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

Service Training

Walzenzug BW 177 D-4

Teile-Nr. 008 099 90

06/2004

Service Training Table of contents

BW 177 D-4

Foreword

A1

Documentation

A2

General

A4

List of components

B1

Technical data

B2

Maintenance

C1

Maintenance table

C2

DEUTZ Diesel engine

D1

Service side

D2

Starter side

D3

Lubrication oil circuit

D4

Fuel system

D5

Checking and adjusting the valve clearance

D6

Plug-in injection pump

D8

Travel system

E1

Travel pump

E3

Servo control

E6

Charge pressure relief valve

E 11

High pressure relief valve

E 12

Pressure override

E 14

Axle drive motor

E 16

Drum drive motor

E 20

Trouble shooting travel system

E 29

Service Training

BW 177 D-4

Vibration

F1

Vibration pump

F3

High pressure protection

F6

Control

F7

Charge pump

F8

Vibration motor

F9

Drum

F 12

Trouble shooting vibration

F 14

Steering

G1

Steering pump

G2

Steering valve

G4

Articulated joint

G6

Trouble shooting steering

G8

Electrical system

H1

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.

BW 177 D-4

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Service Training Documentation For the BOMAG machines described in this training manual the following documentation is additionally available: Attention!

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

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.

BW 177 D-4

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

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

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

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

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

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

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

The cabin is very spacious and clearly arranged. The 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.

BW 177 D-4

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Service Training Important characteristics of the new generation of single drum rollers are • strong ROPS/FOPS according to SAE-standard • wear free service brake by closed hydrostatic travel circuits • disc brakes in axle and drum drive motor serve as parking and emergency brakes • high stability due to low centre of gravity and the use of an articulated joint • operating safety due to the use of monitoring boards for all important system data • automatic engine shut-down at too engine temperature, too low hydraulic oil level (when reaching the lowest permissible level the engine will be shut down after 20 seconds) and too low engine oil pressure.

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

BW 177 D-4

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Service Training 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.

BW 177 Series 4

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BOMAG Central Service

Seite 1 von 2

BOMAG Central Service - Technical data and adjustment values Status: 2004-06-21

Product type:

BW 177 D Serie 4

Type No.: Serial numbers from:

582 20 101 582 20 1001

Engine: Manufacturer: Type: Combustion principle: Cooling: Number of cylinders: Power acc. to ISO 9249: Power data at nominal speed of: Low idle speed: High idle speed: Spec. fuel consumption: Valve clearance, inlet: Valve clearance, outlet: Opening pressure, injection valves: Starter voltage:

Deutz BF4M 2011 4-stroke-Diesel Air-Oil 4 54 kW 2300 1/min 850 +/-150 1/min 2500+/-50 1/min 243 g/kWh 0,3 mm 0,5 mm 210 +8 bar 12 V

Travel pump: Manufacturer: Type: System: Max. displacement: Max. flow ratio: High pressure limitation: Pressure override: Charge pressure, high idle:

Bosch-Rexroth A4VG 56 HW Axial piston-swash plate 56 cm3/U 140 l/min 475 bar 435+/-15 bar 25+/-1 bar

Travel motor, rear: Manufacturer: Type: System: Max. displacement (stage 1): Min. displacement (stage 2): Perm. leak oil quantity:

Sauer-Danfoss 51D80 Axial piston-bent axle 80 cm3/U 40,2 cm3/U 2 l/min

Drum drive: Manufacturer: Type: System: Displacement stage 1: Perm. leak oil quantity:

Poclain MSE 08 1CX Radial piston 1260 cm3/U 1,5 l/min

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BOMAG Central Service

Seite 2 von 2

Vibration pump: Manufacturer: Type: System: Max. displacement:

Bosch-Rexroth A10VG 28 EZ Axial piston-swash plate

28 cm3/U Starting pressure: 365+/-35 bar Operating pressure, soil dependent: ca. 100 bar

Vibration motor: Manufacturer: Type: System: Displacement: Frequency: Amplitude:

Sauer-Danfoss MMF 025 Axial piston-swash plate 25 cm3/U 30/40 Hz 1,8/0,9 mm

Steering and charge pump: Manufacturer: Type: System: Displacement: Max. steering pressure:

Bosch-Rexroth HYZ/19 Gear pump 19 cm3/U 190 +/-10 bar

Steering valve: Manufacturer: Type: System:

Sauer-Danfoss OSPC 315 ON Rotary valve

Rear axle: Manufacturer: Type: Differential: Degree of locking: Reduction ratio:

Dana CHC 192/57LD No-Spin 100 % 43,7

Filling capacities: Engine oil: Hydraulic oil: Vibration bearing housing: Rear axle: Rear axle wheel hubs: AC refrigerant: Compressor oil (filling the system):

13,5 l (SAE 15W-40, API SJ/CF) 60 l (HVLP 46 VI 150) 2x 3,2 l (SAE 15W-40, API SJ/CF) 6,7 l (SAE 90 EP, API GL 5) 0,7 l (SAE 90 EP, API GL 5) 1300 g (R 134a) 100 ml (PAG Ă–l)

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Service Training 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.

BW 177 D Series 4

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Service Training

5.7

Check the water separator

X

5.8

Check the fuel level

X

5.9

Check the hydraulic oil level

Inspection glass

5.10 Check dust precleaner

as required

Dipstick mark

every 5000 oper. hours

Check the engine oil level

every 3000 oper. hours

5.6

every 2000 oper. hours

Remark

every 1000 oper. hours

Maintenance work

every 500 oper. hours

No.

every 250 oper. hours

every 10 op. hours, daily

Running-in instructions after 50 operating hours

Maintenance table

X

X X

5.11 Check tire pressure

X

5.12 Clean engineoil, fuel and hydraulic oil cooler

X

5.13 Check the drive axle oil level

X

5.14 Check oil level in wheel hubs

X

5.15 Check oil level in vibration bearings

X

5.16 Change engine oil and oil filter ele- min. 1x per year menta

X

5.17 Battery service

X

pole grease

5.18 Drain the fuel tank sludge

X

5.19 Change the fuel prefilter element

X

5.20 Check V-belt tension, tighten, replace

X

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

X

5.22 Service the air conditioning

X

5.23 Check, adjust the valve clearance Inlet = 0,3 mm

X

exhaust = 0,5 mm on cold engine

BW 177 D Series 4

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5.24 Oil change in vibration bearingsb

see footer, min. X 1x per year

X

5.25 Oil change in drive axle

min. 1x per year X

X

5.26 Oil change in wheel hubs

min. 1x per year X

X

5.27 Replace the fuel filter cartridge

as required

every 5000 oper. hours

every 3000 oper. hours

X

5.28 Check the engine mounts

X

5.29 Retighten fastening of axle to frame

X X

5.30 Tighten the wheel nuts

X

5.31 Check the ROPS 5.32 Clean the oil bath air filter

every 2000 oper. hours

every 1000 oper. hours

every 500 oper. hours

Remark

every 250 oper. hours

Maintenance work

every 10 op. hours, daily

No.

Running-in instructions after 50 operating hours

Service Training

X X

min. 1x per year

X

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

X

5.34 Replace the hydraulic oil filterd

X

min. every 2 years

5.35 Check the injection valves

X

5.36 Replace the toothed belts

min. every 5 years

5.37 Service the combustion air filter

min. 1x per year,safety cartridge min. every 2 years

X X

5.38 Adjust the scrapers

X

5.39 Adjust the parking brake

X

5.40 Change the tires

X

5.41 Replace the fresh air filter in the cabin

X

5.42 Tightening torques

X

5.43 Engine conservation

X

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

BW 177 D Series 4

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Service Training 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.

BW 177 D Series 4

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Service Training 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.

BW 177 D-4

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Service Training Control side

Fig. 1: Control side BFM 2011 1

Intake pipe

2

Fan

3

V-belt pulley on crankshaft

4

Narrow V-belt

5

Fuel shut-off solenoid

6

Toothed belt cover

7

Shut-down lever

8

Control lever

9

Oil filler neck (on side of crankcase)

10

Oil dipstick

11

Fuel

12

Fuel filter

13

Port for oil heating

14

Lubrication oil filter

15

Injection pumps

16

Oil cooler port

17

Injection valves

18

Fuel return line

BW 177 D-4

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Service Training Exhaust side

Fig. 2: Exhaust side BFM 2011 19

Valve cover

20

Exhaust manifold

21

SAE-housing

22

Starter

23

Crank case

24

Oil line ATL

25

Turbocharger

26

Generator with cover plate

27

Charge air line

BW 177 D-4

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Service Training Lubrication oil circuit

Fig. 3: Lubrication oil circuit 1

Oil sump

2

Suction strainer with suction pipe

3

Oil pump

4

Main oil channel

5

Oil cooled cylinder

6

Cylinder head cooling groove

7

OIl channel for rocker arm lubrication

8

Rocker arm

9

Oil manifold to thermostat

10 Supply to ext. Oil cooler

11 Return flow ext. oil cooler

12 Thermostat housing with thermostat spool

13 OIl channel to oil filter

14 Oil filter

15 Oil channel to camshaft, conrod and crankshaft bearings 16 Oil spray nozzle for piston cooling

17 Oil return flow via crankcase to oil sump

18 Lubrication oil supply to turbo charger

19 Turbocharger

20 Return flow from turbocharger to oil sump

BW 177 D-4

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Service Training Fuel circuit

Fig. 4: Fuel circuit 1

Fuel line from tank to fuel lift pump

2

Fuel lift pump

3

Fuel line from fuel lift pump to fuel filter

4

Fuel filter

5

Fuel line from filter to injection pump

6

Injection pumps

7

Fuel distribution line

8

Injection lines

9

Injection valves

10

Fuel leakage line

11

Fuel overflow line

12

Fuel return line to tank

BW 177 D-4

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