When a BW 75 S-2 stops pulling mid pass, the driveline linkages are the first place to look: a stretched control cable, a slipping travel clutch, or a worn centrifugal clutch. Meanwhile the lift sits half compacted and the crew waits. This 24 page PDF is the BOMAG repair manual for the BW 75 S-2 double vibratory roller, serial numbers 101 020 01 1001 and up, publication number 008 912 49.
It covers the mechanical adjustments that keep this roller working: replacing and adjusting the throttle cable and control cable, checking and setting the travel clutch, replacing the brake cable, adjusting the parking brake, and pulling the centrifugal clutch off its taper. Tightening torques and the factory engine speed settings are included, so you set everything back to spec.
Thirteen bookmarked sections in 24 pages mean you open the file, jump straight to the one procedure you need, and get the machine back in the pass.
What's Inside This Bomag BW 75 S-2 Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety Regulations | 7-8 | Lifting Gear, Cleansing Agents, Fuel Tank, Welding Instructions, Engine Operation, Battery Maintenance |
| General Repair Instructions | 9 | Electrical System, Seals, Gaskets |
| Tightening Torques | 10-11 | Metric Unified Thread, Metric Fine Thread, Screw Dimension, Strength Classes, Torque Wrenches |
| Notes on Repair | 12 | |
| Replacing and Adjusting Throttle Cable | 13-15 | Control Housing, Steering Rod, Ball Head, Throttle Lever, Engine Speed, Centrifugal Clutch |
| Replacing and Adjusting Control Cable | 16-17 | Travel Lever, Control Housing, Roller Bracket, Gearbox Cover, Clutch Engagement Lever, Fork Joint |
| Checking and Adjusting Travel Clutch | 18-19 | Spring Balance, Travel Control Lever, Multi-Disc Clutches, Adjustment Ring, Crankshaft, Decompression Switch |
| Replacing Brake Cable | 20 | |
| Adjusting Parking Brake | 21 | |
| Replacing Centrifugal Clutch | 22-24 | Drive Housing Cover, V-Belt, Socket Head Cap Screw, Grub Screw, Forcing Screw, Taper |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Tightening torque for M8 screw | 25 Nm | p. 10 |
| Tightening torque for M10 screw | 50 Nm | p. 10 |
| Engine speed in travel position MAX | 2200 rpm | p. 14 |
| Full load speed in vibration position | 2700 rpm | p. 15 |
| Maximum oil temperature | 160 °C | p. 7 |
| Engine speed (travel position MAX) | 2200 rpm | p. 14 |
| Engine speed (vibration position) | 2700 rpm | p. 15 |
| Brake piston protrusion | 1-4 mm | p. 21 |
| Torque (M8 screw) | 25 Nm | p. 12 |
| Torque (M10 screw) | 50 Nm | p. 12 |
| Torque (M12 screw) | 88 Nm | p. 12 |
Bomag BW 75 S-2 Common Problems This Manual Covers
Roller will not move, engine runs fine
A worn centrifugal clutch lets the engine rev without ever driving the machine. The manual shows how to open the drive housing cover, remove the V-belt, and pull the clutch off its taper using the forcing screw.
Manual Section: Replacing Centrifugal Clutch p. 22Travel lever slack, drive engages late
A stretched or misadjusted control cable means the travel lever moves but the clutch engagement lever in the gearbox barely responds. The manual covers replacing the cable and setting it correctly at the roller bracket and fork joint.
Manual Section: Replacing and Adjusting Control Cable p. 16Engine speed wrong, vibration feels weak
If the throttle cable is stretched, the engine never reaches its rated speed and compaction per pass drops. The manual gives the adjustment procedure at the control housing and throttle lever, with the specified speeds of 2200 rpm in travel position and 2700 rpm in vibration position.
Manual Section: Replacing and Adjusting Throttle Cable p. 13Travel clutch slipping under load
Multi-disc travel clutches drift out of adjustment and start slipping on the climb out of a trench or fill. The manual shows how to check engagement force at the travel control lever with a spring balance and correct it at the adjustment ring.
Manual Section: Checking and Adjusting Travel Clutch p. 18Parking brake will not hold
When the roller creeps on a ramp with the brake applied, the brake cable or adjustment nut needs setting. The manual walks through the counter nut and adjustment nut procedure and gives the specified brake piston protrusion of 1 to 4 mm.
Manual Section: Adjusting Parking Brake p. 21Frayed or seized brake cable
A sticking brake cable can leave the safety control dragging or the brake locked on. The replacement procedure covers the spring pack, fork head and brake piston, with wheel chocks called out before you start.
Manual Section: Replacing Brake Cable p. 20Fasteners loosening after reassembly
Vibration works screws loose fast if they were not torqued to spec on assembly. The manual lists tightening torques by screw dimension and strength class for metric and metric fine threads.
Manual Section: Tightening Torques p. 10Frequently Asked Questions
Which machines does this manual cover?
The BOMAG BW 75 S-2 double vibratory roller, serial numbers 101 020 01 1001 and up. Check the serial number on your machine's type plate against this range before buying. The publication number is 008 912 49.
Does it include tightening torque specifications?
Yes. The Tightening Torques section lists values by screw dimension and strength class for metric and metric fine threads, for example 25 Nm for M8, 50 Nm for M10 and 88 Nm for M12 screws. p. 10
What are the correct engine speed settings?
The throttle cable section specifies 2200 rpm in the travel position MAX and 2700 rpm full load speed in the vibration position, and shows how to adjust the cable at the control housing to reach them. p. 13
Does this manual cover error codes or electronics?
No. This is a mechanical repair manual for a pre-electronic machine. It covers cable replacement and adjustment, travel and centrifugal clutch work, and brake adjustment. There are no fault codes or diagnostic menus on this roller.
What exactly do I receive with this Bomag BW 75 S-2 Repair Manual?
One searchable PDF covering 24 pages, delivered instantly. No disc, no shipping, no waiting on the post.
Am I free to print this Bomag BW 75 S-2 Repair Manual?
Yes. The PDF has no DRM restrictions, so print any page or section you need for your shop. Works with any standard printer.
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