At 818 pages, this official Bomag BW177 D repair manual PDF (OEM ID 0852794) provides the exact structural and hydraulic teardowns needed to keep your D-40, DH-40, and PDH-40 single drum rollers making grade. Extensive hydraulic schematics trace the closed-loop travel and vibration circuits, detailing the Sauer Danfoss axial piston pumps and Poclain MS drive motors. When the machine refuses to drive or the vibrator shaft speed drops, dedicated troubleshooting charts guide you directly to the faulty charge pressure relief valve or servo control. You will verify system health against concrete figures, like the 435 bar maximum travel pressure on the D-40 or the 12/2.9 V/kW starter rating. Nothing shuts down a paving train faster than a roller parked mid-mat waiting on a single test spec. Download this bookmarked, text-searchable file to your tablet and carry the answers right to the operator's platform.
What's Inside This Bomag BW177 D/DH/PDH-40 Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Symbols Used in This Manual | 8-9 | Danger, Warning, Caution, Note |
| Service and Repair Precautions | 10-30 | Poisonous Substances, Engine (Air Conditioning System, Battery) |
| Specifications and Maintenance Schedule | 31-41 | Fuels and Lubricants (Engine Oil, Approved Engine Oils, Hydraulic Oil, Running-In Instructions), Engine Oil Level, Water Separator, Fuel Level, Hydraulic Oil Level, Dust Separator, Tire Pressure |
| Tests, Adjustments and Flushing | 42-84 | Control Solenoid, Servo Control, High Pressure Port, Charge Pressure Relief Valve, Leak Oil Connection, Travel Control Lever, Special Tools, Checking the Rotary Speeds, Checking and Adjusting the Mechanical Neutral Position of the Travel Pump, Pressure Tests in the Travel Circuit, Flushing - General, Hose Routing for Flushing |
| Trouble Shooting Charts | 85-114 | Neutral Position, Travel Control Cable, High and Charge Pressure, Magnetic Coil, Brake Releasing Pressure, Steering/Charge Pump, Check the Neutral Position, Check the Mechanical O-Position, Adjust the Mechanical 0-Position, Check the Servo Control, Check the Travel Control Cable, Check High and Charge Pressure |
| Drum and Oscillating Articulated Joint | 115-164 | Special Tools, Removing the Drum, Removing and Installing the Drum, Installing the Drum, Repair Overview Drum, Repairing the Drum, Disassembling the Bearing Cover, Removing and Installing the Oscillating Articulated Joint, Dismantling the Oscillating Articulated Joint, Assembling the Oscillating Articulated Joint |
| Service Training | 165-225 | Diesel Engine Monitoring, Travel Pump (Cross-Sectional View of Travel Pump, View of the Rotating Group, Function), Tandem Pump (Tandem Pump, Connections an Adjustment Points) |
| Electrics | 226-392 | Function Test, Instrument Cluster, Electric Control Cabinet with Vibration Module, Plug Assignment with Operating Hour Meter, Bw177D-40, Bw177Dh/Pdh-40 |
| Air Conditioning | 393-441 | Compressor, Condenser, Dryer, Expansion Valve, Evaporator, Defroster Thermostat |
| Sauer Danfoss Axial Piston Pumps (Series 90 and 42) | 442-597 | Variable Displacement Pump, Fixed Displacement Motor, Charge Pump, Multi-Function Valves, Displacement Limiters, Speed Sensors, Manual Displacement Control, Electrical Displacement Control, Charge Relief Valve, Loop Flushing Valve, Filtration Adapters, Shaft Seal |
| Poclain MS Hydraulic Motors | 598-677 | Brake Assembly, Bearing Support, Cylinders Block Assembly, Valving, Cam Assembly, End Cover |
| Sauer Danfoss Series 51 Bent Axis Variable Motors | 678-757 | Basic Hydraulic Circuits, Variable Displacement Motors, Controls, Displacement Limiters, Loop Flushing, Pressure Compensator Regulator |
| Dana 192 Axle and Detroit Locker NoSpin | 758-818 | Maintenance and Lubricant, Planetary Reduction, Bevel Pinion, Differential Unit, Braking Unit, Torque Table, Vehicle Performance, Installation, Maintenance, Trouble Shooting, Exploded Views |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Air conditioning system evacuation time | 45 minutes | p. 19 |
| Air conditioning system run time at idle speed | 10 minutes | p. 19 |
| Starter voltage/power | 12/2.9 V/kW | p. 31 |
| Battery voltage/capacity | 12/100 V/Ah | p. 31 |
| Travel pressure max. BW177D-40 | 435 bar | p. 32 |
| Charge pressure limitation | 25 bar | p. 32 |
| Magnetic coil voltage | 14V | p. 93 |
| Magnetic coil current consumption | 1.8A | p. 93 |
| Engine Oil Capacity | 9qt | p. 38 |
| Brake Releasing Pressure | min. 12 bar | p. 32 |
| Max. Steering Pressure | 200 bar | p. 32 |
| Multi-function Valve Tightening Torque | 89 Nm | p. 181 |
Bomag BW177 D/DH/PDH-40 Common Problems This Manual Covers
Bomag BW177 D-40 travel lever moves forward but the roller is stuck in park and will not drive
Check the brake releasing pressure at the travel motor. Connect a gauge and verify the system reaches at least min. 12 bar to release the brake. If pressure is low, inspect the magnetic coil of the brake valve as shown on page 93.
Manual Section: The Machine Does Not Drive p. 93Drum vibration function is completely inoperative or cuts out intermittently during a compaction pass
Test the magnetic coil of the vibration valve on page 106. Verify the coil receives 12V and draws 2.5A. Next, measure the pilot pressure. If it drops below the nominal approx. 20 bar, inspect the vibration pump and check the vibrator shaft bearings for excessive drag.
Manual Section: No Vibration p. 106Steering system feels sticky, lacks function, or fails to reach the end stops when turning
Measure the steering pressure at the test port. Ensure the steering pump delivers approx. 200 bar as detailed on page 101. If pressure is low, inspect the steering cylinders for internal leaks or check the steering/charge pump flow rate at a nominal engine speed of 2200 rpm.
Manual Section: No Steering Function / Steering Sticky / End Stops Not Reached p. 113Vibrator shaft speed is too low to hit target density on the mat
Check the charge pressure at the test port on page 56 using a 60 bar gauge. Start the engine and verify the system maintains a normal charge pressure of min. 24 bar (page 100). If pressure drops, inspect the flushing valve and flushing spool for contamination.
Manual Section: Vibrator Shaft Speed Too Low p. 108Frequently Asked Questions
How do I check the hydraulic pressure in the travel circuit of the BW177 D/DH/PDH-40?
To check the travel circuit pressure, connect 600 bar pressure gauges to the high pressure test ports MA and MB, and a 60 bar pressure gauge to the charge pressure test port. Start the diesel engine and move the throttle to the maximum speed position. The charge pressure should match the charge pressure at high idle, and the high pressure should also match the charge pressure at high idle. p. 56
What is the correct engine oil change interval for the BW177 D/DH/PDH-40?
The engine oil and oil filter cartridge should be changed at least every 500 operating hours, or at least once per year, whichever comes first. p. 35
What is the correct tightening torque for the multi-function valves on the BW177 D/DH/PDH-40?
The multi-function valves must be tightened with a torque of 89 Nm. p. 44
How do I check the leak oil rate of the vibration motor?
To check the leak oil rate, block the flushing valves with washers, disconnect the leak oil hose, and connect a measuring hose to a measuring beaker. Run the engine at maximum speed and switch the vibration on for one timed minute. The maximum permissible leak oil rate is 0.5 l/min. p. 60
What is the correct coolant mixture ratio for the BW177 D/DH/PDH-40?
The proportion of cooling system protection agent must be between a minimum of 35% and a maximum of 45% relative to the water. p. 37
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