Bomag BW 177 D-4 Single Drum Rollers Service Repair Manual Instant Download

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Service Training
Walzenzug BW 177 D-4
06/2004
Teile-Nr. 008 099 90
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Service Training
Table of contents
Foreword A 1
Documentation A 2
General A 4
List of components B 1
Technical data B 2
Maintenance C1
Maintenance table C2
DEUTZ Diesel engine D 1
Service side D 2
Starter side D 3
Lubrication oil circuit D 4
Fuel system D 5
Checking and adjusting the valve clearance D 6
Plug-in injection pump D 8
Travel system E 1
Travel pump E 3
Servo control E 6
Charge pressure relief valve E 11
High pressure relief valve E 12
Pressure override E 14
Axle drive motor E 16
Drum drive motor E 20
Trouble shooting travel system E 29
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Service Training
Vibration Vibration pump High pressure protection
Control Charge pump Vibration motor
Drum Trouble shooting vibration
F 1 F 3 F 6 F 7 F 8 F 9 F 12 F 14
Steering Steering pump Steering valve
Articulated joint Trouble shooting steering
G 1 G 2 G 4 G 6 G 8
Electrical system
H 1
BW 177 D-4
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Service Training

• Foreword
• Reliable construction equipment is of greatest
  advantage for all parties involved
• for the customer/user it is a basis for an exact
  calculation of utilization periods and the
  completion of projects as scheduled.
• in the rental business it means that the
  equipment can be reliably used and planned
  without having to stock a large number of
  stand-by machines.
• for the manufacturer it means that customers are
  satisfied, provides him with a good image and
  gives him a feeling of confidence.
• It is BOMAGs philosophy to design and produce
  the machines with highest possible reliability.
  This aspect of simple and easy maintenance was
  one of the key issues when developing and
  designing the machine
• the location of components in the machine eases
  maintenance work,
• the high quality standard of BOMAG is the basis
  for the considerable extension of the service and
  maintenance intervals.
• the After Sales Service of BOMAG, including
  excellent operating and maintenance instruction
  manuals, high quality training courses and
  on-site machine demonstrations helps the customer
  to maintain their machines in good condition
  over a long period of time.
• Permanent training of BOMAGs own service
  personnel as well as the service personnel of
  BOMAG Profit Centres and dealers is therefore a
  general prerequisite for BOMAGs excellent
  world-wide service.

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Service Training

• Documentation
• For the BOMAG machines described in this training
  manual the following documentation is
  additionally available
• Attention!
• The currently valid part numbers for the
  documents can be taken from the Doclist or the
  Customer Service page in the BOMAG (BOMAG Secured
  Area) in accordance with the serial number of
  the machine.
• Operating and maintenance instructions
• Spare parts catalogue
• Wiring diagram
• Hydraulic diagram
• Repair instructions
• Service Information
• The document versions valid at the date of
  printing are part of this training manual.

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Service Training
General The new single drum rollers BW 177 D-4
from BOMAG are essentially further developments
of their predecessors, the machines of product
range BW 177 D-3. These machines have been
successfully and reliably used for years on
construction sites all over the world,
especially in earth construction and on sanitary
landfill sites. High compaction power and
excellent traction are characteristics, which are
of utmost importance for this type of
machine. All components installed in these
machines are manufactured in series production
and are subjected to stringent quality tests.
This guarantees a high level of reliability and
safety. As with many other BOMAG products, and
here especially with the large single drum
rollers of the new generation, we have decided
to use the same successful drive concept with
diesel engine (water cooled) and hydrostatic
drives also for these machines. The hydrostatic
drives transfer the output power of the engine
directly to drum, drive wheels and steering. The
drive wheels are driven by fast rotating
hydraulic motors and axle, whereas the drum is
driven by slow running radial piston motors. On
construction machines the work place of the
operator is of utmost importance. Under such
working conditions the health and safety of the
operator must be the greatest concern. The cabin
is very spacious and clearly arranged. The
drivers seat is very comfortable and can be
individually adjusted for every operator, even
for his weight. All control elements and gauges
are within the reach and in the sight of the
operator. A monitoring display with light
emitting diodes and clear pictograms informs the
operator about any operating faults. The
operator is therefore always informed about the
present condition of the machine. The generously
glazed cabin with windscreen wiper and washer
systems for front and rear windscreens, as well
as a heated rear windscreen, offers clear vision
to all sides.
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Service Training

• Important characteristics of the new generation
  of single drum rollers are
• strong ROPS/FOPS according to SAE-standard
• wear free service brake by closed hydrostatic
  travel circuits
• disc brakes in axle and drum drive motor serve as
  parking and emergency brakes
• high stability due to low centre of gravity and
  the use of an articulated joint
• operating safety due to the use of monitoring
  boards for all important system data
• automatic engine shut-down at too engine
  temperature, too low hydraulic oil level (when
  reaching the lowest permissible level the engine
  will be shut down after 20 seconds) and too low
  engine oil pressure.
• The machines of product ranges BW 177 D-4 are
  well designed down to the smallest detail, so
  that they can meet the toughest demands on large
  scale construction sites all over the world.

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Technical data and adjustment values The
following pages contain technical data valid at
the date of printing (see front page of this
manual). Attention! The currently valid
technical data and adjustment values can be taken
from the BOMAG Intranet or Extranet (BOMAG
Secured Area) in accordance with the serial
number of the machine.
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BOMAG Central Service
BOMAG Central Service - Technical data and
adjustment values Status 2004-06-21
Product type Type No. Serial numbers from
BW 177 D Serie 4 582 20 101 582 20 1001
Engine Manufacturer Type Combustion principle
Cooling Number of cylinders Power acc. to ISO
9249 Power data at nominal speed of Low idle
speed High idle speed Spec. fuel consumption
Valve clearance, inlet Valve clearance, outlet
Deutz BF4M 2011 4-stroke-Diesel Air-Oil 4 54
kW 2300 1/min 850 /-150 1/min 2500/-50 1/min
243 g/kWh 0,3 mm 0,5 mm
Opening pressure, injection valves 210 8 bar
Starter voltage 12 V
Travel pump Manufacturer Type System Max.
displacement Max. flow ratio High pressure
limitation Pressure override Charge pressure,
high idle
Bosch-Rexroth A4VG 56 HW Axial piston-swash
plate 56 cm3/U 140 l/min 475 bar 435/-15 bar
25/-1 bar
Travel motor, rear Manufacturer Type System Ma
x. displacement (stage 1) Min. displacement
(stage 2) Perm. leak oil quantity
Sauer-Danfoss 51D80 Axial piston-bent axle 80
cm3/U 40,2 cm3/U 2 l/min
Drum drive Manufacturer Type System
Displacement stage 1 Perm. leak oil quantity
Poclain MSE 08 1CX Radial piston 1260 cm3/U 1,5
l/min
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BOMAG Central Service
Vibration pump Manufacturer Type
System Max. displacement Starting pressure
Bosch-Rexroth A10VG 28 EZ Axial piston-swash
plate 28 cm3/U 365/-35 bar
Operating pressure, soil dependent ca. 100 bar
Vibration motor Manufacturer Type System
Displacement Frequency Amplitude
Sauer-Danfoss MMF 025 Axial piston-swash
plate 25 cm3/U 30/40 Hz 1,8/0,9 mm
Steering and charge pump Manufacturer
Type System Displacement Max. steering
pressure
Bosch-Rexroth HYZ/19 Gear pump 19 cm3/U 190
/-10 bar
Steering valve Manufacturer Type System
Sauer-Danfoss OSPC 315 ON Rotary valve
Rear axle Manufacturer Type
Differential Degree of locking Reduction ratio
Dana CHC 192/57LD No-Spin 100 43,7
Filling capacities Engine oil Hydraulic
oil Vibration bearing housing Rear axle Rear
axle wheel hubs AC refrigerant Compressor oil
(filling the system)
13,5 l (SAE 15W-40, API SJ/CF) 60 l (HVLP 46 VI
150) 2x 3,2 l (SAE 15W-40, API SJ/CF) 6,7 l (SAE
90 EP, API GL 5) 0,7 l (SAE 90 EP, API GL 5) 1300
g (R 134a) 100 ml (PAG Öl)
http//bsa.bomag.spx.com/bsa/tk_components/english
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Maintenance Single drum rollers are heavy-duty
construction machines for extremely difficult
tasks in earth construction. To be able to meet
these demands the machines must always be ready
to be loaded up to their limits. Furthermore,
all safety installations, protections and guards
must always be in place and fully
functional. Thorough maintenance of the machine
is therefore mandatory. This not only guarantees
a remarkably higher functional safety, but also
prolongs the lifetime of the machine and of
important components. The time required for
thorough maintenance is only minor when being
compared with the malfunctions and faults that
may occur if these instructions are not
observed. The maintenance intervals are given in
operating hours. It is quite obvious that with
each maintenance interval all the work for
shorter preceding intervals must also be
performed. During the 2000 hours interval you
must also perform the work described for the
service intervals after 50, 250 and 500
hours. During maintenance work you must only use
the fuels and lubricants mentioned in the table
of fuels and lubricants (oils, fuels, grease
etc.). The designation specified under No in
the first column of the maintenance chart refers
to the corresponding number of the service work
to be performed, as specified in the operating
and maintenance instructions. This also helps to
find detailed information on the individual
maintenance tasks.
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Maintenance table
No. Maintenance work Remark Running-in instructions after 50 operating hours every 10 op. hours, daily every 250 oper. hours every 500 oper. hours every 1000 oper. hours every 2000 oper. hours every 3000 oper. hours every 5000 oper. hours as required
5.6 Check the engine oil level Dipstick mark X
5.7 Check the water separator X
5.8 Check the fuel level X
5.9 Check the hydraulic oil level Inspection glass X
5.10 Check dust precleaner X
5.11 Check tire pressure X
5.12 Clean engineoil, fuel and hydraulic oil cooler X
5.13 Check the drive axle oil level X
5.14 Check oil level in wheel hubs X
5.15 Check oil level in vibration bearings X
5.16 Change engine oil and oil filter ele- menta min. 1x per year X
5.17 Battery service pole grease X
5.18 Drain the fuel tank sludge X
5.19 Change the fuel prefilter element X
5.20 Check V-belt tension, tighten, re- place X
5.21 Check tension of refrigerant com- pressor V-belt , tighten, replace X
5.22 Service the air conditioning X
5.23 Check, adjust the valve clearance Inlet 0,3 mm exhaust 0,5 mm on cold engine X
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No. Maintenance work Remark Running-in instructions after 50 operating hours every 10 op. hours, daily every 250 oper. hours every 500 oper. hours every 1000 oper. hours every 2000 oper. hours every 3000 oper. hours every 5000 oper. hours as required
5.24 Oil change in vibration bearingsb see footer, min. 1x per year X X
5.25 Oil change in drive axle min. 1x per year X X
5.26 Oil change in wheel hubs min. 1x per year X X
5.27 Replace the fuel filter cartridge X
5.28 Check the engine mounts X X
5.29 Retighten fastening of axle to fra- me X
5.30 Tighten the wheel nuts X X
5.31 Check the ROPS X
5.32 Clean the oil bath air filter min. 1x per year X
5.33 Change hydraulic oil and breather filterc min. every 2 years X
5.34 Replace the hydraulic oil filterd min. every 2 years X
5.35 Check the injection valves X
5.36 Replace the toothed belts min. every 5 years X
5.37 Service the combustion air filter min. 1x per year,safety cartridge min. every 2 years X
5.38 Adjust the scrapers X
5.39 Adjust the parking brake X
5.40 Change the tires X
5.41 Replace the fresh air filter in the ca- bin X
5.42 Tightening torques X
5.43 Engine conservation X

1. Oil change intervals depend on quality of oil and
   fuel (sulphur content)
2. Oil change intervals after 50 h, after 500 h,
   after 1000 h and then every 1000 h.

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Service Training

1. Also after repairs in the hydraulic system
2. Also after repairs in the hydraulic system

Note When changing filters use only the
original filters specified in the operating and
maintenance instructions for this machine. The
installation of incorrect filters (e.g.
insufficient pressure resistance) can lead to
severe damage on engine or hydraulic
components. When using diesel fuel with a
sulphur content of more than 0.5, the oil change
intervals must be halved. The same applies when
using engine oils of specification API CF/CF-4.
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• Deutz diesel engine
• Single drum rollers of series BW 177 D-4 are
  powered by a Deutz diesel engine of product range
  BF4M 2011. In contrast to the engines 1011/1012
  previously used by BOMAG, this engine comes with
  external oil cooling, i.e. a separate oil cooler
  and external fan, instead of the well known
  integrated oil cooler/fan system. This
  automotive engine is characterized by the
  following features
• short and compact design,
• low noise level,
• low vibration running,
• low fuel consumption,
• low exhaust emissions,
• good access to all service points and
• extended maintenance intervals (5000 h) for
  toothed timing belt, in comparison to the
  predecessor 1011 F, by installation of an
  automatic tensioning device and improved
  enclosure of the toothed belt.
• The engine is a 4-cylinder 4-stroke inline engine
  with direct fuel injection.

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Control side
Fig. 1 Control side BFM 2011
1 Intake pipe 2 Fan
3 V-belt pulley on crankshaft 4 Narrow V-belt
5 Fuel shut-off solenoid 6 Toothed belt cover
7 Shut-down lever 8 Control lever
9 Oil filler neck (on side of crankcase) 10 Oil dipstick
11 Fuel 12 Fuel filter
13 Port for oil heating 14 Lubrication oil filter
15 Injection pumps 16 Oil cooler port
17 Injection valves 18 Fuel return line
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Exhaust side
Fig. 2 Exhaust side BFM 2011
19 Valve cover 20 Exhaust manifold
21 SAE-housing 22 Starter
23 Crank case 24 Oil line ATL
25 Turbocharger 26 Generator with cover plate
27 Charge air line
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Lubrication oil circuit
Fig. 3 Lubrication oil circuit
2 Suction strainer with suction pipe 4 Main oil
channel 6 Cylinder head cooling groove 8 Rocker
arm
1 Oil sump 3 Oil pump 5 Oil cooled cylinder 7 OIl
channel for rocker arm lubrication 9 Oil manifold
to thermostat
10 Supply to ext. Oil cooler 12 Thermostat
housing with thermostat spool 14 Oil filter
11 Return flow ext. oil cooler 13 OIl channel to
oil filter

• Oil channel to camshaft, conrod and crankshaft
  bearings
• Oil spray nozzle for piston cooling 17 Oil return
  flow via crankcase to oil sump
• 18 Lubrication oil supply to turbo charger 19
  Turbocharger
• 20 Return flow from turbocharger to oil sump

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Fuel circuit

• Fig. 4 Fuel circuit
• Fuel line from tank to fuel lift pump
• Fuel lift pump
• Fuel line from fuel lift pump to fuel filter
• Fuel filter
• Fuel line from filter to injection pump
• Injection pumps
• Fuel distribution line
• Injection lines
• Injection valves
• Fuel leakage line
• Fuel overflow line
• Fuel return line to tank

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