Fayat Group BOMAG BT 65 Operating Instruction, Maintenance Instruction
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Fayat Group BOMAG BT 65 Operating Instruction, Maintenance Instruction

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Operating Instruction
Maintenance Instruction
Original Operating Instructions
BT 65
S/N 101 541 37 1001> / S/N 101 541 38 1001>
Tamper
www.discount-equipment.com
008 204 39 EN
© 12/2018

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Summary of Contents for Fayat Group BOMAG BT 65

  • Page 1 Operating Instruction Maintenance Instruction Original Operating Instructions BT 65 S/N 101 541 37 1001> / S/N 101 541 38 1001> Tamper www.discount-equipment.com 008 204 39 EN © 12/2018...
  • Page 2 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.
  • Page 3 WARNING: Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Always start and operate the engine in a well-ventilated area. If in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system.

  • Page 4: Table Of Contents

    Table of contents Table of contents Introduction............................7 1.1 Foreword............................8 1.2 Machine type plate and engine type plate................10 Technical data............................11 2.1 Noise and vibration data......................13 2.1.1 Noise data..........................13 2.1.2 Vibration data..........................14 Concerning your safety........................15 3.1 Basic prerequisites........................
  • Page 5 Table of contents 3.10 Repair............................33 3.11 Signage............................34 Indicators and control elements......................39 Checks prior to start up........................41 5.1 Notes on safety........................... 42 5.2 Visual inspections and function tests..................43 5.3 Checking the engine oil level..................... 44 5.4 Checking the fuel level; topping up fuel................... 45 5.5 Checking the rubber buffers......................
  • Page 6 Table of contents 8.10.1 Cleaning the machine......................96 8.10.2 Checking, cleaning the spark plug................... 96 Setting up / refitting..........................99 9.1 Changing the tamper foot plate....................100 Troubleshooting..........................101 10.1 Preliminary remarks........................ 102 10.2 Engine faults..........................103 10.3 What to do if the engine has flooded..................105 Disposal.............................

  • Page 7: Introduction

    Introduction Introduction BT 65...

  • Page 8: Foreword

    Introduction – Foreword 1.1 Foreword BOMAG manufactures machines for earth, asphalt and refuse compaction, stabilizers/recyclers as well as planers and pavers. BOMAG’s vast experience in connection with state-of-the-art production and testing methods, such as lifetime tests of all important components and highest quality demands guar- antee maximum reliability of your machine.
  • Page 9 Introduction – Foreword In the course of technical development we reserve the right for technical modifications without prior notification. These operating and maintenance instructions are also available in other languages. Apart from that, you can also order the spare parts catalogue against the serial number of your machine.

  • Page 10: Machine Type Plate And Engine Type Plate

    Introduction – Machine type plate and engine type plate 1.2 Machine type plate and engine type plate Please enter here: Machine type (1): Made by Designation Type Serial number (2): Nominal Power Operating Mass Year of Construction Serial-No. Patent Protection 56154 Boppard;GERMANY Made in Germany B-DEC-0270...

  • Page 11: Technical Data

    Technical data Technical data BT 65...
  • Page 12 Technical data Dimensions B-541-0087 Fig. 3 1030 (13.8) (40.6) (28.7) (13.2) (11.0) Dimensions in millimetres (Dimensions in inch) Weights Basic weight (148) (lbs) Operating weight (CECE) (150) (lbs) Travel characteristics Max. working speed m/min (66) (ft/min) Max. area output (depending on soil) (3616) BT 65...

  • Page 13: Noise And Vibration Data

    Technical data – Noise and vibration data Drive Engine manufacturer Honda Type GXR 120 Cooling Number of cylinders Displacement Rated power SAE J 1349 (3.8) (hp) Rated speed 4200 Exciter system Drive system mechanical Frequency 10 - 11.8 (600 - 708) (bpm) Impact force (3822)

  • Page 14: Vibration Data

    Technical data – Noise and vibration data WARNING! Loss of hearing caused by too high noise bur- dens! – Wear your personal protective equipment (ear protection). Guaranteed sound power level = 108 dB(A), determined acc. to ISO 3744 and EN 500. 2.1.2 Vibration data Hand-arm vibration Vector total of the weighted effective acceleration in three orthog-...

  • Page 15: Concerning Your Safety

    Concerning your safety Concerning your safety BT 65...

  • Page 16: Basic Prerequisites

    Concerning your safety – Basic prerequisites 3.1 Basic prerequisites 3.1.1 General This machine has been built in compliance with the latest technical standard and complies with the applicable regulations and tech- nical rules. However, dangers for persons and property may arise from this machine, if: it is used for purposes other than the ones it is intended for, it is operated by untrained personnel,...

  • Page 17: Personal Protective Equipment

    Concerning your safety – Basic prerequisites CAUTION! Danger of injury if failing to comply! Sections marked accordingly indicate a dangerous situation that could lead to fatal or severe injuries, if this warning is disregarded. NOTICE! Danger of material damage if failing to comply! Sections marked accordingly indicate possible dangers for machines or components.

  • Page 18: Intended Use

    Concerning your safety – Basic prerequisites Safety goggles To protect the eyes against airborne particles and squirting fluids. Face protection To protect the face against airborne particles and squirting fluids. Hard hat To protect the head against falling parts and to protect against injuries.
  • Page 19 Concerning your safety – Basic prerequisites Examples for improper use are: Working in horizontal direction Ramming of poles Vibrating of paving blocks It is not permitted to stand on the machine while working. starting and operation of the machine in explosive environments and in underground mining is prohibited.

  • Page 20: Definition Of Responsible Persons

    Concerning your safety – Definition of responsible persons 3.2 Definition of responsible persons 3.2.1 Operating company The operating company is the natural or juridical person who uses the machine or in who's name the machine is used. The operating company must make sure that the machine is only used for the purpose it is intended for and in strict compliance with the safety regulations mentioned in these operating and mainte- nance instructions.
  • Page 21 Concerning your safety – Definition of responsible persons have made himself familiar with the operation of the machine, be physically and psychologically able to drive and operate the machine. Persons under the influence of alcohol, medication or drugs are not allowed to operate, service or repair the machine.

  • Page 22: Basic Safety Regulations For Safe Operation

    Concerning your safety – Basic safety regulations for safe operation 3.3 Basic safety regulations for safe operation 3.3.1 Remaining dangers, remaining risks Despite careful work and compliance with standards and regula- tions it cannot be ruled out that further dangers may arise when working with and handling the machine.

  • Page 23: Handling Fuels And Lubricants

    Concerning your safety – Handling fuels and lubricants 3.4 Handling fuels and lubricants 3.4.1 Preliminary remarks The operating company must ensure that all professional users have read and follow the corresponding safety data sheets for the individual fuels and lubricants. Safety data sheets provide valuable information about the following characteristics: name of substance...

  • Page 24: Safety Regulations And Environmental Protection Regulations For Handling Oil

    Concerning your safety – Handling fuels and lubricants 3.4.2 Safety regulations and environmental protection regulations for handling oil WARNING! Danger of burning by ignited oil! – Do not allow oil to come into contact with hot components. – Smoking and open fire is prohibited! –...

  • Page 25: Safety Regulations And Environmental Protection Regulations For Handling Gasoline

    Concerning your safety – Handling fuels and lubricants 3.4.3 Safety regulations and environmental protection regulations for handling gas- oline DANGER! Danger to life caused by explosive gas-air mixes! – Do not allow gasoline to come into contact with hot components. –...

  • Page 26: Safety Regulations And Environmental Protection Regulations For Handling Fuel Stabiliser

    Concerning your safety – Handling fuels and lubricants 3.4.4 Safety regulations and environmental protection regulations for handling fuel stabiliser WARNING! Danger of burning by ignited fuel stabilizer! – Do not allow fuel stabilizer to come into contact with hot components. –...

  • Page 27: Loading/Transporting The Machine

    Concerning your safety – Loading/transporting the machine 3.5 Loading/transporting the machine Make sure that persons are not endangered by the machine tipping or sliding off. Do not use damaged or in any other way impaired lashing points. Always use appropriate lifting and lashing means on the lifting and lashing points.

  • Page 28: Start-Up Procedure

    Concerning your safety – Start-up procedure 3.6 Start-up procedure 3.6.1 Prior to starting up Use only machines which are serviced at regular intervals. Become acquainted with the equipment, the indicators and control elements, the working principle of the machine and the working area.

  • Page 29: Operation In Trenches

    Concerning your safety – Start-up procedure 3.6.3 Operation in trenches Applies only to Germany. The vibratory tamper or the vibratory plate were tested outdoors by BG Bau (Germany) regarding CO emissions. The tests were car- ried out in a trench with a width of 1.5 metres, a depth of 3 metres and a length of 10 metres.

  • Page 30: Operation

    Concerning your safety – Operation 3.7 Operation 3.7.1 Persons in the danger area Before taking up work, also after breaks, you should always con- vince yourself that the danger zone is free of persons or obstruc- tions. Give warning signals, if necessary. Stop work immediately if per- sons remain in the danger zone, despite the warning.

  • Page 31: Refuelling

    Concerning your safety – Refuelling 3.8 Refuelling Do not inhale any fuel fumes. Refuel only with the engine shut down. Do not refuel in closed rooms. No open fire, do not smoke. Keep away from ignition and heat sources. Apply measures against electrostatic charging. Do not spill any fuel.

  • Page 32: Maintenance Work

    Concerning your safety – Maintenance work 3.9 Maintenance work 3.9.1 Preliminary remarks Adhere to the specified operating, maintenance and repair meas- ures. The machine must only be serviced by qualified personnel author- ised by the operating company. Keep unauthorised persons away from the machine. Perform maintenance work only with the engine shut down and the spark plug connector disconnected.

  • Page 33: Repair

    Concerning your safety – Repair 3.10 Repair Identify a defect machine with a warning sign. Only operate the machine after it has been repaired. When replacing safety relevant components, only original spare parts must be used. Repairs must only be performed by an expert/qualified person. BT 65...

  • Page 34: Signage

    Concerning your safety – Signage 3.11 Signage Keep stickers and signage in good and legible condition and comply with their meaning. Replace damaged and illegible stickers or signage immediately. OPERATION STOP 3600 - 4200 min 1-2 MINUTEN 1850 - 2000 min 3-6 Sec.
  • Page 35 Concerning your safety – Signage Warning sticker - Follow operating instructions Fig. 7 Warning sticker - Do not inhale exhaust gases Do not operate inside closed areas. Fig. 8 Warning sign - Fire hazard Fill up with fuel only when engine is stopped and has cooled down. Fig.
  • Page 36 Concerning your safety – Signage Instruction sticker - Wear ear defenders Fig. 11 Information sticker - Lifting point Fig. 12 Information sticker - Lashing point Fig. 13 Information sticker - Guaranteed sound capacity level Fig. 14 BT 65...
  • Page 37 Concerning your safety – Signage Information sticker - pre-tensioned spring Fig. 15 Brief operating instructions OPERATION STOP 3600 - 4200 min 1-2 MINUTEN 1850 - 2000 min 3-6 Sec. 3850 - 4200 min Max: 0,3 l 1-2 MINUTEN 18.3 in Low Oil Level = No Start B-DEC-0323 Fig.

  • Page 38: Indicators And Control Elements

    Indicators and control elements Indicators and control elements BT 65...
  • Page 39 Indicators and control elements B-541-0148 Fig. 18 Engine oil level warning light Operating hour meter/engine rpm-meter Engine stop switch Throttle lever Recoil starter Choke lever BT 65...

  • Page 40: Checks Prior To Start Up

    Checks prior to start up Checks prior to start up BT 65...

  • Page 41: Notes On Safety

    Checks prior to start up – Notes on safety 5.1 Notes on safety If the following tests reveal damages or other defects, the machine must not be operated, until these deficiencies have been corrected. Do not operate the machine with defective indicators and control elements.

  • Page 42: Visual Inspections And Function Tests

    Checks prior to start up – Visual inspections and function tests 5.2 Visual inspections and function tests Check fuel tank and lines for condition and leaks. Check bolted connections for tight fit. Check machine for contamination and damage. Check the hydraulic oil cooler for dirt. Check starter rope for chafing.

  • Page 43: Checking The Engine Oil Level

    Checks prior to start up – Checking the engine oil level 5.3 Checking the engine oil level NOTICE! Danger of engine damage! – +Use only oil of the permitted specification Ä Chapter 8.2.1 „Engine oil“ on page 65. The engine cannot be started if the engine oil level is too low.

  • Page 44: Checking The Fuel Level; Topping Up Fuel

    Checks prior to start up – Checking the fuel level; topping up fuel 5.4 Checking the fuel level; topping up fuel DANGER! Danger to life caused by explosive gas-air mixes! – Do not allow gasoline to come into contact with hot components.

  • Page 45: Checking The Rubber Buffers

    Checks prior to start up – Checking the rubber buffers 5.5 Checking the rubber buffers Protective equipment: Working clothes Safety shoes Protective gloves Park the machine safely Ä Chapter 6.4 „Parking the machine in secured condition“ on page 55. Allow the engine to cool down. Check all rubber buffers for tight fit, cracks and tear-offs.

  • Page 46: Operation

    Operation Operation BT 65...

  • Page 47: Adjusting The Guide Handle

    Operation – Adjusting the guide handle 6.1 Adjusting the guide handle Adjust the guide handle to the size of the operator using bores (A) and (B): (A) - Lower guide handle position (B) - Upper guide handle position Ä Chapter 6.4 Park the machine in secured condition „Parking the machine in secured condition“...

  • Page 48: Starting The Engine

    Operation – Starting the engine 6.2 Starting the engine Exhaust fumes contain toxic substances and can damage your health, cause unconsciousness or even death. WARNING! Danger of poisoning by exhaust gases! – Do not inhale exhaust gases. – Avoid operation in closed or partly closed rooms, or ensure adequate ventilation when working in trenches.
  • Page 49 Operation – Starting the engine Set the throttle lever to position "MAX". Fig. 25 Close the choke. Always close the choke to start a cold and warm engine. Fig. 26 Pull the rope by the starter handle, until resistance can be felt.
  • Page 50 Operation – Starting the engine CAUTION! Danger of injury caused by uncontrolled machine movement! – Keep your feet clear of the tamper foot plate. – Always hold on to a running machine. – Always keep an eye on a running machine.
  • Page 51 Operation – Starting the engine If the recoil starter is frequently operated with the choke closed, the engine will draw in too much fuel Ä Chapter 10.3 „What to do and is unable to start ( if the engine has flooded“ on page 105). BT 65...

  • Page 52: Operation

    Operation – Operation 6.3 Operation Guide the machine only by the guide handle. Guide the machine so that your hands do not hit against solid objects. For longer work breaks you should always park the machine in Ä Chapter 6.4 „Parking the machine in secured secured condition condition“...
  • Page 53 Operation – Operation To achieve uniform running you should actuate the throttle lever within the working range (I), depending on condition and density of the soil. ð Working range (I) = 3600 to 4200 min If the machine jumps out of rhythm on heavily compacted soil, you may need to slightly change the engine speed and/or inclination of the machine.

  • Page 54: Parking The Machine In Secured Condition

    Operation – Parking the machine in secured condition 6.4 Parking the machine in secured condition Set the throttle lever to position "MIN" (idle speed). NOTICE! Danger of engine damage! – Do not shut down the engine all of a sudden from full load speed, but let it idle for about two minutes.

  • Page 55: Operating Hour Meter/Engine Rpm-Meter

    Operation – Operating hour meter/engine rpm-meter 6.5 Operating hour meter/engine rpm-meter Engine off Operating the function key (1) switches between operating hours, hour counter and service indicator Engine on Engine speed If the remaining period until the next maintenance is under two hours, the maintenance indicator appears for approx.
  • Page 56 Operation – Operating hour meter/engine rpm-meter Resetting the maintenance indi- Shut down the engine. cator / hour meter Keep pressing the function key (1), until the maintenance indicator or the hour meter is displayed. Press the function key for three seconds. ð...

  • Page 57: Loading/Transporting The Machine

    Loading/transporting the machine Loading/transporting the machine BT 65...

  • Page 58: Loading The Machine

    Loading/transporting the machine – Loading the machine 7.1 Loading the machine Loads may only be attached and hoisted by an expert/qualified person. Do not use lifting points that are damaged or impaired in any other way. Only use lifting and lashing tackle with sufficient load bearing capacity for the weight to be loaded.
  • Page 59 Loading/transporting the machine – Loading the machine WARNING! Danger of burning on hot components! – Wear your personal protective equipment (protective gloves, protective clothing). – Avoid touching hot components. Lay the machine on the rollers. B-541-0017 Fig. 42 BT 65...

  • Page 60: Lashing The Machine To The Transport Vehicle

    Loading/transporting the machine – Lashing the machine to the transport vehicle 7.2 Lashing the machine to the transport vehicle Do not use lashing points that are damaged or impaired in any way. Always use appropriate lashing tackle at the lashing points. Use lashing tackle only in the specified loading direction.

  • Page 61: Maintenance

    Maintenance Maintenance BT 65...

  • Page 62: Preliminary Remarks And Safety Notes

    Maintenance – Preliminary remarks and safety notes 8.1 Preliminary remarks and safety notes DANGER! Danger to life caused by an operationally unsafe machine! – The machine must only be serviced by quali- fied and authorized personnel. – Follow the safety regulations for maintenance work Ä...

  • Page 63: Fuels And Lubricants

    Maintenance – Fuels and lubricants 8.2 Fuels and lubricants 8.2.1 Engine oil 8.2.1.1 Oil quality The following engine oil specifications are permitted: Engine oils for four-stroke engines acc. to API-classification SJ or higher Avoid mixing of engine oils. 8.2.1.2 Oil viscosity Since engine oil changes its viscosity with the temperature, the ambient temperature at the operating location of the engine is of utmost importance when choosing the viscosity class (SAE-class).

  • Page 64: Gear Oil Sae 75W-90

    Maintenance – Fuels and lubricants 8.2.2.2 Fuel stabilizer If the machine is only occasionally used (if it is out of use for longer than four weeks), mix in the correct amount of fuel stabilizer directly after you have purchased fresh fuel. The fuel stabilizer has a limited shelf life.

  • Page 65: List Of Fuels And Lubricants

    Maintenance – List of fuels and lubricants 8.3 List of fuels and lubricants Assembly group Fuel or lubricant Spare parts Filling quantity number Summer Winter Observe the level mark! Engine oil SAE 10W-30 0.3 l Specification: Ä Chapter 8.2.1 „Engine (0.08 gal us) oil“...

  • Page 66: Running-In Instructions

    Maintenance – Running-in instructions 8.4 Running-in instructions 8.4.1 General The following maintenance work must be performed when running in new machines or overhauled engines. NOTICE! Danger of engine damage! – Up to approx. 250 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.

  • Page 67: Maintenance Table

    Maintenance – Maintenance Table 8.5 Maintenance Table Maintenance works Page Weekly 8.6.1 Checking, cleaning the air filter Monthly 8.7.1 Checking the tamper foot Semi-annually 8.8.1 Changing the engine oil Annually 8.9.1 Checking, adjusting the valve clearance 8.9.2 Replacing the spark plug 8.9.3 Replacing the fuel filter 8.9.4...

  • Page 68: Weekly

    Maintenance – Weekly 8.6 Weekly 8.6.1 Checking, cleaning the air filter NOTICE! Danger of engine damage! – Never start the engine after removing the air filter. – Do not let dirt drop into the air duct. – Do not continue using a damaged or soiled air filter.
  • Page 69 Maintenance – Weekly Disassemble the left engine guard. B-541-0093 Fig. 48 Pull the air feed hose (1) and the hose clamp (2) off the cover (3). B-541-0072 Fig. 49 Unscrew the fastening screws (1). Disassemble the cover and air filter (2). Wipe the inside of the air filter housing with a clean cloth.
  • Page 70 Maintenance – Weekly Slide the air filter (2) carefully into the housing. Assemble the cover (3) with fastening screws (1), tightening torque: 3 Nm (2 ft·lbf). 3 Nm B-541-0097 Fig. 52 Connect the air hose (1) with the hose clamp (2) to the cover (3).

  • Page 71: Monthly

    Maintenance – Monthly 8.7 Monthly 8.7.1 Checking the tamper foot NOTICE! Components may get damaged! – Use only oil of the permitted specification Ä Chapter 8.3 „List of fuels and lubri- cants“ on page 67. Protective equipment: Working clothes Protective gloves Park the machine in secured condition Ä...
  • Page 72 Maintenance – Monthly Retighten 4 screws (1) on the tamper foot plate, tightening torque: 60 - 70 Nm (44 - 52 ft·lbf). Fig. 57 Retighten 5 screws (1) on the tamper foot plate, tightening torque: 15 Nm (11 ft·lbf). Fig. 58 BT 65...

  • Page 73: Semi-Annually

    Maintenance – Semi-annually 8.8 Semi-annually 8.8.1 Changing the engine oil NOTICE! Danger of engine damage! – Change the oil only with the engine at oper- ating temperature. – Use only oil of the permitted specification Ä Chapter 8.2.1 „Engine oil“ on page 65. Ä...

  • Page 74: Annually

    Maintenance – Annually 8.9 Annually 8.9.1 Checking, adjusting the valve clearance NOTICE! Danger of engine damage! We recommend to have this work carried out by trained personnel or our after sales service. – Before checking the valve clearance let the engine cool down.
  • Page 75 Maintenance – Annually Disassemble the guide handle fastening screws. Fig. 63 NOTICE! Components may get damaged! – Do not tear off any hoses or cables. Remove the guide handle and secure it to the housing with a fastening screw. Tighten the fastening screw hand-tight. Fig.
  • Page 76 Maintenance – Annually If necessary, remove the spacer ring (2) from the engine. Fig. 66 Checking, adjusting the valve clear- Valve clearance: ance Intake valve (IN) 0.15 mm (0.006 in) Exhaust valve (EX) 0.20 mm (0.008 in) Unscrew the fastening screws for the cylinder head cover. Fig.
  • Page 77 Maintenance – Annually Align the alignment mark on the flywheel rib with the top bore of the fan cover. ð The piston is in top dead centre position of the compres- sion stroke. However, if the exhaust valve is open when aligning the marks, the flywheel must be turned further by 360°.
  • Page 78 Maintenance – Annually Concluding work Clip in the spacer ring (2) on the recoil starter (1). Fig. 73 NOTICE! The recoil starter may get damaged! – Do not mix up the fastening screws for the recoil starter by mistake. Assemble the recoil starter. Fig.

  • Page 79: Replacing The Spark Plug

    Maintenance – Annually Connect the air hose (1) with the hose clamp (2) to the cover (3). B-541-0072 Fig. 76 Assemble the fastening screws, tightening torque: 50 Nm (37 ft·lbf). Fig. 77 Assemble air filter (2) and cover (1). Wait another 20 minutes before starting the engine. After a short test run, check the engine for leaks.

  • Page 80: Replacing The Fuel Filter

    Maintenance – Annually Protective equipment: Working clothes Protective gloves Special tool: 16 mm spark plug spanner Ä Chapter 6.4 Park the machine in secured condition „Parking the machine in secured condition“ on page 55. Allow the engine to cool down for at least 15 minutes. Pull off the spark plug connector (1).
  • Page 81 Maintenance – Annually Set the engine stop switch to position “OFF”. ð The fuel valve is closed. B-541-0066 Fig. 80 Disassemble the left engine guard. B-541-0093 Fig. 81 Disassembling the fuel filter Loosen the hose clamps (1) and (4) and pull the fuel hoses off the fuel filter (2).
  • Page 82 Maintenance – Annually Assembling the fuel filter and filling it with fuel Install the new fuel filter (2) by observing the flow direction. Tighten the fastening screw (3), tightening torque: 10 Nm (7.4 ft·lbf). Connect the lower fuel hoses to the fuel filter with hose clamp (4).

  • Page 83: Cleaning The Fuel Screen

    Maintenance – Annually 8.9.4 Cleaning the fuel screen DANGER! Danger to life caused by explosive gas-air mixes! – Do not allow gasoline to come into contact with hot components. – Smoking and open fire is prohibited. – Keep away from heat sources, sparks and other sources of ignition.
  • Page 84 Maintenance – Annually Unscrew the screws (2) and remove the engine stop switch (1). Fig. 88 Unscrew the fuel valve (2) and remove the seal (1). Clean the screen and check for damage. Replace the fuel valve if damaged. Assemble the fuel valve with a new seal Fig.

  • Page 85: Replacing The Air Filter

    Maintenance – Annually Close the fuel valve (engine stop switch in position "OFF"). Dispose of fuel environmentally. Fig. 92 8.9.5 Replacing the air filter NOTICE! Danger of engine damage! – Do not start the engine after having removed the air filter. Protective equipment: Working clothes Safety shoes...
  • Page 86 Maintenance – Annually Disassemble the left engine guard. B-541-0093 Fig. 94 Pull the air feed hose (1) and the hose clamp (2) off the cover (3). B-541-0072 Fig. 95 Unscrew the fastening screws (1). Disassemble the cover and air filter (2). Wipe the inside of the air filter housing with a clean cloth.

  • Page 87: Checking, Adjusting The Engine Speed

    Maintenance – Annually Connect the air hose (1) with the hose clamp (2) to the cover (3). B-541-0072 Fig. 98 Assemble the left hand engine guard, tightening torque: 25 Nm (18 ft·lbf). 25 Nm B-541-0083 Fig. 99 8.9.6 Checking, adjusting the engine speed 8.9.6.1 Checking the engine speed Preparations...
  • Page 88 Maintenance – Annually Nominal values: Idle speed 1850 to 2000 min Maximum engine speed 3850 to 4200 min Start the engine and run it warm for approx. 15 minutes. Run the machine on ground that can be compacted. Set the throttle lever to position “MIN”. Fig.
  • Page 89 Maintenance – Annually 8.9.6.2 Adjusting the engine speed Protective equipment: Working clothes Safety shoes Protective gloves Ä Chapter 6.4 „Parking the machine Park the machine safely in secured condition“ on page 55. Disassemble the left engine guard. B-541-0093 Fig. 103 WARNING! Danger of burning on hot components! –...

  • Page 90: Replacing The Starter Rope

    Maintenance – Annually 8.9.7 Replacing the starter rope Protective equipment: Working clothes Protective gloves Ä Chapter 6.4 Park the machine in secured condition „Parking the machine in secured condition“ on page 55. Allow the engine to cool down. Disassembling the recoil starter. Fig.
  • Page 91 Maintenance – Annually Secure the coil against winding up. For this purpose tie the coil (2) to the housing (5) with a cable strap (1). Untie the knots of the starter rope at both ends and remove the old starter rope. Thread in the new starter rope (3) and fix it with knots on both ends.

  • Page 92: Changing The Oil In The Tamper Foot

    Maintenance – Annually Screw M6x18 8.9.8 Changing the oil in the tamper foot NOTICE! Components may get damaged! – Drain tamper foot oil only at operating tempera- ture. – Ensure strict cleanliness. – Use only tamper oil of the permitted specifica- tion.
  • Page 93 Maintenance – Annually Fill in fresh oil up to the bottom edge of the filler bore. Clean the filling plug and screw it back in with a new seal ring. B-541-0048 Fig. 114 Check the oil level in the inspection glass, correct if neces- sary.

  • Page 94: As Required

    Maintenance – As required 8.10 As required 8.10.1 Cleaning the machine NOTICE! Danger of engine damage caused by reduced cooling! – Immediately remove any oil or fuel leaks near fuel tank, cylinders or cooling air intake. Protective equipment: Working clothes Safety shoes Protective gloves Ä...
  • Page 95 Maintenance – As required Protective equipment: Working clothes Protective gloves Special tool: 16 mm spark plug spanner Ä Chapter 6.4 Park the machine in secured condition „Parking the machine in secured condition“ on page 55. Allow the engine to cool down for at least 15 minutes. Pull off the spark plug connector (1).

  • Page 96: Setting Up / Refitting

    Setting up / refitting Setting up / refitting BT 65...

  • Page 97: Changing The Tamper Foot Plate

    Setting up / refitting – Changing the tamper foot plate 9.1 Changing the tamper foot plate Only use genuine spare parts when changing the tamper foot plate to a different width. Protective equipment: Protective gloves Working clothes Ä Chapter 6.4 Park the machine in secured condition „Parking the machine in secured condition“...

  • Page 98: Troubleshooting

    Troubleshooting Troubleshooting BT 65...

  • Page 99: Preliminary Remarks

    Troubleshooting – Preliminary remarks 10.1 Preliminary remarks Malfunctions are frequently caused by incorrect operation of the machine or insufficient maintenance. Whenever a fault occurs you should therefore thoroughly read these instructions on correct operation and maintenance. If you cannot locate the cause of a fault or rectify it yourself by fol- lowing the trouble shooting chart, you should contact our customer service department.

  • Page 100: Engine Faults

    Troubleshooting – Engine faults 10.2 Engine faults Fault Possible cause Remedy Engine does not Fuel tank empty Check, fill up if necessary start Fuel system clogged Clean the fuel screen in the tank Replacing the fuel filter Check the fuel screen in the carburettor Have checked by qualified expert per- sonnel Set the engine stop switch to position...
  • Page 101 Troubleshooting – Engine faults Fault Possible cause Remedy Throttle cable incorrectly adjusted Have checked by qualified expert per- sonnel Air filter clogged Clean the air filter, replace if necessary Engine oil level too high Check the engine oil level, if necessary drain off engine down to the "MAX"...

  • Page 102: What To Do If The Engine Has Flooded

    Troubleshooting – What to do if the engine has flooded 10.3 What to do if the engine has flooded WARNING! Loss of hearing caused by too high noise bur- dens! – Wear your personal protective equipment (ear protection). Protective equipment: Hearing protection Safety shoes Set the engine stop switch to position "OFF".
  • Page 103 Troubleshooting – What to do if the engine has flooded Operate the recoil starter 10 to 20 times. Fig. 124 Set the engine stop switch to position "ON". CAUTION! Danger of injury caused by uncontrolled machine movement! – Always hold on to a running machine. –...
  • Page 104 Troubleshooting – What to do if the engine has flooded Cleaning the spark plug Protective equipment: Working clothes Protective gloves Safety goggles Special tool: 16 mm spark plug spanner Pull off the spark plug socket (1). Unscrew the spark plug with a 16 mm spark plug spanner (2).

  • Page 105: Disposal

    Disposal Disposal BT 65...

  • Page 106: Final Shut-Down Of Machine

    Disposal – Final shut-down of machine 11.1 Final shut-down of machine If the machine can no longer be used and needs to be finally shut down you must carry out the following work and have the machine disassembled by an officially recognized specialist workshop. DANGER! Danger to life caused by explosive gas-air mixes!

  • Page 107: List Of Special Tools

    List of special tools List of special tools BT 65...
  • Page 108 List of special tools 16 mm spark plug spanner Fig. : 16 mm spark plug spanner (example) BT 65...
  • Page 109 Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101 Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ choose one of the options to help get the right parts and equipment you are looking for.

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