the best service repair manual

1. Service Training
10/2004Teile-Nr. 008 099 92
BW 177 / 179 DH / PDH-4
Single Drum Roller

2. Service Training
BW 177 / 179 DH / PDH -4
Table of contents
Foreword A 1
Documentation A 2
General A 3
New developments A 5
Technical data and adjustment values B 1
Maintenance C1
Maintenance chart C2
DEUTZ diesel engine with EMR D 1
Service side D 2
Starter side D 3
Lubrication oil circuit D 4
Coolant circuit D 5
Fuel system D 6
EMR D10
Trouble shooting D22
Diagnose SERDIA D24
Checking and adjusting the valve clearance D26
Assembly of the plug-in injection pump D28
Engine components D44
Travel system E 1
Travel pump E 3
Control E 7
Charge pressure relief valve E 8
High pressure relief valve E 9
Pressure override E11
Axle drive motor E14
Drum drive motor E17
Test and adjustment points, travel system E19
Trouble shooting travel system E27

3. Service Training
BW 177 / 179 DH / PDH -4
Vibration F 1
Vibration pump F 3
High pressure relief valves F 6
Control F 7
Vibration motor F 8
Drum F11
Test and adjustment points, vibration system F13
Trouble shooting vibration F15
Steering G 1
Charge pump G 2
Steering pump G 3
Steering valve G 5
Articulated joint G 7
Measuring and adjustment points G 9
Trouble shooting steering G10
Electrics H1
Wiring diagram
Hydraulic diagram

4. Service Training
BW 177 / 179 DH / PDH -4 - A 1 -
Foreword and novelties
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 BOMAG’s 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 BOMAG’s own service personnel as well as the service personnel of BOMAG
Profit Centres and dealers is therefore a general prerequisite for BOMAG’s excellent world-wide service.
This program of permanent training is only possible with appropriate and up-to-date training material for
trainers as well as persons attending the training courses.
This training manual has not only been written as a support for the professional work of the trainer, but
also for the trainees attending these training courses.
The different levels of product training demand, that the training performed by BOMAG, its Profit Centres
or its dealers reflects the high quality of the training conducted at the Training Centre at BOMAG in
Boppard. For this reason we invested a lot of time in the preparation of these materials .
The structure of this training manual enables us to change or up-date individual chapters in case of
alterations to the machine.

5. Service Training
BW 177 / 179 DH / PDH -4 - A 2 -
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.
1. Operating and maintenance instructions
2. Spare parts catalogue
3. Wiring diagram *
4. Hydraulic diagram *
5. Repair instructions
6. Service Information
* The document versions valid at the date of printing are part of this training manual.

6. Service Training
BW 177 / 179 DH / PDH -4 - A 3 -
General
The new single drum rollers BW 177 and 179 DH-4 from BOMAG are essentially further developments
of their predecessors, the machines of product range BW 177 DH-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 driver’s 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.

7. Service Training
BW 177 / 179 DH / PDH -4 - A 4 -
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 and 179 DH-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.

8. Service Training
BW 177 / 179 DH / PDH -4 - A 5 -
Novelties
Themulti-functiontravelleverandthedisplay

9. Service Training
BW 177 / 179 DH / PDH -4 - A 6 -
Control, operation, data collector,

10. Service Training
BW 177 / 179 DH / PDH -4 - A 7 -
Diesel engine with EMR

11. Service Training
BW 177 / 179 DH / PDH -4 - B 1 -
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.

12. BOMAG Central Service - Technical data and adjustment values
Status: 2004-10-19
Product type: BW 177 DH Serie 4
Type No.: 582 21
Serial numbers from: 101 582 21 1001
Engine:
Manufacturer: Deutz
Type: BF4M2012 EMR
Combustion principle: 4-stroke-Diesel
Cooling: Water
Number of cylinders: 4
Power acc. to ISO 9249: 74,9 kW
Power data at nominal speed of: 2200 1/min
Low idle speed: 900+/-200 1/min
High idle speed: 2200 +/-10 1/min
Spec. fuel consumption: 235 g/kWh
Valve clearance, inlet: 0,3 mm
Valve clearance, outlet: 0,5 mm
Opening pressure, injection valves: 220 bar
Starter voltage: 12 V
Travel pump:
Manufacturer: Bosch-Rexroth
Type: A4VG 56 EP
System: Axial piston-swash plate
Max. displacement: 56 cm3/U
Max. flow ratio: 123,2 l/min
High pressure limitation: 475 bar
Pressure override: 435+/-15 bar
Charge pressure, high idle: 25+/-1 bar
Reduction gear, drum:
Manufacturer: Lohmann-Stolterfoht
Type: GFT 17
Transmission ratio: 53,95
Travel motor, rear:
Manufacturer: Sauer-Danfoss
Type: 51D80 RD3N Y7(EP)
System: Axial piston-bent axle
Max. displacement (stage 1): 80 cm3/U
Min. displacement (stage 2): 15 cm3/U
Perm. leak oil quantity: 2 + 10 l/min
Rinsing oil quantity: 10 l/min
Drum drive:
Seite 1 von 3BOMAG Central Service
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13. Manufacturer: Sauer-Danfoss
Type: 51C 060 RD1N 7Y (EP)
System: Axial piston-swash plate
Displacement stage 1: 60 cm3/U
Displacement stage 2: 12 cm3/U
Perm. leak oil quantity: 2 + 7 l/min
Rinsing oil quantity: 7 l/min
Vibration pump:
Manufacturer: Bosch-Rexroth
Type: A10VG 45 EP
System: Axial piston-swash plate
Max. displacement: 45 cm3/U
Starting pressure: 360+/-20 bar
Operating pressure, soil dependent: ca.100 bar
Vibration motor:
Manufacturer: Sauer-Danfoss
Type: MMF 025 PPU
System: Axial piston-swash plate
Displacement: 25 cm3/U
Frequency: 30-40 Hz
Amplitude: 1,8/0,9 mm
Steering and charge pump:
Manufacturer: Bosch-Rexroth
Type: HYZ/19
System: Gear pump
Displacement: 19 cm3/U
Max. steering pressure: 190 +/-10 bar
Steering valve:
Manufacturer: Sauer-Danfoss
Type: OSPC 315 ON
System: Rotary valve
Rear axle:
Manufacturer: Dana
Type: CHC 192/57LD
Differential: No-Spin
Degree of locking: 100 %
Reduction ratio: 43,7
Filling capacities:
Engine coolant: 15 l (50% Water, 50% Anti-freeze agent on
Ethane-diol-basis)
Engine oil: 8,5 l (SAE 15W-40, API SJ/CF)
Hydraulic oil: 60 l (HVLP 46 VI 150)
Seite 2 von 3BOMAG Central Service
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14. Vibration bearing housing: 3,2 l (SAE 15W-40, API SJ/CF)
Rear axle: 6,7 l (SAE 90 EP, API GL 5)
Rear axle wheel hubs: 0,7 l (SAE 90 EP, API GL 5)
Reduction gear, drum: 2,5 l (SAE 90 EP, API GL 5)
AC refrigerant: 1300 g (R 134a)
Compressor oil (filling the system): 100 ml (PAG Öl)
Seite 3 von 3BOMAG Central Service
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15. Service Training
BW 177 / 179 DH / PDH - 4 - C 1 -
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.

16. Service Training
BW 177 / 179 DH / PDH - 4 - C 2 -
Maintenance table
No. Maintenance work Remark
Runningininstructions
after50operatinghours
every10op.hours,daily
every250oper.hours
every500oper.hours
every1000oper.hours
every2000oper.hours
every3000oper.hours
every5000oper.hours
asrequired
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 engine oil, 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
elementa
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,
replace
X
5.21 Check tension of refrigerant
compressor 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

17. Service Training
BW 177 / 179 DH / PDH - 4 - C 3 -
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
frame
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
cabin
X
5.42 Tightening torques X
5.43 Engine conservation X
a. Oil change intervals depend on quality of oil and fuel (sulphur content)
No. Maintenance work Remark
Runningininstructions
after50operatinghours
every10op.hours,daily
every250oper.hours
every500oper.hours
every1000oper.hours
every2000oper.hours
every3000oper.hours
every5000oper.hours
asrequired

18. Service Training
BW 177 / 179 DH / PDH - 4 - C 4 -
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.
b. Oil change intervals after 50 h, after 500 h, after 1000 h and then every 1000 h.
c. Also after repairs in the hydraulic system
d. Also after repairs in the hydraulic system

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20. Service Training
BW 177 / 179 DH / PDH -4 - D 1 -
Deutz diesel engine
The single drum roller of product range BW 177 / 179 DH-4 are driven by a Deutz diesel engine series
BF4M 2012 COM2 with electronic engine management (EMR) . The engine is cooled by an external
radiator. The cooling fan is mounted to the engine fan block and is directly driven by the engine.
These engines are characterized by the following positive features:
• short and compact design,
• low noise level,
• almost vibration-free running,
• low fuel consumption,
• low exhaust emissions (EPA II),
• high power reserves and
• good access to all service points.
Crankcase and cylinders of this engine are made of alloyed cast iron. This provides strength and
ensures high wear resistance.
The forged steel conrods are fitted with compensation weights near the conrod bearing seats. These
weights compensate manufacturing tolerances with respect to weight and centre of gravity.
The pistons are made of an aluminium alloy. The combustion chamber recess is slightly offset from the
middle at its side walls are inclined for 10° towards the inside. All pistons are fitted with three piston rings
and a cast iron ring carrier for the first ring. The pistons are lubricated by an oil mist.
The forged crankshaft is equipped with integrated counterweights.
The block-type cylinder head is made of cast steel. Each cylinder is fitted with one intake and one
exhaust valve. The valve guides are shrunk into the cylinder head. The valve seat rings are made of
high-grade steel and are also shrink fitted.

21. Service Training
BW 177 / 179 DH / PDH -4 - D 2 -
Service side
Fig. 1: Service side BFM 2012
1 Oil filler neck 8 Fuel pump
2 Valve, boost fuel supply 9 Engine mounting
3 Engine solenoid 10 Fuel filter
4 Oil pressure switch 11 Lubrication oil filter
5 Cooling air blower 12 Oil sump
6 Coolant pump 13 Dipstick
7 V-belt pulley 14 Steering/charge pump
1
2
3 4
5
6
7
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