Bomag BT 60/4, BT 65/4 Operating And Maintenance Instructions Manual

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Operating instructions

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Maintenance instructions

BT 60/4 - BT 65/4

S/N 101 540 39 ... (EPA II) S/N 101 540 49 ... (EPA II)

Vibratory Tamper

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Catalogue number

008 113 61

06/2005

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Foreword

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Foreword

BOMAG machines are products from the wide range of BOMAG compaction equipment. BOMAG’s vast experience in connection with state-of-the-art produ ction and testing m ethods, such as lifetime tests of all im portant components and highest qu ality demands guarantee maximum reliability of your machine.

Using thes e instructions will

l help you to become familiar with the machine. l avoid malfunctions caused by unprofessional

operation.

Compliance with the maintenance instructions will

l enhance the reliability of the machine on con-

struction sites,

l prolong the lifetime of the machine, l reduce repair cost s and downtimes.

BOMAG will not assume liability for the function of the machine

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

In the course of technical development we reserve the right for technical modifications without prior notification.

Theseoperatingandmaintenance instructions are also availabl e in other languages.

Your BOM A G dealer will also supply you with information about thecorrectuse of our machines in soil and asphalt construction.

The above notes do not constitute an extension of thewarranty and liabilityconditions specifiedi n the general terms of business of BOMAG.

We wish you successful work with your BOMAG machine.

BOMAG GmbH PrintedinGermany Copyright by BOMAG

l in case of manipulations which do not comply

with the type of use specified in t he safety regulations,

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

tioned in these instructions.

No warranty claims can be lodged in case of damage res ulting from

l operating errors, l inadequate maintenance, l wrong fuels and lubricants.

Please note!

This manual was written for operators and maintenance personnel on cons truct ion sites.

You should on ly operate the machine after you have beeninstructedandincom pliancewiththese instructions.

Strictly obs erv e the safety regulations. Please observe also the guidelines of the Civil En-

gineering Liability Association ”Saf ety Rules for the Operation of Road Rollers and Soil Compactors” and all relevant accident prevention r egulations.

BOMAG 3BT 60/4, BT 65/4

Foreword

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Please fill in

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

Machinetype(Fig.1)

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

Serial-number (Fig. 1 and 2)

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

Engine t y pe (Fig. 3)

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

Engine number (Fig. 3)

Note

Supplement the above data togeth er with th e commissioning protocol.

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

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

Fig. 1

Fig. 2

Fig. 3

BOMAG4 BT 60/4, BT 65/4

Table of Contents

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Technical Data 7 Safety reg ulations 11 Indicators and Controls 15

3.1 General notes 16

3.2 Controls 16

Operation 19

4.1 General notes 20

4.2 Tests before taking into operation 20

4.3 Filling in fuel 21

4.4 Starting the engine 21

4.5 Starting under cold weather conditions 23

4.6 Incorrect starting 24

4.7 Work/operation 24

4.8 Shutting the engine down 26

4.9 Changing t he tamper foot plate 27

4.10 Loading and transport 27

Maintenance 29

5.1 General 30

5.2 Fuels and lubricants 30

5.3 Filling capacities 31

5.4 Running-in instructions 32

5.5 Maintenance chart 33

5.6 Cleaning the machine 34

5.7 Checking the bellows on the tamper 34

5.8 Check the engine oil l evel 35

5.9 Checking the fuel level, topping up fuel 36

5.10 Change t he engine oil 37

5.11 Cleaning, check ing the spark plug, replaci ng if necessary 38

5.12 Tamper foot plate 39

5.13 Check the oil level in the tamper foot 39

5.14 Check, adjust the valve clearance 40

5.15 Cleaning the fuel filter inside the tank 42

5.16 Oil change in tamper foot 43

5.17 Clean, change the double dry air filter cartridge 45

Trouble shooting 47

6.1 General notes 48

6.2 Engine problems 49

BOMAG 5BT 60/4, BT 65/4

1 Technical Data

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BOMAG 7BT 60/4, BT 65/4

Technical Data

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Fig. 4

Dimensions inmmH L L1 W

BT 6 0/4 BT 6 5/4

Weight

Basic weight kg 61 67 Operating weight (CECE) kg 62 68 Engine Honda Honda Type GX 100 (EPA II) GX 100 (EPA II) Cooling Air Air Number of cylinders 1 1 Rated power ISO 9249 kW (PS) 2,5 (3,4) 2,5 (3,4) Rated s peed rpm 4200 4200

Capacities

Fuel tank l 3,0 3,0 Oil in tamper foot l 0,75 1,0 Engine oil l 0,33 0,33

960 735 335 280 1000 735 335 280

BT 60/4 BT 65/4

BOMAG8 BT 60/4, BT 65/4

Technical Data

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Vibration

Frequency Hz 9-11,75 9 ... 11,75 Jumping height mm 60 70 Working speed (soil dependent) Max. areal output (depending on soil) Max. depth effect (depending on soil)

* The right for technical modifications remains reserved

m/min upto20 upto20

/h 336 336

cm up to 55 up to 65

BT 60/4 BT 65/4

BOMAG 9BT 60/4, BT 65/4

Technical Data

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The following noise and vibration data acc. to

- EC Machine Regulation edition 98/37/EC and

- the noise regulation 2000/14/EG, noise p rotection guideline 200 3/10 /EC

- Vibration Pro t ection Regulation 2002/44/EC were determined during conditions typical for this type of equipment and by application of harmo-

nized standards. During operation the se values may vary because of the existing operating conditions.

Noise value

sound pressure level on the operator’s stand:

= 95.3 dB (A) BT 60/4, determined acc. to ISO 11204 and EN 500

= 94,9 dB (A) BT 65/4, determined acc. to ISO 11204 and EN 500

Guaranteed sound capacity level:

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

Danger

Loss of hearing! Wear your p ersonal noise protection means (ea r defenders) before starting operation.

Vibration value

Hand-arm vibration:

Vector total of the weighted effec tive acceleration in three orthogonal directions:

Weighted total vibration value

BT 60/4 a BT 65/4 a

Caution

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

=8.1m/sec2on cr us hed rock determined acc. to ISO 5349 and EN 500

=7,9m/sec2on cr us hed rock determined acc. to ISO 5349 and EN 500

BOMAG10 BT 60/4, BT 65/4

2 Safety regulations

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BOMAG 11BT 60/4, BT 65/4

Safety regulations

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General notes

This BOMAG machine is built in accordance with thestate-o f-the-art and the present technical r ul e s and regulations. However, there is a risk of danger for persons and property if:

l the machine is used for purposes other than

those i t is intended for

l the machine is operated by untrained person-

nel

l the machine is modified or converted in an un-

professional way

l the applicable safety regulations are not ob-

served.

It is therefore of utmost importance that any person involved in the operation, maintenance and repair of the machine reads and applies these safety regulations.This should be confirmed by obtaining the signatures of the customer, if necessary .

Furthermore the following regulations and instructions are obviously also valid:

l applicable accident prevention instructions l generallyacknowledged safetyand roadtraffic

regulations

l country specific regulations.

Who is allowed to operate the machine?

The m ac hine mus t only be operated by trained and aut horized persons which are at least 18 years of age. The responsibilities for the operation of the machine are to be clearly specified and complied with.

Persons under the influence of alcohol, medication or drugs must not operate, service or repair the machine.

Maintenance and repai rs require very specific knowledge and must therefore only be carried out by trained and qualified personnel.

Conversions and alterations to the machine.

Unauthorized conversions to the machine are prohibited for safety reasons.

Original parts and accessories have been specially designed for this machine . We wish to make expressly clearthat we have not tested ora uthorized any original parts or s pecial equipment not supplied by us. The installation and/or use of su ch products can impair the active and/or passive driving safety. The manufacturer expressly excludes any liability for damage resulting from the use of non-original parts or access ories.

Intended use

This mac hine must only be used for:

l Compaction of all types of soils l Repair work in all types of soil l Reinforcement of walkways l Work in trenches l Backfills and compaction of marginal strips

Unintended use

Dangers may h owev er arise from the m ac hine if it is operated by untrained personnel in an unprofessional way or if it is unintentionally used.

Example:

l Working in horizontal direction l Ramming of poles l Compaction of interlocking paving stones

Safety notes in the operating and maintenance instructions:

! Danger

Sections m arked like this point ou t possible dangers for persons.

Caution

Sections m arked like that point out possible dangers forthe machine or forparts of themachine.

Note

Sections marked like this provide technical information concerning the optimal economi ca l utilization of the machine.

BOMAG12 BT 60/4, BT 65/4

Safety regulations

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Loading the machine

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

Secure the machine against tipping over or slipping off.

Persons are highly endangered if t hey step or stand under a suspended load.

With t he machine suspended be aware that the machine may swing about.

Secure the machin e on the transpo rt vehicle against rolling, slipping and turning over.

Starting the machine

Before starting

Familia ri ze yourself with the equipment, the control elements, the workingprinciple of themachine and your work ing area.

Use y our protective outfit (hard hat, s af et y boots etc.). Wear ear defenders.

Check before starting whether:

l the machine shows any obvious defects l all protective devices are properly sec ured in

their place

l all control elements are fully f unc ti onal l the machine is free of oily and combustible

material

l keep all grips and handles free of grease, oils,

fuels, dirt, snow and ice.

Use only m ac hines which have been regula rly serviced.

Starting in closed rooms

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

Operation

l Guide the m achine and take care that you do

not hurt your hands on any obstructions, danger of accident.

l Watch out for unusual noises and the develop-

ment of s moke. Find the cause an d have the fault corrected.

l Do not take your hands off the machine while

the engine is running.

l Keep your feet away from the tamper foot

Parking the machine

Stand the machine on ground as level as possible. Before leaving the machine:

l Secure the machine against tipping over.

Filling in fuel

Refuel only with the engine shut down. Do not refuel in closed rooms. No open fire, do not smoke. Do not spillany fuel. Catch running out fuel, do not

let it seep into the ground. Do not inhale any fuel fumes. Avoid contac t with skin and eyes. Do not swallow.

Maintenance

Maintenance work must only be c arried out by qualified an d authorized personnel.

Keep u nauthorized pers ons away from the machine.

Do not perform maintenance work while the en gine is running.

Park the machine on level and firm ground.

Working on the fuel system

No open fire, do not smoke, do not spill any fuel. Catch runnin g out fuel, do not let it seep into the

ground and dispose of environmentally. Do not breath in fuel fumes.

Working on the engine

When working on t he fuel filter make sure that no dirt falls into the air channel.

Do not work on the hot exhaust, risk of burns! When working on the exhaust c hannel of the en-

gine make sure that no combustion residues fall into the cylinder.

Do not touch the piston with the cleaning tools.

l Do not hold the throttle lever in thearea below

I, as this may damage t he centrifugal clutch.

BOMAG 13BT 60/4, BT 65/4

Safety regulations

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Workingonthetamperfoot

Wipe off spilled oil, catch running out oil and dispose of environme ntal ly.

Store oily material in a specially marked containe r and dispose of environment ally.

Cleaning

Do not clean the machine while the engine is running.

Do not use gasoline or other inflammable substances to cle an the machine.

When using steam cleaning equipment do not subject electric parts andinsulatingmaterial to the direct water jet or cover them beforehand.

Do not guide the water jet directly into the air filter, into the exhaust or into the air intake opening.

After the maintenance work

Reinstall al l protective devices af t er completing maintenance.

Repair

Repairs must only be carried out by qualified and authorized personnel. Always follow our repair i nstructions.

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

Attach a warning tag to the s teering bow if t he machine is defective.

l Do not mix the nozzle in the c arburet t or up by

mistake.

l Adjust the idling speed regulator screw exact-

ly.

l Do not damage the blower wheel when work-

ing on the magnetic ignition.

l Always replace self locking nuts. l Do not open the foot cover on the tam per foot,

spring tens ion. Danger of ac cident!

l Observe the prescribed tightening torques.

BOMAG14 BT 60/4, BT 65/4

3 Indicators and Controls

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BOMAG 15BT 60/4, BT 65/4

Indicators and Controls

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3.1 General notes

Please read this section thoroughly before operating this machine if you are not yet conversant w ith the indicators and control elem ents. All functions are desc r ibed in detail hereunder.

Paragraph 4 Operation contains only concise descriptions of the individual operating steps.

3.2 Controls

Fig. 5

Throttle lever (Fig. 5).

Fig. 6

Engine st op switch (Fig. 6).

Fig. 7

Recoil starter (Fig. 7).

BOMAG16 BT 60/4, BT 65/4

Fig.8

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Fuel cock (Fig. 8).

Indicators and Controls

Fig.9

Choke lever (Fig. 9).

BOMAG 17BT 60/4, BT 65/4

4Operation

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BOMAG 19BT 60/4, BT 65/4

Operation

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4.1 General notes

Please r ead section 3 I ndicat ors and Control Elements thoroughly before opera ting the machine if you are not yet fully familiar with the indicators and control elements of the machine.

All indicators and control eleme nts are described in detail in this chapter.

4.2 Tests before taking into operation

Note

During the running in time the idle speed may increase because of the enhanced moveability of the engine. Idle speed between 1700 and 2000 rpm.

The running in time of the v ibratory tamper is 10 operating hours.

Check

l condition of engine and machine l engine oil level l fuel tan k and fuel lines for leaks l fuel level l concertina wall for damage and leak s l oil filling of tamper cylinder l Visual inspec tion of machine

BOMAG20 BT 60/4, BT 65/4

Operation

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4.3 Filling in fuel

! Danger

Fire hazard! Only fill in fuel with the engine shut down and

the fuel valve closed. Do not spill any fuel! Do not inhale any fuel fumes. No fire, do not sm oke!

Fuel:

Unleaded standard grade gasoline.

4.4 Starting the engine

! Danger

Danger of accident! Always ho ld on to the machine.

Keep your feet away from the tamper plate, because the vibration starts immediately.

Always keep an eye on a running machine. Wear your personal noise protection means

(ear defenders) before starting operation.

Fig. 10

l Turnthefuelshut-off valve (Fig.10)to position

STOP (closed).

Fig. 11

l Tank c ontents m ax. 3,0 Litres. l After filling close the filler cover tightly (Fig.

11).

Fig.12

l Open the fuel cock (Fig. 12).

Fig.13

l Set the throttle lever (Fig. 13) to MAX position.

BOMAG 21BT 60/4, BT 65/4

Operation

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Fig. 14

l Close the choke (Fi g. 14).

Note

Always close the choke to start a cold and warm engine.

Fig. 15

l Pull therope by the starter handle (Fig. 15) un-

til resistance can be felt.

Fig. 16

l Pull the starter han dle quickly and with power

(Fig. 16).

Caution

Do n ot let the starter handle hit back.

l Guide the starter rope back by hand. l If the engine does not start during the first at-

tempt, repeat the starting process.

l Let the starter h andle run back t o initial posi-

tion.

BOMAG22 BT 60/4, BT 65/4

Fig. 17

l Open th e choke (Fig. 17) 3 to 6 seconds after

the e ngine has started running.

Fig. 18

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l Set the throttle lever (Fig. 18) to "MIN" and let

the engine run warm f or 1 to 2 minutes.

Note

Once the engine has warmed up you can start to work with the tamper.

Operation

4.5 Starting under cold weather conditions

Should the engine stop again after approx. 3 to 5 seconds

l close the ch oke once again and repeat the

starting procedure.

BOMAG 23BT 60/4, BT 65/4

Operation

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4.6 Incorrect starting

- engine "drowned" -

When the choke is c losed and the starter rope is operated several times, the engine will draw too much fuel and starting is impos s ible.

Remedy

l Close the fuel shut-off valve l Open the choke l Set the throttle lev er to f ull speed position l Keep on pulling t he the starter rope until the

engine st arts.

If the engine does not start after 10 to 20 starting procedures,

l pull the spark-plug socket off. l screw the spark-plug out. l Operate the start several times. l Dry the spark-plug with a clean cloth or blow it

dry with pressure air. If necessary clean it with awirebrush.

l Screw the spark-plug back in and push t he

spark-plug socket on.

l Repeat the starting procedure.

4.7 Work/operation

! Danger

Danger of accident! Guide the machine only with the handle.

Do n ot let the machine run unattended. Useyourp ersonal noiseprotection means (ear

defenders).

Fig. 19

l Set the throttle lever (F ig. 19) to "MAX"- pos i-

tion.

l The mac hine works at max. frequenc y .

Fig. 20

l In orde r to achieve a smoot h running of the

machine adjust the throttle lever in the range I (Fig. 20), depending on the co ndition and the density of the soil.

BOMAG24 BT 60/4, BT 65/4

Operation

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Fig. 21

l The travel speed can be influenced by altering

the load on the st eering handle (Fig. 21).

No load = slowly forward

Fig. 22

l The travel speed can also be influenced by

varying the pressing force on the steering bow (Fig. 22).

Strong force = fast forward

Fig.23

l During short breaks you should always set the

throttle leverto "MIN"-position (Fig. 23).

Note

This avoids premature wear of the ce ntrifugal clutch and reduces the fuel consumption

Note

The lift height of the material to be compacted should not be higher, than the tamper can m anage.

If t he tamper should get out of rhythm on highly compacted ground, smooth running c an be achieved by s lightly changing the eng ine speed and/or the inclination of the tamper.

BOMAG 25BT 60/4, BT 65/4

Operation

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4.8 Shutting the engine down

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. 26

l Turn the fuel tap (Fig . 26) t o position STOP

(closed).

Fig. 24

l Set the throttle lev er (Fig. 24) to position MIN. l Run the engine fo r a short while with idl e

speed.

Fig. 25

l Press the stop switch (push button) (Fig. 25).

Danger

Danger of burning!

Fig. 27

l Pull the rope by the starter handle (Fig. 27) un -

til resistance can be felt.

l Let the starter handle run back to initial posi-

tion.

Note

This procedure prevents the penetration of damp ness into the engine.

Immediately after shutting down the engine is still hot, do not touch the exhaust.

Park the mach in e so that it cannot turn over.

BOMAG26 BT 60/4, BT 65/4

Operation

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4.9 Changing the tamper foot plate

Fig. 28

l After changing the tamper foot plate (Fig. 28)

tightenthe4 fasteningscr ews with atightening torque of 60 ...70 N m (44...52 ft.lbs).

Note

When changing thetamperfootto a different width use only genuine BOMAG parts.

4.10 Loading and transport

! Danger

Danger of accident! Always shut the engine down to transport the

tamper to lay it on its side. Makesurethatpersonsare notendangeredby

the machine tipping or sliding off. Lash the machine down, so that it is secured

against rolling, sliding and turning over. For lifting the mac hine attach the lifting gear

only to thecross strut on the engine protection bow.

The machine should not swing about too much when being lifted.

Do not stand under suspended loads. Use only safe lifting gear of sufficient load

bearing capacity

After changing the tamper foot check the engine speed, adjust if necessary.

Fig.29

l Always shut the engine down for transport. l Transport the tamper only lying down (Fig. 29)

on the castors.

BOMAG 27BT 60/4, BT 65/4

Operation

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Fig. 30

l Toload the tamper attach the liftingtackle only

to the cross bar of the st eering bow (Fig. 30).

Weights see techn ical data

BOMAG28 BT 60/4, BT 65/4

5 Maintenance

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BOMAG 29BT 60/4, BT 65/4

Maintenance

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5.1 General

When performing maintenance work ensure strict compliance with the resp ectiv e safety instructions and particul arly the safety regulations mentioned in chapter 2 of these operating and maintenance instructions.

Thorough maintenance of the tamper guarantees far longer safe functioning of the machine and prolongs t he lifetime of important com ponents. The effort needed for this w ork is only little compared with the problems that may arise when not observing this rule.

l Always clean tamper and engine thoroughly

before starting maintenance work.

l For maintenance work stand the tamper on

level ground and secure it against tipping over.

l Perform maintenance work only wit h the en-

gine shut down.

l During maintenance work catch running out

oils and fuel environmentally and do not let such substances seep into the ground or into the sewage system. Dispose of oils and fuel environmentally and avoid contact with skin and eyes.

5.2 Fuels and lubricants

Fuel

Quality

Useonlycommerciallya va ilable brand carburettor fuel.

You must use unleaded standard grade gasoli ne.

Engine oil

Use w inter grade engine oil for winter operation! In order to assure perfect cold starting it is import

tochose theviscosity(SAE-class)of theengineo il according to the ambient temperature.

For winter operation below -10 °C the oil change intervals must be shortened.

Frequent causes of faults:

l Operating errors l Incorrect, insufficient maintenance

If you cannot locate the cause of a fault or rectify it yourself b y following t he trouble shooting chart, you should contact the service departm ents at our branch offices or dealers.

Fig. 31

Lubrication oil with a too high viscosity index causes start ing difficulties. The temperature when starting the engine is t herefore of highest importance when choosing the viscosity of engine oil for winter operat ion.

Oil viscosity

Since lubrication oil changes its viscosity with the temperature, the ambient temperature at the operating locat ion of the engine is of utmost importance when choos ing the viscosity c lass (SAEclass) (see diagram).

Occasional falling short of the temperature limit (e.g. use of SAE 15W/40 down to -15 ° C ) may effect the cold starting ability of the engine, but will not cause any engine damage.

BOMAG30 BT 60/4, BT 65/4

Maintenance

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Temperature related l ubrication oil changes can be avoided by usingmulti-purpose oils. Thefoll owing oilchange intervals applyalso whenusing multi-purpose oils.

Regular lubrication oil changes

The longest permis sible time a lubrication oil should remain in an engine is 1 year.

Oil quality

Preferably use oils API- quality class SF and SG.

Tamper foot oil

Use gear oil SAE 90 AP I, GL-5

5.3 Filling capacities

Engine oil: 0.33 l Fuel: 3.0 l

BT 60/4

Tamper foot: 0.75 l

BT 65/4

Tamper foot: 1.0 l

BOMAG 31BT 60/4, BT 65/4

Maintenance

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5.4 Running-in instructions

The following maintenance work must be performed when running in new machines or overhauled engines:

Caution

Duringthe running-inperiod,up toapprox.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.

After approx. 20 operating hours

l Change t he engine oil. l Check maximum engine speed , adjust if nec-

essary.

l Check engine and machine for l eaks. l Retighten the fastening screws on air filter ex-

haust, f uel tank and other attachments.

l Retighten the bolted connections on the ma-

chine.

BOMAG32 BT 60/4, BT 65/4

5.5 Maintenance chart

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No. Maintenance work Remark

5.1

Clean the machine In case of extreme

dust every day

Maintenance

Running-in instructions

every day

every month

every year

as required

5.2

5.5

5.6

5.7

5.8

5.9

5.10

5.11

5.12

5.13

5.14

Checking th e concertina wall on the tamper X Check the engine oil level Dipstick mark X Check the fuel level X Changing the engine oil at least every 100

operating hours or 1x per year

Cleaning, checking the spark plug, replacing if necessary

Taper plate, tighten the bolts X Check the oil level in the tamper foot Oil lev el inspection

glass Checking th e valve clearance X Clean the fuel screen in the tank X Oil change in tamper foot Oil lev el inspection

glass Clean, change the double dry air filter cartridge in case of a drop in

the max. engine

speed

BOMAG 33BT 60/4, BT 65/4

Maintenance every day

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Maintenanceeveryday

5.6 Cleaning the machine

Fig. 32

l Do not guide the water jet directly into the air

filter 1 (Fig. 32) and into the starter/air intake (2).

5.7 Checkingthebellowson the tamper

Fig. 33

l Check the condition of the bellows, inspect for

damage and tight fit.

l Check the hose clamps f or tight fit (Fig. 33).

BOMAG34 BT 60/4, BT 65/4

5.8 Check the engine oil level

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Caution

Check the engine oil level with highest care, to avoid over or underfilling of the engine. Underfilling can damage the eng in e. Overfilling causes excessive development of smoke and can also lead to engine damage

l Stand the tamper on flat an d level ground. l Shut the engine down.

Maintenanceeveryday

Fig.35

l The oillevel must reachthebot tomedgeofthe

filler bo re (Fig. 35), maxim um level.

l To check the oillev el insert the dipstick, but do

not screw it in.

l If the oil level is too low top up oil im mediately.

Fig. 34

l Pull out the dipstick (Fig. 34) and wipe it clean

with a lint-free, clean cloth.

l Push the d ipstick in again.

For quality of oil refer to the table of fuels and lubricants.

l After a running time of approx. 1 minute check

the oil level again with the engine shu t down.

BOMAG 35BT 60/4, BT 65/4

Maintenance every day

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5.9 Checking the fuel level, topping up fuel

Danger

Fire hazard! Refuel only with the engine s hut d ow n and the

fuel cock valve closed. Do not spill any fuel! Do n ot inhale any fuel fumes. No o pen fire, do not smoke!

Fuel:

Unleaded standard gra de petrol

Fig. 36

l Set the fuel valve (Fig. 36) to STOP position

(closed).

Fig. 37

l Tank content max. 3.0 litres. l Close the fillercap again tightly afterrefuelling

(Fig. 37).

BOMAG36 BT 60/4, BT 65/4

Maintenance every month

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5.10 Change the engine oil

! Danger

Dangerof scalding! When draining off hot oil.

Caution

Check the engine oil level with highest care, to avoid over or underfilling of the engine. Underfilling o r overfilling can d am age the engine.

Note

Drain the engine oil only when th e engine is warm. Park the mac hine on level ground.

Environment

Environmental damage!

Maintenance every month

Fig.39

l Unscrew thedrain plug(Fig. 39).

Catch old oil and dispose of environmentally.

Fig. 38

l Unscrew the oil dipstick (Fig. 38).

Fig.40

l Catch running out oil (Fig. 40). l Clean the drain plug and screw it back in w ith

a new seal ring.

Fig.41

l Fill in new engine oil (Fig. 41).

BOMAG 37BT 60/4, BT 65/4

Maintenance every month

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For qualityand quantity of oilrefer to the table of fuels and lubricants.

Fig. 42

l Theoil levelmustrea ch the bottom edgeof the

filler bore (Fig. 42), top up if necessary.

l Push the dipstick in again . l Performa test run, inspect drain plug for leaks

and check oil level.

5.11 Cleaning, checking the spark plug, replacing if necessary

Danger

Danger of burning! Let the engine cool down for approx. 15 min-

utes before cl eaning/changing the spark plug.

Fig. 43

l Pull the spark plug s oc ket off. l Unscrew the spark plug, check the sp ark plug

visually and clean it if necessary (Fig. 43).

Note

In case of excessive combustion residuals or burned off electrodes replace t he spark plug, ensure correct heat value of the spark plug.

l Check theelectrode gap withafeeler gauge,if

necessary adjust t he gap to 0.6...0 .7 mm.

Spark plugs:

NGK: CR5HS B Denso: U16FSR-UB

Caution

Do not use spark plu gs with incorrect heat value.

BOMAG38 BT 60/4, BT 65/4

Maintenance every month

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5.12 Tamper foot plate

Fig. 44

l Retighten the screws (Fig. 44).

5.13 Check the oil level in the tamper foot

Note

Stand the tamper of level ground for a short while, so that all oil can run into the housing.

Fig.45

l Clean the sight glass (Fig. 45). l Check the oil level. l The oil must be visible in the insp ec tion glass,

if neces s ary fill in oil accordingly.

For quality of oil refer to the table of fuels and lubricants.

BOMAG 39BT 60/4, BT 65/4

Maintenance every year

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Maintenanceeveryyear

5.14 Check, adjust the valve clearance

Note

Check and adjust only when the engine is co ld (20 +/- 10 °C). If necessary have this work performed by a specialist workshop. Valve clearance:

Intake v alve (IN) = 0.15 mm (0.006 in) Exhaust valve (EX) = 0.20 mm (0. 008 in)

Fig. 48

l Insert thescrew driver into the recess (Fig. 48)

and t ak e the cylinder head cover carefully off.

Fig. 46

l Remove the top engine cover (Fig. 46).

Fig. 47

l Unscrew the fastening screws for the cylinder

head cover (Fig. 47).

Caution

Do not apply force to remove the cylinder head cover.

Fig. 49

l Remove the recoil starter (Fig. 49).

Fig. 50

l Align the a lignment mark ∆ on the flywheel rib

with the top bore in the fa n cover (Fig. 50).

Replace the cylinder head cover if it is dented.

BOMAG40 BT 60/4, BT 65/4

Note

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The piston is in top dead centre of the compression stroke.

However, if the exhaust valve is open when aligning the marks, the flywheel must be turned further by 360°.

Fig. 51

l Measure the valve clearance between valve

adjustment screw and valve with a feeler gauge 2 (Fig. 51).

Maintenance every year

Fig.53

l Cleanthesealing faces oncylinder headcov er

and cylinder block.

l Apply a bead of liquid gask et (Three Bond

1207B or similar) with a diameter of approx.

1.5 to 2 mm to the inside of the cylinder head cover (Fig. 53).

Note

Attach the cylinder head cover within the next 10 minutes.

Valve clearance

Intake valve (IN) = 0.15 mm (0.006 in) Exhaust valve (EX ) = 0.20 mm (0.008 in)

Fig. 52

l To adjust the valve holdvalve adjustment

screw 1 (Fig. 52) and slacken locking screw (2).

l Turn the valve adjustment screw in oroutin or-

der t o achieve the specified valve clearance.

Wait a noth er 20 minutes before starting the engine.

l Retighten the lock ing screw with a tightening

torque of 7.5 Nm (5.4 lbsft).

BOMAG 41BT 60/4, BT 65/4

Maintenance every year

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5.15 Cleaning the fuel filter inside the tank

Danger

Fire hazard! No fire, do not smoke.

Do n ot inhale any fuel fumes.

Environment

Environmental hazard! Do not spill any fuel. Wipe off spilled fuel.

Fig. 56

l Screw t he strainer and t he fuel shut-off v alve

in with a new seal each (Fig. 56).

Fig. 54

l Disconnect the fuel hose 1 (Fig. 54) from the

fuel shut-off valve (2). Open the fuel shut-off valve, drai n the fuel off.

l Unscrew the fuel sh ut-off valve (2).

Fig. 55

l Screw the strainer (Fi g. 55) out and clean it

withgasoline.

BOMAG42 BT 60/4, BT 65/4

5.16 Oil change in tamper foot

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Note

Change the oi l at operating temperature.

Caution

Ensure strict cleanliness.

l Tip the tamper backwards.

Maintenance every year

Fig.58

l Stand the tamper on its foot and secure it

against tipping ove r .

l Clean the filler plug (Fig. 58) and unscrew it. l Fill in new oil. l Screw the filler plug back in with a new seal

ring.

Fig. 57

l Clean the oil drain plug (Fig. 57) and screw it

out,let the oil runout.

Environment

Environmental damage! Catch old oil and dispose of environmentally.

l Check the seal on the drain plug, replace if

necessary.

l Turn the drain plug in and tighten it.

For quality of oil refer to the table of fuels and lubricants.

Fig.59

l Clean the inspection glass (Fig. 59) andc heck

the oil level.

l The oil must be visible in the insp ec tion glass,

if neces s ary fill in oil accordingly.

BOMAG 43BT 60/4, BT 65/4

Asr equired

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5.17 Clean, change the double dry air filter cartridge

Note

Contamination of the air filter cartridge depends mainly on the proportion of dus t in the intake air, if necessary clean every da y.

In case of wet or sticky contam ination replace the double filter cartridge.

As required

Fig.61

l In case of dry fine dust blow out the filter car-

tridge carefully from in side to outside with dry, clean compressed air (Fig. 61) (max. 6 bar).

Note

Before installation check seals and filter cartridge for dam age, replace if necessary.

Fig. 60

l Remove cover 1 (Fig. 60), take filter cartridge

(2) c arefully out.

Caution

Make sure that no dirt falls into the air intake channel.

Visual inspection/cleaning

Danger

Eye injury! Wear protective clothing (goggles, gloves).

Fig.62

l Removetheprotectiongridonthelefthand

side of the engine (Fig. 62).

BOMAG 45BT 60/4, BT 65/4

As required

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Fig. 63

l Loosen hose clamp 2 (Fig. 63) and pull the air

supply hose ( 1) off the air filter housing.

l Unscrewtwo fastening screws (4) and remove

cover (3) from the air filter housing.

l Pull the dry air filter cartrid ge (5) out of the

housing.

Fig. 64

l If soiled with dry fine dust blow the dry air filter

out from the clean air side (Fig. 64).

l Clean the air filter housing.

Caution

Make sure that no dirt falls into the air intake channel.

Note

Before installation check seals and dry air filter for damage, replace if necessary.

BOMAG46 BT 60/4, BT 65/4

6 Trouble shooting

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BOMAG 47BT 60/4, BT 65/4

Trouble shooting

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6.1 General notes

The following work must only be car ried out by qualified and trained personnel or by the BOMAG sales service.

Please observe strictly the safety regulations in chap ter 2 of these operating and maintenance instructions.

Faults oc c ur frequently due to the fact, that the machine has not been properly operate d or serviced. Theref ore, whenever a fault occurs, read through these instructions on correct operation and maintenance. If you cannot locate the cause of the fault or eliminate it yourself by following the trouble s hooting charts, you should c ontact our customer servicedepartments atour branch office or dealers.

On the following pages you will find a selection of fault remedies. It is quite obvious that we were not able to list all possible causes for fault s .

BOMAG48 BT 60/4, BT 65/4

6.2 Engine problems

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Fault Possibl e cause Remedy

Trouble shooting

Engine does not start

Engine does not crank when operatingthe starter

Starter r ope of recoil starter does not return to initial position

Engine stops frequently in short intervals

Fuel tank empty refuel Fuel system clogged Clean the fuel screen in the tank, clean

the fuel screen in the carburettor Fuel no zzl e clogged Clean the fue l nozzle No ignition spark Replace t he spark plug, hav e the fault

corrected Stop switc h defective Replace stop switch No fuel in c arburet tor Check the f uel supply Starter defective Replace starter Spring broken Replace st arter

Dirt Clean the starter Spring broken Replace st arter

Fuel screen clogged clean

Engine does not runwithfull speed

Enginerunswith high speed, bu t no vibration

Throttle cab le defective replace Throttle cable incorrectly adjusted Adjust the throttle cable Air filter clogged Clean or replace the filter cartridge Too high engine oil le ve l Drain engine oil down to „MAX“ level

(clean intake manifold) Engine def ec ti ve Replace the engine/have the fault correct-

ed Carburettor defec tive Replace the carburettor Exhaust blocked clean Centrifugal clutch defective Change the centrifugal clutch Mechanical defect Have rep aired by the customer service of

BOMAG.

BOMAG 49BT 60/4, BT 65/4