BELLE PCX 500 - Vibratory plate ALTRAD - Free user manual and instructions

USER MANUAL BELLE PCX 500 ALTRAD

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Before you operate or carry out any maintenance on this machine YOU MUST READ and STUDY this manual. WARNING The product can be at risk. The machine or yourself can be damaged or injured if procedures are not carried out in the correct way. CAUTION The life of the operator can be at risk. WARNING WARNING

Contents KNOW how to safely use the unit’s controls and what you must do for safe maintenance. (NB Be sure that you know how to switch the machine off before you switch on, in case you get into dif¿ culty.) ALWAYS wear or use the proper safety items required for your personal protection. If you have ANY QUESTIONS about the safe use or maintenance of this unit, ASK YOUR SUPERVISOR OR CONTACT: Altrad Belle (UK): [phone]

1. Throttle lever. 2. Choke lever. 3. Fuel ON / OFF lever. 4. Engine ON / OFF switch. 5. Air Filter Housing. 6. Fuel Tank. 7. Exhaust. 8. Recoil Starter Handle. 9. Engine oil ¿ ller / dipstick. 10. Engine oil drain plug. 11. Vibrator. 12. Vibrator oil check plug. 13. Attachment point for Water Spray System or Paving Pad. 14. Belt guard. 15. Control Handle. 16. Lifting Point. 17. Attachment points for Transporter Options. N.B. Drawing based a Honda GX160 engine. Please refer to the manufacturer’s literature for Hatz engine details. Environment Safe Disposal. Instructions for the protection of the environment.The machine contains valuable materials. Take the discarded apparatus and accessories to the relevant recycling facilities.

A - Safety Decal (Part No. 19.0.373) Please Read Operators Manual Wear Protective Footwear Wear Ear Protection Wear Eye Protection B - Noise Decal (800-99951 & 800-99942) The Noise Level of the machine during operation is 105 / 107 dB(A) C - Engine RPM Decal A. Safety Decal B. Noise Decal C. Engine RPM Decal D Lifting Point Decal E. Low HAV Decal F. Engine Warning Decal Fast Engine Speed Position Slow Engine Speed Position D - Lifting Point Decal E - Low HAV Decal (800-99965) The machine has a UK Patented Design which reduces HAV levels allowing a greater Usage Time. F - Engine Warning Decal Please Read Engine Manual Petrol is highly À ammable. Turn off the engine and allow time to cool before refuelling. The Engine emits toxic Carbon Monoxide. Do not run the Engine in an enclosed area.

C10 General Safety For your own personal protection and for the safety of those around you, please read andensure you fully understand the following safety information. It is the responsibility of the operator to ensure that he/she fully understands how to operatethis equipment safely. If you are unsure about the safe and correct use of the Plate Compactor, consult your supervisor or Altrad Belle.

• This equipment is heavy and must not be lifted single-handedly, either GET HELP or use suitable lifting equipment. A special transport assembly is available for the compactor (see options).

• Cordon off the work area and keep members of the public and unauthorised personnel at a safe distance.

• Personal Protective Equipment (PPE) must be worn by the operator whenever this equipment is being used (see Health & Safety).

• Make sure you know how to safely switch this machine OFF before you switch it ON in case you get into dif¿ culty.

• Always switch OFF the engine before transporting, moving it around the site or servicing it.

• During use the engine becomes very hot, allow the engine to cool before touching it. Never leave the engine running and unattended.

• Never remove or tamper with any guards ¿ tted, they are there for your protection. Always check guards for condition and security, if any are damaged or missing, DO NOT USE THE COMPACTOR until the guard has been replaced or repaired.

• Do not operate the Compactor when you are ill, feeling tired, or when under the inÀ uence of alcohol or drugs. Fuel Safety

• Before refuelling, switch off the engine and allow it to cool.

• When refuelling, DO NOT smoke or allow naked À ames in the area.

• Spilt fuel must be made safe immediately, using sand. If fuel is spilt on your clothes, change them.

• Store fuel in an approved, purpose made container away from heat and ignition sources.

Fuel is À ammable. It may cause injury and property damage. Shut down the engine, extinguish all open À ames and do not smoke while ¿ lling the fuel tank. Always wipe up any spilled fuel. CAUTION The exhaust fumes produced by this equipment are highly toxic and can kill! CAUTION Improper maintenance or use can be hazardous. Read and Understand this section before you perform any maintenance, service or repairs. CAUTION Health and Safety Vibration Some vibration from the compaction operation is transmitted through the handle to the operator’s hands. The Altrad Belle Plate Compactor range has been speci¿ cally designed to reduce hand/arm vibration levels. Refer to speci¿ cations & technical data for vibration levels and usage times (recommended maximum daily exposure time). DO NOT exceed the maximum usage times. PPE (Personal Protective Equipment). Suitable PPE must be worn when using this equipment i.e. Safety Goggles, Gloves, Ear Defenders, Dust Mask and Steel Toe capped footwear. Wear clothing suitable for the work you are doing. Tie back long hair and remove any jewellery which may catch in the equipment’s moving parts. Dust. The compacting process will occasionally produce dust, which may be hazardous to your health. Always wear a mask that is suited to the type of dust being produced. Fuel. Do not ingest fuel or inhale fuel vapours and avoid contact with your skin. Wash fuel splashes immediately. If you get fuel in your eyes, irrigate with copious amounts of water and seek medical attention as soon as possible. Exhaust Fumes

Pre start-up inspection The following Pre-start-up inspection must be performed before the start of each work session or after every four hours of use, whichever is ¿ rst. Please refer to the service section for detailed guidance. If any fault is discovered, the compactor must not be used until the fault is recti¿ ed. 1. Thoroughly inspect the compactor for signs of damage. Check componenents are present and secure. Pay special attention to the belt drive safety guard ¿ tted between the engine and the vibrator unit.

2. Check the engine oil level and top up as necessary.

3. Check the engine fuel level and top up as necessary.

4. Check for fuel and oil leaks.

Do not operate the compactor indoors or in a con¿ ned space, make sure the work area is adequately ventilated.11 Reasons For Compaction Soil, which has been disturbed or new in¿ ll, subbase and blacktop, will have small voids or air pockets which, if not compacted, will lead to one or more problems occurring. 1. As traf¿ c crosses the surface of an uncompacted area, the material is compressed. This leads to subsidence of the top surface as the material ¿ lls the voids.

2. A similar situation occurs with static loads on uncompacted ground. The load (e.g. a building) will sink.

3. Materials with voids are more susceptible to water seepage, leading to erosion. Water ingress may also cause the soil

to expand during freezing temperatures and contract during dry spells. Expansion and contraction is a major cause of damage to building foundations and normally leads to the structure requiring underpinning. Compaction increases the density of the material and therefore increases its load bearing capacity. Reduces air voids and therefore reduces the risk of subsidence, expansion and contraction, due to ingress of water.

Stage 1: The full base area compacts the material like a standard machine. Stage 2: The base rises onto the ‘Dual Force’ section to give 3 to 4 times the compaction force of standard plates. Compaction Speci¿ cation Various methods have been employed in the past to specify the compaction required for various applications. The factors to consider are, material properties, layer thickness, pressure applied, vibration and number of passess. Greater understanding of how compaction works has lead to new compaction speci¿ cations being introduced. The most up to date speci¿ cation is part of the U.K.’s NRSWA (New Roads & Street Works Act). Civil Engineers are now adopting these speci¿ cations to ensure good compaction for all site work. NRSWA (HAUC speci¿ cation). The speci¿ cation was compiled by HAUC (Highways Authorities & Utilities Committee). The ‘New Roads and Street Works Act 1991, set a new standard for road repairs and reinstatements in the UK. It covers materials, methods, equipment and safety when carrying out reinstatements on roads and footways. The reason for the act is to ensure repairs and reinstatements are carried out to a higher standard and ultimately last longer. This in turn will reduce the need for costly remedial work and reduce traf¿ c delays. There are two categories speci¿ ed for plate compactors.

1. 1400 to 1800kg/m² 2. Over 1800kg/m²

These ¿ gures relate to the static pressure applied by the machine NOTE: No standard single direction plate compactors comply with this minimum speci¿ cation. For highways work always use a ‘Dual Force’ plate compactor. DUAL FORCE Altrad Belle studied the act then developed and patented equipment to enable contractors to comply with the act’s requirements. The NRSWA legislation requires that compaction equipment meets the minimum speci¿ cation. By purchasing an Altrad Belle ‘Dual Force’ plate, you are immediately complying with this part of the act. To comply with the speci¿ cation and maintain surface tolerance, Altrad Belle ‘Dual Force’ base plates are divided into two areas providing two stages of compaction. GB12 Honda GX120 & GX160

1. Open the fuel tap by moving the fuel ON / OFF lever fully to the right.

2. If starting the engine from cold, set the choke ON by moving the choke lever fully

to the left. If restarting a warm engine, the choke is usually not required, however, if the engine has cooled to a degree, partial choke may be required.

3. Turn the engine ON / OFF switch clockwise to the ‘I’ position.

4. Set the throttle to the idle position by moving the throttle lever fully to the right. Do

not start the engine on full throttle, as the compactor will vibrate as soon as the engine starts.

5. Taking a ¿ rm hold of the control handle with one hand, grasp the recoil starter

handle with the other. Pull the recoil starter until engine resistance is felt, then let starter return.

6. Taking care not to pull the starter’s rope fully out, pull the starter handle briskly.

7. Repeat until the engine ¿ res.

8. Once the engine ¿ res gradually set the choke lever to the OFF position by moving it to the right.

9. If the engine fails to ¿ re after several attempts, follow the trouble-shooting guide on page 8.

10. To stop the engine, set the throttle to idle and turn the engine ON / OFF switch anticlockwise to the ‘0’ position.

11. Turn the fuel off.

Hatz 1B20-7 Diesel Engine (please refer to the engine manual for full details)

1. Turn ON the fuel by moving the fuel ON/OFF lever fully to the right.

2. Set the engine speed control to start.

3. Taking a ¿ rm hold of the control handle with one hand, grasp the recoil starter handle with the other. Pull the handle until engine resistance is felt, then let the starter return.

4. Taking care not to pull the starter’s rope fully out, pull the starter handle briskly with both hands.

5. Repeat this procedure until the engine ¿ res.

6. If the engine fails to start after several attempts, consult the engine manual supplied with the compactor.

7. To stop the engine, set the throttle control to idle, then press and hold the red stop button until the engine stops.

Applications Applications/materials fall into three categories:

1. Cohesive materials (less than 20% granular) e.g clay, silt & heavy soils.

2. Granular materials (more than 20% granular) e.g hard core, sand & light soils.

3. Bituminous materials e.g asphalt (tarmac), cold lay (bitumin emulsion products).

The chart shows the HAUC speci¿ cations for layer depth and number of passes for Dual Force’ plates. If standard machines are used, optimum compaction can not be guaranteed, however, if layer depths are reduced and number of passes increased, results can be improved. Moisture content of cohesive & granular materials is critical to effective compaction. If granular material is too dry it will À ow around the plate instead of compacting. If the moisture content is too high the material may dry out after compaction and shrinkage will occur.

• Usually placed in 100mm minimum layer so not speci¿ ed by HAUC. ** The nature of cohesive materials makes plate compaction dif¿ cult. Optimum compaction is not guaranteed and not recommended by HAUC. 1400 - 1800 kg/m

Improper maintenance can be hazardous. Read and Understand this section before you perform any maintenance, service or repairs. CAUTION Throttle Lever Choke Lever Fuel ON/OFF Lever.13

• Take the compactor to where it is required. If using the ‘Detachable’ transport attachment to wheel the unit, tilt the compactor forward to raise the transport wheels off the ground. Swing the transporter frame back, then across to disconnect it from the rear of the compactor. Place the transporter frame somewhere safe until next required. For machines with the ‘Fixed’ transporter tilt the machine forward, pull the transporter rearwards and upwards, lower the machine to the À oor and latch the transporter into the ‘up’ position. Where it is necessary to use lifting equipment to position the compactor, make sure the lifting equipment has a WLL (Working Load Limit) suitable for the compactors weight (see speci¿ cation chart on page 4 or the machine numberplate). Attach suitable chains or slings ONLY to the lifting point on the top of the compactor.

• If the compactor is ¿ tted with the water spray system and the application requires its use, check that the water outlet valve is closed, then ¿ ll the water bottle with clean water.

• Having carried out the checks listed in the ‘pre start’ section, you may start the engine. The Altrad Belle ‘PCX’ range of compactors are ¿ tted with a centrifugal clutch, this allows the engine to run at idle without driving the vibrator. As the engine speed is increased the clutch will engage and will drive the vibrator. For correct operation, the engine speed should be set to maximum.

• Set the throttle to maximum and use the control handle to steer or turn the compactor. The vibrator will not only cause the baseplate to vibrate but will also cause it to travel forward. During normal operation you should not have to push the compactor but allow it to travel at its own pace. The speed of travel will be determined by the condition of the surface being compacted. If the surface to be compacted is on a slope, great care must be taken when controlling the compactor’s direction of travel. If necessary, use a suitable rope attached to the compactor at a low point on the chassis, to allow a helper to take part of the compactor’s weight. Work up and down a slope not across.

• Work the compactor over the surface in an organised pattern until the required compaction has been achieved. Where there are a number of different layers to be compacted on top of each other, compact each layer individually.

• To stop the compactor vibrating, set the throttle to idle. Operating The Compactor

Problem Cause Remedy Engine will not start. No fuel. Open fuel tap. Fill fuel tank. Engine switched off. Switch engine on. Spark plug fouled. Clean and reset plug gap. Engine cold. Close choke. Engine À ooded. Honda, open choke, fully open throttle, pull recoil starter until engine ¿ res. Hatz, move speed control to stop, pull recoil starter 5 times then repeat start procedure. Engine still will not start. Major Fault Contact Agent or Altrad Belle. Unit will not vibrate. Engine speed too slow. Set engine speed control to fast. Drive belt tension loose. Adjust belt tension. Air ¿ lter blocked Clean or renew air ¿ lter. Drive failure. Contact Agent or Altrad Belle. Vibrator failure. Contact Agent or Altrad Belle. Asphalt adhering to plate. Lack of lubrication. Use a water spray system. Paving blocks damaged. Plate in direct contact with material. Use a paving pad. Standard pad used on Dual Force plate. Fit correct Dual Force Pad. Bituminous surface À aking (laminating). Over compaction. Remove and relay. Low travel speed (plate sinking). Layer thickness too deep. Remove some of the material. Moisture content too high or too low. Remove material and adjust.14 Servicing Maintenance The Altrad Belle ‘PCX’ range of Single Direction Plate Compactors are designed to give many years of trouble free operation. It is, however, important that the simple regular maintenance listed in this section is carried out. It is recommended that an approved Altrad Belle dealer carries out all major maintenance and repairs. Always use genuine Altrad Belle replacement parts, the use of spurious parts may void your warranty. Before any maintenance is carried out on the machine, switch off the engine. If working on a petrol engined machine, disconnect the HT lead from the sparkplug. If working on a diesel engine, make sure that the stop switch is in the stop position. Always set the compactor on level ground to ensure any À uid levels will be correctly read. Only use recommended oils (see chart on following page). Running In Period When the compactor is ¿ rst used from new, the engine oil must be changed after the initial running in period (see engine manual for full detail). The vibrator shaft case oil must be replaced after the ¿ rst 100 hours use, then after every 500 working hours. For detail on vibrator shaft case oil replacement, see ‘Vibrator unit’. The belt tension should be checked after 4 hours use. Drive Belt Remove the belt guard then check the belt tension by placing light ¿ nger pressure on the top of the belt, as near central between the engine drive and vibrator pulley. The belt should deÀ ect by between 5mm and 10mm. If the belt tension requires adjustment, loosen the four engine mount bolts enough to allow the engine to be moved. Adjust the engine’s position by turning the tension bolt clockwise to increase belt tension, anti-clockwise to decrease. Once set, retighten the engine mount bolts and check the belt tension a second time. Finally, replace the belt guard ensuring it is correctly and securely ¿ tted.

Oil / Fuel Type & Quantity - Spark Plug Type Vibrator Unit. Remove the plug complete with seal, check that the oil level reaches the bottom thread on the oil plug hole. Top up as necessary with the correct oil (see chart). Routine Maintenance First 4 Hours First Month / 20 Hours 3 Months / 50 Hours 6 Months / 100 Hours Engine Oil Check Level

Petrol Honda GX160 3.6 0.6 - 0.7 Diesel Hatz 1B20-6 S.A.E. 10W 30 0.9 Diesel (BS2869) Refer to Manual N/A N/A Vibrator Turbine Oil 32 0.4 N/A N/A N/A N/A Plug Seal Regular Level Lower part of screw thread15 Assembly Instructions Assembly Instructions for Vibrator

1. Clean out Housing (9) with gun wash then

blow dry with compressed air.

2. Fit rear Bearing (3a) into Housing and push

Shaft (8) into Bearing.

3. Fit front Bearing (3b) onto Shaft and into

4. Fit Bearing Cover ‘B’ (10) c/w Gasket (4a) to

the rear of the Housing.

5. Fit Oil Seal (6) into Bearing Cover ‘A’ (7).

6. Fit Bearing Cover ‘A’ c/w Gasket (4b) to the

front of the Housing.

8. Pour oil into oil drain hole in the housing

until oil just starts to trickle out.

to a torque of 150Nm.

11. Run for approximately 2 minutes to ensure

oil does not leak from the Vibrator. Paving Pad The paving pad has been designed to be used when tamping down paving slabs and block pavers. However, it should not be used for normal compaction work. Before ¿ tting, make sure the paving pad you have is the correct size and the correct type (HAUC ‘Dual Force’ or standard). To ¿ t the Paving Pad (1), place the pad under the plate ensuring the securing holes line up with the holes on the front of the baseplate. The securing coach bolts (4) should be passed through the clamp strip (5) then the paving pad (1) and ¿ nally through the baseplate. They are in turn secured in place with the nut (2) and washer (3). Transporter Attachment The transporter attachment enables the operator to move the compactor to the work place with the minimum of effort. Removable Transporter Attachment To ¿ t the transport attachment, align the pivot bracket with the holes on the rear of the baseplate. The two securing bolts should be passed through the pivot bracket and the baseplate. They are in turn secured in place with the Nyloc nut and washer. Slide the wheel frame onto the pivot bracket, tilt the compactor forward then swing the wheel frame forward and under. Finally, tilt the compactor back and onto the wheels. Fixed Transporter Attachment To ¿ t the transport attachment, align the bracket with the holes on the rear of the bedplate. The two securing bolts should be passed through the bracket and into the bedplate. Fitting Instructions

‘Dual Force’ / HAUC / NRSWA Certi¿ cate Your new Altrad Belle ‘PCX’ single direction plate compactor is warranted to the original purchaser for a period of one-year (12 months) from the original date of purchase. The Altrad Belle warranty is against defects in design, materials and workmanship. The following are not covered under the Altrad Belle warranty: 1. Damage caused by abuse, misuse, dropping or other similar damage caused by or as a result of failure to follow assembly, operation or user maintenance instructions.

2. Alterations, additions or repairs carried out by persons other than Altrad Belle or their recognised agents.

3. Transportation or shipment costs to and from Altrad Belle or their recognised agents, for repair or assessment against a warranty claim, on any machine.

4. Materials and/or labour costs to renew, repair or replace components due to fair wear and tear.

The following components are not covered by warranty.

• Engine spark plug Altrad Belle and/or their recognised agents, directors, employees or insurers will not be held liable for consequential or other damages, losses or expenses in connection with or by reason of or the inability to use the machine for any purpose. Warranty Claims All warranty claims should ¿ rstly be directed to Altrad Belle, either by telephone, by Fax, by Email, or in writing. For warranty claims: Tel: [phone] Fax: [phone] Email : [e-mail] Write to: Altrad Belle Warranty Department, Sheen, Nr. Buxton Derbyshire SK17 0EU England. Warranty

When ¿ tted with a ‘Dual Force’ base plate the Static Weight per Unit Area of this machine is over 1400 kg/m² and so complies with the NRSWA (HAUC speci¿ cation) for plate compactors in the category 1400 – 1800kg/m². Managing Director

5. Air Filter Housing.

10. Engine oil drain plug.

13. Attachment point for Water Spray

Options. N.B. Drawing based a Honda GX160 engine. Please refer to the manufacturer’s literature for Hatz engine details. Environment Safe Disposal. Instructions for the protection of the environment. The machine contains valuable materials. Take the discarded apparatus and accessories to the relevant recycling facilities.

) 2.45 2.64 Usage Time - Honda (Mins) 831 342 Usage Time - Hatz (Mins) 499 43020 Decals A - Safety Decal (Part No. 19.0.373) Please Read Operators Manual Wear Protective Footwear Wear Ear Protection Wear Eye Protection B - Noise Decal (800-99951 & 800-99942) The Noise Level of the machine during operation is 105 / 107 dB(A) C - Engine RPM Decal A. Safety Decal B. Noise Decal C. Engine RPM Decal D Lifting Point Decal E. Low HAV Decal F. Engine Warning Decal Fast Engine Speed Position Slow Engine Speed Position D - Lifting Point Decal E - Low HAV Decal (800-99965) The machine has a UK Patented Design which reduces HAV levels allowing a greater Usage Time. F - Engine Warning Decal Please Read Engine Manual Petrol is highly À ammable. Turn off the engine and allow time to cool before refuelling. The Engine emits toxic Carbon Monoxide. Do not run the Engine in an enclosed area.

C21 General Safety Health and Safety Pre-Start Checks For your own personal protection and for the safety of those around you, please read andensure you fully understand the following safety information. It is the responsibility of the operator to ensure that he/she fully understands how to operatethis equipment safely. If you are unsure about the safe and correct use of the Plate Compactor, consult your supervisor or Altrad Belle.

• This equipment is heavy and must not be lifted single-handedly, either GET HELP or use suitable lifting equipment. A special transport assembly is available for the compactor (see options).

• Cordon off the work area and keep members of the public and unauthorised personnel at a safe distance.

• Personal Protective Equipment (PPE) must be worn by the operator whenever this equipment is being used (see Health & Safety).

• Make sure you know how to safely switch this machine OFF before you switch it ON in case you get into dif¿ culty.

• Always switch OFF the engine before transporting, moving it around the site or servicing it.

• During use the engine becomes very hot, allow the engine to cool before touching it. Never leave the engine running and unattended.

• Never remove or tamper with any guards ¿ tted, they are there for your protection. Always check guards for condition and security, if any are damaged or missing, DO NOT USE THE COMPACTOR until the guard has been replaced or repaired.

• Do not operate the Compactor when you are ill, feeling tired, or when under the inÀ uence of alcohol or drugs. Fuel Safety

• Before refuelling, switch off the engine and allow it to cool.

• When refuelling, DO NOT smoke or allow naked À ames in the area.

• Spilt fuel must be made safe immediately, using sand. If fuel is spilt on your clothes, change them.

• Store fuel in an approved, purpose made container away from heat and ignition sources. Fuel is À ammable. It may cause injury and property damage. Shut down the engine, extinguish all open À ames and do not smoke while ¿ lling the fuel tank. Always wipe up any spilled fuel. CAUTION The exhaust fumes produced by this equipment are highly toxic and can kill! CAUTION Improper maintenance or use can be hazardous. Read and Understand this section before you perform any maintenance, service or repairs. CAUTION Vibration Some vibration from the compaction operation is transmitted through the handle to the operator’s hands. The Altrad Belle Plate Compactor range has been speci¿ cally designed to reduce hand/arm vibration levels. Refer to speci¿ cations & technical data for vibration levels and usage times (recommended maximum daily exposure time). DO NOT exceed the maximum usage times. PPE (Personal Protective Equipment). Suitable PPE must be worn when using this equipment i.e. Safety Goggles, Gloves, Ear Defenders, Dust Mask and Steel Toe capped footwear. Wear clothing suitable for the work you are doing. Tie back long hair and remove any jewellery which may catch in the equipment’s moving parts. Dust. The compacting process will occasionally produce dust, which may be hazardous to your health. Always wear a mask that is suited to the type of dust being produced. Fuel. Do not ingest fuel or inhale fuel vapours and avoid contact with your skin. Wash fuel splashes immediately. If you get fuel in your eyes, irrigate with copious amounts of water and seek medical attention as soon as possible. Exhaust Fumes Pre start-up inspection The following Pre-start-up inspection must be performed before the start of each work session or after every four hours of use, whichever is ¿ rst. Please refer to the service section for detailed guidance. If any fault is discovered, the compactor must not be used until the fault is recti¿ ed. 1. Thoroughly inspect the compactor for signs of damage. Check componenents are present and secure. Pay special attention to the belt drive safety guard ¿ tted between the engine and the vibrator unit.

2. Check the engine oil level and top up as necessary.

3. Check the engine fuel level and top up as necessary.

4. Check for fuel and oil leaks.

Do not operate the compactor indoors or in a con¿ ned space, make sure the work area is adequately ventilated.22 Reasons For Compaction Soil, which has been disturbed or new in¿ ll, subbase and blacktop, will have small voids or air pockets which, if not compacted, will lead to one or more problems occurring. 1. As traf¿ c crosses the surface of an uncompacted area, the material is compressed. This leads to subsidence of the top surface as the material ¿ lls the voids.

2. A similar situation occurs with static loads on uncompacted ground. The load (e.g. a building) will sink.

3. Materials with voids are more susceptible to water seepage, leading to erosion. Water ingress may also cause the soil

to expand during freezing temperatures and contract during dry spells. Expansion and contraction is a major cause of damage to building foundations and normally leads to the structure requiring underpinning. Compaction increases the density of the material and therefore increases its load bearing capacity. Reduces air voids and therefore reduces the risk of subsidence, expansion and contraction, due to ingress of water. Stage 1: The full base area compacts the material like a standard machine. Stage 2: The base rises onto the ‘Dual Force’ section to give 3 to 4 times the compaction force of standard plates. Compaction Speci¿ cation Various methods have been employed in the past to specify the compaction required for various applications. The factors to consider are, material properties, layer thickness, pressure applied, vibration and number of passess. Greater understanding of how compaction works has lead to new compaction speci¿ cations being introduced. The most up to date speci¿ cation is part of the U.K.’s NRSWA (New Roads & Street Works Act). Civil Engineers are now adopting these speci¿ cations to ensure good compaction for all site work. NRSWA (HAUC speci¿ cation). The speci¿ cation was compiled by HAUC (Highways Authorities & Utilities Committee). The ‘New Roads and Street Works Act 1991, set a new standard for road repairs and reinstatements in the UK. It covers materials, methods, equipment and safety when carrying out reinstatements on roads and footways. The reason for the act is to ensure repairs and reinstatements are carried out to a higher standard and ultimately last longer. This in turn will reduce the need for costly remedial work and reduce traf¿ c delays. There are two categories speci¿ ed for plate compactors.

1. 1400 to 1800kg/m² 2. Over 1800kg/m²

These ¿ gures relate to the static pressure applied by the machine NOTE: No standard single direction plate compactors comply with this minimum speci¿ cation. For highways work always use a ‘Dual Force’ plate compactor. DUAL FORCE Altrad Belle studied the act then developed and patented equipment to enable contractors to comply with the act’s requirements. The NRSWA legislation requires that compaction equipment meets the minimum speci¿ cation. By purchasing an Altrad Belle ‘Dual Force’ plate, you are immediately complying with this part of the act. To comply with the speci¿ cation and maintain surface tolerance, Altrad Belle ‘Dual Force’ base plates are divided into two areas providing two stages of compaction.23 Start and Stop Procedure Improper maintenance can be hazardous. Read and Understand this section before you perform any maintenance, service or repairs. CAUTION Applications Applications/materials fall into three categories:

1. Cohesive materials (less than 20% granular) e.g clay, silt & heavy soils.

2. Granular materials (more than 20% granular) e.g hard core, sand & light soils.

3. Bituminous materials e.g asphalt (tarmac), cold lay (bitumin emulsion products).

The chart shows the HAUC speci¿ cations for layer depth and number of passes for Dual Force’ plates. If standard machines are used, optimum compaction can not be guaranteed, however, if layer depths are reduced and number of passes increased, results can be improved. Moisture content of cohesive & granular materials is critical to effective compaction. If granular material is too dry it will À ow around the plate instead of compacting. If the moisture content is too high the material may dry out after compaction and shrinkage will occur.

• Usually placed in 100mm minimum layer so not speci¿ ed by HAUC. ** The nature of cohesive materials makes plate compaction dif¿ cult. Optimum compaction is not guaranteed and not recommended by HAUC. 1400 - 1800 kg/m

1. Open the fuel tap by moving the fuel ON / OFF lever fully to the right.

2. If starting the engine from cold, set the choke ON by moving the choke lever fully

to the left. If restarting a warm engine, the choke is usually not required, however, if the engine has cooled to a degree, partial choke may be required.

3. Turn the engine ON / OFF switch clockwise to the ‘I’ position.

4. Set the throttle to the idle position by moving the throttle lever fully to the right. Do

not start the engine on full throttle, as the compactor will vibrate as soon as the engine starts.

5. Taking a ¿ rm hold of the control handle with one hand, grasp the recoil starter

handle with the other. Pull the recoil starter until engine resistance is felt, then let starter return.

6. Taking care not to pull the starter’s rope fully out, pull the starter handle briskly.

7. Repeat until the engine ¿ res.

8. Once the engine ¿ res gradually set the choke lever to the OFF position by moving it to the right.

9. If the engine fails to ¿ re after several attempts, follow the trouble-shooting guide on page 8.

10. To stop the engine, set the throttle to idle and turn the engine ON / OFF switch anticlockwise to the ‘0’ position.

11. Turn the fuel off.

Hatz 1B20-7 Diesel Engine (please refer to the engine manual for full details)

1. Turn ON the fuel by moving the fuel ON/OFF lever fully to the right.

2. Set the engine speed control to start.

3. Taking a ¿ rm hold of the control handle with one hand, grasp the recoil starter handle with the other. Pull the handle until engine resistance is felt, then let the starter return.

4. Taking care not to pull the starter’s rope fully out, pull the starter handle briskly with both hands.

5. Repeat this procedure until the engine ¿ res.

6. If the engine fails to start after several attempts, consult the engine manual supplied with the compactor.

7. To stop the engine, set the throttle control to idle, then press and hold the red stop button until the engine stops.

Throttle Lever Choke Lever Fuel ON/OFF Lever.24

• Take the compactor to where it is required. If using the ‘Detachable’ transport attachment to wheel the unit, tilt the compactor forward to raise the transport wheels off the ground. Swing the transporter frame back, then across to disconnect it from the rear of the compactor. Place the transporter frame somewhere safe until next required. For machines with the ‘Fixed’ transporter tilt the machine forward, pull the transporter rearwards and upwards, lower the machine to the À oor and latch the transporter into the ‘up’ position. Where it is necessary to use lifting equipment to position the compactor, make sure the lifting equipment has a WLL (Working Load Limit) suitable for the compactors weight (see speci¿ cation chart on page 4 or the machine numberplate). Attach suitable chains or slings ONLY to the lifting point on the top of the compactor.

• If the compactor is ¿ tted with the water spray system and the application requires its use, check that the water outlet valve is closed, then ¿ ll the water bottle with clean water.

• Having carried out the checks listed in the ‘pre start’ section, you may start the engine. The Altrad Belle ‘PCx’ range of compactors are ¿ tted with a centrifugal clutch, this allows the engine to run at idle without driving the vibrator. As the engine speed is increased the clutch will engage and will drive the vibrator. For correct operation, the engine speed should be set to maximum.

• Set the throttle to maximum and use the control handle to steer or turn the compactor. The vibrator will not only cause the baseplate to vibrate but will also cause it to travel forward. During normal operation you should not have to push the compactor but allow it to travel at its own pace. The speed of travel will be determined by the condition of the surface being compacted. If the surface to be compacted is on a slope, great care must be taken when controlling the compactor’s direction of travel. If necessary, use a suitable rope attached to the compactor at a low point on the chassis, to allow a helper to take part of the compactor’s weight. Work up and down a slope not across.

• Work the compactor over the surface in an organised pattern until the required compaction has been achieved. Where there are a number of different layers to be compacted on top of each other, compact each layer individually.

• To stop the compactor vibrating, set the throttle to idle. Operating The Compactor Troubleshooting Guide Problem Cause Remedy Engine will not start. No fuel. Open fuel tap. Fill fuel tank. Engine switched off. Switch engine on. Spark plug fouled. Clean and reset plug gap. Engine cold. Close choke. Engine À ooded. Honda, open choke, fully open throttle, pull recoil starter until engine ¿ res. Hatz, move speed control to stop, pull recoil starter 5 times then repeat start procedure. Engine still will not start. Major Fault Contact Agent or Altrad Belle. Unit will not vibrate. Engine speed too slow. Set engine speed control to fast. Drive belt tension loose. Adjust belt tension. Air ¿ lter blocked Clean or renew air ¿ lter. Drive failure. Contact Agent or Altrad Belle. Vibrator failure. Contact Agent or Altrad Belle. Asphalt adhering to plate. Lack of lubrication. Use a water spray system. Paving blocks damaged. Plate in direct contact with material. Use a paving pad. Standard pad used on Dual Force plate. Fit correct Dual Force Pad. Bituminous surface À aking (laminating). Over compaction. Remove and relay. Low travel speed (plate sinking). Layer thickness too deep. Remove some of the material. Moisture content too high or too low. Remove material and adjust.25 Servicing Maintenance The Altrad Belle ‘PCX’ range of Single Direction Plate Compactors are designed to give many years of trouble free operation. It is, however, important that the simple regular maintenance listed in this section is carried out. It is recommended that an approved Altrad Belle dealer carries out all major maintenance and repairs. Always use genuine Altrad Belle replacement parts, the use of spurious parts may void your warranty. Before any maintenance is carried out on the machine, switch off the engine. If working on a petrol engined machine, disconnect the HT lead from the sparkplug. If working on a diesel engine, make sure that the stop switch is in the stop position. Always set the compactor on level ground to ensure any À uid levels will be correctly read. Only use recommended oils (see chart on following page). Running In Period When the compactor is ¿ rst used from new, the engine oil must be changed after the initial running in period (see engine manual for full detail). The vibrator shaft case oil must be replaced after the ¿ rst 100 hours use, then after every 500 working hours. For detail on vibrator shaft case oil replacement, see ‘Vibrator unit’. The belt tension should be checked after 4 hours use. Drive Belt Remove the belt guard then check the belt tension by placing light ¿ nger pressure on the top of the belt, as near central between the engine drive and vibrator pulley. The belt should deÀ ect by between 5mm and 10mm. If the belt tension requires adjustment, loosen the four engine mount bolts enough to allow the engine to be moved. Adjust the engine’s position by turning the tension bolt clockwise to increase belt tension, anti-clockwise to decrease. Once set, retighten the engine mount bolts and check the belt tension a second time. Finally, replace the belt guard ensuring it is correctly and securely ¿ tted. Routine Maintenance First 4 Hours First Month / 20 Hours 3 Months / 50 Hours 6 Months / 100 Hours Engine Oil Check Level

Oil / Fuel Type & Quantity - Spark Plug Type Vibrator Unit. Remove the plug complete with seal, check that the oil level reaches the bottom thread on the oil plug hole. Top up as necessary with the correct oil (see chart). Oil Type Quantity (Gals) Fuel Type Capacity (Gals) Spark Plug Type Electrode Gap (mm) Gasoline Honda GX100 S.A.E. 10W 30 0.15 Unleaded

Gasoline Honda GX160 0.95 0.6 - 0.7 Diesel Hatz 1B20-6 S.A.E. 10W 30 0.23 Diesel (BS2869) Refer to Manual N/A N/A Vibrator Turbine Oil 32 0.1 N/A N/A N/A N/A Plug Seal Regular Level Lower part of screw thread26 Assembly Instructions Assembly Instructions for Vibrator

1. Clean out Housing (9) with gun wash then

blow dry with compressed air.

2. Fit rear Bearing (3a) into Housing and push

Shaft (8) into Bearing.

3. Fit front Bearing (3b) onto Shaft and into

4. Fit Bearing Cover ‘B’ (10) c/w Gasket (4a) to

the rear of the Housing.

5. Fit Oil Seal (6) into Bearing Cover ‘A’ (7).

6. Fit Bearing Cover ‘A’ c/w Gasket (4b) to the

front of the Housing.

8. Pour oil into oil drain hole in the housing

until oil just starts to trickle out.

to a torque of 150Nm.

11. Run for approximately 2 minutes to ensure

oil does not leak from the Vibrator. Paving Pad The paving pad has been designed to be used when tamping down paving slabs and block pavers. However, it should not be used for normal compaction work. Before ¿ tting, make sure the paving pad you have is the correct size and the correct type (HAUC ‘Dual Force’ or standard). To ¿ t the Paving Pad (1), place the pad under the plate ensuring the securing holes line up with the holes on the front of the baseplate. The securing coach bolts (4) should be passed through the clamp strip (5) then the paving pad (1) and ¿ nally through the baseplate. They are in turn secured in place with the nut (2) and washer (3). Transporter Attachment The transporter attachment enables the operator to move the compactor to the work place with the minimum of effort. Removable Transporter Attachment To ¿ t the transport attachment, align the pivot bracket with the holes on the rear of the baseplate. The two securing bolts should be passed through the pivot bracket and the baseplate. They are in turn secured in place with the Nyloc nut and washer. Slide the wheel frame onto the pivot bracket, tilt the compactor forward then swing the wheel frame forward and under. Finally, tilt the compactor back and onto the wheels. Fixed Transporter Attachment To ¿ t the transport attachment, align the bracket with the holes on the rear of the bedplate. The two securing bolts should be passed through the bracket and into the bedplate. Fitting Instructions

‘Dual Force’ / HAUC / NRSWA Certi¿ cate Your new Altrad Belle ‘PCX’ single direction plate compactor is warranted to the original purchaser for a period of one-year (12 months) from the original date of purchase. The Altrad Belle warranty is against defects in design, materials and workmanship. The following are not covered under the Altrad Belle warranty: 1. Damage caused by abuse, misuse, dropping or other similar damage caused by or as a result of failure to follow assembly, operation or user maintenance instructions.

2. Alterations, additions or repairs carried out by persons other than Altrad Belle or their recognised agents.

3. Transportation or shipment costs to and from Altrad Belle or their recognised agents, for repair or assessment against a warranty claim, on any machine.

4. Materials and/or labour costs to renew, repair or replace components due to fair wear and tear.

The following components are not covered by warranty.

• Engine spark plug Altrad Belle and/or their recognised agents, directors, employees or insurers will not be held liable for consequential or other damages, losses or expenses in connection with or by reason of or the inability to use the machine for any purpose. Warranty Claims All warranty claims should ¿ rstly be directed to Altrad Belle, either by telephone, by Fax, by Email, or in writing. For warranty claims: Tel: [phone] Fax: [phone] Email : [e-mail] Write to: Altrad Belle Inc, 3959 Electric Road, Roanoke, Suite 360, VA, 24018, USA Warranty This machine is ¿ tted with a ‘Dual Force’ base plate.

When ¿ tted with a ‘Dual Force’ base plate the Static Weight per Unit Area of this machine is over 1400 kg/m² and so complies with the NRSWA (HAUC speci¿ cation) for plate compactors in the category 1400 – 1800kg/m². Managing Director