Bomag BW 177 D-3 DH-3 PDH-3, BW 178 DH-3 PDH-3 Single Drum Roller Operating & Maintenance Manual

Operating instructions Maintenance instructions

BW 177 D-3 / DH-3 / PDH-3 BW 178 DH-3 / PDH-3 S/N 101 581 06 .....> S/N 101 581 07 .....> S/N 101 581 08 .....> S/N 101 581 16 .....> S/N 101 581 17 .....>

Single drum roller

Catalogue number

008 168 81

05/2003

Foreword BOMAG machines are products from the wide range of BOMAG compaction equipment.

You should only operate the machine if you are fully familiar with the contents of these instructions.

BOMAG's vast experience, together with the most up-to-date production and testing methods, including service life tests of all important components and highest quality demands, guarantee maximum reliability of your machine.

You must also observe all applicable safety regulations.

F oreword

Please observe also the guidelines of the Civil Engineering Liability Association "Safety Regulations for the Operation of Road Rollers and Soil Compactors" and the applicable accident prevention instructions.

These instructions comprise: l

Safety regulations

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Operating instructions

l

Maintenance instructions

l

Trouble shooting

For your own safety you should only use BOMAG-spare parts.

We reserve the right for technical modifications without prior notification.

These operating and maintenance instructions are also available in other languages.

Using these instructions will l

help you to get to know the machine.

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avoid malfunctions caused by unexpert operation.

Compliance with the maintenance instructions will l

increase the reliability of your machine on the site,

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increase the service life of the machine,

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reduce repair costs and downtimes.

A spare part catalogue can be obtained from your BOMAG dealer when giving him the serial number of your machine.

Information about the correct use of our machines in earth work and for asphalt applications can be obtained from your BOMAG dealer.

The above points do not constitute an extension of the warranty and liability conditions specified in the general terms of business of BOMAG. We wish you much success with your BOMAG machines.

BOMAG shall not assume liability for safe functioning of the machine

BOMAG GmbH & Co. OHG Printed in Germany

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if it is handled in a way which does not comply with the usual modes of use,

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if it is used for purposes other than those mentioned in the instructions.

Copyright by BOMAG

No warranty claims can be lodged for damage resulting from l

operating errors,

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insufficient maintenance and

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wrong fuels and lubricants.

Please note!

This manual has been written for the operator and the service personnel at the site.

Keep this manual always close at hand, e.g. in the tool compartment of the machine or in the container provided.

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3

Foreword Please fill in ............................

Machine type (Fig. 1) ............................

Serial No. (Fig. 1 and 2) ............................

Engine type (Fig. 3) ............................

Engine No. (Fig. 3)

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Note

Fig. 1

Fill in the above listed data when receiving the machine.

Upon receipt of the machine our organization will instruct you about correct operation and maintenance.

Please observe strictly all safety regulations and notes on potential dangers!

Fig. 2

Fig. 3

4

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Table of Contents

Technical Data Safety regulations Indicators and Controls Operation

Maintenance

7 15 23

3.1 General notes 3.2 Description of indicators and control elements

24 24

4.1 General notes 4.2 Tests before starting to operate 4.3 Starting the engine 4.4 Starting with jump leads 4.5 Driving the machine 4.6 Emergency exit 4.7 Operating the parking brake, stopping the machine 4.8 Shutting the engine down 4.9 Switching the vibration on and off 4.10 Adjusting the steering wheel 4.11 Adjusting the seat 4.12 Operating the hood 4.13 Towing in case of an engine failure 4.14 Transport

36 36 37 39 40 42 42 43 44 45 46 46 47 49

5.1 General notes on maintenance 5.2 Fuels and lubricants 5.3 Table of fuels and lubricants 5.4 Running-in instructions 5.5 Maintenance chart 5.6 Checking the engine oil level 5.7 Checking, cleaning the water separator 5.8 Checking, cleaning the fuel filter water separator 5.9 Checking, cleaning the water separator 5.10 Checking the fuel level 5.11 Checking the coolant level 5.12 Checking the hydraulic oil level 5.13 Checking the V-belt 5.14 Checking the dust separator on the oil bath air filter 5.15 Cleaning the air conditioning condenser 5.16 Checking the tire pressure 5.17 Adjusting the scrapers 5.18 Changing engine oil and oil filter cartridge 5.19 Cleaning the cooling fins on engine and hydraulic oil cooler 5.20 Checking the oil level in the drive axle

52 53 56 57 58 60 60 61 61 62 63 63 64 64 65 66 66 68 70 71

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51

5

Table of Contents

Trouble shooting

6

5.21 5.22 5.23 5.24 5.25 5.26 5.27 5.28 5.29 5.30 5.31 5.32 5.33 5.34 5.35 5.36 5.37 5.38 5.39 5.40 5.41 5.42 5.43 5.44 5.45 5.46 5.47 5.48 5.49

Checking the oil level in the left/right hand planetary drives Checking the oil level in the vibration bearing Check the oil level in the drum drive gear Service the air conditioning Servicing the battery Draining the sludge from the fuel tank Changing the fuel filter cartridges Changing the fuel pre-filter cartridge Checking V-belt tension, idler pulley and blower hub Changing the oil in the drive axle Changing the oil in the planetary drive Changing the oil in the drum drive gear Changing the oil in the vibration bearing Checking the fastening elements on the engine Tightening the fastening of the axle on the frame Tightening the wheel nuts Checking the ROPS Cleaning the oil bath air filter Checking, adjusting the valve clearance Changing the hydraulic oil and the breather filter Changing the hydraulic oil filter Change the coolant Checking, cleaning, changing the combustion air filter Bleeding the fuel system Adjusting the parking brake Changing the tires Checking the fresh air filter for the cabin Tightening torques Engine conservation

6.1 General notes 6.2 Engine

71 72 72 73 76 77 77 79 80 82 83 84 85 86 86 87 87 88 89 91 92 93 95 98 99 100 101 101 102

103

104 105

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1 Technical Data

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Technical Data

Fig. 4

Dimensions in mm

A

B

D

H2

H

K

L

O1

O2

S

W

BW 177 D-3

2492

1816

1222

2835

2132

354

5182

65

65

22

1686

*

Weights Operating weight (CECE) with ROPS-cabin Front axle load (CECE) Rear axle load (CECE) Static linear load Travel characteristics Travel speed (1) Travel speed (2) Max. gradability with vibration Engine Engine manufacturer Type Cooling Number of cylinders Rated power SAE J 1995 Rated speed Fuel Electrical equipment

8

BW 177 D-3

kg

7320

kg kg kg/cm

3950 3370 23,4

km/h km/h %

0 ... 6 0 ... 10 45

kW 1 rpm V

BOMAG

Cummins 4 B 3.9 C Water 4 56 2200 Diesel 12

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Technical Data *

Drive system Driven axles

BW 177 D-3 hydrostatic 2

Brakes Service brake Parking brake

hydrostatic hydr.-mech.

Steering Type of steering Steering operation

articulated hydrostatic

Vibration Drive system Frequency Amplitude

Hz mm

hydrostatic 30/40 1,8/0,9

Tires Tire size Air pressure

bar

14.9-24, 6PR AWT 1,9

Litres Litres Litres Litres Litres

60 150 13 approx. 15 -

Tank contents Hydraulic oil Fuel Engine oil Coolant Water *

The right for technical modifications remains reserved

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Technical Data

Fig. 5

Dimensions in mm

A

B

D

H2

H

K

L

O1

O2

S

W

BW 177 DH-3

2492

1816

1228

2835

2132

354

4900

65

65

25

1686

BW 177 PDH-3 2492

1816

1208

2835

2132

354

4900

65

65

15

1686

*

Weights Operating weight (CECE) with ROPS-cabin Front axle load (CECE) Rear axle load (CECE) Static linear load Travel characteristics Travel speed (1) Travel speed (2) Travel speed (3) Max. gradability with vibration Engine Engine manufacturer Type Cooling Number of cylinders Rated power SAE J 1995 Rated speed

10

BW 177 DH-3

BW 177 PDH-3

kg

7450

7610

kg kg kg/cm

4080 3370 24,2

4240 3370 25,1

km/h km/h km/h %

0 ... 4 0 ... 6,5 0 ... 14 55

0 ... 4 0 ... 6,5 0 ... 14 55

kW 1 rpm

Cummins 4 BT 3.9 C Water 4 75 2200

Cummins 4 BT 3.9 C Water 4 75 2200

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Technical Data *

Fuel Electrical equipment Drive system Driven axles

V

Brakes Service brake Parking brake Steering Type of steering Steering operation Vibration Drive system Frequency Amplitude

Hz mm

Tires Tire size Air pressure Tank contents Hydraulic oil Fuel Engine oil Coolant *

BW 177 DH-3 Diesel 12 hydrostatic 2

BW 177 PDH-3 Diesel 12 hydrostatic 2

hydrostatic hydr.-mech.

hydrostatic hydr.-mech.

articulated hydrostatic

articulated hydrostatic

hydrostatic 30/40 1,8/0,9

hydrostatic 30/40 1,7/0,85

14.9-24, 6PR AWT bar

1,9

14.9-24, 6PR Dyna Torque 1,9

Litres Litres Litres Litres

60 150 13 approx. 15

60 150 13 approx. 15

The right for technical modifications remains reserved

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Technical Data

Fig. 6

Dimensions in mm

A

B

D

H2

H

K

L

O1

O2

S

W

BW 178 DH-3

2572

1816

1228

2835

2132

354

4965

65

65

25

1686

BW 178 PDH-3 2572

1816

1228

2835

2132

354

4965

65

65

15

1686

*

Weights Operating weight (CECE) with ROPS-cabin Front axle load (CECE) Rear axle load (CECE) Static linear load Travel characteristics Travel speed (1) Travel speed (2) Travel speed (3) Travel speed (4) Max. gradability with vibration

BW 178 DH-3

BW 178 PDH-3

kg

7970

8150

kg kg kg/cm

4230 3740 25,1

4410 3740 -

km/h km/h km/h km/ %

0 ... 4 0 ... 6 0 ... 14 55

0 ... 4 0 ... 6,5 0 ... 6,5 0 ... 6,5 55

Cummins 4 BT 3.9 C Water 4

Cummins 4 BT 3.9 C Water 4

Engine Engine manufacturer Type Cooling Number of cylinders

12

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Technical Data *

Rated power DIN ISO 9249 Rated speed Fuel Electrical equipment Drive system Driven axles

kW 1 rpm V

Brakes Service brake Parking brake Steering Type of steering Steering operation

BW 178 DH-3 75

BW 178 PDH-3 75

2200 Diesel 12 hydrostatic 2

2200 Diesel 12 hydrostatic 2

hydrostatic hydr.-mech.

hydrostatic hydr.-mech.

articulated hydrostatic

articulated hydrostatic

Vibration Drive system Frequency Amplitude

Hz mm

hydrostatic 30/40 1,8/0,9

hydrostatic 30/40 1,7/0,85

Tires Tire size Air pressure

bar

14.9-24, 6PR AWT 1,6

14.9-24, 6PR DY. TO. 1,6

Litres Litres Litres Litres

60 150 13 approx. 15

60 150 13 approx. 15

Tank contents Hydraulic oil Fuel Engine oil Coolant *

The right for technical modifications remains reserved

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Technical Data The following noise and vibration data acc. to - EC Machine Regulation edition (98/37/EC) and - Noise Emission Regulation 2000/14/EC were determined at nominal speed of the drive engine and with vibration running. The machine was standing on an elastic base.

During operation these values may vary because of the existing operating conditions.

Noise value The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is sound pressure level at the work place of the operator (with cabin): LpA

= BW 177 D-3 - 73,3 dB(A)

LpA

= BW 178 DH-3 - 72,5 dB(A)

The nose emission value for the machine according to the noise emission regulation 2000/14/EG is guaranteed sound capacity level of the machine: LwA

= BW 177 D-3 - 104,6 dB(A)

LwA

= BW 178 DH-3 - 89,2 dB(A)

These sound values were determined according to ISO 3744 for the sound capacity level (LWA) and ISO 11204 for sound pressure level (LpA) at the place of the operator.

Vibration value The vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are: Vibration of the entire boy (driver’s seat) The weighted effective acceleration value determined in accordance with ISO 7096 is γ ≤0.5 m/sec2.

Hand-arm vibration values The weighted effective acceleration value determined in accordance with EN 500/ISO 5349 , liegt bei γ ≤2.5 m/sec2.

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2 Safety regulations

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Safety regulations General

Unintended use

This BOMAG machine is built in accordance with the latest technical standard and the valid technical rules and regulations. There is, however, a risk of danger for persons and property if:

Dangers may, however, arise from the machine if it is used by untrained personnel in an unprofessional way or if it is used for purposes other than those mentioned in these instructions.

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the machine is used for purposes other than those it is intended for

Starting and operation of the machine in an explosive environment is prohibited.

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the machine is operated by untrained personnel

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the machine is modified or converted in an unprofessional way

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the applicable safety regulations are not observed.

Each person involved in operation, maintenance and repair of the machine must therefore read and apply these safety regulations.

This should be confirmed by obtaining the signatures of the customer, if necessary.

Furthermore the following regulations and instructions are obviously also valid: l

applicable accident prevention instructions

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generally acknowledged safety and road traffic regulations

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country 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: l

compaction of bituminous materials, e.g. road surface layers. (AC and AD machines only)

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medium and heavy compaction tasks in earth work (road sub-bases)

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This machine must only be operated with fully functional safety equipment.

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The machine should be checked by an expert once every year.

16

Do not work with vibration on hard concrete, on a cured concrete layer or heavily frozen ground.

Who is allowed to work with the machine?

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 complied with.

Persons under the influence of alcohol, medication 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 machine Unauthorized conversions to the machine are prohibited for safety reasons.

Original parts and accessories have been specially designed for this machine. We wish to make expressly clear that we have not tested or authorized any original parts or special equipment not supplied by us. The installation and/or use of such products can impair the active and/or passive driving 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 maintenance instructions: Danger Sections marked like this point out possible dangers for persons. !

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Safety regulations Caution Sections marked like this point out possible dangers for the machine or for parts of the machine. !

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Note

Sections marked like this provide technical information concerning the optimal economical use of the machine.

Towing the machine Since the machine is not fitted with a towing hitch, the machine cannot be towed with a tow bar.

If the machine has to be towed urgently out of the danger zone because of other risks, this must only be done on level ground or uphill using chains and ropes. For this purpose towing ropes of sufficient tensile strength must be fastened on the lifting eyes.

After releasing the brake the machine can only be braked by the towing vehicle.

Environment Sections marked like this highlight activities for the safe and environmental disposal of fuels and lubricants as well as replaced parts.

Before releasing the brake block the machine with chocks to prevent unintended rolling.

Checking the roll-over protection structure (ROPS)

Observe all environment protection regulations.

Information and safety stickers/decals on the machine Keep stickers/decals complete (see spare parts catalogue) and fully legible and observe their meaning.

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, damage, 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 torques). Screws and nuts must not be damaged, distorted or deformed.

Replace damaged or illegible stickers/decals immediately.

Loading the machine Use only strong and stable loading ramps. The ramp inclination must be lower than the gradability of the machine.

Secure the machine against turning over or slipping off.

No additional parts must be welded or bolted on and no holes must be drilled without the permission of the dealer, since this may impair the strength of the structure.

Starting the machine

Secure the machine on the transport vehicle against rolling off, slipping and turning over.

Before starting

Persons are highly endangered if l

they step or stand under loads being lifted

Operation of the machine is only permitted when sitting in the operator's seat.

l

they remain in the drive range of the machine during a demonstration or during loading.

Use only machines which have been properly serviced at regular intervals.

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.

Become acquainted with the equipment, the control elements, the working mode of the machine and the area you will be working in.

Use your personal protective outfit (hard hat, safety boots etc.).

Check before mounting the machine if: l

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there are persons or obstructions beside or under the machine

17

Safety regulations l

the machine is free of any oily and combustible material

l

all handrails, steps and platforms are free of grease, oils, fuels, dirt, snow and ice

l

Driving the machine Persons in the danger area If the machine should turn over and the cabin door is closed, the right hand side cabin window can be used as an emergency exit.

the engine compartment hood is closed and locked

Check if there are persons or obstacles in the danger area before starting or resuming work, especially when driving in reverse.

To climb onto the machine use steps and handrails.

Check before starting, whether: l

the machine shows any obvious defects

l

all protective devices are properly secured in their place

l

If necessary give warning signals. Stop work immediately, if persons remain in the danger area despite the warning.

Do not stand in the machine's articulation area while the engine is running. Danger of injury!

steering, brakes, control elements, lighting and warning horn are in order

Driving

l

the seat is correctly adjusted

l

the mirrors (if available) are clean and correctly adjusted.

Do not start the machine if any gauges, control lights or controls are defective.

In emergency situations and in case of danger operate the emergency stop switch immediately. Do not use the emergency stop switch as service brake.

Resume operation only after eliminating the danger that has led to the actuation of the emergency stop.

Do not take any loose objects with you or fasten them to the machine.

If the machine comes in contact with high voltage power lines:

On machines with ROPS you should always wear your seat belt!

l

do not leave the operator's stand

Starting

l

Start and operate the machine only from the operator's seat

warn others from coming close to the machine or touching it

l

For starting set all control levers to "neutral position".

if possible move the machine out of the danger zone

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have the power shut off

Do not use any starting aids such as Start Pilot or ether.

Operate the machine only from the operator's stand.

After starting check all gauges.

Keep the cabin doors closed.

Starting with jump leads

Do not adjust the operator's seat while driving.

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.

Do not climb onto or off the machine while it is driving.

Never start the engine by bridging the electrical connections on the starter, because the machine would probably start to move immediately.

Choose the travel direction only when the machine is standing.

Do not use the machine to transport persons.

Starting in closed rooms

If you recognize unusual noises and the development of smoke, detect the cause and have the fault corrected.

Exhaust gases are toxic! Always ensure an adequate supply of fresh air when starting in closed rooms!

Always keep a safe distance to excavations and embankments and avoid all activities which could impair the stability of the machine.

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Safety regulations Do not work with vibration on hard concrete, cured asphalt or hard frozen ground.

When driving under flyovers, bridges, tunnels, power lines etc. ensure sufficient distance.

Filling the fuel tank Do not inhale fuel fumes.

Refuel only after shutting the engine and the auxiliary heater down.

Driving on gradients and slopes

Do not refuel in closed rooms.

Do not drive on gradients which exceed the maximum gradability of the machine.

No open fire, do not smoke.

Always drive extremely carefully on slopes and always directly up or down the slope, never diagonally. Change to the lower speed range before approaching the inclination.

Wet and loose soils reduce the ground adhesion of the machine on gradients and slopes considerably. Higher risk of accidents!

Do not spill any fuel. Catch running out fuel, do not let it seep into the ground.

Wipe off spilled fuel. Keep fuel free of dirt and water.

Leaking fuel tanks can cause explosions. Ensure tight fit of the fuel tank filling cover, replace it if necessary.

Fire protection measures

Behaviour in traffic

Make yourself acquainted with the location and the operation of fire extinguishers. Observe fire warning and fire fighting installations.

Match your speed to the working conditions.

Always give way to loaded vehicles.

Switch the lights on if the visibility is poor.

Keep away from edges and embankments.

Maintenance work

Check the effect of vibration

Strictly apply the specified maintenance tasks, including the changing of parts.

When compacting with vibration check the effect on nearby buildings and underground supply lines (gas, water, sewage, power lines) and stop vibratory compaction if necessary.

Never use the vibration on hard (frozen, concrete) ground. Risk of bearing damage!

Park the machine on level and firm ground.

Do not perform maintenance work while the machine is driving or the engine is running.

Before leaving the machine: l

move the travel control lever to neutral position

l

apply the parking brake

l

shut the engine down and pull the ignition key out lock the cabin door

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secure the cabin against unauthorized use.

In case of maintenance and assembly work overhead make sure to use the prescribed or other safe access steps, ladders and gangways. Do not use parts of the machine as access steps.

Keep unauthorized persons away from the machine.

Parking the machine

l

Maintenance work must only be carried out by skilled and authorized personnel.

Park the machine on ground as level and firm as possible.

Pull the ignition key out.

Secure the articulated joint with the articulation lock.

Working on hydraulic lines

Parking on gradients or slopes

Depressurize hydraulic lines before working on them. Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury. Consult a doctor if you are injured by pressurized hydraulic oil as otherwise serious infections may result.

Secure the machine against rolling away, place metal chocks in front of and behind the drums.

When adjusting the hydraulic system do not stand behind the drums/wheels.

Do not jump off the machine, but use access steps and hand rails.

Mark parked machines, which could be an obstruction, by attaching clearly visible signs.

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Safety regulations Do not change the setting of high pressure relief valves.

Drain the hydraulic oil at operating temperature danger of scalding!

Drain the hydraulic oil at operating temperature danger of scalding!

Wipe off spilled oil, catch running out oil and dispose of environmentally.

Catch running out hydraulic oil and dispose of environmentally.

Store used filters and other oily materials in a specially marked refuse container and dispose of environmentally.

Always collect and dispose of biodegradable hydraulic oils separately.

Do not leave any tools or other parts, which could lead to damage, in the engine compartment.

Do not start the engine after draining the hydraulic oil.

Working in the electric system

Check all connections and fittings for leakages once all work is completed (with the lines still depressurized!).

Disconnect the battery and cover it with insulating material before starting to work in the electric system.

Changing of hydraulic hoses Hydraulic hoses must be examined visually at regular intervals.

Do not use fuses with higher Ampere ratings and do not repair fuses with a piece of wire. Fire hazard!

Hydraulic hoses must be changed immediately in case of:

Always disconnect the battery before starting to weld on the machine.

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l

l

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Working on the battery

damage to the outer surface down to the lining (e.g. chafings, cuts, cracks)

When working on the battery do not smoke, do not use open fire.

embrittlement of the outer surface (development of cracks in the hose material) deformation under pressurized and depressurized conditions, which are not in accordance with the natural shape of the hydraulic hose deformation in bends such as squeezed spots, extreme bends, layer separation, formation of blisters

Do not let hands or clothes come in contact with acid. Treat acid injuries with clear water and consult a doctor.

Metal objects (e.g. tools, rings, wrist watches) must not touch the battery poles - danger of short circuits and fire!

When recharging maintenance free batteries remove all plugs to avoid the accumulation of highly explosive gases.

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leakages

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non-observance of installation requirements.

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separation of the hydraulic hose from the crimped fitting

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corrosion of the crimped fitting, which impairs the function and the strength

Shut the charging current down before disconnecting charging clamps.

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do not mix up hoses by mistake

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damage or deformation of the fitting which effects the function and the strength or impairs the hose/hose connection.

Ensure an adequate supply of fresh air, especially if the battery is to be charged in a closed room.

Only the use of genuine BOMAG hoses ensures that the correct type of hose (pressure range) is used at the right place.

Working on the engine

Observe all relevant instructions when starting with an auxiliary battery.

Dispose of used batteries environmentally.

Working on the fuel system Do not inhale fuel fumes.

No open fire, do not smoke, do not spill any fuel.

Catch running out fuel, do not let it seep into the ground and dispose of environmentally.

Shut the engine down before opening the engine compartment hood.

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Safety regulations Working on wheels and tires Explosion-like bursting of tires and parts of tires and rims can cause most severe or even fatal injuries.

The assembly of tires must only be carried out by experienced personnel and with the correct equipment. If necessary have the tires assembled in a qualified workshop.

Always ensure correct tire pressure and do not exceed the max. permissible pressure.

Examine the tires every day for too low pressure, cuts, bulges, faulty rims, missing wheel studs or nuts. Do not drive with faulty tires or wheels.

Non-stick emulsion must only be mixed of water and non-stick additives according to the instructions of the non-stick agent manufacturer. Strictly observe the regulations for the protection of the environment.

Cleaning Do not clean the machine while the engine is running.

Do not use gasoline or other easily inflammable substances for cleaning purposes.

When using high pressure cleaning equipment do not subject electrical parts and insulating materials to the direct water jet or cover them beforehand. l

Do not guide the water jet into the exhaust or into the air filter.

After maintenance work Reinstall all protections and guards once all maintenance work is completed.

Repair Attach a warning tag to the steering wheel if the machine is defective.

Repairs must only be performed by qualified persons who have been instructed for this purpose.

Use our repair instructions.

Exhaust gases are highly dangerous! Always ensure an adequate supply of fresh air when starting in closed rooms!

Test Depending on the type of application and the operating conditions vibratory equipment has to be examined by a specialist whenever required, but at least once every year.

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Safety regulations

22

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3 Indicators and Controls

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Indicators and Controls 3.1

General notes

3.2

Description of indicators and control elements

Please read this section thoroughly before operating this machine if you are not yet conversant with the indicators and control elements. All functions are described in detail hereunder.

Paragraph 4 Operation contains only concise descriptions of the individual operating steps.

Fig. 7

No. 1 = Fuses in electric installation box F03, 15A = Vibration F05, 30A = Socket F06, 15A = Water sprinkler system* F07, 15A = Hazard light* F08, 15A = Indicator* F09, 15A = Parking tail light, left* F10, 15A = Parking tail light, right* F11, 15A = Head lights, StVZO* F13, 30A = Starting F14, 15A = Engine solenoid, warning horn F18, 15A = Working head lights, front* F19, 15A = Working head lights, front, left* F22, 15A = Working head lights, rear* F24, 15A = Monitoring, gauges F25, 15A = Solenoid valve brake/travel F37, 40A = Sprinkler system, pump* F38, 20A = Omegameter, Terrameter* F40, 25A = Cabin heating F51, 15A = Anti-Spin-Control ASC* !

Danger

Fire hazard!

Do not use fuses with higher ampere ratings and do bridge fuses. *

24

BOMAG

Optional equipment

BW 177/178 D/DH/PDH-3

Indicators and Controls

Fig. 8

Fig. 10

No. 2 = Operating hour meter

No. 4 = Push button for warning horn

counts the operating hours while the engine is running All service work must be carried out according to the reading of the operating hour meter.

Fig. 11

No. 5 = Rotary switch, vibration Position "middle" = vibration off Fig. 9

No. 3 = Fuel gauge

Position "left"

= low amplitude, high frequency

Position "right" = high amplitude, low frequency

shows the fuel level in the fuel tank.

BW 177/178 D/DH/PDH-3

BOMAG

25

Indicators and Controls

Fig. 12

Fig. 14

No. 6 = Rotary switch speed ranges (D and PD machines)

No. 8 = Rotary switch for speed ranges (DH and PDH machines with ASC**)

Position "turtle" = working speed

Position "turtle" = Working speed range on level ground or on inclinations steeper than 15%

Position "rabbit"

= transport speed

Position "rabbit, low" = Working speed range on level ground and on inclinations, with high working speed Position "rabbit, high" = Transport range, e.g. to drive to the work location, vibration not possible

Fig. 13

No. 7 = Rotary switch for speed ranges without ASC* Position "turtle" = Working speed range on level ground Position "Drum" = if the drum starts to slip Position "Wheels"

= if the wheels are slipping

Position "Rabbit" = Transport speed range, e.g. to drive to the work location

Fig. 15

No. 9 = RPM-meter for vibrator shaft*** shows the vibrator shaft speed when the vibration is switched on.

Scale value x 100 = revolutions per minute

*

26

Anti Slip Control

** Anti Slip Control *** Option

BOMAG

BW 177/178 D/DH/PDH-3

Indicators and Controls

Fig. 16

Fig. 17

No. 10 = Emergency stop switch

No. 11 = Rotary switch, lighting (StVZO) *

The engine will be shut down and the brake will close.

Position "left"

!

= light off

Position "middle" = fender lights on, with the ignition switch in position "I" or "P"

Danger

Position "right" = travel lights on, with ignition switch in position "I".

Danger of accident!

Operate only in emergency situations during operation, do not use as a service brake.

The machine should only be started again after the danger, that caused the actuation of the emergency stop switch, has been removed. operate

= push the button completely down, it will automatically lock in end position.

unlock

= turn the button clockwise and release it.

to drive

= move the travel lever first to braking position, then start the engine and choose the travel direction.

For safety reasons the travel system of the machine will only be enabled after the travel lever has been shifted back to braking position.

Fig. 18

No. 12 = Rotary switch working lights ** Position "left"

Position "right" = working lights on, with ignition switch in position "I".

* **

BW 177/178 D/DH/PDH-3

= light off

BOMAG

Option Option

27

Indicators and Controls The control and warning lights on the fault monitoring board flash: No. 1

i

= Air filter cartridge dirty. Clean, change the cartridge.

Note

If the air filter service indicator lights up work may still be continued until the end of the day.

No. 2

= engine oil pressure too low, the warning buzzer sound too and the engine shuts down after 10 seconds. Check the engine oil level, if necessary have the engine repaired.

No. 3

= hydraulic oil filter dirty, the warning buzzer will sound and the engine will be shut down after 2 minutes.

Change the filter element, check the hydraulic system if the indicator lights up too early.

No. 4

= battery not being charged, check the V-belt, have the generator repaired if necessary.

No. 5

= brake applied or travel lever in "neutral"-position with the engine running

No. 6

= direction indicators switched on

No. 7

= hazard light switched on

No. 8

= coolant temperature too high, the warning buzzer sounds too and the engine shuts down after 2 minutes.

Clean the radiator.

No. 9

= malfunction of the "ASC"** anti-spincontrol.

Fig. 19

No. 13 = Rotary switch for direction indicators left / right* Position "middle" = direction indicator off Position "left or right" = front and rear direction indicators on the respective side light up, the control light 6 in the fault monitoring board flashes

i Fig. 20

No. 14 = Fault monitoring board

i

Note

After switching the ignition on all lamps on the fault monitoring board light up for self-testing.

Note

Further trouble shooting via the flash code on the ASC control unit in the electric installation box.

Operation of the machine may be continued, but the service departtment should be informed.

No. 10

The display will also show functions, which are only preassembled as options but not really installed.

= Coolant too low, the warning buzzer will also sound and the engine will be shut down after 10 seconds.

Replace a defective fault monitoring board immediately. *

28

Option

**

BOMAG

Option

BW 177/178 D/DH/PDH-3

Indicators and Controls

Fig. 21

Fig. 23

No. 15 = Push button for vibration

No. 17 = Throttle lever

l

Pre-select or activate the frequency with the vibration selection switch

Position "I"

= full load position, operating position for driving and vibration

l

Press the switch to switch the vibration on and off.

Position "II"

= idling speed position

Caution Always drive and vibrate with max. engine speed! Use the travel lever the regulate the travel speed! !

No. 18 = Locking plate for throttle lever pull

= the throttle lever can be moved to position "II"

release

= the throttle lever locks in position "I".

Fig. 22

No. 16 = Travel lever Position "middle" = brake position for service brake Position "middle, right" = parking brake, to start the engine Position "I"

= forward travel

Position "II"

= reverse travel

Fig. 24

No. 19 = Ignition switch

i

Note

If the engine speed is forced down when driving up steep inclines, move the travel lever slightly back.

This reduces the load on hydraulic system and diesel engine.

BW 177/178 D/DH/PDH-3

Position "P"/"0" = ignition off, the key can be pulled out, engine not running.

Position "I"

BOMAG

= ignition on, all control and warning lights on the fault monitoring board light up for a

29

Indicators and Controls moment. The lighting can be switched on.

i

Note

The engine can only be started when the travel lever is in braking position.

The ignition switch is provided with a lock against repetitive starting. To repeat the starting procedure you must first turn the ignition switch back to "0"-position.

Position "II"

= turn further against spring pressure, the engine starts, return the ignition key to position "I" when the engine starts

Caution Run the engine warm for a short while before starting to work. Do not let the engine run at idling speed for longer than 10 minutes. !

Do not shut the engine down all of a sudden from full speed, but let it idle for a while for temperature equalization.

Fig. 26

No. 21 = Rotary switch for hazard light system** Position "left"

= hazard light switched off, the control lights go out.

Position "right" = hazard light switched on, control light 7 on fault monitoring board lights up.

Fig. 27

No. 22 = Tachometer*** shows the travel speed of the machine.

Fig. 25

No. 20 = Shut-off valve for cabin

i

heater*

black scale

= km/h

red scale

= M.P.H.

Note

The heat exchanger of the cabin heater receives the heat energy from the engine coolant circuit.

Position "I"

= cabin heater off

Position "II"

= cabin heater full power

*

30

Option

** Option *** Option

BOMAG

BW 177/178 D/DH/PDH-3

Indicators and Controls

Fig. 28

Fig. 30

No. 23 = Rpm-meter for diesel

engine*

shows the speed of the diesel engine.

No. 25 = Pedal for dozer blade (BW 177 PDH-3) Position "0"

= Stop position. Dozer blade at rest

Position "I"

= Dozer blade up

Position "II"

= Dozer blade down

Position "II"

= Float position to level loose soil when driving in reverse

Scale value x 100 = revolutions per minute

Danger

!

Danger of squashing!

Do not work under the lifted, unsupported dozer blade, support the blade if necessary.

Fig. 29

No. 24 = Main fuse for battery 125A

i

=

(F00)

Note

The main fuse is located in the battery compartment

Fig. 31

No. 26 = Fuse box, cabin**

*

Option

BW 177/178 D/DH/PDH-3

(a) -

= not used

(b) 7.5A

= Inside light

(c) 7.5A

= Windscreen wiper/washer, rear

**

BOMAG

Optional equipment

31

Indicators and Controls (d) 7.5A

= Windscreen wiper/washer, front

(e) 7.5A

= Flashing beacon

(f) 7.5A

= Heating blower, radio

!

Danger

Fire hazard!

Do not use fuses with higher ampere ratings and do not bridge fuses.

Fig. 33

No. 28 = Inside light switch on

= turn lamp glass clockwise

switch off

= turn lamp glass anti-clockwise

Fig. 32

No. 27 = Switches in cabin* (a)

= Toggle switch windscreen wiper/ washer, rear = 1. step wiping = 2. step washing = Toggle switch. windscreen wiper/ washer, front

Fig. 34

= 1. step wiping

Loosen the adjustment knob to operate the slide.

= 2. step washing

Slide to the left = Circulation air position

(c)

= Toggle switch for heating blower

(d)

= Toggle switch for flashing beacon

Slide to the right

(b)

No. 29 = Fresh air intake slide

= Fresh air position

Switch the heating blower on as well

*

32

Optional equipment

BOMAG

BW 177/178 D/DH/PDH-3

Indicators and Controls maximum fan speed, turn the slewable air discharge nozzles to the desired direction. Once the inside of the cabin has cooled down adjust fan and thermostat to the desired temperature.

i

Note

If the cabin has extremely heated up set the thermostat to max. cooling, turn the rotary switch for "Fan" to the highest blowing range, open the cabin window and close it again after a few minutes.

Then adjust the air conditioning to the desired temperature.

Fig. 35

No. 30 = Rotary switch for fan* Position "0"

= Fan off

Position "1"

= minimum fan range

Position "2"

= medium fan range

If no cooling can be noticed when the air conditioning is running, turn both thermostats and the rotary switch for "Fan" to "0". Perform trouble shooting.

Position "3"

= maximum fan range

switch off

i

= Turn rotary switch "Fan" and both thermostats to "0".

Note

If, during operation of the air conditioning system the warning buzzer sounds with a continuous tone switch the air conditioning off and clean the condenser.

Fig. 36

No. 31 = Rotary switch, air conditioning thermostat (air blowing temperature)** Position "0"

= Air conditioning switched off

turn clockwise = Air conditioning switched on, air blowing temperature becomes cooler.

Fig. 37

No. 32 = Omega-meter*** Caution Always keep the cabin door closed when the air conditioning system is in operation. !

switch on

* **

a compaction measuring instrument, which continually shows the load bearing values during the compaction pass.

= Start the engine, set the thermostat to max. cooling power, turn the rotary switch "fan" to

Optional equipment Optional equipment

BW 177/178 D/DH/PDH-3

Omega value increase

= higher load bearing capacity

*** Option

BOMAG

33

Indicators and Controls constant

= end of compaction

1 digit

= 20 Omega values

34

BOMAG

BW 177/178 D/DH/PDH-3

4 Operation

BW 177/178 D/DH/PDH-3

BOMAG

35

Operation 4.1

General notes

Please read section 3 Indicators and Control Elements thoroughly before operating the machine if you are not yet fully familiar with the indicators and control elements of the machine.

4.2

Tests before starting to operate

The following tests must be performed before each work day or before a longer work period.

All indicators and control elements are described in detail in this chapter.

!

Danger

Danger of accident!

Please observe strictly the safety regulations in chapter 2 of these operating and maintenance instructions!

Park the machine on level ground.

l

Check: l

Fuel tank and fuel lines for leaks

l

Bolted connections for tight fit

l

Function of the steering

l

Check the machine for cleanliness and damage

l

availability of the appropriate operating and maintenance instructions,

l

check if the machine has been properly serviced.

i

Note

For a description of the following work refer to the section "maintenance every 10 operating hours" engine oil level

l

i

Note

Hydraulic systems, which are filled with Panolin HLP Synth. 46, the same oil must be used for filling up. In case of any other ester based oil consult the lubrication service department of the respective oil manufacturer. l

Check the hydraulic oil level, top up if necessary.

l

Check the coolant level, top up if necessary.

!

Danger

Fire hazard!

Do not refuel in closed rooms l

36

BOMAG

Check the fuel level, top up if necessary.

BW 177/178 D/DH/PDH-3

Operation l

Check water separator in the fuel system, drain if necessary.

l

Adjust the scrapers if necessary

l

Tire pressure. Pressure see technical data.

4.3 !

Starting the engine

Danger

Danger of accident!

Caution Ensure equal pressure in both tires. !

Always wear your seat belt.

Fig. 38 l

Wear your seat belt (Fig. 38).

Fig. 39 l

BW 177/178 D/DH/PDH-3

BOMAG

Check, whether the travel lever (Fig. 39) is locked to the right in braking position.

37

Operation

Fig. 40 l

Turn the rotary vibration selector switch (Fig. 40) to position "0", vibration off.

Fig. 43

Turn the ignition switch (Fig. 43) to position "I".

l

Fig. 44 Fig. 41 l

Check, whether the emergency stop switch (Fig. 41) has been unlocked.

All control and warning lights (Fig. 44) on the fault monitoring board light for a short moment.

The charge control light (4), the engine oil pressure warning light (2) and the brake warning light (5) light up.

Caution Do not start for longer than 20 seconds at once, but interrupt the starting procedure for one minute. !

If the engine has not started after 2 tries, detect the cause.

Fig. 42 l

38

Shift the throttle lever (Fig. 42) to approx. 1/2 full speed position and hold it.

BOMAG

BW 177/178 D/DH/PDH-3

Operation 4.4

Starting with jump leads

!

Caution Wrong connection will cause severe damage to the electrical system.

Fig. 45 l

Turn the ignition switch to position "II", the starter will crank the engine.

l

As soon as the engine ignites release the ignition key to position "I" return.

l

Once the engine runs properly, reduce the engine speed.

Fig. 46

Caution Run the engine warm for a short while, do not run at idling speed for more than 10 minutes. !

BW 177/178 D/DH/PDH-3

l

When starting with an external battery connect both plus poles (Fig. 46) first and both minus poles (earth cable) after.

l

Perform the work steps described in the previous paragrapf.

l

After starting disconnect the minus poles (earth cable) first and the plus poles after.

BOMAG

39

Operation 4.5 !

Driving the machine

Danger

Danger of accident!

Wet and loose soils considerably reduce the ground adhesion of the machine on inclinations and slopes.

Soil conditions and weather influences impair the gradability of the machine.

Do not drive up and down inclinations exceeding the maximum gradability of the machine (see technical data).

Fig. 48 l

Do not drive without wearing your seat belt.

Pre-select the desired travel speed range (Fig. 48) (D and PD machines).

Always give way to loaded transport vehicles!

Before starting to drive make sure that the drive range is absolutely safe. !

Caution Always keep the cabin door closed while driving with the machine. With the door opened and the machine fully articulated extreme oscillations of the machine may damage the door.

Fig. 49 l

Pre-select the desired travel speed range (Fig. 49) (D and PD machines).

Fig. 47

Close the cabin door (Fig. 47).

l

Caution Pre-select the travel speed range at standstill. !

Fig. 50 l

40

BOMAG

Pre-select the desired travel speed range (Fig. 50) (DH and PDH machines with ASC).

BW 177/178 D/DH/PDH-3

Operation Important notes on travel operation Caution When changing the travel direction hold the travel lever for a moment in "0"-position, until the machine has stopped, before actuating to the new travel direction. !

Do not operate jerkily!

Do not use the throttle lever to control the travel speed! Control the travel speed with the travel lever. During operation the throttle lever must remain in full load position.

Fig. 51

When driving up and down inclinations move the travel lever slowly back towards neutral to brake the machine.

Shift the throttle lever to position "I" (Fig. 51) full load lock it.

l

If the engine speed drops when driving up extreme inclinations move the ravel lever slightly back, if necessary change to the lower speed range.

Always use the lowest speed range (turtle) to drive up and down inclinations.

Fig. 52

Push the travel lever (Fig. 52) to the left out of braking position and move it slowly to the desired travel direction.

l

i

Note

Shift the travel lever out of "0"-position slowly to forward or reverse, the machine will drive forward or reverse at a speed which corresponds with the displacement of the travel lever.

Returning the travel lever towards neutral will brake the machine and in "0"-position of the travel lever the machine will stop. !

Danger

Danger of accident!

On inclinations and slopes pull the travel lever to the right and lock it in braking position.

BW 177/178 D/DH/PDH-3

BOMAG

41

Operation 4.6

Emergency exit

4.7

If the machine should turn over and the cabin door is closed, the right hand side cabin window can be used as an emergency exit.

Operating the parking brake, stopping the machine

Fig. 53

Move the travel lever (Fig. 53) slowly to "neutral"-position and lock it to the right in braking position.

l

The hydrostatic drive decelerates the machine automatically, the parking brake closes after approx.

2 seconds.

i

Note

The parking brake will also close automatically when shutting the engine down.

42

BOMAG

BW 177/178 D/DH/PDH-3

Operation 4.8

Shutting the engine down

!

Caution Straighten the articulated joint to allow easy access from and to the cabin.

Fig. 56

Turn the ignition switch (Fig. 56) to position "0" or "P" and pull the ignition key out.

l

i Fig. 54

Move the travel lever (Fig. 54) slowly to "neutral"-position and lock it to the right in braking position.

l

Note

After shutting the engine down with the throttle lever the "general warning light" will light and the warning buzzer will sound, until the ignition switch has been turned to "0"-position. The parking brake closes automatically after shutting the engine down.

Danger Danger of accident! !

On extremely steep gradients place suitable chocks in front of or behind the drum and the wheels.

Secure the machine properly against unauthorized use, pull the ignition key out, lock the cabin door.

Fig. 55

Pull the locking plate 19 (Fig. 55) up and set the throttle lever (18) to position "II" (idling speed).

l

i

Note

Do not shut the engine suddenly down from full speed, but let it idle for a while for temperature equalization.

BW 177/178 D/DH/PDH-3

BOMAG

43

Operation 4.9

!

Switching the vibration on and off

Selecting the vibration

Danger

Risk of damage!

When compacting with vibration check the effect of the vibration on nearby buildings and underground supply lines (gas, water, sewage, electricity), stop vibratory compaction if necessary.

Do not use the vibration on hard (frozen, concrete) ground. Risk of bearing damage!

Fig. 58

Caution When working on asphalt

Choose the amplitude/frequency with the rotary switch (Fig. 58).

l

!

Vibration at standstill creates transverse dents in the asphalt, therefore: l

only switch the vibration on after shifting the travel lever to the desired direction.

l

Switch the vibration off before stopping the machine.

Switching the vibration on

Fig. 59

Set the throttle lever (Fig. 59) to full speed position "I".

l

!

Fig. 57 l

44

Switch to the working speed range (Fig. 57) (turtle or rabbit, small) (DH and PDH machines with ASC).

Caution

Only switch the vibration on when the engine is running at full speed.

BOMAG

BW 177/178 D/DH/PDH-3

Operation 4.10 Adjusting the steering wheel*

Fig. 60 l

Actuate the push button (Fig. 60) in the travel lever during operation, the drum will vibrate.

Switching the vibration off l

Fig. 61

Actuate the push button again and turn the rotary vibration switch back to "0"-position after work.

l

To adjust the height of the steering wheel pull the lever (Fig. 61) up and adjust the steering wheel to the desired height.

l

To adjust the inclination of the steering wheel press the lever down and adjust the inclination of the steering wheel. !

Danger

Danger of accident!

After adjusting the steering wheel make sure that it is properly locked.

*

BW 177/178 D/DH/PDH-3

BOMAG

Option

45

Operation 4.11 Adjusting the seat

4.12 Operating the hood !

Danger

Danger of accident!

If the hood needs to be opened further for maintenance or repair work, support it safely.

Fig. 62 l

To adjust the seat in longitudinal direction disengage the lever a (Fig. 62) and slide the seat forward or back.

l

To adjust the weight turn the lever (b) and read the weight in the sight glass (c).

l

To adjust the inclination of the back rest operate lever (d) and tilt the backrest forward or back.

Fig. 64 l

Unlock the lock 1 (Fig. 64).

l

To unlock the hood press the latch (2) down and pull the handle (3) back.

Fig. 63 l

To adjust the height of the seat lift the seat up (Fig. 63) and engage it in the disired position.

Fig. 65 l

When lifting the seat completely up it will sink down to lowest position.

46

BOMAG

Pull the support (Fig. 65) out of the bracket in the hood and hook it at the bottom into the frame or at the top into the traverse.

BW 177/178 D/DH/PDH-3

Operation 4.13 Towing in case of an engine failure All machines Danger Mortal danger! !

Since the machine is not fitted with a towing hitch, the machine cannot be towed with a tow bar.

If the machine has to be towed urgently out of the danger zone because of other risks, this must only be done on level ground or uphill using chains and ropes.

For this purpose towing ropes of sufficient tensile strength must be fastened on the lifting eyes.

Fig. 67 l

Slacken counter nuts 1 (Fig. 67) and back off approx. 8 mm.

l

Turn the brake releasing screws (2) completely in against the stop.

After releasing the brake the machine can only be braked by the towing vehicle.

Caution From this stop turn the screw in for maximum another turn to release the brake!

Before releasing the brake block the machine with chocks to prevent unintended rolling.

Turn the screws in evenly on both sides.

l

Secure the machine with wheel chocks against unintentional rolling.

l

Attach the towing ropes safely to the front or rear lifting eyes.

!

l

Turn the screws in alternately for Âź turn at a time.

l

Repeat this measure on the opposite wheel side.

D and PD machines

Fig. 66

Slacken the middle hexagon on both valves (Fig. 66) for approx. 2 to 3 turns.

l

Fig. 68 l

Remove plug 1(Fig. 68).

Caution Do not turn the valves out completely. !

BW 177/178 D/DH/PDH-3

BOMAG

47

Operation l

Place an U-section (5) across the brake housing (2) and turn the screw (4) into the tapped bore (3), until it bottoms.

l

Turn the nut (6) down and tighten it approx. one revolution. The drum must rotate freely.

Additionally on DH and PDH machines

Fig. 70

Turn the brake releasing screws (Fig. 70) back in again, until they abut against the brake piston.

l

Fig. 69 l

Loosen clamp 1 (Fig. 69).

l

Press the emergency control button (2) in and turn it clockwise against the end stop.

i

Note

The pump lever extension is stored in the tool box in the cabin. l

Insert the pump lever extension (3) and operate the pump, until the brake is released.

After towing !

Caution Before loosening ropes or chains block the machine with chocks to prevent unintended rolling.

l

Turn the high pressure relief valve cartridges tightly back in.

l

Turn all brake releasing screws of the axle evenly back out, until they are light moving again.

Fig. 71 l

Unscrew the brake releasing screws (Fig. 71) for two turns and tighten the counter nuts.

l

Repeat this adjustment procedure on the opposite wheel side.

i

If necessary replace the seal ring under the counter nut if it is leaking.

For this purpose completely unscrew the brake releasing screw, replace the seal ring and lubricate the screw with silicone grease.

Reinstall the screw with a new seal ring and adjust the protrusion as described above. l

48

Note

BOMAG

Unlock the emergency control button and lock it with the clamp. (only DH and PDH machines).

BW 177/178 D/DH/PDH-3

Operation 4.14 Transport !

Danger

Danger of accident!

Use only strong and stable loading ramps.

Make sure that no persons are endangered if the machine should turn over or slip off.

Lash the machine down so that it is properly secured against rolling off, slipping and turning over.

Do not step or stand under loads being lifted.

Always use shackles on the lashing points to load, lash or lift the machine.

Fig. 73 l

Lash the machine to the transport vehicle (Fig. 73), fasten the lashing gear at the four lifting hooks on front and rear frame.

l

Support the front frame to avoid overstretching of the rubber buffers.

Fig. 72 l

Attach the articulation lock (Fig. 72).

Fig. 74 l

To lift the machine attach the lifting gear to the four lifting eyes (Fig. 74).

Weights: see technical data. l

BW 177/178 D/DH/PDH-3

BOMAG

After the transport remove the articulation lock and fasten it in its receptacle.

49

Operation

50

BOMAG

BW 177/178 D/DH/PDH-3

5 Maintenance

BW 177/178 D/DH/PDH-3

BOMAG

51

Maintenance l

Do not let the suction hose disturb the sludge on the bottom of the drum.

l

Do not draw off fuel from near the bottom of the fuel drum.

When servicing the machine pay careful attention to all applicable safety instructions.

l

Thorough maintenance of the machine ensures maximum reliability and prolongs the service life of importants components. The work involved is small when compared with the problems which may arise if these instructions are not observed.

Fuel left in the fuel drum is not suitable for the engine and should only be used for cleaning purposes.

Notes on the engine performance

5.1

General notes on maintenance

The terms left/right are always related to travel direction forward. l

Clean machine and engine thoroughly before starting maintenance work.

l

For maintenance work park the machine on level ground.

l

Maintenance work must generally be carried out with the engine shut down.

l

Depressurize hydraulic lines before working on them.

Combustion air and fuel injection rates of the diesel engine have been carefully adjusted and determine the engine's performance and temperature level as well as the quality of the exhaust gas.

If your machine has to operate permanently in "thin air" (at high altitudes) and with full power, you should consult the after sales service of BOMAG or the service department of the engine manufacturer.

Notes on the hydraulic system

l

Disconnect the battery and cover it with insulation material before starting to work on electrical components.

l

Always attach the articulation lock (transport lock) before starting to work in the articulation area of the machine.

Environment During maintenance catch all running oil, coolant and fuel and do not let it seep into the ground or into the sewage system. Catch oils, coolant and fuel and dispose of environmentally.

Notes on the fuel system

Cleanliness is of utmost importance when servicing the hydraulic system. Make sure that no dirt or other contaminating substances fall into the system. Small particles can flute valves, cause pumps to seize and block restrictors and pilot bores, thereby causing costly repairs. l

If during the daily oil level check the oil level is found to have dropped, check all lines, hoses and components for leakages.

l

Seal external leakages immediately. If necessary inform the responsible service station.

l

Do not store hydraulic oil drums outdoors or at least under a cover. Water may penetrate through the bunghole when the weather changes.

l

Always use the filtering and filling unit (BOMAG part-no. 007 610 01) to fill the hydraulic system. This unit is fitted with a fine filter, which cleans the hydraulic oil and prolongs the service life of the filter.

l

Clean fittings, filler caps and their immediate surrounding area before removing them, so that no dirt can fall in.

l

Do not leave the tank opening unnecessarily open, cover it so that no dirt can fall in.

The lifetime of the diesel engine depends decisively on the cleanliness of the fuel. l

l

l

52

Keep the engine free of dirt and water as this could damage the injection elements of the engine.

Zinc lined drums are not suitable for storing fuel.

The fuel drum should rest for a longer period of time before drawing off fuel.

BOMAG

BW 177/178 D/DH/PDH-3

Maintenance Notes on the cooling system On high performance diesel engines the preparation and control of the coolant is of special importance, since the non-observance may cause engine damage as a result of corrosion, cavitation or freezing.

The coolant is prepared by mixing the cooling water with a cooling system protection agent (ethylene glycol / propylene glycol).

Mixing of cooling system protection additives to the cooling water is necessary in all climatic zones. It prevents corrosion, lowers the freezing point and raises the boiling point of the coolant.

5.2

Fuels and lubricants

Engine oil The use of high quality brand HD-oils in connection with the specified filter and oil change intervals prolongs the lifetime of the engine and increases its performance.

Do not use any running-in oil for new or overhauled engines.

Oil viscosity It is recommended by CUMMINS to use preferably oils of the viscosity class SAE 15W-40.

To ensure perfect cold starting it is important to choose the viscosity (SAE grade) of the engine oil with respect to the ambient temperature.

Fig. 75

Although cold starting abilities may be impaired if the temperature occasionally drops below the limit (e.g. use of SAE 15W/40 down to -15°C), this will not cause any damage to the engine.

Having to change the lubrication oil due to changes in temperature can be avoided by using multigrade oils. The oil change intervals given below are also valid for multigrade oils.

Oil quality Lubrication oils are differentiated according to their performance and quality class. The commonly used specifications are those according to API (American Petroleum Institute) and CCMC (Committee of Common Market Automobile Constructors).

BW 177/178 D/DH/PDH-3

BOMAG

53

Maintenance disturbing separations can also be expected with winter diesel fuel.

Permitted API-oils API

= CE/SG

Permitted CCMC-oils

Hydraulic oil

CCMC

The hydraulic system is operated with hydraulic oil HV 46 (ISO) with a kinematic viscosity of 46 mm2/ s at 40°C (104°F). For topping up or changing the hydraulic oil use only quality hydraulic oil of type HVLP according to DIN 51524, part 3, or hydraulic oils type HV according to ISO 6743/3. The viscosity index (VI) should be at least 150 (refer to the specifications of the manufacturer).

= D4

If oil of quality class CE/SG is not available, oils of the quality class CC/CD or CD/SF may also be used, if the oil change intervals are halved.

Lubrication oil change intervals The longest period of time that lubrication oil should remain in the engine is 6 months. If the oil change intervals specified below are not reached during 6 months, the lubrication oil must be changed at least once every 6 months, irrespective of the operating hours.

Biodegradable hydraulic oil On request the hydraulic system may also be filled with synthetic ester based biodegradable hydraulic oil (Panolin HLP Synth. 46). This quickly biologically degradable hydraulic oil is in accordance with a mineral oil based hydraulic oil acc. to DIN 51524.

API: CE/ SG = 250 operating hours CCMC/ D4 = 250 operating hours

Systems filled with Panolin HLP Synth. 46, the same oil must be used for filling up. When changing from a mineral oil based hydraulic oil to a ester based biodegradable hydraulic oil consult the lubrication oil service department of the oil manufacturer.

API: CC/ CD resp.

CD/SF = 125 operating hours

Fuels

Check the filter more frequently after changing to the new oil.

Quality Use only commercially available brand diesel fuel with a low sulphur contents.

Oil for drive axle

Ensure strict cleanliness when filling in fuel. Under low ambient temperatures use only winter diesel fuel. Always top the fuel tank up in due time to make sure that the fuel tank does not run dry, as otherwise filter and injection lines must be bled.

For the axle use only multi-purpose gear oil of APIClass GL5 SL of viscosity class SAE 90.

The additives in this oil ensure low wear lubrication under all operating conditions.

The following fuel specifications are permitted: DIN/EN 590; DIN 51 601; Nato Codes: F-54, F-75; BS 2869: A1 and A2; ASTM D 975-78: 1-D and 2D.

Lubrication grease Use an EP-high pressure grease, lithium saponified (penetration 2), for lubrication purposes.

Winter fuel

Coolant

Danger Danger of explosion!

Anti-feeze agents must be used under any climatic conditions as a protection against freezing, corrosion and boiling.

!

Do not mix diesel fuel with gasoline or alcohol.

During winter use only winter diesel fuel to avoid clogging caused by paraffin separation.

Under extremely low ambient temperatures

54

Caution Do not mix different coolants and additives. !

BOMAG

BW 177/178 D/DH/PDH-3

Maintenance If cooling system protection additives are not available in tropical countries, it is also possible to use a corrosion protection agent (CUMMINS Liquid DCA).

Do not add more than 50% cooling system protection agent, unless a lower anti-freeze protection is required, but an anti-freeze agent proportion of 68% should under no circumstances be exceeded. The anti-freeze protection effect drops at too high concentrations.

Use only soft tap water (drinking water) for the coolant mixture.

The water must not contain more than 300 ppm hardening agents or 100 ppm sulphate or chloride.

The cooling system must be continuously monitored. This applies for the coolant level as well as for the concentration of the cooling system protection agent.

The concentration of cooling system protection agent must be checked with a refractometer (Fleetguard Part No. CC2800). Other measuring instruments are not suitable for high performance diesel engines.

The coolant must be changed every two years.

Environment Cooling system protection agents must be disposed of environmentally.

Specification for cooling system protection agents ASTM4958 (GM6038M) Anti-freeze agent concentrations Ethylene Glycol 40 %

=

-23 °C (-10 °F)

50 %

=

-34 °C (-34 °F)

60 %

=

-54 °C (-65 °F)

68 %

=

-71 °C (-90 °F)

Propylene Glycol 40 %

=

-21 °C (-6 °F)

50 %

=

-33 °C (-27 °F)

60 %

=

-49 °C (-56 °F)

68 %

=

-63 °C (-82 °F)

BW 177/178 D/DH/PDH-3

BOMAG

55

Maintenance 5.3

Table of fuels and lubricants

Assembly

Fuel or lubricant Summer

Winter

Quantity approx.

Attention Observe the level marks

Engine

Engine oil CCMC-D4 or API: CE/SG

without oil filter change approx. 13 litres

SAE 15W/40 (-20 °C to +40 °C) Fuel Diesel Hydraulic system

Winter diesel fuel

Hydraulic oil (ISO), HV46, kinem. viscosity

approx. 125 litres approx. 60 litres

46 mm2/s at 40 °C Vibration bearings

Engine oil SAE 15W/40

BW 177/178 approx. 3,2 litres

Drive axle

Gear oil SAE 90, API GL5

approx. 6,7 litres

Planetary gear, axle

Gear oil SAE 90, API GL5

approx. 0,7 litre per side

Drum drive gear

Gear oil SAE 90, API GL5

approx. 2,5 litres, DH and PDH machines

Cooling system

Coolant

Air conditioning system Tires

Refrigerant R134A Water Calcium chloride (CaCl2) or magnesium chloride (MgCl2)

56

BOMAG

approx. 15 litres approx. 1300g approx. 120 litres approx. 63 kg (only BW 178)

BW 177/178 D/DH/PDH-3

Maintenance 5.4

Running-in instructions

When taking new machines into operation or when starting up overhauled engines, the following maintenance work must be carried out: !

Caution Up to approx. 250 operating hours check the engine oil level twice every day.

Depending on the engine load the oil consumption will drop to its normal level after approx. 100 to 250 operating hours.

After 50 operating hours l

Tighten all screw connections on intake and exhaust manifold, oil sump and engine mounts.

l

Tighten the screw connections on the machine.

l

Tighten the fastening screws for the wheels with the specified torque.

l

Change the oil in the drive axle.

l

Change the oil in the planetary drive.

l

Change the oil in the drum drive transmission

After 500 operating hours l

Change the oil in the vibration bearing

l

Change the oil in the drum drive transmission (DH and PDH machines)

After 1000 operating hours l

BW 177/178 D/DH/PDH-3

BOMAG

Check the valve clearance, adjust if necessary.

57

Maintenance 5.5

Maintenance chart

With all maintenance intervals perform also the work for shorter preceding service intervals.

No.

Designation

Note

Every 10 operating hours 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14

Check the engine oil level Checking, cleaning the water separator Checking the fuel filter water separator Check the water separator Check the fuel level Check the coolant level Check the hydraulic oil level Checking the V-belt

Dipstick mark Aspirating engines

Check the dust separator on the oil bath air filter

5.15

Clean the air conditioning condenser

Turbo charged engines

Inspection glass

Every 50 operating hours 5.16 5.17

Check the tire pressure Adjust the scrapers

see technical data

Every 250 operating hours 5.18 5.19 5.20 5.21 5.22 5.23 5.24

Changing engine oil and oil filter cartridge Clean the cooling fins on engine and hydraulic oil cooler Check the oil level in the drive axle Check the oil level in the planetary gears Check the oil level in the vibration bearings Check the oil level in the drum drive gear Service the air conditioning

min. 1x per year

DH and PDH machines

Every 500 operating hours 5.25 5.26 5.27 5.28 5.29

58

Servicing the battery Drain the sludge from the fuel tank Change the fuel filter cartridge Changing the fuel pre-filter cartridge Checking V-belt tension, idler pulley and fan hub

BOMAG

distilled water, pole grease

Turbo charged engines

BW 177/178 D/DH/PDH-3

Maintenance No.

Designation

Note

Every 1000 operating hours 5.30 5.31 5.32 5.33 5.34 5.35 5.36 5.37 5.38

Change the oil in the drive axle Change the oil in the planetary gears Changing the oil in the drum drive gear Change the oil in the vibration bearings Check the engine mounts Check the fastening of the axle on the frame Tighten the wheel nuts Check the ROPS Clean the oil bath air filter

min. 1x per year min. 1x per year DH and PDH machines, at least 1x per year min. 1x per year

Every 2000 operating hours 5.39

Check, adjust the valve clearance

5.40 5.41 5.42

Changing hydraulic oil and breather filter* Changing the hydraulic oil filter* Change the coolant

Intake = 0,25 mm (0,010 IN), exhaust = 0,5 mm (0.020 IN, with cold engine) at least every 2 years at least every 2 years at least every 2 years

As required 5.43

Cleaning, changing the combustion air filter

5.44 5.45 5.46 5.47 5.48 5.49

Bleed the fuel system Adjust the parking brake Change the tires Chang the fresh air filter in the cabin Tightening torques Engine conservation

min. 1x every year, safety cartridge at least every 2 years

* Also in case of repairs in the hydraulic system.

BW 177/178 D/DH/PDH-3

BOMAG

59

Every 10 operating hours Every 10 oper ating hours

5.6

i

Checking the engine oil level

5.7

i

Note

The machine must stand on level ground. Shut the engine down and wait for approx. 15 minutes until all oil has run back into the oil sump.

Checking, cleaning the water separator

Note

The service intervals for the water separator depend on the water content in the fuel and can therefore not be determined precisely. After taking the engine into operation you should therefore check the water separator every day for signs of water.

After cleaning the filter must be refilled with fuel.

See chapter "maintenance as required", bleeding the fuel system.

Environment Catch running out fuel and dispose of environmentally.

Fig. 76 l

Pull the oil dipstick (Fig. 76) out, wipe it clean with a lint-free cloth and reinsert it until it bottoms.

l

Pull the oil dipstick out again.

l

The oil level must be between the "L" and "H"marks.

l

Top up oil immediately if the oil level is too low.

l

If the oil level is too high detect the cause and drain the oil off.

Caution Before a longer work period fill the oil up to the "MAX"-mark.

Fig. 77 l

Slacken the clamping nut 2 (Fig. 77) and flip the bow (1) t the side.

l

Take the filter bowl (4) with filter screen (3) off and clean it.

l

After reassembling check the filter bowl for tight fit.

!

Filling quantity between "L" and "H" mark 4cylinder engine: approx. 1 Liter For quality and quantity of oil refer to the table of fuels and lubricants.

60

BOMAG

BW 177/178 D/DH/PDH-3

Every 10 operating hours 5.8

!

Checking, cleaning the fuel filter water separator

5.9

i

Danger

Note

The service intervals for the water separator depend on the water content in the fuel and can therefore not be determined precisely. After taking the engine into operation you should therefore check the filter bowl initially every day for signs of water.

Danger of injury!

Support the engine hood for all maintenance and repair work.

i

Checking, cleaning the water separator

Note

The service intervals for the water separator depend on the water content in the fuel and can therefore not be determined precisely. After taking the engine into operation you should therefore check the water separator every day for signs of water.

Environment Catch running out fuel and dispose of environmentally.

If a to high quantity is drained off, the filter must be refilled with fuel. See chapter "maintenance as required", bleeding the fuel system.

Environment Catch running out fuel and dispose of environmentally.

Fig. 79 l

Slacken the drain plug (Fig. 79) for a few turns and catch running out fuel / water.

l

Tighten the drain plug again and check for leaks, if necessary replace the seal ring.

Fig. 78 l

Slacken the drain plug (Fig. 78) for a few turns and catch running out fuel / water.

l

Tighten the drain plug again and check for leaks, if necessary replace the seal ring.

BW 177/178 D/DH/PDH-3

BOMAG

61

Every 10 operating hours 5.10 Checking the fuel level !

Danger

Fire hazard!

When working on the fuel system do not use open fire, do not smoke, do not refuel in closed rooms, do not inhale any fuel fumes.

Caution Contaminated fuel can cause malfunction or even damage of the engine. !

If necessary, fill in fuel through a funnel with screen. l

If necessary top up with fuel (diesel or winter diesel).

For quality of fuel refer to the table of fuels and lubricants.

Fig. 80

Check the fuel level on the fuel gauge (Fig. 80).

l

i

Note

Do not drive the fuel tank dry, as otherwise the fuel system needs to be bled. l

Clean the area around the filler opening.

Fig. 81 l

62

Open the fuel tank cover (Fig. 81).

BOMAG

BW 177/178 D/DH/PDH-3

Every 10 operating hours 5.11 Checking the coolant level !

5.12 Checking the hydraulic oil level

Danger

Danger of scalding!

!

Never remove the cap from the compensation tank when the engine is hot.

Caution

In mit Panolin HLP Synth. 46, the same oil must be used for filling up. In case of any other ester based oil consult the lubrication service department of the respective oil manufacturer.

Fig. 82

Check the coolant level (Fig. 82).

l

Fig. 83

Check the oil level in the inspection glass (Fig. 83) on the hydraulic oil tank.

l

Caution If during the daily coolant level check the coolant level is found to have dropped, check all lines, hoses and engine for leakages. !

Do not use any radiator sealing agents to seal leakages.

Do not fill any cold liquids into a hot engine. l

approx. 3 cm below the upper edge of the inspection glass.

Minimum level middle of inspection glass.

To top up unscrew the lid and fill in coolant up to the MAX-mark.

For quality of coolant refer to paragraph 5.2, fuels and lubricants.

Normal level

Caution If during the daily oil check the oil level is found to have dropped, check all lines, hoses and components for leakages. !

l

If necessary fill in hydraulic oil through the filler neck.

For quality and quantity of oil refer to the table of fuels and lubricants.

BW 177/178 D/DH/PDH-3

BOMAG

63

Every 10 operating hours 5.13 Checking the V-belt

5.14 Checking the dust separator on the oil bath air filter*

Fig. 84 l

Check the condition of the V-belt (Fig. 84).

Fig. 85

Small cracks in transverse direction are permitted.

l

Crack in longitudinal direction are not permitted. l

Replace the V-belt in case of broken out material, intersecting cracks in longitudinal and transverse direction or fraying.

*

64

If the dust reaches the mark loosen the clamp (Fig. 85), take the cover off and clean the bowl.

BOMAG

Option

BW 177/178 D/DH/PDH-3

Every 10 operating hours 5.15 Cleaning the air conditioning condenser

i

Note

The normal maintenance interval is 250 operating hours.

Caution Under very dusty conditions it may be necessary to clean several times a day, in order to maintain the cooling power of the air conditioning system. !

Fig. 87 l

Clean the condenser fins (Fig. 87) from above with compressed air or a cold water jet.

Danger Danger of accident! !

Do not clean with a hot water jet. Heat will cause extreme overpressure, which could cause damage or explosion of the system.

Use access steps and grips to mount and dismount the machine. l

Fold the condenser on the engine hood open.

Fig. 86 l

Clean the condenser fins (Fig. 86) from underneath with compressed air or a cold water jet.

BW 177/178 D/DH/PDH-3

BOMAG

65

Every 50 operating hours Every 50 oper ating hours

5.16 Checking the tire pressure

5.17 Adjusting the scrapers

Caution Since the tires are filled with water, you should always turn the inflation valve to top position to check the tire pressure!

smooth drum only

!

Always close the valves with the dust cap.

Fig. 89

Fig. 88

l

Check the condition and adjustment of the front and rear scrapers, adjust or replace the scraper rubber if necessary.

l

To adjust the scrapers 1 (Fig. 89) loosen the fastening screws (2) in the slots and push the scraper bracket towards the drum until the scraper touches.

l

Retighten the fastening screws.

Check the tire pressure with a pressure gauge and the tire inflation valve 1 (Fig. 88) in top position.

l

Nominal value see "technical data".

padfoot drum only

i

Note

Ensure even pressure in all tires. l

Screw the valve caps back on.

Fig. 90

66

l

Check condition and adjustment of scrapers 2 (Fig. 90), adjust or replace the teeth if necessary.

l

To adjust the scrapers (2) slacken the fastening screws (1) in the slots and move the scrap-

BOMAG

BW 177/178 D/DH/PDH-3

Every 50 operating hours er towards the drum, leaving a gap of approx.

25 mm. l

Retighten the fastening screws.

BW 177/178 D/DH/PDH-3

BOMAG

67

Every 250 operating hours Every 250 operating h ours

5.18 Changing engine oil and oil filter cartridge !

Caution

The oil change at 250 operating hours refers to the use of oils of oil quality class API CE/SG or CCM D4 respectively.

When using oils of quality classes API CC/CD or CD/SF the oil change intervals must be halved (see chapter 5.2, fuels and lubricants).

Fig. 92

Drain the engine oil only when the engine is warm.

Danger Danger of scalding! !

l

Unscrew the filter cartridge (Fig. 92) using an appropriate filter wrench.

l

Clean the sealing face on the filter carrier from any dirt.

When draining off hot oil.

By hot oil when unscrewing the engine oil filter.

Environment Catch running out oil and dispose of environmentally together with the engine oil filter cartridge.

Fig. 93 l

Fill the filter cartridge (Fig. 93) with fresh engine oil.

l

Slightly oil the rubber seal on the new filter cartridge.

Fig. 91 l

Unscrew the drain plug (Fig. 91) and catch running out oil (BW 178/179-3).

l

Turn the drain plug tightly back in.

68

BOMAG

BW 177/178 D/DH/PDH-3

Every 250 operating hours

Fig. 94

Fig. 96

l

Turn the new filter cartridge (Fig. 94) on by hand, until the seal contacts.

l

Tighten the filter element for another half turn.

l

Check the oil level again (Fig. 96), if necessary fill up to the top dipstick mark.

Fig. 95 l

Fill in new engine oil (Fig. 95).

For quality and quantity of oil refer to the table of fuels and lubricants. l

Tighten the oil filler cap properly.

l

After a short test run check the oil level on the dipstick, if necessary top up to the top dipstick mark.

l

Check filter cartridge and drain plug for leaks after a short test run.

l

Shut the engine down and wait for about 15 minutes, so that all oil can flow back into the oil sump.

BW 177/178 D/DH/PDH-3

BOMAG

69

Every 250 operating hours Cleaning with cold cleansing agent

5.19 Cleaning the cooling fins on engine and hydraulic oil cooler

Caution Protect electrical equipment such as generator, regulator and starter against the direct water jet. !

Danger Danger of injury! !

Perform cleaning work only after the engine has cooled down and with the engine stopped.

l

Spray the engine with a suitable cleansing agent, e.g. cold cleanser, let it soak in for a while and spray it off with a strong water jet.

l

Run the engine warm for a while to avoid corrosion.

Caution Do not damage any cooling fins on the cooler core when cleaning. !

i

Note

Dirt on fan blades and oil cooler reduce the cooling effect. Dirt deposits in these areas are substantially supported by oil and fuel on these surfaces. For this reason you should always seal and oil or fuel leaks in the vicinity of the cooling fan or the oil cooler and clean the cooling surfaces after.

Cleaning with compressed air

i

Note

Start to blow out from the exhaust side.

Fig. 97 l

70

Blow the coller (Fig. 97) out with compressed air.

BOMAG

BW 177/178 D/DH/PDH-3

Every 250 operating hours 5.20 Checking the oil level in the drive axle

5.21 Checking the oil level in the left/right hand planetary drives

Fig. 98 l

Unscrew the oil level inspection plug (Fig. 98) and check the oil level.

The oil level must reach the bottom edge of the level bore. l

Top up oil, if necessary.

For quality of oil refer to the table of fuels and lubricants. l

Turn the level inspection plug tightly back in.

BW 177/178 D/DH/PDH-3

Fig. 99 l

Drive the machine, until both plugs 1 (Fig. 99) are in horizontal position.

l

Clean the plug and screw it out.

The oil level must reach the lower edge of the bore, top up oil if necessary.

For quality of oil refer to the table of fuels and lubricants. l

Screw the plug tightly back in.

l

Repeat the same procedure on the opposite side.

BOMAG

71

Every 250 operating hours 5.22 Checking the oil level in the vibration bearing

5.23 Check the oil level in the drum drive gear

Fig. 100

Fig. 101

l

Drive the machine until the oil level control plug 1 (Fig. 100) is vertically below the hub.

l

Move the machine until one plug 1 (Fig. 101) is in horizontal and one plug (2) in top position.

l

Clean the plug and screw it out.

l

Clean and unscrew plug (1).

The oil level must reach the lower edge of the bore l

If necessary top up oil through the filler and drain bore (2).

For quality of oil refer to the table of fuels and lubricants.

72

The oil level must reach the bottom edge of the bore. l

If necessary clean and unscrew plug (2) and fill in oil.

For quality of oil refer to the table of fuels and lubricants.

BOMAG

BW 177/178 D/DH/PDH-3

Every 250 operating hours 5.24 Service the air conditioning Cleaning the condenser !

Caution A soiled condenser results in a considerable reduction of air conditioning power.

Under extremely dusty conditions it may be necessary to clean the condenser several times per day.

If, during operation of the air conditioning system, the warning buzzer sounds switch the air conditioning off and clean the condenser.

Fig. 103

Danger Danger of accident!

Checking the refrigerant level l

Start the engine.

Do not clean with a hot water jet. Heat will cause extreme overpressure, which could cause damage or explosion of the system.

l

Switch the air conditioning on.

!

l

Clean the condenser fins (Fig. 103) from above with compressed air or a cold water jet.

Use access steps and grips to mount and dismount the machine.

Caution In case of formation of foam have the air conditioning system inspected by the service department. !

Fig. 104 l

Turn the rotary fan switch (Fig. 104) to position "2", middle fan stage.

l

Open the air outlet openings on both control units.

Fig. 102 l

Clean the condenser fins (Fig. 102) from underneath with compressed air or a cold water jet.

BW 177/178 D/DH/PDH-3

BOMAG

73

Every 250 operating hours

Fig. 105

Fig. 107

Turn the rotary switch for the air conditioning thermostat (Fig. 105) clockwise. The air flow cools down.

l

i

If the white float (Fig. 107) inside the inspection glass of the drier/collector unit floats at the bottom, inform the service department.

l

Note

i

The adjusted temperature must be below the actual temperature inside the cabin, so that the compressor will be switched on.

Note

The refrigerant level is not correct. l

Refrigerant must be filled up, if necessary the air conditioning system must be checked for leaks.

Checking the moisture level of the drying agent

Fig. 106

Check whether the white float (Fig. 106) inside the inspection glass of the drier/collector unit floats right at the top.

l

i

Note

The refrigerant level is correct.

Fig. 108 l

blue

= drying agent o.k.

purple

= moisture level of drying agent too high.

l

74

Check the moisture indication pearl (Fig. 108) inside the inspection glass of the drier/collector unit.

BOMAG

Inform the service department. Replace drier/ collector unit, check air conditioning system.

BW 177/178 D/DH/PDH-3

Every 250 operating hours Caution Have the drier/collector unit replaced by the service department every year before the operating season. !

Checking the condition of the drier/collector unit Caution According to the regulation for pressure reservoirs all pressure reservoirs must be repeatedly inspected by a specialist. In this sense repeated inspections are external examinations, normally on pressure reservoirs in operation. In connection with this inspection the drier/collector unit must be visually examined twice every year. During these inspections special attention must be paid to corrosion and mechanical damage. If the reservoir is not in proper condition it must be replaced for safety reasons, as a precaution to protect operators and third parties against any danger arising from the handling and operation of pressure reservoirs. !

!

Danger

Danger of injury!

In case of mechanical damage or corrosion on this drier/collector unit this unit must be replaced, to avoid bursting and further damage.

Fig. 109 l

Check the drier/collector unit (Fig. 109) for mechanical damage or rust.

BW 177/178 D/DH/PDH-3

BOMAG

75

Every 500 operating hours Every 500 operating h ours

5.25 Servicing the battery !

Danger

Danger of causticization !

When working on the battery do not use open fire, do not smoke!

Do not let acid come in contact with skin or clothes!

Wear protective clothing!

Do not lay any tools on the battery!

Fig. 111

For recharging remove the plugs from the battery to avoid the accumulation of highly explosive gases.

Environment Dispose of the old battery environmentally.

l

Remove the battery (Fig. 111) and clean the battery compartment.

l

Clean the outside of the battery.

l

Clean battery poles and pole clamps and grease them with pole grease (Vaseline).

l

Check the fastening of the battery.

l

On serviceable batteries check the acid level, if necessary top up to the filling mark with distilled water.

Fig. 110 l

76

Unscrew both fastening screws (Fig. 110) from the seat console and fold the seat forward.

BOMAG

BW 177/178 D/DH/PDH-3

Every 500 operating hours 5.26 Draining the sludge from the fuel tank !

5.27 Changing the fuel filter cartridges

Danger

!

Danger

Fire hazard!

Fire hazard!

When working on the fuel system do not use open fire, do not smoke!

When working on the fuel system do not use open fire, do not smoke, do not spill any fuel.

Do not spill any fuel.

Catch running out fuel, do not let it seep into the ground.

Catch running out fuel, do not let it seep into the ground.

Do not inhale any fuel fumes.

Do not inhale any fuel fumes.

Fig. 113 Fig. 112 l

l

Unscrew the cap (Fig. 112) and drain off approx. 5 litres of fuel.

l

Unscrew both filter cartridges (Fig. 113) with a suitable filter wrench.

l

Clean the sealing faces on the filter carrier from all dirt.

Turn the cap tightly back in.

BW 177/178 D/DH/PDH-3

BOMAG

77

Every 500 operating hours Observe 'Bleeding the fuel system' in the paragraph "Maintenance as Required".

Fig. 114 l

Fill the new filter cartridges (Fig. 114) with clean fuel according to the table of fuels and lubricants.

l

Cover the seal rings lightly with oil.

Fig. 115 l

Screw the filter cartridges on by hand until the seal touches the filter head 1 (Fig. 115).

l

Tighten for a 3/4 turn (2).

i

Note

Small amounts of air, which enter the fuel system when changing the filter, are automatically discharged through the return line.

Manual bleeding l

if the filter has not been filled with fuel before removal,

l

if the injection pump has been changed,

l

if injection lines were changed

l

if the fuel tank has been driven empty.

78

BOMAG

BW 177/178 D/DH/PDH-3

Every 500 operating hours 5.28 Changing the fuel pre-filter cartridge !

Danger

Fire hazard!

When working on the fuel system do not use open fire, do not smoke and do not spill any fuel.

Catch running out fuel, do not let it seep into the ground.

Fig. 117

Do not inhale any fuel fumes.

Fig. 116 l

Unscrew the fuel filter cartridge (Fig. 116) using an appropriate filter wrench.

l

Clean the sealing face on the filter carrier from any dirt.

l

Unscrew the water separator from the filter cartridge.

BW 177/178 D/DH/PDH-3

l

Apply a thin coat of oil to the rubber seal of the water separator 1 (Fig. 117).

l

Screw the water separator on by hand (2), until the seal contacts.

l

Tighten the water separator for another half turn (3).

l

Fill the filter cartridge with clean diesel fuel (4).

l

Apply some oil to the rubber seal of the filter element (5) and screw it on by hand, until the seal contacts.

l

Tighten the filter element for another half turn (6).

l

Check the filter cartridge for leaks after a short test run.

BOMAG

79

Every 500 operating hours 5.29 Checking V-belt tension, idler pulley and blower hub

Fig. 120 l

Check the bearings for idler pulley 1 (Fig. 120) and blower hub (2), replace if necessary.

l

Reinstall the V-belt.

Fig. 118 l

Lift the idler pulley up by means of a socket wrench (Fig. 118) and take the V-belt off.

Fig. 121 l

Check the V-belt tension (Fig. 121).

Fig. 119 l

Check the condition of the V-belt (Fig. 119).

Small cracks in transverse direction are permitted.

Cracks in longitudinal direction are not permitted.

Replace the V-belt in case of broken out material, intersecting cracks in longitudinal and transverse direction or fraying.

Fig. 122

We recommend to use the Cummins V-belt tension tester (Fig. 122) Part. No. ST-1293.

80

BOMAG

BW 177/178 D/DH/PDH-3

Every 500 operating hours Nominal value: 267 to 578 N (60 to 130 Lbf)

BW 177/178 D/DH/PDH-3

BOMAG

81

Every 1000 operating hours Every 1000 operating hour s

5.30 Changing the oil in the drive axle

i

Note

On other axle versions drain and filler plugs are of slightly different design. Perform the oil change accordingly.

Caution Drain oil only at operating temperature. !

Fig. 124

Environment Catch old oil and dispose of environmentally.

l

Fill in oil through the oil level inspection bore (Fig. 124), until it has reached the bottom edge of the bore.

For quality and quantity of oil refer to the table of fuels and lubricants. l

Retighten the filler and level inspection plug.

Fig. 123 l

Clean and unscrew all level inspection and drain plugs (Fig. 123).

l

Drain and catch all oil.

l

Clean the drain plug and turn it back in with a new seal ring.

82

BOMAG

BW 177/178 D/DH/PDH-3

Every 1000 operating hours 5.31 Changing the oil in the planetary drive !

Caution

Drain the oil only at operating temperature.

Change the oil on both sides of the axle.

Environment Catch the old oil and dispose of environmetally.

Fig. 126 l

Move the drive wheel until the plug (Fig. 126) in the housing is in horizontal position.

l

Fill in oil, until it reaches the lower edge of the bore.

For quality and quantity of oil refer to the table of fuels and lubricants. l

Screw the plug back in.

l

Repeat the oil change on the opposite side.

Fig. 125 l

Move the drive wheel until the plug (Fig. 125) is in lowest position.

l

Clean the plug and screw it out.

l

Drain the oil off and catch it.

BW 177/178 D/DH/PDH-3

BOMAG

83

Every 1000 operating hours For quality and quantity of oil refer to the table of fuels and lubricants.

5.32 Changing the oil in the drum drive gear

l

Turn filler plug (2) and drain and level inspection plug (1) tightly back in.

Fig. 127 l

Move the drum, until the drain and level inspection plug 2 (Fig. 127) is in bottom position.

l

Clean and unscrew the oil filler plug (1) as well as the drain and level inspection plug.

Environment Catch running out oil.

Fig. 128 l

Once all oil has been drained off move the drum, until the oil filler plug 2 (Fig. 128) is in top position and the drain and level inspection plug (1) is in horizontal position.

l

Fill in oil, until it starts to run out through the level inspection bore.

84

BOMAG

BW 177/178 D/DH/PDH-3

Every 1000 operating hours For quality and quantity of oil refer to the table of fuels and lubricants.

5.33 Changing the oil in the vibration bearing

l

Fit oil level control plug (1) and drain and filler plug (2) with new sealing rings and screw them back in.

Fig. 129 l

Move the drum until the drain and filler plug 2 (Fig. 129) reaches its lowest position.

l

Clean the oil level control plug (1) aswell as the drain and filler plug and screw them out.

Environment Catch running out oil.

Fig. 130 l

Once the oil has run out move the drum until the oil level control opening 1 (Fig. 130) is vertically below the hub.

l

Fill in oil until it starts to run out through the oil level control bore.

BW 177/178 D/DH/PDH-3

BOMAG

85

Every 1000 operating hours 5.34 Checking the fastening elements on the engine

5.35 Tightening the fastening of the axle on the frame

Fig. 131

Fig. 132

l

Check the fastening of air intake and exhaust tube (Fig. 131) on the cylinder heads for tight fit.

l

Check the bellows and clamps between air filter, turbo charger and charge air line as well as the lubrication oil line for tight fit.

l

Check the fastening screws for the oil sump and the engine mounts for tight fit.

86

l

BOMAG

Check all fastening nuts for the axle studs for tight fit (Fig. 132).

BW 177/178 D/DH/PDH-3

Every 1000 operating hours 5.36 Tightening the wheel nuts

5.37 Checking the ROPS

i

Note

With the cabin assembled the ROPS (Roll Over Protection Structure) is integrated in the cabin.

Please observe also the respective section in the safety regulations in this manual.

Fig. 133 l

Tighten the wheel nuts (Fig. 133) in a crosswise pattern.

Tightening torques 550 Nm (405 ft-lb) (M22x1,5) Fig. 134

Check the cabin, especially the ROPS (Fig. 134) for cracks, corrosion, damage and missing fastening elements.

l

i

Note

Unusual movements and noises (vibrations) during operation indicate damage or loose fastening elements.

BW 177/178 D/DH/PDH-3

l

Check the fastening screws for the cabin (ROPS) to the operator's platform for tight fit.

l

Check the suspension buffers for the operator's stand for tight fit.

l

Check the condition and the fastening of the seat belt.

BOMAG

87

Every 1000 operating hours 5.38 Cleaning the oil bath air filter*

Fig. 135 l

Loosen the quick locks (Fig. 135), take the filter bowl off and empty it.

l

Clean the filter mesh by repetitive dipping into diesel fuel.

l

Clean the filter bowl with diesel fuel and fill in engine oil up to the level mark.

l

Reinstall the filter bowl.

*

88

Option

BOMAG

BW 177/178 D/DH/PDH-3

Every 2000 operating hours Every 2000 operating hours

Caution Loosen the pin again after the adjustment process.

5.39 Checking, adjusting the valve clearance !

!

Caution

Before checking the valve clearance let the engine cool down for at least 30 minutes. The engine temperature should be lower than 60 °C. After a short test run check the engine for leaks. l

Remove the air filter.

Fig. 138

The engaged position (Fig. 138) of the adjustment pin is exactly corresponding with the upper dead centre of the first cylinder during the compression stroke.

l

Fig. 136 l

Remove all valve covers 1 (Fig. 136).

Fig. 139

Caution Loosen the pin (Fig. 139) again after the adjustment process. !

Fig. 137 l

Push the adjustment pin (Fig. 137) in and turn the crankshaft of the engine until it clicks into place.

BW 177/178 D/DH/PDH-3

BOMAG

89

Every 2000 operating hours

Fig. 140

l

Check the valve clearance on all other valves (Fig. 142) and adjust it if necessary.

l

Check the gasket for the cylinder head cover, replace if necessary.

Inlet valve (I) 0,25 mm (0.010 IN)

l

Reinstall the cylinder head cover.

Exhaust valve (E) 0,50 mm (0.020 IN)

l

Swing the ventilation valve back into position and fasten it.

l

Fasten the air filter and ensure correct fit of combustion air hoses and hose clamps.

l

Check the clearance between the rocker arm and the valve (Fig. 140) with a feeler gauge, adjust if necessary.

Fig. 142

Nominal value:

Fig. 141 l

90

Mark the V-belt pulley (Fig. 141) and turn the engine one revolution (360°) further.

BOMAG

BW 177/178 D/DH/PDH-3

Every 2000 operating hours 5.40 Changing the hydraulic oil and the breather filter

i

Note

See also section 5.1 "Notes on the Hydraulic System".

Caution Apart from the normal oil change intervals the hydraulic oil must also be changed after major repairs in the hydraulic system. !

Fig. 143

Change the hydraulic oil only at operating temperature.

l

Unscrew the plug (Fig. 143) and drain the hydraulic oil off.

Clean the area around the hydraulic oil tank, the filler opening and the breather filter.

l

Check the sealing ring (1), replace if necessary and screw the plug tightly back in.

Do not use any detergents to clean the system.

Do not start the engine after draining the hydraulic oil.

Change the hydraulic oil filter element with every hydraulic oil change.

!

Danger

Danger of scalding!

Danger of scalding by hot oil.

Environment Catch running out oil and dispose of environmentally.

i

Fig. 144 l

Take the filler cap (Fig. 144) off.

l

Fill in hydraulic oil through the screen.

Note

The hydraulic oil filter element should only be changed after the test run.

i

Note

For filling the hydraulic system we recommend to use the filling and filtering unit (BOMAG part-no.

079 930 35) with fine filter. This not only filters the hydraulic oil, but also prolongs the lifetime of the hydraulic oil filter and protects the hydraulic system. l

Check the oil level in the inspection glass.

Nominal value: approx. 3 cm below the upper edge of the inspection glass

BW 177/178 D/DH/PDH-3

BOMAG

91

Every 2000 operating hours For quality and quantity of oil refer to the table of fuels and lubricants.

i

Note

The breather filter for the hydraulic tank is located in the filler cap and must therefore be replaced with the filler cap. l

5.41 Changing the hydraulic oil filter

Close the tank with the new filler cap.

!

Danger

Danger of scalding!

There is a danger of scalding by hot oil when unscrewing the filter.

Caution If the filter has to be changed together with the hydraulic oil, the filter should in any case be changed after the oil change and the test run. !

Do not use the oil in the filter bowl.

Environment Catch running out oil, dispose of oil and filter element environmentally.

i

Note

The filter element must be changed with every hydraulic oil change and after major repairs in the hydraulic system.

Fig. 145 l

Unscrew the cap nut 4 (Fig. 145) and take the filter bowl (5) with the filter element (3) off.

l

Examine the sealing face on the filter element thoroughly for any visible dirt.

Caution Visible impurities may be an early indicator for a failure of system components and predict the !

92

BOMAG

BW 177/178 D/DH/PDH-3

Every 2000 operating hours possible malfunction of important parts. In such a case you should perform trouble shooting and replace or repair the defective components. Nonobservance may lead to total damage of the hydraulic system.

Do not clean or reuse the filter element. l

Take the old filter element (3) out and clean the filter bowl and the thread.

l

Reinstall the filter bowl with the new filter element, check the condition of the O-rings (1) and (2), replace if necessary.

l

After a test run check the filter for leaks.

5.42 Change the coolant !

Danger

Danger of scalding!

Change the coolant only when the engine is cold.

Environment Catch running out coolant and dispose of environmentally.

Fig. 146 l

Set the cock valve (Fig. 146) for the cabin heater to position "warm".

Fig. 147

BW 177/178 D/DH/PDH-3

l

Unscrew the drain plug (Fig. 147), let the coolant run out and catch it.

l

Turn the drain plug back in tightly after all coolant has run out.

BOMAG

93

Every 2000 operating hours

Fig. 148 l

Unscrew the cap and fill in coolant up to the MAX-mark (Fig. 148).

For quality of coolant refer to the chapter 5.2, fuels and lubricants. l

Start the diesel engine and run it warm to operating temperature.

l

Let the engine cool down and check the coolant level again, top up if necessary.

94

BOMAG

BW 177/178 D/DH/PDH-3

As required As r equired

5.43 Checking, cleaning, changing the combustion air filter !

i

Note

Once the air filter service indicator lights up, work may be continued until the end of the day.

Caution

Perform cleaning, maintenance and repair work only with the engine shut down. Do not start the engine after removing the filter element.

Do not use gasoline or hot fluids to clean the filter element.

After cleaning the filter element must be inspected for damage using a torch.

Air filter elements with damaged paper bellows or seal lips must be replaced in any case.

The main filter element must be replaced after 3 times cleaning, but at the latest after one year, irrespective of the operating hours.

Fig. 150 l

Remove the maintenance cover (Fig. 150).

Each cleaning interval must be marked with a cross on the cover of the filter element.

Cleaning does not make sense if the air filter element is covered with a sooty deposit. Use a new filter element.

Incorrectly handled filter elements may become ineffective because of damage (e.g.: cracks) and cause engine damage.

Fig. 151 l

Release the locking hook (Fig. 151) and take the filter hood off.

l

Clean filter hood and dust discharge valve.

Fig. 149

Maintenance of the dry air filter is due when control light 1 (Fig. 149) in the fault monitoring board lights permanently when the engine is running, but at the latest after one year.

BW 177/178 D/DH/PDH-3

BOMAG

95

As required

Fig. 152

Carefully loosen the main filter element (Fig. 152).

l

The main filter element is located directly on the air intake tube, thereby providing a seal on the inside of the filter cover. Carefully remove the main filter element, in order to reduce the released amount of dust. To release the seal pull the main filter element carefully up, down and sideways or turn it (Fig. 152) .

Caution Avoid contact between main filter element and housing. !

Fig. 154

Clean the sealing face on the outlet tube (Fig. 154).

l

Dust on the outer diameter of the outlet tube can impair effective sealing.

Check the old main filter element.

l

The old main filter element can be of help to discover foreign particles on the sealing face, which could lead to leaks. A line of dust on the clean air side of the filter may be a sign for such a leak.

Eliminate this problem before installing a new main filter element. l

If the main filter element is damaged, the safety element must be replaced as well.

l

Clean or replace the main filter element.

i

Note

We generally recommend to change the filter. A new filter element is far less expensive than a possible engine damage. l

Fig. 153 l

96

Pull the main filter element (Fig. 153) carefully out of the housing.

Examine the main filter element thoroughly for damage.

Before installing the new main filter element check it for possible damage from transport, cleaning or incorrect handling. Especially on the inside of the open end (sealing area). Do not install damaged filter elements. l

BOMAG

If necessary use safety elements.

BW 177/178 D/DH/PDH-3

As required

Fig. 155

Fig. 156

Insert the main filter element (Fig. 155).

l

The radial sealing area is located at the inside of the open filter edge. This critical sealing area must be under slight tension after the filter has been installed. In order to achieve a tight seal apply pressure to the outer edge of the filter and not to the moveable centre.

i

Note

For cleaning purposes fit a tube to the compressed air gun (Fig. 156), the end of which should be bent for approx. 90°.

The length should reach down to the bottom of the element.

Reinstall the filter hood with the dust discharge valve.

l

Caution The dust discharge valve must point vertically downwards.

Blow the main filter element out with compressed air (max. 5 bar) from inside to outside by moving the tube up and down inside the element, until it if free of dust.

l

Examine the main filter element with a torch for cracks and holes in the paper bellows.

l

!

Dry cleaning of the main filter element !

Danger

Eye injury!

Wear protective clothing (goggles, gloves).

Caution Do not continue to use a damaged main filter element. If in doubt use a new main filter element. !

Changing the safety filter element Caution The safety filter element must not be cleaned and should not be used again after it has been removed. !

The safety filter element must be replaced: If the main filter element is defective. after three times cleaning of the main filter element, at the latest after 2 years,

BW 177/178 D/DH/PDH-3

BOMAG

97

As required if the warning light comes on again after servicing the main filter cartridge. l

Remove the housing cover and pull the main filter element off.

5.44 Bleeding the fuel system Bleeding low pressure fuel lines and fuel filter

Fig. 157 l

Pull the safety element (Fig. 157) out by turning it lightly.

l

Push in a new safety filter element.

l

Reassemble main filter element and cover.

Fig. 158 l

Slacken the bleeding screw (Fig. 158).

l

Operate the fuel pump, until fuel runs out without air bubbles.

l

Retighten the bleeding screw.

Bleeding the injection pump

Fig. 159 l

98

BOMAG

Turn the ignition to 'I' (Fig. 159).

BW 177/178 D/DH/PDH-3

As required 5.45 Adjusting the parking brake !

Caution Have adjustment work on the brake performed by a specialist! Always adjust both sides.

l

Secure the machine with chocks against unintentional rolling.

l

Start the diesel engine to release the brake.

Fig. 160 l

Slacken the bleeding screw (Fig. 160).

l

Operate the fuel pump, until fuel runs out without air bubbles.

l

Retighten the bleeding screw.

Bleeding the high pressure fuel lines !

Danger

High pressure can damage your skin. Do not bleed while the engine is hot – fire hazard.

Fig. 162 l

Unlock the travel lever (Fig. 162) by pushing it to the left, but do not actuate it to position "I" or "II".

The parking brake is released

Fig. 161 l

Slacken the fuel line on the injection nozzle (Fig. 161).

l

Crank the engine with the starter so that the air can escape.

Fig. 163

l

Start the engine and run it at idle speed.

l

Unscrew the locking plate 2 (Fig. 163).

l

Bleed all lines, one after the other, until the engine runs regularly.

l

Turn the square (1) in anti-clockwise direction against the end stop.

BW 177/178 D/DH/PDH-3

BOMAG

99

As required 5.46 Changing the tires !

Danger

Danger of accident!

Observe all safety notes for the lifting of loads. l

Place a jack (min. 5 t bearing capacity) under the rear frame and jack the machine up so that the wheel can turn freely.

l

Unscrew the wheel nuts and take the wheel off.

Fig. 164 l

To adjust the clearance turn the square 1 (Fig. 164) three revolutions back in clockwise direction.

l

Screw the locking plate back on.

l

Pull the plug off the brake valve and try to drive.

The machine must be braked.

Fig. 165

100

l

Attach the wheel (Fig. 165) and tighten the wheel nuts crosswise with 550 Nm (405 ft. lb.).

l

Check the tire pressure, see technical data.

BOMAG

BW 177/178 D/DH/PDH-3

As required 5.47 Checking the fresh air filter for the cabin

5.48 Tightening torques

Fig. 167

Fig. 166 l

Unscrew the fastening screws for the filter holders (Fig. 166) and take the filters out.

l

Insert the new filter and reassemble the filter bracket.

* Strength classes for screws with untreated, nonlubricated surface. The screw quality is stamped on the screw heads.

8.8 = 8G 10.9 = 10K 12.9 = 12K Axle - frame

l

M 24

= 880 Nm

Wheel nuts

l

M 22x1,5

= 550 Nm

The values result in a 90% utilization of the screws yielding point at a coefficient of friction of Âľ tot. = 0,14. The tightening torques are not valid when using MOS2 lubricants.

i

Note

Self locking nuts must always be replaced after they have been unscrewed.

BW 177/178 D/DH/PDH-3

BOMAG

101

As required 5.49 Engine conservation If the engine is to be shut down for a longer period of time (e.g. over winter), we recommend to apply the following conserving measures to avoid corrosion: l

Clean the engine, including the cooling system: With cold cleansing agent and a water jet or, even better, with a steam cleaner.

l

Run the engine warm and shut it down.

l

Drain off the still hot engine oil and fill in anticorrosion engine oil.

l

Drain off the coolant and fill in system protection agent.

l

Drain the fuel from the tank, mix it well with 10% anti-corrosion oil and fill it back in.

l

Run the engine for 10 minutes until all lines, filters, pumps and nozzles with this conserving mixture and the new engine oil has been distributed to all parts.

l

Now crank the engine several times (without ignition) to spray the combustion chambers.

l

Take the V-belts off and spray the grooves of the V-belts with anti-corrosion oil. Remove the anti-corrosion oil before resuming operation.

l

Close intake and exhaust openings tightly.

i

Note

Depending on the weather conditions these conserving measures will provide protection for approx. 6 to 12 months.

Before taking the engine back into operation all conserving oil must be drained off and replaced by regular engine oil, see chapter "Fuels and Lubricants" according to the API-(MIL)-classification.

Anti-corrosion oils are those that comply with the specification MIL-L-21260 B or TL 9150037/2 or Nato Code C 640/642.

A machine with a conserved engine must be marked by attaching a clearly visible warning tag.

102

BOMAG

BW 177/178 D/DH/PDH-3

6 Trouble shooting

BW 177/178 D/DH/PDH-3

BOMAG

103

Trouble shooting 6.1

General notes

The following work must only be carried out by qualified and trained personnel or by the sales service.

Please observe strictly the safety regulations in chapter 2 of these operating and maintenance instructions.

Faults occur frequently due to the fact, that the machine has not been properly operated or serviced. Therefore, whenever a fault occurs, read through these instructions on correct operation and maintenance. If you cannot locate the cause of the fault or eliminate it yourself by following the trouble shooting charts, you should contact our customer service departments at our branch office or dealers.

Danger Danger of injury! !

Keep away from rotating parts of the engine.

104

BOMAG

BW 177/178 D/DH/PDH-3

Trouble shooting 6.2

Engine

Faults

Possible cause

Remedy

The engine does not start

Starter defective or pinion not engaging

Have examined by a specialist

Fuel tank empty

Fill and bleed the tank

Temperature below starting limit

Use winter fuel and engine oil acc. to the ambient temperature.

Fuel filter clogged, in winter due to paraffin separation.

Change the filter. use winter fuel

Fuel lines leaking

Check all line connections for leakages and tighten the fittings.

Battery discharged or not connected

Tighten the pole clamps, check the cable connections

Injection valves or injection pump defective

Have examined by a specialist

Battery power too low, battery clamps loose or oxidized, causing the starter to turn too slowly

Have the battery checked, clean the terminal clamps, tighten them and cover them with acid free grease

Especially during winter: the use of too viscous engine oil

Use engine oil suitable for the ambient temperature

Fuel supply restricted, in winter fuel system clogged due to paraffin separation

Change the fuel filter. Check the line connections for leaks and tighten the fittings.

Use winter fuel in the cold season.

Incorrect valve clearance

Adjust the valve clearance

Injection valve defective

Have examined by a specialist

Injection lines leaking

Check the lines for leakages

Turbo charger defective

Have examined by a specialist

Dry air filter dirty

clean, replace if necessary

Excessive play in the throttle cable

Adjust the throttle cable, change it if necessary

The engine starts poorly and works irregularly with poor power

BW 177/178 D/DH/PDH-3

BOMAG

105

Trouble shooting Faults

Possible cause

Remedy

Excessive exhaust smoke

Engine oil level too high

Drain the oil to the upper dipstick mark

Dry air filter dirty

clean, replace if necessary

Exhaust gas turbo-charger defective

Have examined by a specialist

Poor compression due to burned or broken compression rings or incorrect valve clearance

Have compression rings and pistons examined by a specialist, adjust the valve clearance

Incorrect valve clearance

Adjust the valve clearance

Cooling fins on radiator extremely soiled (the warning light "engine oil temperature" lights)

Clean the cooling fins

Injection valve defective

Have examined by a specialist

Engine oil level too low

Top up engine oil to the upper dipstick mark

Filling capacity of the injection pump not correctly adjusted

Have adjusted by a specialist

Cooling air flow restricted

Clean the cooling air duct

V-belt loos or broken

Tension or replace the V-belt

Engine oil level too high

Drain the engine oil down to the upper dipstick mark

Dry air filter dirty

clean, change if necessary

Exhaust gas turbo-charger defective

Have examined by a specialist

Charge air hose leaking

Check fastening and connections

Incorrect valve clearance

Adjust the valve clearance

Injection valve defective

Have examined by a specialist

Engine oil level too low (control light "engine oil pressure" lights, the warning buzzer sounds)

Top up oil

Leakages in the lubrication system

Shut the engine down immediately, check fittings on oil lines, lubrication oil filter and oil cooler for leaks, if necessary tighten the fittings.

Generator speed too low

Check the V-belt tension, replace the Vbelt if necessary

The generator does not charge the battery, because generator or regulator is defective

Have examined by a specialis

Engine overheats, shut down immediately!

Poor engine power

Engine oil pressure too low

The charge control light lights during operation, the warning buzzer sounds

106

BOMAG

BW 177/178 D/DH/PDH-3

Trouble shooting

BW 177/178 D/DH/PDH-3

BOMAG

107

Trouble shooting

108

BOMAG

BW 177/178 D/DH/PDH-3