Bomag BW 900-2 User manual

Operating instructions
Maintenance instructions
Catalogue number
008 152 91 10/2002
BW 900-2
S/N 901 800 00 ....> S/N 861 800 02 ....>
Tandem Vibratory Roller

Foreword
BOMAG 3 BW 900-2
F oreword
BOMAG machines are products from the wide
range of BOMAG compaction equipment.
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 guarantees maxi-
mum reliability of your machine.
The instructions comprise:
lSafety regulations
lOperating instructions
lMaintenance instructions
lTroubleshooting
Using this manual will
lhelp you to become acquainted with the ma-
chine.
lavoid malfunctions caused by operating er-
rors.
Compliance with the maintenance instructions will
lincrease the reliability of the machine on the
construction site,
lprolong the lifetime of the machine.
lreduce repair costs and downtime.
BOMAG will not assume liability for the function of
the machine
lif it is handled in a way not complying with the
usual modes of use,
lif it is used for purposes other than the ones it
is intended for (see safety regulations).
No warranty claims can be lodged in case of dam-
age resulting from
loperating errors,
linsufficient maintenance and
lwrong fuels and lubricants.
Please note!
This manual was written for operators and mainte-
nance personnel on construction sites.
Always keep this manual close at hand, e.g. in the
tool compartment of the machine or in a specially
provided container. These operating and mainte-
nance instructions are part of the machine.
You should only operate the machine if you are ful-
ly acquainted with the contents of these instruc-
tions.
Strictly observe the safety regulations.
Please observe also the guidelines of the Civil En-
gineering Liability Association "Safety Rules for
the Operation of Road Rollers and Soil Compac-
tors" and all relevant accident prevention regula-
tions.
For your own personal safety you should only
use original spare parts from BOMAG.
In the course of technical development we re-
serve the right for technical modifications
without prior notification.
These operating and maintenance instructions are
also available in other languages.
Furthermore, the spare parts catalogue is availa-
ble from your BOMAG dealer against the serial
number of your machine.
Your BOMAG dealer will also supply you with in-
formation about the correct use of our machines in
soil and asphalt construction.
The above notes do not constitute an extension of
the warranty and liability conditions specified in the
general terms of business of BOMAG.
We wish you successful work with your BOMAG
machine.
BOMAG GmbH & Co. OHG
PrintedinGermany
Copyright by BOMAG

Foreword
BOMAG 4 BW 900-2
Please fill in
............................
Machinetype(Fig.1)
............................
Serial No. (Fig. 1 and 2)
............................
Engine type (Fig. 3)
............................
Engine No. (Fig. 3)
i
Note
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. 1
Fig. 2
Fig. 3

Table of Contents
BOMAG 5 BW 900-2
Technical Data 7
Safety regulations 11
Indicators and Controls 19
3.1 General notes 22
3.2 Description of indicators and control elements 22
Operation 29
4.1 General notes 30
4.2 Tests before starting to operate 30
4.3 Starting the engine 31
4.4 Starting with jump leads 33
4.5 Driving the machine 33
4.6 Stopping the machine, operating the parking brake 34
4.7 Switching the vibration on or off 35
4.8 Switching the gravity sprinkler system on or off 36
4.9 Stopping the engine/machine 36
4.10 Adjusting the driver's seat 37
4.11 Towing 38
4.12 Loading and transport 39
Maintenance 41
5.1 General notes on maintenance 42
5.2 Fuels and lubricants 43
5.3 Fuels, lubricants and filling capacities 44
5.4 Running-in instructions 45
5.5 Maintenance table 46
5.6 Checking the engine oil level 47
5.7 Checking the fuel level 47
5.8 Checking the hydraulic oil level 48
5.9 Checking the hydraulic oil filter element 48
5.10 Check the water level 49
5.11 Cleaning the scrapers 49
5.12 Cleaning the cooling air intake opening 50
5.13 Greasing the articulated joint 51
5.14 Checking, cleaning the dry air filter 51
5.15 Cleaning, checking the spark plug 53
5.16 Changing the engine oil 53
5.17 Changing the engine oil filter 55
5.18 Changing the fuel pre-filter 56
5.19 Cleaning the sprinkler system 56
5.20 Checking the condition of the battery, greasing the poles 58
5.21 Checking, adjusting the valve clearance 59
5.22 Cleaning, changing the dry air filter 61

Table of Contents
BOMAG 6 BW 900-2
5.23 Changing the hydraulic oil 63
5.24 Changing the hydraulic oil filter element 64
5.25 Water sprinkler system, maintenance in the event of frost 65
5.26 Tightening torques for screws with metric unified thread 65
5.27 Engine conservation 66
Trouble shooting 67
6.1 General notes 68
6.2 Engine faults 69

BOMAG 7 BW 900-2
1 Technical Data

Technical Data
BOMAG 8 BW 900-2
Fig. 4
Dimensions in
mm
A B C D H H2 KK2 LO1/O2 W
BW 900-2 1143 956 458 560 1620 2340 200 372 2080 28 900
*BW 900-2
Weights
Operating weight CECE kg 1326
Mean static linear load
CECE
kg/cm 7,4
Dimensions
Working width mm 900
Travel characteristics
Travel speed (1) km/h 0 to 4
Travel speed (2) km/h 0 to 7,5
Max. gradability without/
with vibration (soil de-
pendent)
% 40/30

Technical Data
BOMAG 9 BW 900-2
Drive
Engine manufacturer/type Honda GX 620
Cooling Air
Number of cylinders 2
Rated power ISO 9249 kW (PS) 14,9 (20,3)
Rated speed 1 rpm 3000
Battery V/AH 12/..
Drive system hydrostatic
Driven axles front + rear
Brakes
Service brake hydrostatic
Parking brake hydro.-mechanical
Steering
Type of steering Oscill.-articul.
Steering operation hydrostatic
Steering/oscillation angle Degree 30/6
Vibration system
Vibrating drum front
Drive system hydrostatic
Frequency Hz 65
Amplitude mm 0,5
Centrifugal force kN 13,5
Water sprinkler system
Type of sprinkling Gravity feed
Filling capacities
Fuel, unleaded standard
grade gasoline
l34
Water l 189
Hydraulic oil l 15
* The right for technical modifications remains reserved
*BW 900-2

Technical Data
BOMAG 10 BW 900-2

BOMAG 11 BW 900-2
2 Safety regulations

Safety regulations
BOMAG 12 BW 900-2
General
This BOMAG machine is built in accordance
with the latest technical standard and the valid
technical rules and regulations. There is, how-
ever, a risk of danger for persons and property
if:
lthe machine is used for purposes other than
those it is intended for
lthe machine is operated by untrained person-
nel
lthe machine is modified or converted in an un-
professional way
lthe applicable safety regulations are not ob-
served.
Each person involved in operation, mainte-
nance and repair of the machine must there-
fore read and apply these safety regulations.
This should be confirmed by obtaining the sig-
natures of the customer, if necessary.
Furthermore the following regulations and instruc-
tions are obviously also valid:
lapplicable accident prevention instructions
lgenerally acknowledged safety and road traffic
regulations
lcountry specific safety regulations. It is the
duty of the operator to know and observe
these regulations. This applies also for local
regulations and the regulations for various
types of manual work. If the recommendations
in this manual differ from the regulations valid
in your country, you must strictly observe the
regulations in your country.
Intended use
This machine must only be used for:
lcompaction of bituminous material, e.g. road
surface layers
llight compaction work in earth construction
(road sub-bases)
lYou should only operate the unit with fully
functional safety equipment.
lHave the machine inspected by an expert
once every year.
Unintended use
Dangers may, however, arise from the machine if
it is used by untrained personnel in an unprofes-
sional way or if it is used for purposes other than
those mentioned in these instructions.
Do not work with vibration on hard concrete, on a
cured concrete layer or heavily frozen ground.
Starting and operation of the machine in an explo-
sive environment is prohibited.
Who is allowed to work with the ma-
chine?
The machine must only be operated by trained
and authorized persons which are at least 18
years of age. The responsibilities for the operation
of the machine must be clearly specified and com-
plied with.
Persons under the influence of alcohol, medica-
tion or drugs must not operate, service or repair
the machine.
Maintenance and repair tasks require 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 special-
ly designed for this machine. We wish to make ex-
pressly clear that we have not tested or authorized
any original parts or special equipment not sup-
plied by us. The installation and/or use of such
products can impair the active and/or passive driv-
ing safety. The manufacturer expressly excludes
any liability for damage resulting from the use of
non-original parts or accessories.
Safety notes in the operating and main-
tenance instructions:
!
Danger
Sections marked like this point out possible
dangers for persons.

Safety regulations
BOMAG 13 BW 900-2
!
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.
Environment
Sections marked like this highlight activities
for the safe and environmental disposal of fu-
els and lubricants as well as replaced parts.
Observe all environment protection regula-
tions.
Information and safety stickers/decals
on the machine
Keep stickers/decals complete (see spare parts
catalogue) and fully legible and observe their
meaning.
Replace damaged or illegible stickers/decals im-
mediately.
Loading the machine
Always check the fastening of the central lifting
hook before attempting to lift the machine.
Use only strong and stable loading ramps. The
ramp inclination must not exceed the gradability of
the machine.
Secure the machine against turning over or slip-
ping off.
Secure the machine on the transport vehicle
against rolling, sliding and tipping over.
Persons are highly endangered if
lthey step or stand under loads being lifted
lthey remain in the drive range of the machine
during a demonstration or during loading.
The machine must not swing about when lifted off
the ground.
Use only safe lifting gear of sufficient load bearing
capacity.
Attach the lifting gear only to the specified lifting
points.
Towing the machine
You should generally use a tow bar.
Max. towing speed 1 km/h (1.6 mph), max. towing
distance 500 m (1640 ft.).
Before releasing the multi-disc brakes secure the
machine properly against unintended rolling.
Checking the roll-over protection
structure (ROPS)
The machine frame must not be distorted, bent or
cracked in the area of the ROPS structure.
The ROPS structure must not show any rust, dam-
age, hairline cracks or open fractures.
The ROPS must not rattle about when driving the
machine. This would mean that the fastening
screws are insufficiently fastened. All screwed
connections must be tight and in accordance with
the specifications (observe the tightening tor-
ques). Screws and nuts must not be damaged,
distorted or deformed.
No additional parts must be welded or bolted on
and no holes must be drilled without the permis-
sion of the dealer, since this may impair the
strength of the structure.
Starting the machine
Before starting
Operation of the machine is only permitted when
sitting in the operator's seat.
Use only machines which have been properly
serviced at regular intervals.
Become acquainted with the equipment, the con-
trol elements, the working mode of the machine
and the area you will be working in.
Use your personal protective outfit (hard hat, safe-
ty boots etc.).
Check before mounting the machine if:
lthere are persons or obstructions beside or
under the machine
lthe machine is free of any oily and combustible
material
lall handrails, steps and platforms are free of
grease, oils, fuels, dirt, snow and ice
lthe engine compartment hood is closed and
locked

Safety regulations
BOMAG 14 BW 900-2
To climb onto the machine use steps and hand-
rails.
Check before starting, whether:
lthe machine shows any obvious defects
lall protective devices are properly secured in
their place
lsteering, brakes, control elements, lighting
and warning horn are in order
lthe seat is correctly adjusted
lthe mirrors (if available) are clean and correct-
ly adjusted.
Do not start the machine if any gauges, control
lights or controls are defective.
Do not take any loose objects with you or fasten
them to the machine.
On machines with ROPS you should always wear
your seat belt!
Starting
Start and operate the machine only from the oper-
ator's seat
For starting set all control levers to "neutral posi-
tion".
Do not use any starting aids such as Start Pilot or
ether.
After starting check all gauges.
Starting with jump leads
Connect plus with plus and minus with minus
(ground cable) - always connect the ground cable
last and disconnect it first! Wrong connections
may cause severe damage in the electric system.
Never start the engine by bridging the electrical
connections on the starter, because the machine
would probably start to move immediately.
Starting in closed rooms
Exhaust gases are toxic! Always ensure an ade-
quate supply of fresh air when starting in closed
rooms!
Driving the machine
Persons in the endangered area
Before starting or resuming work and especially
when reversing, check that there are not any per-
sons or obstructions in the endangered area.
If necessary give warning signals. Stop work im-
mediately if persons remain in the danger area de-
spite the warning.
Do not step or stand in the articulation area of the
machine when the engine is running. Risk of
squashing!
Driving
In events of an emergency operate the emergency
stop switch immediately. Do not use the emergen-
cy stop switch as a service brake.
Restart the machine only after the danger, that has
caused the actuation of the emergency stop, has
been eliminated.
If the machine has come in contact with high-volt-
age power lines:
ldo not leave the operator's stand
lwarn others from coming too close to the ma-
chine or touching it
lif possible drive the machine out of the danger
zone
lhave the power shut off
Operate the machine only from the operator's
seat.
Do not adjust the seat while driving.
Do not climb onto or off the machine while driving.
Change the travel direction only while the machine
is standing.
Do not use the machine to transport persons.
Stop the machine if you notice unusual noises or
the development of smoke. Investigate the cause
and have the fault corrected.
Keep a sufficient distance to excavations and em-
bankments and make sure that your work does not
impair the stability of the machine.
Do not work with vibration on hard concrete, on a
cured bitumen surface or heavily frozen ground.
When passing under flyovers, bridges, tunnels,
electric power lines etc. keep a sufficient distance.
Driving on slopes and gradients
Do not drive up and down gradients, which exceed
the max. gradability of the machine.
Always drive extremely carefully on slopes and al-
ways straight up and down the slope. Change to
the lower speed range before approaching the
slope.

Safety regulations
BOMAG 15 BW 900-2
Wet and loose soils reduce the ground adhesion of
the machine on gradients and slopes. Higher risk
of accident!
Behaviour in traffic
Match the speed of the machine to the working
conditions.
Always allow loaded transport vehicles to pass.
Switch the lights on when the visibility is poor.
Keep clear of edges and embankments.
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, electric
power supply), stop vibratory compaction if neces-
sary.
Do not activate the vibration on hard (frozen, con-
crete) ground. Risk of bearing damage!
Parking the machine
Park the machine on level and firm ground.
Before leaving the machine:
lreturn the travel lever to neutral position
lapply the parking brake
lshut the engine down and pull the ignition key
out
lsecure the machine against unauthorized use.
Do not jump off the machine, use access steps
and hand rails.
Always secure parked machines, which could be
in the way, with appropriate measures.
Parking on slopes and gradients
Secure the machine against rolling, place metal
chocks in front of and behind the drums.
Filling the fuel tank
Do not inhale any fuel fumes.
Refuel only with the engine stopped.
Do not refuel in closed rooms.
No open fire, do not smoke.
Do not spill any fuel. Catch running out fuel, do not
let it seep into the ground.
Wipe off spilled fuel. Keep dirt and water away
from fuel.
Leaking fuel tanks can cause explosion. Ensure
tight fit of the fuel tank lid, if necessary replace im-
mediately.
Fire protection measures
Become acquainted with the location and the han-
dling of fire extinguishers. Observe all possibilities
for fire alarm and fire fighting.
Maintenance work
Comply with the maintenance work described in
the operating and maintenance instructions, in-
cluding the information concerning the replace-
ment of parts.
Maintenance work must only be performed by
qualified and authorized persons.
For overhead maintenance and assembly work
use the access steps and working platforms pro-
vided or other secure means. Do not use machine
parts as access steps.
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 horizontal, level and firm
ground.
Pull the key out of the ignition switch.
Lock the articulated joint with the articulation lock.
Working on hydraulic lines
Always relieve the hydraulic pressures before
working on hydraulic lines. Hydraulic oil escaping
under pressure can penetrate the skin and cause
severe injury. When being injured by hydraulic oil
consult a medical doctor immediately, as other-
wise this may cause severe infections.
Do not step in front of or behind the drums/wheels
when performing adjustment work in the hydraulic
system.
Do not change the setting of high pressure relief
valves.
Drain hydraulic oil at operating temperature - dan-
ger of scalding!
Catch hydraulic oil and dispose of environmental-
ly.
Always catch and dispose of biodegradable hy-
draulic oils separately.

Safety regulations
BOMAG 16 BW 900-2
Do not start the engine after draining the hydraulic
oil.
After finishing work (with the system still depressu-
rized!) check all connections and fittings for leaks.
Changing hydraulic hoses
Hydraulic hoses must be inspected visually at reg-
ular intervals.
Hydraulic hoses must be immediately replaced if:
lthe outer layer is damaged down to the inlay
(e.g. chafing, cuts, cracks)
lthe outer layer is brittle (formation of cracks in
the hose material)
lthe hose shows deformations in pressurized
and depressurized condition, which do not
comply with the genuine shape of the hydrau-
lic hose
lthe hose shows deformations in bends, e.g.
squeezing, buckling, layer separation, forma-
tion of blisters
lleakages.
linstallation faults.
lseparation of the hydraulic hose from the fit-
ting
lcorrosion of the fitting impairing both function
and strength.
lDo not mix up hoses by mistake.
ldamage or deformation of fittings impairing the
function and strength of the hose/hose con-
nection. Only genuine replacement hydraulic
hoses from BOMAG ensure that the correct
hose type (pressure range) is used at the right
location.
Working on the engine
Shut the engine down before opening the engine
hood.
Drain the engine oil at operating temperature -
danger of scalding!
Wipe off spilled oil, catch oil and dispose of envi-
ronmentally.
Store used filters and other oil contaminated ma-
terials in a separate, specially marked container
and dispose of environmentally.
Do not leave any tools or other objects, that could
cause damage, in the engine compartment.
Workingonelectricalequipment
Before starting to work on electric parts of the ma-
chine disconnect the battery and cover it with insu-
lating material.
Do not use fuses with higher ampere ratings and
do not repair fuses with a piece of wire. Fire haz-
ard!
Always disconnect the battery before starting
welding work on the machine.
Workingonthebattery
When working on the battery do not smoke, do not
use open fire!
Do not let acid come in contact with hands or
clothes! When injured by acid flush off with clear
water and seek medical advice.
Metal objects (e.g. tools, rings, watch straps) must
not come in contact with the battery poles - danger
of short circuit and burning!
When recharging maintenance-free batteries re-
move all plugs, to avoid the accumulation of explo-
sive gases.
Observe the applicable instructions when starting
with an auxiliary battery.
Dispose of old batteries environmentally.
Switch off the charging current before removing
thechargingclamps.
Ensure sufficient ventilation, especially if the bat-
tery is to be charged in a closed room.
Working on the fuel system
Do not inhale any fuel fumes.
No open fire, do not smoke, do not spill any fuel.
Catch fuel running out, do not let it seep into the
ground and dispose of environmentally.
Cleaning work
Do not clean the machine while the engine is run-
ning.
Do not use gasoline or other inflammable sub-
stances for cleaning.
When cleaning with steam cleaning equipment do
not subject electrical parts and insulation material
to the direct jet of water, or cover it beforehand.
lDo not guide the water jet into the exhaust and
into the air filter.

Safety regulations
BOMAG 17 BW 900-2
After maintenance work
After completion of maintenance work reinstall all
guards and safety features.
Repair
Attach a warning tag to the steering wheel if the
machine is defective.
Repairs must only be performed by qualified per-
sons who have been instructed for this purpose.
Use our repair instructions.
Exhaust gases are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
in closed rooms!
Test
Depending on the type of application and the op-
erating conditions vibratory equipment has to be
examined by a specialist whenever required, but
at least once every year.

Safety regulations
BOMAG 18 BW 900-2

BOMAG 19 BW 900-2
3 Indicators and Controls

Indicators and Controls
BOMAG 20 BW 900-2
Fig. 5