Operating instructions

Maintenance instructions

BW 62 H / BW 65 H
S/N 101 100 60 ....> S/N 101 100 61 ....> S/N 101 100 62 ....> S/N 101 100 63 ...> S/N101 100 64 ...>
S/N 101 100 70 ....> S/N 101 100 71 ....> S/N 101 100 72 ....> S/N 101 100 73 ...> S/N 101 100 74 ...>

Double vibratory roller

Catalogue number
008 103 41 03/2006
 Foreword

The BOMAG tandem vibratory rollers are prod- For your own safety you should only use
F oreword

ucts from the wide range of BOMAG compac-
tion equipment.
BOMAG's vast experience, together with the
most up-to-date production and testing meth-
ods, including service life tests of all important
components and highest quality demands,
guarantee maximum reliability of your ma-
chine.
Using this instruction will
l help you to get to know the machine.
l avoid malfunctions caused by unexpert opera-
tion.
Compliance with the maintenance instructions will
l increase the reliability of your machine on the
site,
l prolong the service life of the machine,
l reduce repair costs and downtimes.
BOMAG shall not assume liability for safe func-
tioning of the machine
l if it is handled in a way which does not comply
with the usual modes of use,
l if it is used for purposes other than those men-
tioned in the instructions.
BOMAG spare parts.
We reserve the right for technical modifica-
tions without prior notification.
These operating and maintenance instructions are
also available in other languages.
You can also receive the spare parts catalogue
and the repair instructions from your BOMAG
dealer when giving the serial number of your ma-
chine.
You can also obtain information about the correct
use of our machines in earth and asphalt construc-
tion from your BOMAG dealer.
The above mentioned notes do not constitute an
extension of the warranty and liability conditions
specified in the general terms of business of
BOMAG.
We wish you much success with your BOMAG
machine.
BOMAG GmbH & Co. OHG
Printed in Germany
Copyright by BOMAG

No warranty claims can be lodged for damage re-

sulting from
l operating errors,
l unsufficient maintenance and
l wrong fuels and lubricants.

Please note!
This manual has been written to be used by oper-
ators and service personnel on the site.
You should only perform operations to the ma-
chine if you are fully conversant with the contents
of these instructions.
Please observe strictly the safety regulations.
Please observe also the guidelines of the Civil En-
gineering Liability Association "Safety Regulations
for the Operation of Road Rollers and Soil Com-
pactors" and the relevant accident prevention in-
structions.

BW 62/65 H BOMAG 3
Foreword

Please fill in
............................
Machine type (Fig. 1)
............................
Serial No. (Fig. 1 and 2)
............................
Engine type (Fig. 3)
............................
Engine No. (Fig. 3)

i Note Fig. 1
Fill in the above listed data when receiving the ma-
chine.
Upon receipt of the machine our organization will
instruct you about correct operation and mainte-
nance.
Please observe strictly all safety regulations and
notes on potential dangers!

Fig. 2

Fig. 3

4 BOMAG BW 62/65 H
 Table of Contents

Technical Data 7
Safety regulations 11
Operation 17
3.1 General notes 18
3.2 Tests before starting operation 18
3.3 Starting the engine 19
3.4 Adjusting the steering rod 22
3.5 Releasing the parking brake 22
3.6 Driving the machine 23
3.7 Switching the vibration on or off 24
3.8 Switching the gravity sprinkler system on and off 25
3.9 Applying the parking brake 26
3.10 Shutting the engine down 26
3.11 Loading and transport 27
Maintenance 29
4.1 General notes on maintenance 30
4.2 Fuels and lubricants 31
4.3 Table of fuels and lubricants 33
4.4 Running-in instructions 34
4.5 Maintenance chart 35
4.6 Cleaning the engine 36
4.7 Checking the engine oil level 36
4.8 Checking the fuel level 37
4.9 Checking the hydraulic oil level 37
4.10 Checking the water level 38
4.11 Changing the engine oil 39
4.12 Changing the engine oil filter 40
4.13 Cleaning, changing the dry air filter 40
4.14 Checking, adjusting the valve clearance 41
4.15 Cleaning cooling fins and cooling air intake openings 42
4.16 Checking, tensioning, changing the drive V-belt 43
4.17 Checking, tensioning, changing the toothed belt for the vibration system 44
4.18 Greasing the gears 46
4.19 Checking the rubber buffers 46
4.20 Cleaning the crank handle guide 47
4.21 Servicing the battery 47
4.22 Changing the fuel filter 48
4.23 Changing the hydraulic oil 49
4.24 Changing the hydraulic oil filter 50
4.25 Water sprinkler system, cleaning, maintenance in the event of frost 51
4.26 Adjusting the scrapers 52

BW 62/65 H BOMAG 5
Table of Contents

4.27 Checking the water separator 52

4.28 Tightening torques for screws with metric unified thread 53
4.29 Engine conservation 53
Trouble shooting 55
5.1 General notes 56
5.2 Engine faults 57

6 BOMAG BW 62/65 H
 1 Technical Data

BW 62/65 H BOMAG 7
 Technical Data

Fig. 4

Dim. mm (inch) A B C D H K L L1 O1 O2 W
BW 62 H 550 712 200 400 960 110 2200 2320 92 20 600
BW 65 H 550 762 200 400 960 110 2200 2320 92 20 650

*
BW 62 H BW 65 H

Weights
Basic weight kg (lbs) 558 (1230) 675 (1488)
Operating weight (CECE) kg (lbs) 592 (1305) 709 (1563)
Static linear load kg/cm (lbs) 4,9 (10.8) 5,5 (12.1)

Dimensions
Working width mm (in) 600 (23.6) 650 (25,6)
Measurements see sketch see sketch

Travel performance
data
Travel speed in forwards km/h (mph) 0 - 5,5 (0 - 3.4) 0 - 5,5 (0 - 3.4)
Travel speed in reverse km/h (mph) 0 - 2,5 (0 - 1.6) 0 - 2,5 (0 - 1.6)

Max. gradability (de-

pending on soil)
without/with vibration % 40/35 40/35

8 BOMAG BW 62/65 H
 Technical Data

* BW 62 H BW 65 H
Drive
Engine manufacturer/type Hatz 1 D 41 S Hatz 1 D 41 S
Cooling air air
Working cycles 4 4
Number of cylinders 1 1
Rated power ISO 9249 kW (hp) 5,6 (7,6) 5,6 (7,6)
Nominal speed rpm 2800 2800
Fuel diesel diesel
Drive system hydrostatic hydrostatic
Starter crank handle crank handle
Driven drums front + rear front + rear

Vibration system
Vibrating drums front + rear front + rear
Drive system mechanical mechanical
Frequency Hz 55 55
Amplitude mm (in) 0,45 (0.017) 0,45 (0.017)
Centrifugal force kN 8,5 11

Capacities
Fuel tank (diesel) l (Usgal) 5 (1.32) 5 (1.32)
Water tank l (USgal) 60 (15.9) 60 (15.9)
Hydraulic oil tank l (USgal) approx. 13,5 (3.6) approx. 13,5 (3.6)

Water sprinkler system

System gravity gravity
* Technical modifications reserved

BW 62/65 H BOMAG 9
Technical Data

The following noise and vibration data acc. to

- EC Machine Regulation edition 98/37/EC and

- the noise regulation 2000/14/EG, noise protection guideline 2003/10/EC

- Vibration Protection Regulation 2002/44/EC

were determined during conditions typical for this type of equipment and by application of harmo-
nized standards.

During operation these values may vary because of the existing operating conditions.

Noise value
sound pressure level on the operator’s stand:
LpA = 87 dB(A), BW 62H determined acc. to ISO 11204 and EN 500
LpA = 87 dB(A), BW 65H determined acc. to ISO 11204 and EN 500

Garanteed sound capacity level:

LWA = 105 dB(A), BW 62H determined acc. to ISO 3744 and EN 500
LWA = 105 dB(A), BW 65H determined acc. to ISO 3744 and EN 500

! Danger
Loss of hearing!
Wear your personal noise protection means (ear defenders) before starting operation.

Vibration value
Hand-arm vibration:
Vector total of the weighted effective acceleration in three orthogonal directions:

Weighted total vibration value

BW 62H ahw = 3.2 m/sec2 on crushed rock determined acc. to ISO 5349 and EN 500
BW 65H ahw = 4.4 m/sec2 on crushed rock determined acc. to ISO 5349 and EN 500

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

10 BOMAG BW 62/65 H
 2 Safety regulations

BW 62/65 H BOMAG 11
Safety regulations
General notes
This BOMAG machine has been built accord-
ing to latest technical standards and meets all
valid technical rules and regulations. However,
there is a risk of danger for persons and prop-
erty when:
l the machine is used for purposes other than
those it 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 com-
plied with
It is therefore of utmost importance that any
person involved in operation, maintenance
and repair of the machine reads and follows
these safety regulations. This should be con-
firmed by obtaining the signatures of the cus-
tomer if necessary.
Furthermore the following regulations and instruc-
tions must be complied with:
l applicable accident prevention regulations,
l generally acknowledged safety and road traffic
regulations as well as
l country specific regulations
Intended use
Diese Maschine ist nur zu verwenden für:
l Compaction of bituminous materials (road lay-
ers)
l Light compaction work in earth construction
(road subbase)
Unintended use
Dangers may however arise from this machine if it
is put to improper or unintended use by untrained
personnel.
The steering rod must not be used as a seat to ride
on during work.
Who is allowed to operate the ma-
chine?
The machine must only be operated by trained
and authorized persons, which are at least 18
12
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, medica-
tion or drugs must not operate, service or repair
the machine.
Maintenance and repairs require very specific
knowledge and must therefore only be carried out
by trained and qualified personnel.
Conversions and alterations to the ma-
chine
Unauthorized conversions to the machine are pro-
hibited for safety reasons.
Original parts and accessories have been de-
signed especially for the machine. We wish to
make expressly clear, that we have not tested or
authorized any original parts or special equipment
not supplied by us. The installation and/or use of
such products can also impair the active and/or
passive driving safety. The manufacturer express-
ly excludes any liability for damage resulting from
the use of non-original parts and accessories.
Safety notes in the operating and main-
tenance instructions:
Danger
!
Sections marked like this point out possible
dangers for persons.
Caution
!
Sections marked like this point out possible
dangers for the machine or for parts of the ma-
chine.
i Note
Sections marked like this provide technical infor-
mation concerning the optimal economical use of
the machine.
Safety decals on the machine
Keep safety decals in good and legible condition
and comply with their meaning.
Replace damaged or illegible safety decals.
BOMAG BW 62/65 H

Loading the machine
Use only strong and stable loading ramps. The
ramp inclination must be lower than the gradability
of the machine.
Secure the machine against turning over or slip-
ping off.
Secure the machine on the transport vehicle
against rolling, slipping and turning over.
Persons are highly endangered when
l stepping or standing under loads being lifted
l they remain in the drive range of the machine
during an ongoing demonstration and during
loading.
The machine must not swing about when being lift-
ed.
Secure the machine on the transport vehicle
against rolling, slipping and turning over.
Starting the machine
Before starting
Familiarize yourself with the equipment, the con-
trol elements, the working principles of the ma-
chine and the area where you will be working.
Use your protective outfit (hard hat, safety boots
etc.).
Check before starting the machine whether:
l persons or obstacles are beside or under the
machine
l the machine is free of oily and combustible
material
l all handles are free of grease, oils, fuels , dirt,
snow and ice
l the machine shows any obvious faults
l all guards and protective devices are properly
fastened
l steering, brakes and control elements are in
good working order.
Do not start the machine if any gauges, control
lights or control elements are defective.
Do not take any loose objects with you or secure
them to the machine.
Use only machines that have been properly serv-
iced according to schedule.
BW 62/65 H
Safety regulations
Starting
l Take a correct position to the machine to start
the engine and hold the crank handle correct-
ly.
l Do not use any starting aids such as Start Pilot
or ether.
Starting with jump leads
Connect plus with plus and minus with minus
(earth cable) - connect the earth wire last and dis-
connect it first! Wrong connections will cause seri-
ous damage in the electrical system.
Starting in closed rooms
Exhaust fumes are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
in closed rooms!
Driving the machine
Persons in the danger zone
Before starting to work, even after short breaks,
check, if there are any persons or obstructions in
the working range of the machine.
If necessary give warning signals. Stop work im-
mediately if persons remain in the danger zone de-
spite the warning.
Driving
Do not use the machine to transport persons.
Change the travel direction only while the machine
is standing.
Move the travel control lever slowly to start and
stop the machine.
Always guide the machine so that you do not hit
your hands against solid obstructions. Danger of
injury!
Guide and operate the machine only from the pre-
determined operating side
Keep away from edges and slopes.
Stop the machine if you notice unusual noises or
the development of smoke. Investigate the cause
and have the fault corrected.
Always let loaded transport vehicles pass.
Driving on slopes and gradients
Do not drive up and down inclines which are
steeper than the maximum gradability of the ma-
chine.
BOMAG 13
Safety regulations
Always drive extremely carefully on slopes and al-
ways directly up or down the slope. Always shift to
the lower speed range when approaching the
slope.
The steering rod must always point uphill when
driving up or down slopes.
Wet and loose soils reduce the ground adhesion of
the machine on slopes and gradients considera-
bly. Higher risk of accidents!
When driving in traffic
Match the travel speed to the working conditions.
Always let loaded transport vehicles pass.
Keep away from edges and slopes.
Check the effect of vibration
When compacting with vibration check the effect
of the vibration on nearby buildings and under-
ground supply lines (gas, water, sewage and elec-
tricity), stop vibratory compaction immediately if
required.
Do not vibrate on hard (frozen, concrete) ground.
Risk of bearing damage!
Parking the machine
Park the machine on ground as level and firm as
possible.
Before leaving the machine:
l set the control lever to neutral position
l apply the parking brake
l shut the engine down and pull the ignition key
out
Do not use the decompression lever to shut the
engine down.
Mark parked machines, which could be an ob-
struction, with a clearly visible sign.
Parking on slopes and gradients
Park the machine transverse to the slope or se-
cure the machine against rolling. Place metal
chocks under the drums.
Filling the fuel tank
Do not breathe in any fuel fumes
Only refuel with the engine shut down.
Do not refuel in closed rooms.
14
No open fire, do not smoke.
Do not spill any fuel. Catch running out fuel and do
not let it seep into the ground.
Maintenance
Maintenance work must only be carried out by
qualified and authorized personnel.
Keep unauthorized persons away from the ma-
chine.
Do not perform maintenance work while the ma-
chine is driving or the engine is running.
Park the machine on level and firm ground.
Pull the ignition switch out.
Working on hydraulic lines
Depressurize hydraulic lines before starting to
work. Hydraulic oil escaping under pressure can
penetrate the skin and cause serious injuries.
Consult a doctor immediately if you are injured by
pressurized oil, as otherwise serious infections
may develop.
Do not stand in front of or behind the drums when
adjusting the hydraulic system.
Do not change the setting of pressure relief valves.
Drain hydraulic oil at operating temperature - dan-
ger of scalding!
Catch running out hydraulic oil and dispose of en-
vironmentally.
Always catch biodegradable hydraulic oils in a
separate container and dispose of separately.
Do not start the engine after draining the hydraulic
oil.
Check all connections and fittings for leakages af-
ter all work is completed (with the system still de-
pressurized!).
Changing hydraulic hoses
Hydraulic hoses must be examined visually at reg-
ular intervals.
Hydraulic hoses must not be interchanged by mis-
take.
Hydraulic hoses must be changed immediately in
case of:
l damage to the outer surface down to the lining
(e.g. chafings, cuts, cracks)
l embrittlement of the outer surface (develop-
ment of cracks in the hose material)
BOMAG BW 62/65 H
 Safety regulations

l deformation under depressurized and pressu-
rized conditions which are not in accordance
with the natural shape of the hydraulic line
l deformation in bends, e.g. creasings, layer
separations, formation of blisters
l leakages
l non-conformity with installation requirements
l separation of the hydraulic hose from the
crimped fitting
l corrosion of the crimped fitting which will effect
the function and reduce the strength
l hydraulic lines must not be mixed up by mis-
take (reversal of function)
l damage or deformation of the fitting which ef-
fects the function and the strength of the hose
to hose connection.
Only the use of genuine BOMAG hydraulic hoses
ensures that the correct type of hose (pressure
range) is used at the right place.
Working on the engine
Drain the engine oil at operating temperature -
danger of scalding!
Wipe off spilled oil, catch running out oil and dis-
pose of environmentally.
Store used filters and other oily materials in a spe-
cially marked container and dispose of environ-
mentally.
Working on electrical equipment
Catch running out fuel, do not let it seep into the
ground and dispose of environmentally.
Water sprinkler system
In the event of frost the water sprinkler system
must be drained or filled with an anti-freeze mix-
ture.
Cleaning
Do not clean the machine while the engine is run-
ning.
Never use petrol or any other highly inflammable
substances for cleaning purposes.
When using steam cleaning equipment do not
subject electrical parts and insulating materials to
the direct water jet or cover them beforehand.
Do not guide the water jet directly into the exhaust.
Do not guide the cleaning jet directly into the oil
bath air filter or into the opening for the crank han-
dle.
After completing maintenance
Reinstall all guards and protective devices after
completing maintenance.
Repair
Attach a warning tag to the steering rod if the ma-
chine is defective.
Repairs must only be carried out by qualified and
authorized personnel. Always follow the repair in-
structions.

Before starting to work on electrical equipment dis-

connect the battery and cover it with insulating ma-
terial.

Working on the battery

When working on the battery do not smoke, no
open fire.
Do not let hands or clothes come in contact with
acid. Clean injuries caused by acid with clear wa-
ter and consult a doctor.
Do not lay any tools on the battery.
When recharging the battery remove all plugs to
avoid the accumulation of highly explosive gases.
Dispose of used batteries environmentally.

Working on the fuel system

No open fire, do not smoke, do not spill any fuel.

BW 62/65 H BOMAG 15
Safety regulations

16 BOMAG BW 62/65 H
 3 Operation

BW 62/65 H BOMAG 17
Operation
3.1 General notes
Please read section 3 Indicators and Control Ele-
ments thoroughly before operating the machine if
you are not yet fully familiar with the indicators and
control elements of the machine.
All indicators and control elements are described
in detail in this chapter.
18
3.2 Tests before starting opera-
tion
Please observe strictly the safety instructions.
Refer also to the detailed description in the chap-
ter on maintenance.
Top up missing lubricants according to the mainte-
nance instructions.
Park the machine on ground as level as possible.
Check:
l Fuel tank and fuel lines for leaks
l Condition of engine and machine
l Tight fit of screwed connections
l Neutral setting of the travel system (the vibra-
tory roller must not move forward or reverse
when the travel lever is in neutral position).
l The fuel level
l The water separator for water
l The water level in the sprinkler system.
l Check the engine oil level.
l Check the hydraulic oil level.
l Check the function of the reversing protection
system.
i Note
If the hydraulic system is filled with BP Biohyd SE
46, use only the same oil to fill up. In case of other
ester based hydraulic oils consult the lubrication
service department of the oil manufacturer.
l Check the scrapers, adjust them if required.
l Inspect the machine visually.
BOMAG BW 62/65 H
 Operation

3.3 Starting the engine i Note

Always return the decompression lever to initial
position, as shown in (Fig. 6), in case of incorrect
operation or to repeat the starting procedure.
! Danger
Danger of accident! l Insert the crank handle.

Mind your feet. Always keep an eye on a run-

ning machine.

i Note
The vibration must be switched off.

Fig. 7

l Stand in correct position to the machine (Fig.

7).
l Hold the crank handle properly.
l Turn the crank handle slowly with both hands
Fig. 5
in direction of arrow until it engages.

l Shift the throttle lever (Fig. 5) to position l Now turn the crank handle with increasing
"MAX". speed, so that the engine starts after approx. 5
revolutions.

i Note
Powerful turning of the crank handle must ensure
the positive connection between handle and en-
gine, which must under no circumstances be inter-
rupted during the starting process.

Fig. 6

l Pull the decompression lever 2 (Fig. 6) in di-

rection of arrow to the end stop. The decom-
pression lever clicks into position.

BW 62/65 H BOMAG 19
 Operation

Fig. 8 Fig. 10

l After the five revolutions of the crank handle l Set the decompression lever 2 (Fig. 10) to
the decompression lever 2 (Fig. 8) will have re- middle position.
turned to its initial position.

i Note
If the engine does not start, repeat the starting pro-
cedure by starting with (Fig. 6).

Fig. 11

l Insert the crank handle (Fig. 11).

l Crank the engine several times (crank it free),
until it rotates lightly.

Fig. 9

l Fasten the crank handle (Fig. 9).

i Note
Before starting work run the engine warm for a
short while at idling speed position "MIN" (not
longer than 5 minutes).

Cold start, winter operation

Danger
!

Danger of explosion!
Do not use any starting aids such as Start Pilot
or ether.

20 BOMAG BW 62/65 H
 Operation

Fig. 12 Fig. 14

l Pull the lid 1 (Fig. 12) off the dozing facility. Fill
in engine oil until it reaches the upper edge,
put the lid back on and press it firmly in.
i Note
Use max. 2 fillings immediately after each other.
l Perform the normal starting procedure.
l Turn the ignition key 1 (Fig. 14) to position I:
the charge control light (2) lights up.
l Turn the ignition switch further to position II,
start the engine.
l Release the ignition switch as soon as the en-
gine is running. The charge control light will go
out.

i Note i Note

Before starting work run the engine warm for a Before starting work run the engine warm for a
short while at idling speed position "MIN" (not short while at idling speed position "MIN" (not
longer than 5 minutes). longer than 5 minutes).

Starting with a battery *

Fig. 13

l Move the throttle lever 1 (Fig. 13) to position

"MAX".

* Option

BW 62/65 H BOMAG 21
Operation

3.4 Adjusting the steering rod 3.5 Releasing the parking brake

i Note
For optimal work, the steering rod must be adjust-
ed to the size of the operator.

Fig. 16

l Pull the control lever (Fig. 16) and lock it on the

left hand side at the symbol "parking brake re-
leased".
Fig. 15

l Slacken the hexagon screws 2 (Fig. 15) on left

and right hand side.
l Slacken the hexagon screws (1) on right and
left hand side only so far, that the steering rod
can be adjusted to the correct working height.
l Retighten the hexagon screws (1 and 2).

22 BOMAG BW 62/65 H
 Operation

3.6 Driving the machine

! Danger
Danger of accident!
Before starting to drive make sure that the
working range is safe.
Soil condition and weather influences impair
the gradability of the machine.
Do not drive up or down gradients exceeding
the maximum gradability of the machine!
Fig. 18
Operate the machine only with a properly ad-
justed steering rod. l Move the lever 1 (Fig. 18) slowly forward, the
machine will accelerate infinitely in forward di-
rection.
i Note
Before starting work run the engine warm for a Reverse travel
short while at idling speed position "MIN" (not
longer than 5 minutes).
i Note
The travel control lever is part of a safety control.
It will automatically return to "0"-position when tak-
ing the hand off. The machine will brake automat-
ically.

! Danger
Danger of injury!
To avoid accidents during reverse travel, the
machine should only be guided by holding the
steering handle from the side.
Do not walk backwards.
Fig. 17

l Shift the throttle lever (Fig. 17) to position

"MAX.".

Forwards travel

i Note
The travel control lever is part of a safety control.
It will automatically return to "0"-position when tak-
ing the hand off. The machine will brake automat-
ically.

Fig. 19

l Move the lever 1 (Fig. 19) slowly backwards,

the machine will accelerate infinitely in reverse

BW 62/65 H BOMAG 23
Operation

direction. The speed in reverse is slower than

the speed in forward. 3.7 Switching the vibration on
or off
Changing the travel direction (driving
curves)
l Change the direction by pushing and pulling i Note
on the steering handle. Vibration at standstill leaves transverse impres-
sions in the ground. You should therefore:
Reversing protection C4 only switch the vibration on when the machine is
driving.
switch the vibration off before the machine comes
to a halt.

! Caution
Risk of bearing damage!
Do not actuate the vibration on hard (frozen,
concrete) ground.

i Note
The throttle lever must be in "MAX" position.

Fig. 20

i Note
On machines with reversing protection the contact
button 1 (Fig. 20) is pressed in when being caught
beween an obstruction and the machine. The trav-
el control returns to neutral, even when holding the
travel lever in reverse.

Fig. 21
Position "I" and
"II" = range for driving forwards and
reverse with vibration. Max.
travel speed: 2.5 km/h.
Position "III" = range for forwards travel only.
Vibration cannot be switched
on. Max. travel speed: 5.0 km/
h.
Position "0" = Service brake

Switching the vibration on

l Drive in range "I" or "II" (Fig. 21).

24 BOMAG BW 62/65 H
 Operation

3.8 Switching the gravity sprin-

kler system on and off

Fig. 22

l Move the lever 1 (Fig. 22) forward to switch the

vibration on.

Switching the vibration off Fig. 24

Position "I" = Sprinkler system switched on
Position "II" = Sprinkler system switched off

! Caution
In case of frost the water sprinkler system
must be drained completely or filled with a
anti-freeze mixture.

Fig. 23

l Move the lever 1 (Fig. 23) backwards to switch

the vibration off.

i Note
The vibration will stop after a short while.

BW 62/65 H BOMAG 25
Operation

3.9 Applying the parking brake 3.10 Shutting the engine down

! Danger
Danger of accident!
When stopping the machine on a slope always
place a suitable chock in front of or behind the
drums before shutting the engine down.

i Note
The engine is fitted with a low oil level shut-down
facility.

Fig. 25

Caution
!

The parking brake must only be applied to hold

the machine once it has stopped.
l Pull the control lever (Fig. 25) out and lock it in
left hand position at the symbol "parking brake
applied".

Fig. 26

l Release the travel lever 1 (Fig. 26) slowly. The

travel lever will automatically return to neutral
position.

Fig. 27

l Shift the throttle lever (Fig. 27) to position

"MIN." (idling speed).

26 BOMAG BW 62/65 H
 Operation

i Note
3.11 Loading and transport
Do not stop the engine suddenly from full speed,
but let it idle for a while in position "MIN" for tem-
perature equalization.
! Danger
Danger of accident!
! Caution
Use only strong and stable loading ramps.
Never use the decompression lever to shut the
Make sure, that no persons are endangered by
engine down.
the machine tipping or slipping off.

Fig. 28
Fig. 30
l Set the throttle lever (Fig. 28) to position
l Lash the machine to the transport vehicle, at-
"STOP".
tach the lashing gear to the hooks (Fig. 30).

with electric starter *

Danger
!

Danger of accident!
i Note
Lash the machine down, so that is properly se-
Additional steps to shut the engine down.
cured against rolling, slipping or turning over.
Always use shackles on the lifting points to
load, lash or lift the machine
Do not step or stand under loads being lifted.
The machine must not swing about when be-
ing lifted.

Fig. 29

l Turn the ignition key 1 (Fig. 29) to position "0",

the charge control light (2) goes out.
l Pull the ignition key out.
* Option

BW 62/65 H BOMAG 27
Operation

Fig. 31

l When lifting the machine with lifting gear insert

the hook into the eye on the central lifting de-
vice.

Weights see technical data.

28 BOMAG BW 62/65 H
 4 Maintenance

BW 62/65 H BOMAG 29
Maintenance
4.1 General notes on mainte-
nance
Pay careful attention to all applicable safety in-
structions and especially the safety regulations in
chapter 2 of these operating and maintenance in-
structions when carrying out maintenance work.
Thorough maintenance of the machine ensures
maximum reliability and prolongs the service life of
important components. The work involved is only
minor when compared with the problems which
may arise when not observing these instructions.
l Clean machine and engine thoroughly before
starting maintenance work.
l Park the machine on level ground to perform
service work.
l The machine must generally be serviced with
the engine shut down.
l Depressurize hydraulic lines before starting to
work on them.
l Disconnect the battery and cover it with insu-
lating material before working on electric com-
ponents.
The terms "right/left" always refer to the travel di-
rection of the machine.
l Collect oils and fuels and do not let them seep
into the ground or into the sewage system.
Dispose of oils and fuels environmentally.
l Always catch and dispose of biodegradable
oils environmentally.
Frequent reasons for faults
l Incorrect operation
l Incorrect, insufficient maintenance
If you cannot identify the reason for a fault by fol-
lowing the trouble shooting chart or cannot elimi-
nate it yourself, please contact one of our service
stations at our branch offices or dealers.
Notes on the fuel system
The service life of the diesel engine depends
mainly on the cleanliness of the fuel.
l Keep fuel free of dirt and water, as this may
cause damage to the injection elements on the
engine.
30
l The fuel drum should rest for a longer period
of time before drawing off fuel.
l Fuel should be stored in a place where the
spillage of fuel does not cause any harm.
l Do not let the suction pipe disturb the sludge
at the bottom of the fuel drum.
l Fuel left in the drum is not suitable for the en-
gine and should only be used for cleaning pur-
poses.
Notes on the engine performance
Combustion air and fuel injection rates of the die-
sel engine have been carefully adjusted and deter-
mine the engine's performance and temperature
level as well as the quality of the exhaust gas.
If your engine has to work continually in "thin air"
(at high altitudes) and with full power, you should
contact the After Sales Service of BOMAG or the
service department of the engine manufacturer.
Notes on the hydraulic system
Cleanliness is of utmost importance when working
on the hydraulic system. Make sure that no dirt or
other contaminating substances enter the system.
Small particles can flute valves, cause pumps to
seize and block restrictors and pilot bores, thereby
resulting in costly repairs.
l If during the daily inspection the hydraulic oil
level is found to have dropped, check all lines,
hoses and components for leaks.
l Seal external leaks immediately and inform
your nearest service station, if necessary.
l If possible use a filling and filtering unit to fill
the hydraulic system.
l Clean fittings, filler cap and their adjacent area
before unscrewing or removing them, to avoid
dirt entering the system.
l Do not leave the tank opening unnecessarily
open, but cover it to avoid dirt falling into the
tank.
BOMAG BW 62/65 H

4.2 Fuels and lubricants
Engine oil
Use only winter grade engine oil for winter opera-
tion!
To ensure perfect cold starting it is important to
choose the viscosity (SAE grade) of the engine oil
with respect to the ambient temperature.
The oil change intervals must be shortened when
working at temperatures below -10 °C (14 °F).
Fig. 32
Lubrication oil with a too high viscosity index will
cause starting difficulties. The temperature when
starting the engine is therefore decisive for choos-
ing the correct viscosity for winter operation.
Oil viscosity
Since the viscosity of the lubrication oil changes
with the temperature, the ambient temperature at
the engine's operating location determined the vis-
cosity class (SAE grade) to be used (see dia-
gram).
Although cold starting abilities may be impaired if
the temperature occasionally drops below the limit
(e.g. use of SAE 15W/40 down to -15°C/5°F), this
will not damage the engine.
Temperature related lubrication oil changes can
be avoided by using multigrade oils. The oil
BW 62/65 H BOMAG
Maintenance
change intervals given below also apply for multi-
grade oils.
Regular lubrication oil change inter-
vals
The longest period that lubrication oil should re-
main in the engine is one year. If the oil change in-
tervals specified below are not reached during one
year, the lubrication oil must be changed at least
once per year, irrespective of the indicated operat-
ing hours.
Oil quality
Oils of the API-quality classes CD/SE or CD/SF,
SHPD-oils or oils of the quality class CCMC-D2-
D3-PD1 should preferably be used. When using
oils of API-quality class CC/SE the oil change in-
tervals must be reduced.
Lubrication oil change intervals
Oil change intervals (operating hours) for oil
quality
Aspirating engines
API:CD/SE
or CD/SF = 6 months
SHPD = 6 months
CCMC-D2
D3-PD1 = 6 months
! Caution
These intervals only apply when using a diesel
fuel with a maximum of 0.5% sulfur (by weight)
and for ambient temperatures above -10°C
(14°F).
When using fuels with more than 0.5% - 1%
sulfur or at ambient temperatures below -10 °C
(14 °F), the oil change intervals given in the ta-
ble must be halved. In case of fuels having a
sulfur content of 1% - 1.5%, the intervals for
changing the engine oil must be halved and
the engine oil must have a TBN * of approx. 12
x % S-content.
* Totale Base Number
31
Maintenance

Example aspirating engines: Winter fuel

l Use in tropical climate, fuel 0.8% sulfur, lubri-
cation oil CD/SE, oil change every 3 months.
l Use in tropical climate, fuel 1.2% sulfur, oil
change every 3 months, lubrication oil CD/SE
or CD/SF with TBN approx. 14 mg KOH/g.
Lubrication oil quality classes
The API-classification is used to grade the oil qual-
ities.
The oil manufacturer is solely responsible for clas-
sifying a product.
i Note
When changing to a higher quality oil after a longer
operating period, we recommend that the first
change of the higher grade oil be performed after
25 operating hours.
During the winter period use only winter grade die-
sel fuel to avoid clogging caused by paraffin sepa-
ration. Separation can also be expected at very
low temperatures even when using winter grade
diesel fuel.
In most cases it is also possible to mix in fuel ad-
ditives to improve the flow properties. Consult the
engine manufacturer for details.
Biodegradable hydraulic oil
The hydraulic system can also be operated with
ester based biodegradable hydraulic oil BP Biohyd
SE 46
This biodegradable hydraulic oil BP Biohyd SE 46
meets the requirements of a mineral oil based hy-
draulic oil according to DIN 51524.
Always use the same oil to top up, if the hydraulic
system is filled with BP Biohyd SE 46.

Fuels When changing from a mineral oil based hydraulic

Quality
Use only commercially available brand diesel fuels
with a sulfur content of less than 0.5% and pay at-
tention to cleanliness when filling in fuel. Higher
sulfur contents will effect the oil change intervals.
Use only winter grade diesel fuel at low tempera-
tures. The machine should never run out of fuel, as
otherwise the filter and the injection lines will have
to be bled.
oil to an ester based biodegradable hydraulic oil
consult the lubrication oil service department of
the oil manufacturer.
Check the hydraulic oil filter more frequently after
changing to the other hydraulic oil.
Lubrication grease
Use an EP-high pressure grease, lithium saponi-
fied (penetration 2) for lubrication purposes.

The following fuel specifications are permitted:

DIN 51601; Nato Codes: F-54, F-75, F-76; BS
2869: A1 and A2; ASTM D 975-78: 1-D and 2-D;
VV-F-800a: DF-A, DF-1 and DF-2.

Danger
!

Fire hazard!
Only ever mix diesel fuel with standard grade
gasoline (never supergrade gasoline) in the
tank itself. Fill up with the necessary quantity
of petrol before adding diesel fuel. Diesel-
gasoline mixtures are as inflammable as gaso-
line itself.
No open fire, do not smoke.

32 BOMAG BW 62/65 H
 Maintenance

4.3 Table of fuels and lubri-

cants

Assemblies Fuels, Lubricants Approx. quantity

Summer Winter Attention

Observe level marks

Engine Engine oil API: CD/SE or CD/SF approx. 1 l (0.26 USgal)

SHPD CCMC-D2-D3-PD1 to oil level mark

SAE 15W/40 SAE 10W

(-10°C to +40°C) (-5°C to -30°C)

(14°F to 104°F) (23°F to -22°F)

Fuel diesel winter diesel fuel 5 l (1.32 USgal)

(-12 °C) (10.4°F)

Hydraulic system Hydraulic oil (ISO), HV32, kinematic viscosity to middle of dipstick
32 mm2/s at 40°C or ester based biodegradable hy-
draulic oil

approx. 13,5 l (3.57 US-

gal)

Water sprinkler system water water 60 l (15.85 USgal)

Gears grease as required

BW 62/65 H BOMAG 33
Maintenance

4.4 Running-in instructions

Maintenance after the first 25 hours of opera-

tion
l Change the engine oil.
l Check the engine for leaks.
l Check valve clearance and setting of the de-
compression facility, adjust if necessary.
l Tighten the fastening screws for air filter, ex-
haust manifold, fuel tank and other attach-
ments.
l Tighten the screwed connections on the ma-
chine.
l Check and, if necessary, tension toothed and
V-belts for the vibration drive.
l Check for leaks.

Maintenance up to 200 operating hours

l Check the engine oil level twice every day.
New engines have a higher oil consumption.
Depending on the load condition for the engine the
oil consumption will drop to the normal rate after
about 100 to 200 operating hours. Then the oil lev-
el needs to be checked only once per day.

Fig. 33

i Note
For various maintenance tasks the covering of the
machine needs to be folded to the front. To do so
unscrew both hexagon screws 1 (Fig. 33) from the
right and left hand side.

34 BOMAG BW 62/65 H
 Maintenance

4.5 Maintenance chart

With each maintenance interval perform also

the work for shorter preceeding intervals.

Pos. Description Note

Maintenance every day

4.6 Cleaning machine/engine
4.7 Checking the engine oil level to upper dipstick mark
4.8 Checking the fuel level
4.9 Checking the hydraulic oil level to middle of dipstick mark
4.10 Checking the water level summer: water winter: anti-freeze mixture
Maintenance every 6 months
4.11 Changing the engine oil at least 1 x per year
4.12 Changing the engine oil filter
4.13 Cleaning, changing the dry air filter
4.14 Checking, adjusting the valve clearance
4.15 Cleaning cooling fins and cooling air intake openings
4.16 Checking, tensioning, changing the drive V-belt
4.17 Checking, tensioning, changing the toothed belt for
the vibration system
4.18 Greasing the gears
4.19 Checking the rubber buffers
4.20 Greasing the crank handle guide
4.21 Servicing the battery
Dim. mm (inch)
4.22 Changing the fuel filter
4.23 Changing the hydraulic oil (at least 1 x per year) observe the dipstick
4.24 Changing the hydraulic oil filter
As required
4.25 Water sprinkler system, cleaning, maintenance in the
event of frost
4.26 Adjusting the scrapers
4.27 Checking the water separator
4.28 Tightening torques for screws with metric unified Observe the tighteneing torques
threads
4.29 Engine conservation

*The engine oil change intervals must be halved SE, engine oil change every quarter of a year or
when using diesel fuel with a sulfur content of every 125 operating hours.
more than 0.5% by weight. The same applies
when using engine oil of API-class CC/SE or SF.
Example: Fuel 1% sulfur and lubrication oil CC/

BW 62/65 H BOMAG 35
 Maintenance every day

Maintenance every day

4.6 Cleaning the engine 4.7 Checking the engine oil lev-
el

i Note
Park the machine on level ground so that the en-
gine is in horizontal position.

Fig. 34

Caution
!

Do not guide the water jet directly into the air

intake opening on the engine air filter, into the
exhaust 1 (Fig. 34) and into the opening for the
crank handle (2).
l After wet cleaning run the engine to evaporate
all water and to avoid corrosion.
Fig. 35
l Shut the engine down.
l Pull the dipstick 1 (Fig. 35) out, wipe it off with
a lint-free clean cloth and reinsert it until it bot-
toms.
l Pull the oil dipstick out again.
l The oil level must reach the upper dipstick
mark.
l Top up oil immediately, if the oil level is too
low.

For quality of oil refer to the table of fuels and

lubricants.
l Check the oil level again with the engine shut
down after running it for approx. 1 minute.

36 BOMAG BW 62/65 H
 Maintenance every day

4.8 Checking the fuel level 4.9 Checking the hydraulic oil
level
! Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke.
Do not refuel in closed rooms.
Do not breathe in any fuel fumes.

Fig. 37

l Clean the area around the filler opening.

l Remove the filler cap.
l Check the hydraulic oil level on the dipstick.
The oil level must be between the "MIN" and
"MAX" marks (Fig. 37).
Fig. 36 l Top up hydraulic oil if the oil level is too low.
l Clean the area around the filler opening (Fig. For quality of oil refer to the table of fuels and
36). lubricants.
l Open the fuel tank cap and check the fuel level
visually.
i Note
If, during the daily oil level inspection, the hydraulic
!Caution oil level is found to have dropped, check all pipes,
Dirty fuel can cause severe damage to the en- hoses and components for leaks.
gine.
If the hydraulic system is filled with BP Biohyd SE
l If necessary fill in fuel through a funnel with 46 use only the same oil to top the system up. In
strainer. case of other ester based oils consult the lubrica-
tion service department of the respective oil man-
For quality of fuel refer to the table of fuels and ufacturer.
lubricants.

BW 62/65 H BOMAG 37
Maintenance every day

4.10 Checking the water level

Fig. 38

l Open the lid 1 (Fig. 38) and check the water

level.
l If necessary top up water and close the lid.

i Note
In the event of frost observe the special notes "wa-
ter sprinkler system, maintenance in the event of
frost".
Make sure that the breather bore is free.

38 BOMAG BW 62/65 H
 Maintenance every 6 months

Maintenance every 6 m onths

4.11 Changing the engine oil

i Note
Drain the engine oil only when the engine is warm.
Park the machine on level ground so that the en-
gine is in horizontal position.
The oil change interval of 6 months is only applica-
ble if the sulfur content in the fuel is less than 0.5%
For other fuels the oil change intervals must be re-
duced (see chapter 4.2).
Fig. 40

! Danger l Unscrew the drain plug 1 (Fig. 40) and catch

running out old oil.
Danger of scalding!
l Screw the drain plug back in with a new seal-
There is a danger of scalding when draining ing ring (2).
hot engine oil.
l Fill in new engine oil through the filler opening
2 (Fig. 39).
! Caution
Environmental hazard! For quality and quantity of oil refer to the table
of fuels and lubricants.
Catch running out old oil and dispose of envi-
l Reinsert the oil dipstick.
ronmentally.
Change the engine oil filter with every oil
change.

Fig. 41

l Check the oil level again on the dipstick 1 (Fig.

41) after a short test run. The oil level should
Fig. 39
reach the upper dipstick mark, top up oil if nec-
l Pull the dipstick 1 (Fig. 39) out. essary.

BW 62/65 H BOMAG 39
Maintenance every 6 months

4.12 Changing the engine oil fil- 4.13 Cleaning, changing the dry
ter air filter

! Danger ! Caution
Danger of scalding! Do not use gasoline or hot fluids to clean the
filter cartridge.
There is a danger of scalding by hot oil when
changing the engine oil filter. Dry air filter cartridges with damaged filter ele-
ments or sealing rings must be changed. We
therefore recommend to keep at least one car-
!Caution
tridge in stock.
Catch running out oil and dispose of environ-
The dry air filter cartridge must be changed af-
mentally together with the engine oil filter car-
ter 2 times cleaning, but at the latest after 1
tridge.
year.
Each cleaning should be marked with a cross
on the filter cartridge.
Cleaning is useless if the cartridge is covered
with a sooty deposit. Use a new cartridge.
Incorrectly handled filter cartridges can be in-
effective because of damage (e.g. cracks) and
lead to engine failures.
Always change the filter cartridge in case of
moist or oily dirt.

Fig. 42

l Unscrew the cap 1 (Fig. 42).

l Wipe the sealing surface on the engine clean.
l Insert the new filter caertridge with the recess
(2) pointing downwards.
l Check the sealing ring (3) in the cap.
l Screw the cap on (1) oil tight.
l Inspect the engine for leaks and check the oil
level after a short test run.
Fig. 43

l Unscrew the wing nut and remove the lid 1

(Fig. 43).
l Pull the filter cartridge out.

40 BOMAG BW 62/65 H
 Maintenance every 6 months

4.14 Checking, adjusting the

valve clearance

Checking the valve clearance

i Note
Check and adjust the valve clearance only when
the engine is cold.

Fig. 44

! Danger
Eye injuries!
Wear protective clothes (protective goggles,
gloves).
l Blow the filter cartridge out with compressed
air (max. 5 bar) from inside to outside (Fig. 44).

Fig. 46

l The decompression lever 2 (Fig. 46) must be

in initial position.
l Crank the engine in direction of rotation until
compression resistance can be felt.
l Remove the valve cover.

Fig. 45

l Insert the filter cartridge 2 (Fig. 45).

l Check the sealing surface (3) on the housing.
l Attach the lid (1) and fasten it with the wing
nut.

i Note
Do not damage the gasket on the filter housing
Fig. 47
when tightening the lid.
l Check the valve clearance on both valves 1
(Fig. 47) with a feeler gauge.

BW 62/65 H BOMAG 41
Maintenance every 6 months
The valve clearance for both valves is 0.1 mm
(0.004 in).
Adjust the valve clearance on both valves.
l Loosen the hexagon nut 3 (Fig. 47).
l Adjust the setscrew (2) with a screwdriver, so
that the feeler gauge fits through the gap be-
tween rocker arm and valve shaft with just no-
ticeable resistance after tightening the
hexagon nut (3)
l Use a new gasket (4).
l Attach the valve cover and tighten it evenly.
l Check for leaks after a short test run.
42
4.15 Cleaning cooling fins and
cooling air intake openings
i Note
Dirty operating conditions, especially deposits of
lubrication oil and fuel on the cooling fins of the en-
gine and the cooling air intake opening reduce the
cooling considerably. You should therefore seal all
oil or fuel leaks near the cooling blower, the cylin-
der or the cooling air intake and clean the cooling
fins after.
Fig. 48
l Loosen dried on dirt from all cooling fins with a
suitable brush and blow it off with compressed
air (Fig. 48).
l Use a cold cleansing agent if the engine is cov-
ered with oily dirt.
! Caution
Do not guide the water jet directly into the dry
air filter, the exhaust or the opening for the
crank handle.
l Let the cleansing agent soak in for a while,
clean it off with a water or steam jet and blow
it dry with compressed air.
l Run the engine warm for a short while to avoid
corrosion.
BOMAG BW 62/65 H
 Maintenance every 6 months

Compression measurement approx. 10 to

4.16 Checking, tensioning, 15 mm.
changing the drive V-belt l Tighten all four fastening screws 1 (Fig. 50).

Changing the V-belt

Checking the V-belt

Fig. 51
Fig. 49
l Loosen all four fastening screws 1 (Fig. 51) on
l Check the condition and the tension of the V-
the frame.
belt 1 (Fig. 49), change the V-belt if it is dam-
aged. l Insert two pry bars between rubber buffers and
frame and push the upper structure back to
Compression measurement approx. 10 to unload the V-belt.
15 mm.
l Install the new V-belt, tension it correctly and
check it.
Tensioning the V-belt

Fig. 50

l Loosen all four fastening screws 1 (Fig. 50) on

the frame.
l Insert two pry bars between rubber buffers and
frame and push the upper structure up.
l Check the V-belt tension.

BW 62/65 H BOMAG 43
Maintenance every 6 months

Compression measurement approx. 10 to

4.17 Checking, tensioning, 15 mm.
changing the toothed belt
for the vibration system Tensioning the toothed belt

Checking the toothed belt

Fig. 53

l Slacken two fastening screws 1 (Fig. 53) for

the clutch.
Fig. 52
l Pull the clutch up by using a spring scale with
l Remove the belt guard a tensile force of 90 to 120 N (66 to 88.5 lbs)
and tighten both fastening screws.
l Check condition and tension of the toothed
belt 1 (Fig. 52), change the belt if it is dam-
aged. i Note
The toothed belt tension reaches the required val-
ue of approx. 10 to 15 mm.

44 BOMAG BW 62/65 H
 Maintenance every 6 months

Changing the toothed belt l Tension and check the toothed belt.
l Install the belt guard.

Fig. 54

l Slacken both hexagon screws 1 (Fig. 54),

press the clutch (2) down and take the toothed
belt (3) off.
l After removing the toothed belt mark the vibra-
tor shafts (4 and 5) with arrows pointing down-
wards.

i Note
The eccentric weights on the vibrator shafts will al-
ways point downwards after taking the toothed belt
off.

Fig. 55

l Turn the vibrator shaft 5 (Fig. 55) for exactly

180° and install the new toothed belt in this po-
sition.

! Caution
If this adjustment is not correct, the machine
will behave very erratically when working with
vibration.

BW 62/65 H BOMAG 45
Maintenance every 6 months

4.18 Greasing the gears 4.19 Checking the rubber buffers

Fig. 56 Fig. 57

l Remove the guard (Fig. 56).
l Remove all old grease and apply new grease
to the gears.
For quality of grease refer to the table of fuels
and lubricants.
l Reinstall the guard.
l Inspect all rubber buffers 1 (Fig. 57) between
upper structure and frame and engine (2) for
cracks and damage and replace damaged
buffers.
l Check the tight fit of all rubber buffers.

46 BOMAG BW 62/65 H
 Maintenance every 6 months

4.20 Cleaning the crank handle 4.21 Servicing the battery *

guide
Danger
!

Danger of causticization!
When working on the battery do not use open
fire, do not smoke!
Do not let acid come in contact with skin or
clothes!
Do not lay any tools on the battery!
When recharging the battery remove all plugs
to avoid the accumulation of highly explosive
gases.
Dispose of used batteries environmentally.
Fig. 58

l Clean the guide (Fig. 58) and the crank handle

from all dirt, apply some oil or grease.

Fig. 59

l Open the battery cover (Fig. 59).

l Clean battery poles and clamps and grease
them with pole grease (vaseline).
l Tighten the pole clamps.
l Check the fastening of the battery.
l Check the condition of the vibration insulation
mats, change them if necessary.

Caution
!

Do not forget to reinstall the battery cover.

* Option

BW 62/65 H BOMAG 47
 Maintenance every year

Install the new fuel filter and observe the cor-

Maintenance every year

l
4.22 Changing the fuel filter rect flow direction.
l Fill the fuel tank.

! Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke.
Do not spill any fuel.
Do not breathe in any fuel fumes.

Fig. 60

l Unscrew the drain plug 1 (Fig. 60) and catch

running out fuel.
l Screw the drain plug back in.

Fig. 61

l Pull the fuel filter 2 (Fig. 61) out of the upper

and lower hoses.

i Note
Flush the fuel tank with clean diesel fuel if it is dirty.

48 BOMAG BW 62/65 H
 Maintenance every year

l Unscrew the drain plug 1 (Fig. 62) and catch

4.23 Changing the hydraulic oil running out old oil.
l Screw the drain plug in with a new sealing ring.
Refer also to the section "Notes on the hydrau-
lic system".
i Note
Replace the hydraulic oil filter before filling in hy-
i Note
draulic oil.
Apart from the normal oil change intervals, the hy-
draulic oil must also be changed after major re-
pairs in the hydraulic system.
l Drive the machine, until the hydraulic oil
reaches the operating temperature.
l Clean the area around the filler opening.
l Open the filler cap.

! Caution
Do not start the engine after draining the hy-
draulic oil. Do not run the pumps without oil.
When changing from mineral oil based hydrau-
lic oil to ester based biodegradable hydraulic Fig. 63

oil consult the lubrication service department

of the respective oil manufacturer. i Note
We recommend to use a filling and filtering unit
Danger
!
with a fine filter to fill the hydraulic system.
Danger of scalding! For quality and quantity of oil refer to the table
Danger of scalding by hot oil! of fuels and lubricants
l Fill in new hydraulic oil (Fig. 63).
l Attach the filler cap.
l Check the hydraulic oil level on the dipstick.
l Perform a test run and check the system for
leaks.

Bleeding the hydraulic system

l Run the engine for max. 3 minutes at idling
speed to bleed the hydraulic system.

Fig. 62

! Caution
Environmental hazard!
Catch running out old oil and dispose of envi-
ronmentally.

BW 62/65 H BOMAG 49
Maintenance every year

4.24 Changing the hydraulic oil

filter

i Note
The hydraulic oil filter must be changed with each
hydraulic oil change and after major repairs in the
hydraulic system.
Always drain the hydraulic oil tank first and change
the filter before refilling the tank.

Fig. 64

l Loosen the hydraulic oil filter cartridge 1 (Fig.

64) with a suitable filter wrench and screw it
off.
l Wipe the sealing surface on the tank clean.
l Apply a thin coat of clean oil to the rubber seal
(2) on the new filter cartridge.
l Screw the new filter cartridge on and tighten it
hand tight.
l After filling the hydraulic system run the engine
and check the filter for leaks.

50 BOMAG BW 62/65 H
 As required

Flush the tank out with clean water.

As r equired

l
4.25 Water sprinkler system,
l Flush both spray bars thoroughly with clean
cleaning, maintenance in water.
the event of frost l Reinstall and fasten the spray bars.
l Screw the drain cover back on.

Caution
!
l Fill the tank with an anti-freeze mixture (water
and anti-freeze agent, e.g. glysanthene).
In the event of frost the water sprinkler system
must be drained or filled with an anti-freeze
mixture. i Note
Close the shut-off valve 2 (Fig. 66) only when anti-
freeze mixture starts to run out from both spray
bars.

Fig. 65

l Fold the covering for the machine to the front.

l Unscrew the drain cover (Fig. 65).

Fig. 66

l Open the drain valve 2 (Fig. 66).

l Pull the water supply hoses from the spray
bars (1).
l Pull a cotter pin out of each spray bar on the
opposite side.
l Turn the spray bars and pull them out of their
brackets.

BW 62/65 H BOMAG 51
As required

4.26 Adjusting the scrapers 4.27 Checking the water separa-

tor

! Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke.
Do not spill any fuel.
Do not breathe in any fuel fumes.

Fig. 67

l Slacken all three hexagon screws 1 (Fig. 67)

on the brackets.
l Adjust the scrapers (2) parallel to the drum
with a gap of approx. 1 mm
l Tighten the hexagon screws.

i Note
Adjust the other scrapers in the same way.
Fig. 68

i Note
Water in the separator is clearly noticeable.
l Unscrew the drain plug 1 (Fig. 68) and catch
water with fuel.
l Screw the drain plug back in.

52 BOMAG BW 62/65 H
 As required

4.28 Tightening torques for 4.29 Engine conservation

screws with metric unified
If the engine is to be shut down for a longer period
thread of time (e.g. during the winter) we recommend the
following conservation measures for the engine to
avoid corrosion:
i Note
l Clean the engine including the cooling system:
Self locking nuts must always be replaced by new with cold cleansing agent or, even better, with
ones after they have been unscrewed. a steam cleaner.
l Run the engine warm and shut it down.
l Drain the still warm engine oil and fill in anti-
corrosion engine oil.
l Drain the fuel from the fuel tank, mix it well with
10% anti-corrosion oil and fill it in again. In-
stead of mixing anti-corrosion oil with the fuel
it is also possible to fill the tank with injection
pump testing oil with anti-corrosive properties
(e.g. Calibration Fluid B)
l Run the engine for 10 minutes until all lines, fil-
ters, pump and nozzles are filled with the con-
Fig. 69
serving mixture and the new engine oil is
* Strength classes for screws with untreated, non- distributed to all parts.
lubricated surfaces. The quality designations are
stamped on the screw heads. l After running the engine remove the valve cov-
er and spray the rocker chamber with a mix-
8.8 = 8G ture of diesel fuel and 10% anti-corrosion oil.
10.9 = 10K After this screw the cover back on.
12.9 = 12K l Crank the engine several times by hand (throt-
The values result in a 90% utilization of the screw's tle lever in stop position) to spray the combus-
yielding point at a coefficient of friction of μ total = tion chamber.
0.14. The tightening torques are not applicable l Take the V-belt off and spray the grooves in
when using MoS2 lubricants. the V-belt pulleys with anti-corrosion oil. Re-
move the anti-corrosion oil before taking the
machine back into operation.
l Close the air intake opening on the air filter
and the exhaust tube.

i Note
Depending on weather conditions these conserv-
ing measures will provide protection for approx. 6
- 12 months.
The conserving oil must be replaced by engine oil
according to the API- (MIL) classification before
taking the machine into service.
Anti-corrosion oils are those that comply with the
MIL-L-21260 or TL 9150-037/2 resp. Nato Code
C 640/642.

BW 62/65 H BOMAG 53
As required

! Caution
Mark a machine with a conserved engine by at-
taching a clearly visible warning tag.

54 BOMAG BW 62/65 H
 5 Trouble shooting

BW 62/65 H BOMAG 55
Trouble shooting

5.1 General notes

The following work must only be carried out by

qualified and trained personnel or by the
BOMAG sales service.

Please observe strictly the safety regulations

in chapter 2 of these operating and mainte-
nance instructions.

! Danger
Risk of injury!

56 BOMAG BW 62/65 H
 Trouble shooting

5.2 Engine faults

Faults Possible cause Remedy

Fuel supply Fuel tank empty Fill in fuel

faulty
Air in the injection system The system is self-bleeding

Fuel filter clogged (can be noticed if no Change the fuel filter, fill in fuel
fuel runs out when pulling the fuel line off)

Engine difficult Oil too viscous Drain the oil and fill in thinner oil
to crank

No compression incorrect valve clearance Check and adjust the valve clearance

Black exhaust Air filter clogged Clean the air filter

fumes possibly
poor engine Incorrect valve clearance Adjust the valve clearance
power (speed Injection nozzle defective Change the injection nozzle
drops) injection
pump not faulty Oil level in crankcase too high Drain the oil down to the "Max"-mark on
the dipstick

Too low engine The throttle lever does not stay in position Tighten the nuts
power (speed
drops)

Engine power Air in the injection system Check the function of the breather valve
drops No black
exhaust fumes Fuel filter blocked Change the fuel filter

Engine over- Lack of cooling air Clean the cooling air inlet Clean the cool-
heats ing fins

Injection system out of order Have the injection system inspected

Too much oil in the crankcase Drain the oil down to the "Max"-mark on
the dipstick

BW 62/65 H BOMAG 57
Trouble shooting

Faults Possible cause Remedy

Engine stalls Fuel supply out of order

Fuel tank empty Fill in fuel

Fuel filter clogged (can be noticed, if no Change the fuel filter

fuel runs out after pulling the fuel hose off)

Vacuum in the fuel tank Clean the breather bore in the filler cap.

The throttle lever returns to "Stop" by it- Tighten the nuts

self.

Mechanical shut-down because the oil Top up oil

level is too low

Lack of oil Have the engine repaired, do not continue

to work (risk of total damage!)

58 BOMAG BW 62/65 H