BORMANN PRO BTC5105 Ground Compressor Petrol Engine Instruction Manual

: June 13, 2024
: BORMANN PRO

Table of Contents

SPECIFICATIONS
APPLICATIONS
FUNCTIONS AND CONTROLS
FOR SAFE OPERATION
HAZARDS AND RISKS
OPERATION
- GENERAL OPERATION
- PRIOR TO OPERATION
STARTING
TRANSPORTATION
SHUTDOWN
SERVICE AND STORAGE
CARE & PREVENTIVE MAINTENANCE
SERVICE
TROUBLESHOOTING
WARRANTY
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BORMANN PRO BTC5105 Ground Compressor Petrol Engine

WARNING
To reduce the risk of injury, all operators and maintenance personnel must read and understand these instructions before operating, changing accessories or performing maintenance on equipment we produced. All possible situations cannot be covered in these instructions. Care must be given by everyone using, maintaining or work near this equipment.

CAUTION
NO OIL IN ENGINE
Fill the engine with oil to the correct level before starting the engine.

SPECIFICATIONS

Technical Data

The manufacturer reserves the right to make minor changes to product design and technical specifications without prior notice unless these changes significantly affect the performance and safety of the products. The parts described / illustrated in the pages of the manual that you hold in your hands may also concern other models of the manufacturer’s product line with similar features and may not be included in the product you just acquired.
To ensure the safety and reliability of the product and the warranty validity, all repair, inspection, repair or replacement work, including maintenance and special adjustments, must only be carried out by technicians of the authorized service department of the manufacturer.
Always use the product with the supplied equipment. Operation of the product with non-provided equipment may cause malfunctions or even serious injury or death. The manufacturer and the importer shall not be liable for injuries and damages resulting from the use of non-conforming equipment.

APPLICATIONS

The Plate Compactor is a machine that compacts the ground and it intends to make the surface smooth, by transmitting vibration through vibrating plate, which power is generated from a single motor in vibrator case. This machine is suitable for making the ground surface smooth, leveling the soil, beaching, and finishing the asphalt paving.

Applications as follows:

Trench compaction Earth works
Road maintenance Landscaping
Brick paving Driveway toppings
Earth works
Landscaping
Driveway toppings

This machine is hard to move forward on soil with much water (especially clay soil). It is not suitable for such application. This machine is difficult to level ground including big stones due to insufficient compacting force. Plate compactor is mainly used for compacting surface smoother and it is nor effective for jobs that require heavy compaction. In case of compacting ground deeply into lower layer, it is recommended for use. Tamping Rammer, Vibrator Compactor and Vibration Roller, which compact force, are rather effective. Please use this compactor for compacting surface soil, sediment, sand, beaching and asphalt. It is not recommended to be used for the other applications.

Warning for incorrect application and abuse

FUNCTIONS AND CONTROLS

Motor:

The motor is controlled by an ON/OFF switch or push button, which is mounted on the motor below the fuel tank. The motor speed is controlled by a remote throttle lever which is mounted on the machine handle. The motor is fitted with an oil alert device which will stop the motor or prevent starting.
The motor speed is controlled by a remote throttle lever which is mounted on the machine handle. The motors are fitted with an oil alert device which will stop the motor or prevent starting when the crankcase oil level falls below a safe level.

Drive belt:

Tension of the drive belt is adjustable. Loosen the four nuts which secure the motor to the base plate, adjust the set screws, which bear against the motor crankcase to achieve the required belt tension. Ensure that the four nuts and the set screw lock nuts are tightened after adjustment.

FOR SAFE OPERATION

This safety alert symbol identifies important safety messages throughout this manual and on the machine.
When you see this symbol, carefully read the message that follows. Your safety is at stake!

Foreword:

It is important to read this manual carefully so that you will fully understand the operational characteristics and performance of the plate compactor. Proper maintenance procedures will insure long life and top performance of the unit.

Safety:

This section outlines basic safety procedures that apply to the operation, maintenance and adjustment of the plate compactor. This unit is designed as a powerful, productive machine that should be operated with respect and caution. Misuse or carelessness can result in serious injury or damage or both. Safety precautions must be observed at all times.

Operator Qualifications:

Before operating this equipment, the individual should read this manual. Whenever possible, he should be shown how to operate the unit by an experienced operator. Inexperience is hazardous in operating any machine or attachment. Trial and error is not the way to become familiar with a piece of equipment. This is expensive, diminishes equipment’s life. The machine should not be left unattended when operating.

General Safety:

Protection is required. Wear hard hat, shatterproof glassed, steel toed boots and other protective devices required by job conditions. Avoid jewellery or loose clothing. These could be caught in controls or in moving parts and cause serious injury.

Starting Safety:

Poisonous fumes. Start and operate only in well ventilated area. Breathing exhaust gases can result sickness or death.

Servicing Safety:

Flammable liquid: Stop engine and do not smoke or allow work in immediate area when refueling. Fire or explosion could result from flames or sparks.
Moving parts: Shutdown engine before performing.
Service or maintenance: Contact with moving parts can cause serious injury.
Temperature: Allow machine and engine to cool before performing service or maintenance. Contact with hot components can cause serious bums.

SHUTDOWN

EMERGENCY SHUTDOWN

Move throttle lever to “OFF” position and also turn stop switch to “OFF”.

NORMAL SHUTDOWN

Move throttle lever quickly from “ON” to “OFF” and run the engine for 3 to 5 minutes at low speed. When engine cools, turn stop switch to “OFF” position, close the shutoff fuel valve.

HAZARDS AND RISKS

Never allow any person to operate the machine without adequate instructions.
Ensure that all operators will read, understand and follow the operating instructions.
Serious injury could result from improper or careless use of this machine.
Plate compactors are heavy units and should be positioned by two people of appropriate strength, using the lifting handles provided on the machine, along with the correct lifting techniques.

MECHANICAL HAZARDS

Do not operate the machine unless all protective guards are in place.
Keep hands and feet clear of rotating and moving parts as they will cause injury if contacted.
Ensure that the motor operation switch is in the OFF position and the spark plug ignition lead is disconnected before removing the guards or making adjustments.
Ensure that both the machine and the operator are stable by setting up on level terrain and the machine will not tip over, slide or fall while in operation or unattended.
Do not leave the machine in operation while is unattended.
Ensure that the walls of a trench are stable and will not collapse due to the action of vibration, prior to commencing compaction.
Ensure that the area to be compacted does not contain any “live” electrical cables, gas, water or communication services which may be damaged by the action of the vibration.
Exercise care when operating unit. Exposure to vibration or repetitive work actions may be harmful to hands and arms.
Never stand on the unit while it is operating.
Do not increase the governed no-load motor speed above 3.500 r/min. Any increase may result personal injury and damage to the machine.
Be careful not to contact with muffler when the engine is hot, since it can cause severe burns.
Ensure that repairs to the motor and machine are carried out by specialists.

FIRE AND EXPLOSION HAZARDS

Petrol is extremely flammable and explosive under certain conditions.
Ensure that petrol is only stored in an approved storage container.
Do not refuel the motor while it is in operation or hot.
Do not refuel the motor in the vicinity of sparks, a naked flame or a person smoking.
Do not overfill the fuel tank and avoid spilling petrol when refueling. Spilled petrol or petrol vapor may ignite. If spillage occurs, ensure that the area is dry before starting the motor.
Ensure that the fuel tank cap is securely fitted after refueling.

CHEMICAL HAZARDS

Do not operate or refuel a petrol or diesel motor in a confined area without adequate ventilation.
Carbon monoxide exhaust gases from internal combustion motor driven units can cause death in confined spaces.

NOISE HAZARDS

Excessive noise can lead to temporary or permanent loss of hearing.
Wear an approved hearing protection device to limit noise exposure. As required by Occupational Health and Safety regulations.

PROTECTIVE CLOTHING

Always wear approved hearing protection when working in a confined work space. Protective goggles and a dust mask should be worn when working in a dusty environment. Protective clothing and footwear may also be desirable when working with hot mix bitumen.

ADDITIONAL HAZARDS

Slip/Trip/Fall is a major cause of serious injury or death. Beware of uneven or slippery work surfaces. Take care when working in the vicinity of unprotected holes or excavations.

OPERATION

GENERAL OPERATION

The machine is best suited to the compaction of bituminous and granular materials e.g. granular soils, gravels and sands or mixtures of both. Cohesive soils such as silt and clay could be better compacted by the use of the impact force produced by a vibrating rammer.
Where possible, the site should be graded and leveled before commencing compaction.
Correct moisture content in soil is vital to proper compaction. Water acts as a lubricant to help soil slide particles together. Too little moisture means inadequate compaction; too much moisture leaves water-filled voids that weaken the soil’s load bearing ability.
Use unleaded grade petrol and ensure that the fuel is free from contamination.
The vibratory motion provides a self propelling action. Position the handle at the opposite end of the machine to the vibrator.
Start the motor using the recoil starter. (If the motor is fitted with an on/off switch this must first be turned to ON before starting.)
Increase the motor speed to the maximum setting, using the hand throttle lever, before commencing compacting.
The machine should be controlled by grasping the handle with both hands and applying restraint to control the forward motion. If forward or backward motion is problematic, adjust the red handle or nuts (item 21, 22 in components list), steer the machine by moving the handle sideways to the right or left.
Always maintain good footing so that you do not slip and loose control when starting or operating the machine.

PRIOR TO OPERATION

Make sure that all dirt, etc., are thoroughly removed from the unit prior to operation. Special effort should be given to the button face to the vibrating plate and those areas adjacent to the cooling air inlet of engine, carburetor, and air cleaner.
Check all bolts and screws for tightness and make sure all bolts and screws are securely tightened. Loose bolts and screws may cause damage to the unit.
Check the V-belt for tightness. The normal slack should be approximately 10-15 mm (1/2’’) when the belts are forcibly depressed in the middle position between the two sheaves.
If there is excess belt play. There could be a decrease in the impact force or erratic vibration, causing machine damage.
Check the engine oil level and if it is low, it should be refilled. Use the proper motor oil as suggested in the table below. (Fig.1)
Remove the oil plug in the vibrator assembly and check the oil level. Make sure the compactor’s level when checking. The oil level should be up to the oil plug. Every month or every 200 hours of operation, replace the oil.

Season Temperature	Grade of Motor oil (higher than MS class)

Spring, Summer or Autumn
+120oF to +40oF| SAE 30
Winter
+40oF to +15oF| SAE 20
Below +15oF| SAE 10W-30

IMPORTION

Use the motor oil SAE

When changing the oil, the old oil can be drained by tipping the unit. The oil will drain easily while is hot.
A regular grade gasoline should be used in the engine.
When filling the fuel tank, make sure the fuel filter is used.

CAUTION

Be careful with the operating place and ventilation. Avoid operating the machine in a closed room, tunnel, or other badly ventilated places, since its exhaust contains deadly poisonous carbon monoxide. If the machine is employed unavoidable operated in such a place, discharge the exhaust out of the room by suitable means.
Be careful with hot members. Mufflers and other hot members are dangerous. Do not touch them with unprepared hand.
Observe the following cautions when transporting. Tighten the fuel tank cap securely and turn off the fuel supply during the draining of petrol from the fuel tank before transporting over long distances or uneven roads.
Stop engine without fail before replenishing fuel tank. Never replenish gasoline while the engine is running or remains hot, otherwise spilled or evaporated fuel is liable to catch fire from engine sparks or muffler heat. Wipe off spilled fuel, if any, before starting engine. Be careful not to spill fuel.
Keep inflammable way from the vicinity of the exhaust port. Be careful with the use of inflammables, since the exhaust port is subjected to a high temperature.

STARTING

Gasoline Engine

Turn the STOP switch clock-wise to the position “I” (ON). (Fig.2)
Open the fuel cock. (Fig.3)
Set the speed control lever 1/3 to 1/2 of the way towards the high speed position. (Fig.4)

Close the choke lever

If the engine is warm or the ambient temperature is high, open the choke lever half-way, or keep it fully open.
If the engine is cold or the ambient temperature is low, close the choke lever fully. (Fig.5)
Pull the starter handle slowly until resistance is felt. This is the “compression” point.
Return the handle to its original position and pull swiftly.
Do not pull out the rope all the way.
After starter the engine, allow the starter handle to return to its original position while still holding the handle.(Fig.6)

Diesel Engine

Turn the throttle lever to START position (open about 30 degrees). (Fig.7)

Operate Starter

In case of recoil starter pull the starter knob slowly, you will reach a point where resistance becomes stronger (compression point). By pulling it further, you will find a point where resistance is reduced. Return the knob slowly to its original place. (Fig.7)

CAUTION

Do not pull the rope all the way and do not take you hand off the pulled knob but slowly return it original position.
After starting up the engine, be sure to perform a warm up for 2 to 3 minutes. This should be performed without fail, particularly during winter season

OPERATION

As the engine warms up, gradually move the choke lever to the OPEN position. (Fig.8)
Move the speed control lever from the Low to the High position.
When the engine speed reaches approximately 2,300-2,600rpm, the centrifugal clutch engages. If the engine speed increased very slowly, it is possible that the clutch can slip. Do not operate the speed control lever slowly. (Fig.9,

OIL ALERT SYSTEM (Optional)

The Oil Alert system is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. Before the oil level in the crankcase can fall below a safe limit, the Oil Alert System will automatically stop the engine (the engine switch will remain in the ON position).

TRANSPORTATION

Be sure to stop the engine while transporting.
Screw up the fuel tank cap securely and close the fuel valve to avoid fuel leaking.
In transportation by car, place the machine in a secure way so not to move or fall down. In case of driving a long distance or off-road, remove fuel from tank.

SHUTDOWN

To stop the engine in an emergency, turn the stop switch to the OFF position.
Under normal conditions, use the following procedure:

Set the speed control lever at the low speed position and allow the engine to run at low speed for 2 or 3 minutes before stopping. ( Fig.11)
Tum the stop switch to the OFF position. (Fig.12)
Close the fuel cock. (Fig.13)

SERVICE AND STORAGE

Flammable liquid: Stop engine and do not smoke or allow work in immediate area when refueling. Fire or explosion could result from flames or sparks.
Moving parts: Shutdown engine before performing service or maintenance. Contact with moving parts can cause serious injury.
High temperature: Allow machine and engine to cool before performing service or maintenance. Contact with hot components can cause serious burn.

Daily Service

Remove mud, dirt, etc, from the unit.
Clean bottom face of the vibrating plate.
Check the air cleaner element and clean if necessary.
Check all nuts, bolts, and screws for tightness and re-tighten as necessary.

Weekly Service

AIR CLEANER SERVICE (Fig.14)

Dirty air cleaner element will cause starting difficulty, power loss, engine malfunctions, and shorten engine life extremely.
Keep the air cleaner element clean.

URETHANE FOAM ELEMENT

Remove the element and wash it in kerosene or diesel fuel. Then saturate it in a mixture of 3 parts kerosene or diesel fuel and 1 part engine oil. Squeeze the element to remove the mixture and install it in the air cleaner.

URETHANE FOAM DUAL STRUCTURE

Clean the urethane foam in the same way as described above.
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.
Remove spark plug, clean and adjust the spark plug gap to 0.6-0.7mm (0.02-0.03 in). (Fig.15)
Drain the motor oil of the engine and replace with new specified oil. (Fig.16)

NOTE

When the engine is new, the first oil change must be made after 20 hours of operation and replenish the oil tank before operating.

Monthly Service

Change the oil in the vibrator assembly.

Storage

When storing the compactor for long periods after operation:

Thoroughly drain the fuel from the fuel tank, fuel pipe and carburetor.
Pour a few drops of motor oil into the cylinder by removing the spark plug.
Rotate the engine several times by hand so that the cylinder interior is covered with oil.
Clean the outer surface of the machine with an oil moistened cloth.
Cover the unit and store in a humidity-free area.

CARE & PREVENTIVE MAINTENANCE

Check the oil level in the motor crankcase daily. Check the vibrator oil level weekly. Inspect the rubber antivibration mounts for wear or deterioration. Clean the underside of the plate regularly to prevent a build up of material.

SERVICE

Change the oil in the motor crankcase regularly to minimize wear. Inspect, clean and/or replace the motor air cleaner regularly, particularly when operating in a dusty environment. Inspect, clean and/or replace the spark plug regularly. Check all fasteners for tightness as the machine is subject to vibration. Check V belt tension, wear and that it is running correctly. Adjust or replace as required.

Vibrator oil check

Place the plate compactor horizontally on a flat surface. Make sure the compactor is level when checking the oil in the vibrator assembly.
Check vibrator oil level by removing the plug (vibrator oil gauge) as shown in Fig.17. The oil level should be up to the oil plug. If oil is required, replace using SAE motor oil, as suggested in the table Fig.1.
When changing the vibrator oil, remove the drain plug (Fig.17), and simply tip the compactor to drain the oil.

Note that the oil will drain more easily while it is hot.

TROUBLESHOOTING

BEARINGS

The following bearings are sealed:

Centrifugal clutch – grease lubricated
Vibrator – oil bath lubricated

FINISH

The machine is finished in gold equipment enamel, the handle in black backed enamel. Exposed metal surface is zinc electroplated for corrosion protection.

SYMPTOM	POSSIBLE CAUSES AND CORRECTION
Motor will not start

Check the ON/OFF switch to ensure that it is switched “ON”.
Check the fuel supply.
If a motor is ﬁtted check the crankcase oil level as and oil sensor device is ﬁtted to these motors which prevents starting and stops the motor when the oil level is low.

Motor stops|

Check the fuel supply.

Petrol Motor lacks power.|

Check the condition of the air ﬁlter

Insufficient vibration|

Check for a slipping or a missing see belt.

Machine is not moving freely|

Check the underside of the plate for a build up of material.

WARRANTY

The machinery have been manufactured according to strict standards set by our company, which are aligned with the respective European quality standards. The diesel and gasoline powered machines are provided with a warranty period of 24 months for non-professional use and 12 months for professional use. The warranty is valid from the date of purchase of the product. Proof of the warranty right is the purchase document of the machine (retail receipt or invoice). Under no circumstances shall the company cover the relevant cost of spare parts and respective required working hours unless a copy of the purchase document is presented. In case the repair has to be done by our service department the cost of transportation (to and from) is entirely borne by the sender (client). The said machines must be sent for repair to the company or to an authorized workshop in the appropriate way and means of transport.

WARRANTY EXEMPTIONS AND RESTRICTIONS:

Spare parts that wear out naturally as a consequence of being used (blade, chain, recoil starter, spark plug, trimmer line etc.).
Machinery damaged as a result of non-compliance with the instructions of the manufacturer.
Machinery poorly maintained or taken care of.
Use of improper spare parts or accessories.
Machinery given to third entities free of charge.
Storing the machine with fuel.
Damage as a result of mistaken assembly.
Damage as a result of mixing of fuel with machine oil by mistake.
Damage as a result of poor quality of fuel or lubricant.
Damage as a result of not cleaning the generator as required.
Equipment that has been modified or disassembled by unauthorized personnel.
Equipment used for rent.

The warranty covers only the free of charge replacement of the component that presents a manufacturing defect or material failure. In case of lack of a specific spare part the company reserves the right to replace the machine with another of the same kind. After all warranty procedures have been concluded, the warranty period of the machine shall not be extended or renewed. Replacement of a spare part with repair charge is covered by a 1 year warranty of good operation, subject to compliance with the warranty terms. The spare parts or machinery that are replaced remain in the possession of our company. Requirements, other than those mentioned in this warranty form, regarding repairing a machine or damage thereof, do not apply. Greek law and relative regulations apply to this warranty.

This appliance is a quality product. It was designed in compliance with current technical standards and made carefully using normal, good quality materials.
The warranty period is 24 months for non-professional use and 12 months for professional use and commences on the date of purchase, which can be verified by the receipt, invoice or delivery note. During this warranty period all functional errors, which, despite the careful treatment described in our operating manual, are verifiably due to material flaws, will be rectified by our aft er-sales service staff . The warranty takes the form that defective parts will be repaired or replaced with perfect parts free of charge at our discretion. Replaced parts will become our property. Repair work or the replacement of individual parts will not extend the warranty period not will it result in a new warranty period being commenced for the appliance. No separate warranty period will commence for spare parts that may be ted. We cannot off er a warranty for damage and defects on appliances or their parts caused by the use of excessive force, improper treatment and servicing. This also applies for failures to comply with the operating manual and the installation or spare and accessory parts that are not included in our range of products. In the event of interference with of modifications to the appliance by unauthorized persons, the warranty will be rendered void. Damages that are attributable to improper handling, over loading, or natural wear and tear are excluded from the guarantee. Damages caused by the manufacturer or by a material defect will be corrected at no charge by repair or by providing spare parts. The prerequisite is that the equipment is handed over assembled, and complete with the proof of sale and guarantee. For a guarantee claim, only use the original packaging. That way, we can guarantee quick and smooth guarantee processing. Please send us the appliances post-paid or request a Freeway sticker. Unfortunately we will be unable to accept appliances that are not postpaid. The warranty does not cover parts that are subject to natural wear and tear. If you wish to make a warranty claim, report faults or order spare parts or accessories, please contact the after-sales center: Subject to change without prior notice.

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