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

Service Training

Foreword

Reliable construction equipment is of greatest advantage for all parties involved:

•for the customer/user it is a basis for an exact calculation of utilization periods and the completion of projects as scheduled.

•in the rental business it means that the equipment can be reliably used and planned without having to stock a large number of stand-by machines.

•for the manufacturer it means that customers are satisfied, provides him with a good image and gives him a feeling of confidence.

It is BOMAG’s philosophy to design and produce the machines with highest possible reliability. This aspect of simple and easy maintenance was one of the key issues when developing and designing the machine:

•the location of components in the machine eases maintenance work,

•the high quality standard of BOMAG is the basis for the considerable extension of the service and maintenance intervals.

•the After Sales Service of BOMAG, including excellent operating and maintenance instruction manuals, high quality training courses and on-site machine demonstrations helps the customer to maintain their machines in good condition over a long period of time.

Permanent training of BOMAG’s own service personnel as well as the service personnel of BOMAG Profit Centres and dealers is therefore a general prerequisite for BOMAG’s excellent world-wide service.

This program of permanent training is only possible with appropriate and up-to-date training material for trainers as well as persons attending the training courses.

This training manual has not only been written as a support for the professional work of the trainer, but also for the trainees attending these training courses.

The different levels of product training demand, that the training performed by BOMAG, its Profit Centres or its dealers reflects the high quality of the training conducted at the Training Centre at BOMAG in Boppard. For this reason we invested a lot of time in the preparation of these materials .

The structure of this training manual enables us to change or up-date individual chapters in case of alterations to the machine.

Documentation

For the BOMAG machines described in this training manual the following documentation is additionally available:

Attention!

The currently valid part numbers for the documents can be taken from the Doclist or the Customer Service page in the BOMAG (BOMAG Secured Area) in accordance with the serial number of the machine.

1.Operating and maintenance instructions

2.Spare parts catalogue

3.Wiring diagram *

4.Hydraulic diagram *

5.Repair instructions

6.Service Information

* The document versions valid at the date of printing are part of this training manual.

General

The new single drum rollers BW 177 D-4 from BOMAG are essentially further developments of their predecessors, the machines of product range BW 177 D-3.

These machines have been successfully and reliably used for years on construction sites all over the world, especially in earth construction and on sanitary landfill sites.

High compaction power and excellent traction are characteristics, which are of utmost importance for this type of machine.

All components installed in these machines are manufactured in series production and are subjected to stringent quality tests. This guarantees a high level of reliability and safety.

As with many other BOMAG products, and here especially with the large single drum rollers of the new generation, we have decided to use the same successful drive concept with diesel engine (water cooled) and hydrostatic drives also for these machines. The hydrostatic drives transfer the output power of the engine directly to drum, drive wheels and steering.

The drive wheels are driven by fast rotating hydraulic motors and axle, whereas the drum is driven by slow running radial piston motors.

On construction machines the work place of the operator is of utmost importance. Under such working conditions the health and safety of the operator must be the greatest concern.

The cabin is very spacious and clearly arranged. The driver’s seat is very comfortable and can be individually adjusted for every operator, even for his weight.

All control elements and gauges are within the reach and in the sight of the operator.

A monitoring display with light emitting diodes and clear pictograms informs the operator about any operating faults. The operator is therefore always informed about the present condition of the machine.

The generously glazed cabin with windscreen wiper and washer systems for front and rear windscreens, as well as a heated rear windscreen, offers clear vision to all sides.

Important characteristics of the new generation of single drum rollers are

•strong ROPS/FOPS according to SAE-standard

•wear free service brake by closed hydrostatic travel circuits

•disc brakes in axle and drum drive motor serve as parking and emergency brakes

•high stability due to low centre of gravity and the use of an articulated joint

•operating safety due to the use of monitoring boards for all important system data

•automatic engine shut-down at too engine temperature, too low hydraulic oil level (when reaching the lowest permissible level the engine will be shut down after 20 seconds) and too low engine oil pressure.

The machines of product ranges BW 177 D-4 are well designed down to the smallest detail, so that they can meet the toughest demands on large scale construction sites all over the world.

Technical data and adjustment values

The following pages contain technical data valid at the date of printing (see front page of this manual).

Attention!

The currently valid technical data and adjustment values can be taken from the BOMAG Intranet or Extranet (BOMAG Secured Area) in accordance with the serial number of the machine.

BOMAG Central Service - Technical data and adjustment values

Status: 2004-06-21

Product type:BW 177 D Serie 4

Type No.:582 20

Serial numbers from:101 582 20 1001

Engine:

Manufacturer:Deutz

Type:BF4M 2011

Combustion principle:4-stroke-Diesel

Cooling:Air-Oil

Number of cylinders:4

Power acc. to ISO 9249:54 kW

Power data at nominal speed of:2300 1/min

Low idle speed:850 +/-150 1/min

High idle speed:2500+/-50 1/min

Spec. fuel consumption:243 g/kWh

Valve clearance, inlet:0,3 mm

Valve clearance, outlet:0,5 mm

Opening pressure, injection valves:210 +8 bar

Starter voltage:12 V

Travel pump:

Manufacturer:Bosch-Rexroth

Type:A4VG 56 HW

System:Axial piston-swash plate

Max. displacement: 56 cm3/U

Max. flow ratio:140 l/min

High pressure limitation:475 bar

Pressure override:435+/-15 bar

Charge pressure, high idle:25+/-1 bar

Travel motor, rear:

Manufacturer:Sauer-Danfoss

Type:51D80

System:Axial piston-bent axle

Max. displacement (stage 1): 80 cm3/U

Min. displacement (stage 2): 40,2 cm3/U

Perm. leak oil quantity:2 l/min

Drum drive:

Manufacturer:Poclain

Type:MSE 08 1CX

System:Radial piston

Displacement stage 1: 1260 cm3/U

Perm. leak oil quantity:1,5 l/min

Vibration pump:

Manufacturer:Bosch-Rexroth

Type:A10VG 28 EZ

System:Axial piston-swash plate

Max. displacement: 28 cm3/U

Starting pressure:365+/-35 bar

Operating pressure, soil dependent:ca. 100 bar

Vibration motor:

Manufacturer:Sauer-Danfoss

Type:MMF 025

System:Axial piston-swash plate

Displacement: 25 cm3/U

Frequency:30/40 Hz

Amplitude:1,8/0,9 mm

Steering and charge pump:

Manufacturer:Bosch-Rexroth

Type:HYZ/19

System:Gear pump

Displacement: 19 cm3/U

Max. steering pressure:190 +/-10 bar

Steering valve:

Manufacturer:Sauer-Danfoss

Type:OSPC 315 ON

System:Rotary valve

Rear axle:

Manufacturer:Dana

Type:CHC 192/57LD

Differential:No-Spin

Degree of locking:100 %

Reduction ratio:43,7

Filling capacities:

Engine oil:13,5 l (SAE 15W-40, API SJ/CF)

Hydraulic oil:60 l (HVLP 46 VI 150)

Vibration bearing housing:2x 3,2 l (SAE 15W-40, API SJ/CF)

Rear axle:6,7 l (SAE 90 EP, API GL 5)

Rear axle wheel hubs:0,7 l (SAE 90 EP, API GL 5)

AC refrigerant:1300 g (R 134a)

Compressor oil (filling the system):100 ml (PAG Öl)

Maintenance

Single drum rollers are heavy-duty construction machines for extremely difficult tasks in earth construction. To be able to meet these demands the machines must always be ready to be loaded up to their limits. Furthermore, all safety installations, protections and guards must always be in place and fully functional.

Thorough maintenance of the machine is therefore mandatory. This not only guarantees a remarkably higher functional safety, but also prolongs the lifetime of the machine and of important components.

The time required for thorough maintenance is only minor when being compared with the malfunctions and faults that may occur if these instructions are not observed.

The maintenance intervals are given in operating hours. It is quite obvious that with each maintenance interval all the work for shorter preceding intervals must also be performed. During the 2000 hours interval you must also perform the work described for the service intervals after 50, 250 and 500 hours.

During maintenance work you must only use the fuels and lubricants mentioned in the table of fuels and lubricants (oils, fuels, grease etc.).

The designation specified under No: in the first column of the maintenance chart refers to the corresponding number of the service work to be performed, as specified in the operating and maintenance instructions. This also helps to find detailed information on the individual maintenance tasks.

Maintenance table

5.6 Check the engine oil levelDipstick markX

5.7 Check the water separatorX

5.8 Check the fuel levelX

5.9 Check the hydraulic oil levelInspection glass

5.10 Check dust precleanerX

5.11 Check tire pressureX

5.12 Clean engineoil, fuel and hydraulic oil cooler

5.13 Check the drive axle oil levelX

5.14 Check oil level in wheel hubsX

5.15 Check oil level in vibration bearingsX

5.16 Change engine oil and oil filter elementa min. 1x per yearX

5.17 Battery servicepole greaseX

5.18 Drain the fuel tank sludgeX

5.19 Change the fuel prefilter elementX

5.20 Check V-belt tension, tighten, replace

5.21 Check tension of refrigerant compressor V-belt , tighten, replace

5.22 Service the air conditioningX

5.23 Check, adjust the valve clearanceInlet = 0,3 mm exhaust = 0,5 mm on cold engine

5.24 Oil change in vibration bearingsb see footer, min. 1x per year

5.25 Oil change in drive axlemin. 1x per yearXX

5.26 Oil change in wheel hubsmin. 1x per yearXX

5.27 Replace the fuel filter cartridgeX

5.28 Check the engine mountsXX

5.29 Retighten fastening of axle to frame

5.30 Tighten the wheel nutsXX

5.31 Check the ROPSX

5.32 Clean the oil bath air filtermin. 1x per yearX

5.33 Change hydraulic oil and breather filterc min. every 2 years

5.34 Replace the hydraulic oil filterd min. every 2 years

5.35 Check the injection valvesX

5.36 Replace the toothed beltsmin. every 5 years X

5.37 Service the combustion air filtermin. 1x per year,safety cartridge min. every 2 years

5.38 Adjust the scrapers

5.39 Adjust the parking brakeX

5.40 Change the tires X

5.41 Replace the fresh air filter in the cabin X

5.42 Tightening torques X

5.43 Engine conservation X

a.Oil change intervals depend on quality of oil and fuel (sulphur content)

b.Oil change intervals after 50 h, after 500 h, after 1000 h and then every 1000 h.

c.Also after repairs in the hydraulic system

d.Also after repairs in the hydraulic system

Note:

When changing filters use only the original filters specified in the operating and maintenance instructions for this machine. The installation of incorrect filters (e.g. insufficient pressure resistance) can lead to severe damage on engine or hydraulic components.

When using diesel fuel with a sulphur content of more than 0.5%, the oil change intervals must be halved. The same applies when using engine oils of specification API CF/CF-4.

Deutz diesel engine

Single drum rollers of series BW 177 D-4 are powered by a Deutz diesel engine of product range BF4M 2011. In contrast to the engines 1011/1012 previously used by BOMAG, this engine comes with external oil cooling, i.e. a separate oil cooler and external fan, instead of the well known integrated oil cooler/fan system. This automotive engine is characterized by the following features:

•short and compact design,

•low noise level,

•low vibration running,

•low fuel consumption,

•low exhaust emissions,

•good access to all service points and

•extended maintenance intervals (5000 h) for toothed timing belt, in comparison to the predecessor 1011 F, by installation of an automatic tensioning device and improved enclosure of the toothed belt.

The engine is a 4-cylinder 4-stroke inline engine with direct fuel injection.

The combustion method with direct fuel injection enables the use of a less expensive casting for the cylinder head, highest possible utilization of fuel and minimum heat transfer to the coolant.

This in turn enables the use of a smaller and more compact radiator.

Both the crankcase with cylinders as well as the cylinder head of this ebngine are made of a cast iron alloy. This provides strength and ensures high wear resistance.

The forged steel conrods are fitted with compensation weights near the conrod bearing seats. This weight compensates manufacturing tolerances with respect to weight and centre of gravity.

The pistons are made of an aluminium alloy. The combustion trough has been specially designed for efficient combustion. All pistons are fitted with three piston rings and are lubricated by an oil mist.

Each cylinder is fitted with one intake and one exhaust valve. The valve guides are shrunk into the cylinder head.

Control side

1Intake pipe2Fan

3V-belt pulley on crankshaft4Narrow V-belt

5Fuel shut-off solenoid6Toothed belt cover

7Shut-down lever8Control lever

9Oil filler neck (on side of crankcase)10Oil dipstick

11Fuel12Fuel filter

13Port for oil heating14Lubrication oil filter

15Injection pumps16Oil cooler port

17Injection valves18Fuel return line

Fig. 1: Control side BFM 2011

19Valve cover20Exhaust manifold

21SAE-housing22Starter

23Crank case24Oil line ATL

25Turbocharger26Generator with cover plate

27Charge air line

Exhaust side

Fig. 2: Exhaust side BFM 2011

Lubrication oil circuit

circuit

1Oil sump2Suction strainer with suction pipe

3Oil pump4Main oil channel

5Oil cooled cylinder6Cylinder head cooling groove

7OIl channel for rocker arm lubrication8Rocker arm

9Oil manifold to thermostat10Supply to ext. Oil cooler

11Return flow ext. oil cooler 12Thermostat housing with thermostat spool

13OIl channel to oil filter14Oil filter

15Oil channel to camshaft, conrod and crankshaft bearings

16Oil spray nozzle for piston cooling17Oil return flow via crankcase to oil sump

18Lubrication oil supply to turbo charger19Turbocharger

20Return flow from turbocharger to oil sump

Fig. 3: Lubrication oil

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Fuel circuit

1Fuel line from tank to fuel lift pump

2Fuel lift pump

3Fuel line from fuel lift pump to fuel filter

4Fuel filter

5Fuel line from filter to injection pump

6Injection pumps

7Fuel distribution line

8Injection lines

9Injection valves

10Fuel leakage line

11Fuel overflow line

12Fuel return line to tank

Fig. 4: Fuel circuit