service repair manual

1. Service Training
06/2004Teile-Nr. 008 099 90
BW 177 D-4
Walzenzug

2. Service Training
BW 177 D-4
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

3. Service Training
BW 177 D-4
Vibration F 1
Vibration pump F 3
High pressure protection F 6
Control F 7
Charge pump F 8
Vibration motor F 9
Drum F 12
Trouble shooting vibration F 14
Steering G 1
Steering pump G 2
Steering valve G 4
Articulated joint G 6
Trouble shooting steering G 8
Electrical system H 1

4. Service Training
BW 177 D-4 - A 1 -
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 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 D-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 D-4 - A 3 -
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 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 D-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 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.

8. Service Training
BW 177 Series 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.

9. BOMAG Central Service - Technical data and adjustment values
Status: 2004-06-21
Product type: BW 177 D Serie 4
Type No.: 582 20
Serial numbers from: 101 582 20 1001
Engine:
Manufacturer: Deutz
Type: BF4M 2011
Combustion principle: 4-stroke-Diesel
Cooling: Air-Oil
Number of cylinders: 4
Power acc. to ISO 9249: 54 kW
Power data at nominal speed of: 2300 1/min
Low idle speed: 850 +/-150 1/min
High idle speed: 2500+/-50 1/min
Spec. fuel consumption: 243 g/kWh
Valve clearance, inlet: 0,3 mm
Valve clearance, outlet: 0,5 mm
Opening pressure, injection valves: 210 +8 bar
Starter voltage: 12 V
Travel pump:
Manufacturer: Bosch-Rexroth
Type: A4VG 56 HW
System: Axial piston-swash plate
Max. displacement: 56 cm3/U
Max. flow ratio: 140 l/min
High pressure limitation: 475 bar
Pressure override: 435+/-15 bar
Charge pressure, high idle: 25+/-1 bar
Travel motor, rear:
Manufacturer: Sauer-Danfoss
Type: 51D80
System: Axial piston-bent axle
Max. displacement (stage 1): 80 cm3/U
Min. displacement (stage 2): 40,2 cm3/U
Perm. leak oil quantity: 2 l/min
Drum drive:
Manufacturer: Poclain
Type: MSE 08 1CX
System: Radial piston
Displacement stage 1: 1260 cm3/U
Perm. leak oil quantity: 1,5 l/min
Seite 1 von 2BOMAG Central Service
21.06.2004http://bsa.bomag.spx.com/bsa/tk_components/english/search_components_result.asp?...

10. Vibration pump:
Manufacturer: Bosch-Rexroth
Type: A10VG 28 EZ
System: Axial piston-swash plate
Max. displacement: 28 cm3/U
Starting pressure: 365+/-35 bar
Operating pressure, soil dependent: ca. 100 bar
Vibration motor:
Manufacturer: Sauer-Danfoss
Type: MMF 025
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 oil: 13,5 l (SAE 15W-40, API SJ/CF)
Hydraulic oil: 60 l (HVLP 46 VI 150)
Vibration bearing housing: 2x 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)
AC refrigerant: 1300 g (R 134a)
Compressor oil (filling the system): 100 ml (PAG Öl)
Seite 2 von 2BOMAG Central Service
21.06.2004http://bsa.bomag.spx.com/bsa/tk_components/english/search_components_result.asp?...

11. Service Training
BW 177 D Series 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.

12. Service Training
BW 177 D Series 4 - C 2 -
Maintenance table
No. Maintenance work Remark
Running-ininstructions
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 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

13. Service Training
BW 177 D Series 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 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
a. Oil change intervals depend on quality of oil and fuel (sulphur content)
b. Oil change intervals after 50 h, after 500 h, after 1000 h and then every 1000 h.
No. Maintenance work Remark
Running-ininstructions
after50operatinghours
every10op.hours,daily
every250oper.hours
every500oper.hours
every1000oper.hours
every2000oper.hours
every3000oper.hours
every5000oper.hours
asrequired

14. Service Training
BW 177 D Series 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.
c. Also after repairs in the hydraulic system
d. Also after repairs in the hydraulic system

15. Service Training
BW 177 D-4 - D 1 -
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.
The combustion method with direct fuel injection enables the use of a less expensive casting for the
cylinder head, highest possible utilization of fuel and minimum heat transfer to the coolant.
This in turn enables the use of a smaller and more compact radiator.
Both the crankcase with cylinders as well as the cylinder head of this ebngine are made of a cast iron
alloy. This provides strength and ensures high wear resistance.
The forged steel conrods are fitted with compensation weights near the conrod bearing seats. This
weight compensates manufacturing tolerances with respect to weight and centre of gravity.
The pistons are made of an aluminium alloy. The combustion trough has been specially designed for
efficient combustion. All pistons are fitted with three piston rings and are lubricated by an oil mist.
Each cylinder is fitted with one intake and one exhaust valve. The valve guides are shrunk into the
cylinder head.

16. Service Training
BW 177 D-4 - D 2 -
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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18. Service Training
BW 177 D-4 - D 3 -
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

19. Service Training
BW 177 D-4 - D 4 -
Lubrication oil circuit
Fig. 3: Lubrication oil circuit
1 Oil sump 2 Suction strainer with suction pipe
3 Oil pump 4 Main oil channel
5 Oil cooled cylinder 6 Cylinder head cooling groove
7 OIl channel for rocker arm lubrication 8 Rocker arm
9 Oil manifold to thermostat 10 Supply to ext. Oil cooler
11 Return flow ext. oil cooler 12 Thermostat housing with thermostat spool
13 OIl channel to oil filter 14 Oil filter
15 Oil channel to camshaft, conrod and crankshaft bearings
16 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

20. Service Training
BW 177 D-4 - D 5 -
Fuel circuit
Fig. 4: Fuel circuit
1 Fuel line from tank to fuel lift pump
2 Fuel lift pump
3 Fuel line from fuel lift pump to fuel filter
4 Fuel filter
5 Fuel line from filter to injection pump
6 Injection pumps
7 Fuel distribution line
8 Injection lines
9 Injection valves
10 Fuel leakage line
11 Fuel overflow line
12 Fuel return line to tank