Engine damage and performance problems
caused by the use of fuels with higher ethanol or
methanol percentages than the ones specified
above are not covered under warranty.
viscosity
Since lubrication oil changes its viscosity with the
temperature, the ambient temperature at the oper-
ating location of the engine is of utmost impor-
tance when choosing the viscosity class (SAE-
class) (see diagram (Fig. 30)).
SAE10W-30 is recommended for general use un-
der any temperature. When using single purpose
oil you must choose the correct viscosity for the
area of use.
Temperature related lubrication oil changes can
be avoided by using multi-purpose oils. The follow-
ing oil change intervals apply also when using mul-
ti-purpose oils.
Change intervals
The longest permissible time the lubrication oil
should remain in an engine is 1/2 year or 100 op-
erating hours.
BT 60/4, BT 65/4
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Engine
- Engine oil Engine oil API SJ or higher 0,3 l to oil level mark
SAE 30 (+10 °C to
+30 °C)
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Caution
During the running-in period, up to approx. 200
operating hours, check the engine oil level
twice every day.
Depending on the load the engine is subjected
to, the oil consumption will drop to the normal
level after approx. 100 to 200 operating hours.
BT 60/4, BT 65/4
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as required
annually
monthly
No. Maintenance work Comment
daily
5.6 Clean the machine in case of extreme dust clean X
every day
5.7 Check the bellows on the tamper X
5.8 Check the engine oil level Dipstick mark X
5.9 Check the fuel level X
5.10 Change the engine oil at least every 100 operating X
hours or 1x per year
5.11 Clean, check the spark plug, replace if nec- X
essary
5.12 Taper plate, tighten the bolts X
5.13 Check the oil level in the tamper foot Inspection glass X
5.14 Check, adjust the valve clearance Intake: 0.15 mm X
Exhaust: 0.20 mm
5.15 Change the fuel filter X
5.16 Clean the fuel screen X
5.17 Oil change in tamper foot X
5.18 Clean, change the double dry air filter car- in case of a drop in the max. en- X
tridge gine speed
Fig. 31
● Do not guide the water jet directly into the air Fig. 32
filter 1 (Fig. 31) and into the starter/air intake ● Check the condition of the bellows, inspect for
(2). damage and tight fit.
● Check the hose clamps for tight fit (Fig. 32).
BT 60/4, BT 65/4
Q
o Caution
Check the engine oil level with highest care, to
avoid over or underfilling of the engine. Under-
filling can damage the engine. Overfilling caus-
es excessive development of smoke and can
also lead to engine damage
i Note
The engine cannot be started if the engine oil level Fig. 34
is too low.
● The oil level must reach the bottom edge of the
● Stand the tamper on flat and level ground. filler bore (Fig. 34), maximum level.
● Shut down the engine. ● To check the oil level insert the dipstick, but do
not screw it in.
● If the oil level is too low top up oil immediately.
● Push the dipstick in again.
Fig. 33
| Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke, do not spill any fuel.
Do not refuel in closed rooms.
Shut down the engine, close the fuel valve.
| Danger Fig. 36
Health hazard! ● Clean the area around the filler cover, unscrew
Do not inhale any fuel fumes. the filler cover (Fig. 36).
o
● Fill in fuel through a funnel with screen.
Caution ● Close the tank again.
Contaminated fuel can cause malfunction or
even damage of the engine.
For quality and quantity of oil refer to the "table
of fuels and lubricants".
Environment
Catch running out fuel, do not let it seep into
the ground.
Fig. 35
BT 60/4, BT 65/4
\
| Danger
Danger of sclading when draining off hot oil.
o Caution
Park the machine on level ground.
Drain the engine oil only when the engine is
warm.
o
Caution
Fig. 38
● Unscrew the oil drain plug (Fig. 38), let the old
Check the engine oil level with highest care, to oil run out and catch it.
avoid over or underfilling of the engine. Under-
filling or overfilling can damage the engine. ● Clean the drain plug and screw it back in with
a new seal ring.
● Fill in fresh engine oil through the oil filler
Environment
opening.
Catch running out old oil, do not let it seep into
the ground and dispose off environmentally. For quality and quantity of oil refer to the "table
of fuels and lubricants".
i Note
The engine cannot be started if the engine oil level
is too low.
Fig. 39
BT 60/4, BT 65/4
4
|
Danger
Danger of burning!
Let the engine cool down for approx. 15 min-
utes before cleaning/changing the spark plug.
Fig. 41
Fig. 40
i Note
In case of excessive combustion residuals or
burned off electrodes replace the spark plug, en-
sure correct heat value of the spark plug.
● Check the electrode gap with a feeler gauge, if
necessary adjust the gap to 0.6...0.7 mm.
Spark plugs:
NGK: CR5HSB
Denso: U16FSR-UB
o
Caution
Do not use spark plugs with incorrect heat val-
ue.
i Note
Stand the tamper of level ground for a short while,
so that all oil can run into the housing.
Fig. 42
BT 60/4, BT 65/4
i Note
Check and adjust only when the engine is cold (20
+/- 10 °C). If necessary have this work performed
by a specialist workshop. Valve clearance:
Intake valve (IN) = 0.15 mm (0.006 in)
Exhaust valve (EX) = 0.20 mm (0.008 in)
Fig. 45
Fig. 43
Fig. 46
Fig. 44
o Caution
Fig. 47
BT 60/4, BT 65/4
i Note
The piston is in top dead centre of the compres-
sion stroke.
However, if the exhaust valve is open when align-
ing the marks, the flywheel must be turned further
by 360°.
Fig. 50
Fig. 49
~ Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke.
Do not spill any fuel.
~
Danger
Health hazard! Fig. 52
Do not inhale any fuel fumes. ● Loosen hose clamp (1) (Fig. 52) and pull the
fuel hoses off the fuel filter.
Environment ● Loosen the clamping screws (3) and take off
Catch running out fuel, do not let it seep into the fuel filter (2).
the ground. ● Install the new fuel filter and observe the flow
Dispose of the used fuel filter environmentally. direction (arrow).
● Fasten clamps and hose clips.
Fig. 51
BT 60/4, BT 65/4
Q
~ Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke and do not spill any fu-
el.
Clean the fuel screen filter only when the en-
gine is cold.
~
Danger
Fig. 54
Health hazard! ● Unscrew the fuel screen (Fig. 54) and clean it
with gasoline.
Do not inhale any fuel fumes.
● Check the condition of the screen grid (holes),
replace if necessary.
Environment
Catch running out fuel and dispose of environ-
mentally.
Fig. 55
o
Caution
For quality and quantity of oil refer to the "table
of fuels and lubricants".
Ensure strict cleanliness. ● Screw the filler plug back in with a new seal
Change the oil at operating temperature. ring.
Environment
Catch running out old oil, do not let it seep into
the ground and dispose off environmentally.
● Tip the tamper backwards.
Fig. 58
Fig. 56
Fig. 57
BT 60/4, BT 65/4
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As r equired
i Note
Contamination of the air filter cartridge depends
mainly on the proportion of dust in the intake air, if
necessary clean every day.
In case of wet or sticky contamination replace the
double filter cartridge.
Fig. 60
i Note
Before installation check seals and filter cartridge
for damage, replace if necessary.
Fig. 59
o
Caution
Make sure that no dirt falls into the air intake
channel.
Visual inspection/cleaning
~
Danger
Fig. 61
BT 60/4, BT 65/4
4
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Fig. 62
Fig. 63
● If soiled with dry fine dust blow the dry air filter
out from the clean air side (Fig. 63).
● Clean the air filter housing.
o
Caution
Make sure that no dirt falls into the air intake
channel.
i Note
Before installation check seals and dry air filter for
damage, replace if necessary.
6 Trouble shooting
BT 60/4, BT 65/4
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Engine oil level too low Check the engine oil level
Engine stops frequently in Fuel system clogged Clean the fuel screen in the tank
short intervals Replace the fuel filter
Clean the fuel screen in the carburettor
Engine does not run with full Throttle cable defective replace
speed
Throttle cable incorrectly adjust- Adjust the throttle cable
ed
Too high engine oil level Drain engine oil down to "MAX" level
(clean intake manifold)
Engine runs with high speed, Centrifugal clutch defective Change the centrifugal clutch
but no vibration
Mechanical defect Have repaired by the customer service
of BOMAG.
BT 60/4, BT 65/4
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