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Bomag BW 156 D-3, Service Manual

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Service Training

BW 156/177 D-3/DH-3/PDH-3
BW 178/179 D-3/DH-3/PDH-3

Table of contents

Foreword

A 1

Documentation

A 2

General

A 4

List of components

B 1

Technical data

B 2

Maintenance

B 26

Maintenance table

B 27

Cummins Diesel engine

C 1

External engine parts Cummins 4B 3.9-C

C 3

External engine parts Cummins 4BT 3.9-C

C 5

Adjusting the valve clearance

C 11

Changing the injection pump

C 12

Travel system

D 1

Brake control

D 4

Travel pump

D 5

Multi-function valve

D 13

Charge pressure relief valves

D 15

Flushing valve

D 16

Drum drive motor 

D 17

Axle drive motor

D 21

Drum drive motor ( GFT17) DH/PDH versions

D 23

Trouble shooting travel system

DTr 1

Summary of Contents for BW 156 D-3

Page 1: ...Service Training Single Drum Rollers BW 156 177 D 3 DH 3 PDH 3 BW 156 177 D 3 DH 3 PDH 3 008 098 14 Edition 04 2000...

Page 2: ...gine C 1 External engine parts Cummins 4B 3 9 C C 3 External engine parts Cummins 4BT 3 9 C C 5 Adjusting the valve clearance C 11 Changing the injection pump C 12 Travel system D 1 Brake control D 4...

Page 3: ...7 Vibration motor E 8 Drum E 11 Trouble shooting vibration system ETr 1 Steering F 1 Steering pump F 3 Steering valve F 5 Articulated joint F 7 Trouble shooting steering system FTr 1 Electrical system...

Page 4: ...s for our customers and we therefore would like to ask you to inform us about your ideas and suggestions The introduction of new or enhanced products obviously emphasizes the necessity of training for...

Page 5: ...3 008 140 20 101 580 80 0101 BW 179 DH 3 008 140 20 101 580 83 0101 BW 179 PDH 3 008 140 20 101 580 82 0101 2 Spare parts catalogue Machine type Catalogue No from serial number to serial number BW 15...

Page 6: ...580 11 0101 BW 177 D 3 058 120 124 101 580 10 0101 BW 177 DH 3 058 120 136 101 580 14 0101 BW 177 PDH 3 058 120 136 101 580 13 0101 BW 178 D 3 058 120 187 101 580 70 0101 BW 178 DH 3 058 120 136 101 5...

Page 7: ...h 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 a...

Page 8: ...w centre of gravity and the use of an articulated joint operating afety due to the use of monitoring boards for all important system data automatic engine shut down at too high coolant temperature too...

Page 9: ...ine oil filter 10 Cummins engine 4B3 9 BW 156 D 3 PD 3 4BT 3 9 BW 179 D 3 PD 3 11 Wheels with axle and axle drive motor 12 Vibration pump 13 Travel pump 14 Hydraulic oil filter 15 Hand pump for hood 1...

Page 10: ...246 Starter voltage power V kW 12 2 9 Valve clearance inlet mm 0 254 Valve clearance outlet mm 0 508 Injection valve opening pressure bar 245 253 Travel pump Manufacturer Sauer Type 90 RO 55 System Ax...

Page 11: ...erating pressure max bar 435 15 Leak oil quantity max l min 2 Axle Manufacturer Clark Hurth Type 172 Transmission ratio i 27 Vibration pump Manufacturer Sauer Type 42 R 028 System Axial piston Displac...

Page 12: ...ump Displacement cm 3 rev 22 5 max steering pressure bar 435 15 Steering valve Manufacturer Danfoss Type OSPC 500 ON System Rotary spool valve Filling capacities Coolant 50 water 50 anti freeze l 15 E...

Page 13: ...clearance inlet mm 0 254 0 254 Valve clearance outlet mm 0 508 0 508 Injection valve opening pressure bar 245 253 245 253 Travel pump Manufacturer Sauer Sauer Type 90 RO 55 90 RO 55 System Axial pisto...

Page 14: ...nt range 2 cm3 rev 31 4 31 4 Operating pressure max bar 435 15 435 15 Leak oil quantity max l min 2 2 Axle Manufacturer Clark Hurth Clark Hurth Type 172 172 Reduction ratio i 27 i 27 Vibration pump Ma...

Page 15: ...steering pressure bar 200 10 200 10 Steering valve Manufacturer Danfoss Danfoss Type OSPC 500 ON OSPC 500 ON System Rotary spool valve Rotary spool valve Filling capacities Coolant 50 water 50 anti f...

Page 16: ...Starter voltage power V kW 12 2 9 Valve clearance inlet mm 0 254 Valve clearance outlet mm 0 508 Injection valve opening pressure bar 245 253 Travel pump Manufacturer Sauer Type 90 RO 55 System Axial...

Page 17: ...ing pressure max bar 435 15 Leak oil quantity max l min 2 Axle Manufacturer Clark Hurth Type 172 Transmission ratio i 27 Vibration pump Manufacturer Sauer Type 42 R 028 System Axial piston Displacemen...

Page 18: ...pump Displacement cm 3 rev 22 5 max steering pressure bar 200 10 Steering valve Manufacturer Danfoss Type OSPC 500 ON System Rotary spool valve Filling capacities Coolant 50 water 50 anti freeze l 15...

Page 19: ...clearance inlet mm 0 254 0 254 Valve clearance outlet mm 0 508 0 508 Injection valve opening pressure bar 245 253 245 253 Travel pump Manufacturer Sauer Sauer Type 90 RO 55 90 RO 55 System Axial pist...

Page 20: ...ent range 2 cm3 rev 59 6 59 6 Operating pressure max bar 435 15 435 15 Leak oil quantity max l min 2 2 Axle Manufacturer Clark Hurth Clark Hurth Type 172 172 Reduction ratio i 27 i 27 Vibration pump M...

Page 21: ...2 5 max steering pressure bar 200 10 200 10 Steering valve Manufacturer Danfoss Danfoss Type OSPC 500 ON OSPC 500 ON System Rotary spool valve Rotary spool valve Filling capacities Coolant 50 water 50...

Page 22: ...V kW 12 2 9 Valve clearance inlet mm 0 254 Valve clearance outlet mm 0 508 Injection valve opening pressure bar 245 253 Travel pump Manufacturer Sauer Type 90 RO 55 System Axial piston Control Swash...

Page 23: ...perating pressure max bar 435 15 Leak oil quantity max l min 2 Axle Manufacturer Clark Hurth Type 172 Transmission ratio i 27 Vibration pump Manufacturer Sauer Type 42 R 028 System Axial piston Displa...

Page 24: ...pump Displacement cm 3 rev 22 5 max steering pressure bar 435 15 Steering valve Manufacturer Danfoss Type OSPC 500 ON System Rotary spool valve Filling capacities Coolant 50 water 50 anti freeze l 15...

Page 25: ...e clearance inlet mm 0 254 0 254 Valve clearance outlet mm 0 508 0 508 Injection valve opening pressure bar 245 253 245 253 Travel pump Manufacturer Sauer Sauer Type 90 RO 55 90 RO 55 System Axial pis...

Page 26: ...System Axial piston Axial piston Displacement range 1 cm 3 rev 110 110 Displacement range 2 cm 3 rev 31 4 31 4 Operating pressure max bar 435 15 435 15 Leak oil quantity max l min 2 2 Vibration pump...

Page 27: ...3 rev 22 5 22 5 max steering pressure bar 200 10 200 10 Steering valve Manufacturer Danfoss Danfoss Type OSPC 500 ON OSPC 500 ON System Rotary spool valve Rotary spool valve Filling capacities Coolant...

Page 28: ...V kW 12 2 9 Valve clearance inlet mm 0 254 Valve clearance outlet mm 0 508 Injection valve opening pressure bar 245 253 Travel pump Manufacturer Sauer Type 90 RO 55 System Axial piston Control Swash...

Page 29: ...perating pressure max bar 435 15 Leak oil quantity max l min 2 Axle Manufacturer Clark Hurth Type 172 Transmission ratio i 27 Vibration pump Manufacturer Sauer Type 42 R 028 System Axial piston Displa...

Page 30: ...pump Displacement cm 3 rev 22 5 max steering pressure bar 435 15 Steering valve Manufacturer Danfoss Type OSPC 500 ON System Rotary spool valve Filling capacities Coolant 50 water 50 anti freeze l 15...

Page 31: ...e clearance inlet mm 0 254 0 254 Valve clearance outlet mm 0 508 0 508 Injection valve opening pressure bar 245 253 245 253 Travel pump Manufacturer Sauer Sauer Type 90 RO 55 90 RO 55 System Axial pis...

Page 32: ...0 System Axial piston Axial piston Displacement range 1 cm 3 rev 110 110 Displacement range 2 cm 3 rev 31 4 31 4 Operating pressure max bar 435 15 435 15 Leak oil quantity max l min 2 2 Vibration pump...

Page 33: ...3 rev 22 5 22 5 max steering pressure bar 200 10 200 10 Steering valve Manufacturer Danfoss Danfoss Type OSPC 500 ON OSPC 500 ON System Rotary spool valve Rotary spool valve Filling capacities Coolant...

Page 34: ...ed 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...

Page 35: ...e axle X Change the oil in the planetary drives X Change the oil in the axle reduction gear X Change the oil in the drum drive reduction gear X Change the oil in the vibrator housings drives see note...

Page 36: ...xle X X X X Check the oil level in the vibrator housings X X X X Check the oil level in the drum drive gear DH and PDH X X X X Darin the sludge from the fuel tank X X X Battery maintenance Grease the...

Page 37: ...her filter min every 2 years X X Change the hydraulic oil filter min every 2 years and after repairs in the hydraulic system X X Change the coolant min every 2 years X X Clean replace the combustion a...

Page 38: ...to severe damage on engine or hydraulic components The coolant for the water cooled engine must always be mixed with 40 to 50 anti freeze additive even under hot environmental conditions as a preventi...

Page 39: ...rbo charger and has a power of 75 kW The 4 cylinder four stroke engines are water cooled The combustion method with direct fuel injection enables the use of a less expensive casting for the cylinder h...

Page 40: ...alled in the cylinder block in a similar way It delivers the engine oil from the oil sump to the individual lubrication points Excellent emission values and high availability of engine power are achie...

Page 41: ...ernal engine parts Cummins 4B 3 9 C BW 156 D 3 DH 3 PDH3 BW 177 AD 3 DH 3 PDH 3 Fig 1 Air intake side 4B 3 9 C 1 Fuel filter 2 Water separator 3 Oil dipstick 4 Fuel lift pump 5 Oil filler neck 6 Injec...

Page 42: ...ce Training BW 156 177 D 3 PD 3 C 4 BW 178 179 D 3 PD 3 Fig 2 View starter side 4B 3 9 C 1 Generator 2 Coolant temperature sensor 3 Water pump 4 Coolant inlet port 5 Engine oil filter 6 Starter 1 2 3...

Page 43: ...nal engine parts Cummins 4BT 3 9 C BW 178 D 3 DH 3 PDH3 BW 179 D 3 DH 3 PDH 3 Fig 3 Injection pump side 4BT 3 9 C 1 Fuel filter 2 Water separator 3 Oil dipstick 4 Fuel lift pump 5 Oil filler neck 6 In...

Page 44: ...ter side 4BT 3 9 C 1 Exhaust outlet turbo charger 2 Turbo charger 3 Lubrication oil line to turbo charger 4 Fresh air intake 5 Coolant outlet port 6 Generator 7 Coolant inlet 8 Lubrication oil filter...

Page 45: ...ank 2 Fuel lift pump 3 Fuel line to fuel filter 4 Fuel water separator 5 Fuel filter 6 Low pressure supply line 7 Additional turbo charger control line 8 Injection pump 9 Fuel return line 10 High pres...

Page 46: ...179 D 3 PD 3 Fig 6 Lubrication system closed open Pump cooler Oil sump Filter By Pass Valve to filter from Filter Main oil channel closed open Pressure control valve Lub oil pump Main flow filter oil...

Page 47: ...wer components to the valves from oil cooler Main oil channel Main oil channel from main oil channel to cam shaft to piston cooling nozzle to conrod bearing Crank journal Crankshaft Main journal Rocke...

Page 48: ...g oil cooler 4 Coolant flow around cylinder 5 Coolant to cylinder head 6 Coolant to thermostat housing 7 Coolant to cylinder block 8 Thermostat 9 Coolant flow along injection nozzle 10 Coolant diversi...

Page 49: ...179 D 3 PD 3 Adjusting the valve clearance Nominal value Inlet valve 0 25 mm Outlet valve 0 51 mm Set cylinder 1 to injection TDC Fig 9 Turn the crankshaft 360 further Fig 10 Flywheel side 4 3 2 1 Ou...

Page 50: ...damage your engine You should therefore thoroughly clean all surfaces of the injection pump including all line connections and fittings that have to be disassembled Clean the areas around the cover f...

Page 51: ...ce Training BW 156 177 D 3 PD 3 C 13 BW 178 179 D 3 PD 3 Note After finding the top dead centre pull the pin back out Take the cover off the gear housing Unscrew the nut with the washer from the pump...

Page 52: ...Service Training BW 156 177 D 3 PD 3 C 14 BW 178 179 D 3 PD 3 Pull the injection pump drive gear from the shaft Unscrew the four fastening nuts from the injection pump Take the injection pump off...

Page 53: ...linder 1 is in top dead centre position The fuel injection pump is fitted with an adjustment pin 1 in the governor housing to fix the pump shaft relative to the top dead centre of cylinder 1 After the...

Page 54: ...Service Training BW 156 177 D 3 PD 3 C 16 BW 178 179 D 3 PD 3 Unscrew the plug Take the adjustment pin out...

Page 55: ...stment tooth does not correspond with the slot in the adjustment pin the injection pump must be turned until both parts match Turn the adjustment pin around so that the slot can be pushed over the adj...

Page 56: ...y before assembling the parts Gear and shaft should be cleaned with a fuel free cleansing agent Negligence may cause slipping of the gear on the shaft Note The shaft has a key way for a woodruff key h...

Page 57: ...Service Training BW 156 177 D 3 PD 3 C 19 BW 178 179 D 3 PD 3 Tighten the fastening nuts Tightening torque Fastening nuts 44 Nm...

Page 58: ...ear on with the washer and tighten it Tightening torque 10 to 15 Nm Note Do not exceed the specified tightening torque This is not the final tightening value for the fastening nut Pull the adjustment...

Page 59: ...torque 24 Nm Tighten the fastening nut for the injection pump drive gear Tightening torque 178 Nm Reinsert the cover into the timing gear housing and fasten it Reconnect fuel and oil lines Fasten cont...

Page 60: ...ining BW 156 177 D 3 PD 3 C 22 BW 178 179 D 3 PD 3 Tightening torques High pressure fuel lines 30 Nm Low pressure fuel fittings 15 Nm Bleed fuel injection pump and high pressure lines see operating in...

Page 61: ...1 BW 178 179 D 3 PD 3 Travel system Fig 1 Hydraulic diagram travel system BW 156 D 3 177 D 3 AD 3 1 Travel pump 2 Axle drive motor 3 Drum drive motor Poclain from charge pressure filter vibration cui...

Page 62: ...PD 3 D 2 BW 178 179 D 3 PD 3 Fig 2 Hydraulic diagram travel system BW 156 177 178 179 DH 3 PDH 3 from charge pressure filter Charge supply vibration Releasing the brake 1 Travel pump 2 Axle drive mot...

Page 63: ...quantities are replaced by the charge circuit through the boost check valves in the travel pump The charge pump draws the hydraulic oil out of the hydraulic oil tank and delivers it through the hydrau...

Page 64: ...the machine is additionally equipped with multi disc brakes in drum drive and both wheel drives When engaging the travel lever in neutral position the multi disc brakes will close and the machine can...

Page 65: ...al piston pump with variable displacement for hydrostatic power transmission in a closed hydraulic circuit Fig 3 Hydraulic diagram for travel pump 1 Travel pump 2 Control 3 Charge pressure relief valv...

Page 66: ...e position through neutral both the oil flow direction and the travel direction of the machine will change All valves as well as the safety and control elements required for pump operation in a closed...

Page 67: ...ction of travel pump 1 Holder for swashing cradle 2 Sliding block 3 Servo piston 4 Servo lever 5 Servo valve 6 Feed back device 7 Bearing for swashing cradle 8 Guide for swashing cradle 9 Swashing cra...

Page 68: ...Service Training BW 156 177 D 3 PD 3 D 8 BW 178 179 D 3 PD 3 Fig 6 Travel pump rotating assembly...

Page 69: ...178 179 D 3 PD 3 Fig 7 Cross section of travel pump function 1 Drive shaft 2 Drive shaft bearing 3 Swashing cradle 4 Pistons with slipper pads 5 Cylinder block 6 Multi function valves 7 Charge pump no...

Page 70: ...one of the two possible flow directions the working pistons perform a full stroke movement in the cylinder block with every complete revolution The slipper pads are hydrostatically balanced and are re...

Page 71: ...of the mechanical input signal A mechanical feedback device ensures a fixed relation between the mechanical input signal and the swashing angle of the swash plate A mechanical device spring avoids dam...

Page 72: ...device in the control the swash plate will return to neutral position interrupt the pump flow rate and brake the machine under the following conditions when shutting the engine down if the external c...

Page 73: ...ride works as a pre control unit for the control piston of the pressure relief valve The pressure relief valve the pressure setting of which is higher than the pressure level of the pressure override...

Page 74: ...usted pressure of the pressure override is exceeded pressure fluid will flow through a restriction in the control piston causing a pressure increase on the servo side Here the pressure is normally low...

Page 75: ...function to replace leakages and flushing quantities in the closed travel and vibration circuits and to supply the necessary pilot oil for the controls on travel and vibration pumps the travel speed...

Page 76: ...e pressure difference between the two sides of the closed circuit A and B If the pressure in one side is higher than in the other this pressure will move the valve out of neutral position against the...

Page 77: ...ic motors Fig 12 Radial piston motor Poclain 1 Drive shaft with output flange 2 Piston with roller 3 Oil distributor 4 Brake piston 5 Multi disc brake 6 Cylinder block 7 Cam ring 8 Bearing plate The d...

Page 78: ...he working pistons inside the cylinders are pressed with their rollers against the cam race of the torque module and roll along the cam profile This transforms the axial movement of the pistons to a r...

Page 79: ...n This is the start of a rotation Due to the pressure on the back of the piston the roller will move along the cam thereby causing a rotary movement of the cylinder block Piston position 2 At this poi...

Page 80: ...tion The oil behind the piston is connected with the low pressure side and the retracting piston presses it back to the pump Piston position 5 The oil supply back to the pump comes close to an end the...

Page 81: ...iston motor series 51 D 110 in with variable displacement The DH PDH versions use the same motor as drum drive motor only with a different connecting housing Fig 14 Axial piston motor 1 Control piston...

Page 82: ...ressure ports A and B High pressure hydraulic oil flows through the corresponding high pressure port to the back of the working pistons Since the pistons are arranged under an angle to the output shaf...

Page 83: ...from Sauer and a reduction gear GFT17 from Lohmann Stolterfoth The function of the axial piston motor is identical with the function of the axle drive motor and does thereofre not need to be explaine...

Page 84: ...Fastening to drum 4 Ball bearing 5 Locating pin for bearing 6 Planet gear stage 2 7 Rotating housing hollow wheel stages 1 and 2 8 Planet carrier stage 1 9 Planet gear stage 1 10 Drive shaft sun gear...

Page 85: ...shooting steps described in this training manual are identical with the problems and trouble shooting steps in the operating and maintenance instructions for this machine However in this manual we ha...

Page 86: ...rives with travel lever in NEUTRAL Check neutral position Fig F1 Adjust the travel cable Fig F2 Check mechanical 0 position Fig F3 OK no yes OK Adjust the mechanical 0 position Fig F4 no OK no yes Che...

Page 87: ...veability OK no yes yes Replace the steering charge pump Check charge pressure relief valve Fig F7 OK no yes OK no yes Replace the charge pressure relief valve Check the leakage of the brake Fig F8 Ch...

Page 88: ...ssures OK yes no Check ax le drive motor travel pump Fig F13 Check flushing valve on drum drive motor axial piston motor Fig F14 OK no yes Replace repair the drum drive motor Replace the flushing valv...

Page 89: ...Check travel cable for play and wear OK no yes OK Adjust replace the travel cable no Continue with machine does not drive from check charge pressure yes Check the thermostat valve Fig F16 Replace the...

Page 90: ...neutral position and both sides of the closed circuit have identical pressure charge pressure If the machine moves in this condition on flat ground you should perform trouble shooting by applying the...

Page 91: ...3 PD 3 DTr 3 Fig F2 Adjusting the travel cable Slacken the counter nut on the travel cable bracket to adjust the travel contgrol cable turn the adjustment nut until the correct neutral position bores...

Page 92: ...s piston is connected with the swash plate and its position determines the position of the swash plate If the piston is out of neutral position the swash plate actuates the working pistons whereby oil...

Page 93: ...pressure gauges to the high pressure test ports Pull the plug off the brake solenoid valve and block the drum Start the engine and run it with max speed Read the pressure gauges and adjust the mechani...

Page 94: ...3 PD 3 BW 178 179 D 3 PD 3 DTr 6 Fig F5 Checking the servo control Disassemble the servo control Check piston and linkages for moveability and wear Check the nozzles clean if necessary replace a defec...

Page 95: ...g BW 156 177 D 3 PD 3 BW 178 179 D 3 PD 3 DTr 7 Fig F6 Checking the charge pressure Connect a 60 bar pressure gauge to the charge pressure test port Start the engine and run it with max speed Nominal...

Page 96: ...aining BW 156 177 D 3 PD 3 BW 178 179 D 3 PD 3 DTr 8 Fig F7 Checking the charge pressure relief valve Unscrew the valve and check for dirt and damage Replace a defective charge pressure relief valve i...

Page 97: ...charge pressure the brake cannot be released Release the brake by shifting the travel lever out of braking position Disconnect the brake lines one after the other from drum drive and wheel drive motor...

Page 98: ...nnect a 60 bar pressure gauge to the charge pressure test port Pull the plug off the brake solenoid valve and block the drum Start the engine and run it with max speed Drive the machine against the cl...

Page 99: ...release the brake disengage the travel lever from the braking position use an appropriate meter to measure the voltage and current draw on the magnetic coil of the solenoid valve Nominal values BW 17...

Page 100: ...the brake discs cannot open Install a pressure test port with a 60 bar pressure gauge to the brake releasing line Start the engine and release the brake disengage the travel lever from the braking pos...

Page 101: ...nd close them with suitable plugs Perform a high pressure test Fig F9 If the specified pressure values are reached after disconnecting the drum drive motor whereas they have not been reached while the...

Page 102: ...gh pressure hoses from the travel pump Close the pump port with pressure resistant plugs Perform a high pressure test Fig F9 If the specified pressure values are now reached and the drum drive motor i...

Page 103: ...n case of a failure on one of the flushing valves a too high oil quantity may be flushed out and the charge circuit may not be able to replace this quantity The charge pressure will drop and important...

Page 104: ...178 179 D 3 PD 3 DTr 16 Fig F15 back to vibration Checking the engine speed Start the engine and run it with max speed Measure the engine speed with a suitable RPM meter e g digital optical RPM meter...

Page 105: ...orm trouble shooting Do not start to operate the machine unless the fault has been corrected First check the function of the thermostat valve Up to a temperature of 60 C all leak oil flushing and retu...

Page 106: ...valves e g in case ofa defective pressure override which is also part of the multi function valve will cause very quick overheating of the hydraulic oil Pull the plug off the brake solenoid valve Blo...

Page 107: ...tudes This enables a perfect adaptation of the machine to various types of soil and application profiles The vibratio drive is a closed hydraulic circuit The circuit consists of the vibration pump the...

Page 108: ...motor will be reversed Since the end stops for the two directions have different settings the angle positions between swash plate and stroke direction of the pistons are different to both sides This a...

Page 109: ...the swash plate out of neutral position the displacement for the chosen travel direction will increase from 0 to maximum displacement Changing the swash plate position through neutral to the opposite...

Page 110: ...e Training BW 156 177 D 3 PD 3 E 4 BW 178 179 D 3 PD 3 Function Fig 4 Cross section of vibration pump 1 Servo piston 2 Working pistons 3 Charge pump 4 Valve plate 5 Roller bearing 6 Swash plate 1 2 3...

Page 111: ...face of the swash plate and are at the same time held on the sliding surface by a retaining device During each rotation the piston pass through their upper and lower dead centre back to their initial...

Page 112: ...emote control converts the electric input signal to a load controlling output signal Since the pump is not equipped with a proportional control but a 12 Volt solenoid valve the pump is always actuated...

Page 113: ...45 bar charge pressure 29 bar The screw type cartridges of the high pressure relief valves contain also the boost check valves for the closed vibration circuit The function of these valves has already...

Page 114: ...m both sides it is most suitable for the use in closed hydraulic circuits The output speed of the motor depends on the oil quantity supplied by the vibration pump Fig 7 Cross section of vibration moto...

Page 115: ...ion shaft This resistance causes a hydraulic starting pressure which is limited to 365 bar by the corresponding high pressure relief valve Once the vibrator shaft has reached its final speed the press...

Page 116: ...e neutral setting spring so that oil can flow out of the low pressure side Fig 9 Flushing valve 1 Flushing spool 2 Flushing pressure relief valve The flushing valve is fitted with a downstream 13 bar...

Page 117: ...ge over weight 2 Vibration bearing 9 Coupling vibrat motor vibrat shaft 3 Basic eccentric weight 10 Tavel bearing 4 Vibrator housing 11 Travel bearing housing 5 Cooling fan 12 Rubber buffer 6 Vibrator...

Page 118: ...le shooting steps described in this training manual are identical with the problems and trouble shooting steps in the operating and maintenance instructions for this machine However in this manual we...

Page 119: ...OK Start pressure too low Charge pr start pressure too low Replace repair the vibration pump OK no yes Check flushing valve on vibration motor Fig V7 Treplace the flushing valve Replace repair the vi...

Page 120: ...or low amplitude Check magnetic oil on vibration valve Fig V4 Voltage current OK no yes Perform trouble shooting in electric system Check the solenoid valve OK no yes Replace the solenoid valve Check...

Page 121: ...Adjust the speed for high or low frequency Fig V5 no yes Check the vibration pressures Fig V1 Check vibrator shaft bearings replace if necessary Fig V6 Check the vibration pump Fig V3 OK Charge press...

Page 122: ...vibration motor coupling A too high operating pressure is an indicator for damaged vibration bearings or overfilling of the vibration bearing housing Connect 600 bar pressure gauges to the high press...

Page 123: ...aining BW 156 177 D 3 PD 3 BW 178 179 D 3 PD 3 ETr 3 Fig V2 Checking the coupling on the vibration motor Disassemble the vibration motor Check the coupling parts between motor and shaft Replace defect...

Page 124: ...gh pressure ports on the vibration pump with plugs Check the vibration pressures see Fig V2 If the pressure values are now reached whereas they were not reached while the vibration motor was connected...

Page 125: ...ETr 5 Fig V4 Checking the magnetic coil of the vibration valve Switch the ignition on Switch the vibration on with high or low frequency Measure the voltage applied to the magnetic coil and the curren...

Page 126: ...shaft speed is less than 10 the corresponding frequency can be adjusted on the vibration pump Slacken the counter nut on the respective adjustment screw Turn the adjustment screw until the required v...

Page 127: ...ce Training BW 156 177 D 3 PD 3 BW 178 179 D 3 PD 3 ETr 7 Fig V6 Checking the vibrator shaft bearings Disassemble the vibration motor Check the moveability of the vibration bearings Replace defective...

Page 128: ...3 PD 3 BW 178 179 D 3 PD 3 ETr 8 Fig V7 Checking the flushing valve on the vibration motor Unscrew the flushing valve from the vibration motor Check the flushing spool for damage and moveability Repla...

Page 129: ...and the pressure resistant connecting hoses The steering pump delivers the hydraulic oil from the tank to the steering valve and the connected steering unit If the steering is not operated the complet...

Page 130: ...e of the steering wheel and delives this oil to the steering cylinders The steering cylinders extend or retract and articulate the machine The steering unit is fitted with an integrated pressure relie...

Page 131: ...ling Drive gear and driven gear are positioned by a bearing plate in such a way that the gears mesh with minimum clearance when rotating The displacement chambers are created between the tooth flanks...

Page 132: ...l be losses from the pressure side to the suction side An axial pressure field presses the bearing plate on the cover side against the front face of the gears making sure that only a very little quant...

Page 133: ...ock consists mainly of the distributor valve the rating pump the steering pressure relief valve and the shock valves Fig 3 Steering valve 1 Neutral setting springs 6 Ring gear 2 Housing 7 Gear 3 Inner...

Page 134: ...hock valves in each pressure side to the steering cylinders These valves are adjusted to 240 bar The valves compensate extreme pressure peaks which may occur e g when driving over obstructions and pro...

Page 135: ...ly bolted to the rear frame The front console is fastened with screws to the rear cross member of the front frame The rocker bearings between front and rear console ensure that both frame parts of the...

Page 136: ...o the front console When turning the steering wheel the steering cylinders will extend or retract respectively whereby the piston rods swivel the front console around the vertical pin The machine arti...

Page 137: ...ooting steps described in this training manual are identical with the problems and trouble shooting steps in the operating and maintenance instructions for this machine However in this manual we have...

Page 138: ...ravel system OK Check the steering pressure Fig L1 Check moveability of articulated joint and steering cylinders OK yes no Check steering charge pump Fig L2 OK no yes Replace repair the steering charg...

Page 139: ...ng the steering pressure Connect a 600 bar pressure gauge to the steering pressure test port Start the engine and run it with max speed Turn the steering against an end stop and hold the steering whee...

Page 140: ...elief valve between steering pump outlet and high pressure hose to the steering valve Connect a 600 bar pressure gauge Start the engine low idle speed and read the pressure gauge Nominal value 200 bar...

Page 141: ...the cylinders is defective After this test reconnect the hoses To find out which cylinder is defective you should proceed as follows Start the engine and if possible steer fully to left or right and...

Page 142: ...ional ASC Anti Spin Control enables optimal traction of tires and drum This ensures safe travel behaviour on difficult ground and maximum gradability on a hill Since the diode module is only used in t...

Page 143: ...Service Training BW 156 177 D 3 PD 3 G 2 BW 178 179 D 3 PD 3 Supply Fig 1 Power supply...

Page 144: ...attery minus to vehicle ground potential 31 Note Potentials 30 31 and B are always directly connected with the battery The current is only be interrupted if the battery is empty or disconnected Genera...

Page 145: ...Service Training BW 156 177 D 3 PD 3 G 4 BW 178 179 D 3 PD 3 Starting Fig 2 Ignition and starting circuit...

Page 146: ...onitoring unit A15 Fig 3 supplies the coil of relay K22 40 with current the relay switches Current flows from potential K11 fuse F14 37 the closed EMERGENCY STOP switch S01 37 the closed contacts of r...

Page 147: ...new starting attempt the ignition must first be switched off lock against repetitive starting Ignition switch S00 in position 1 ignition on with the engine running When the engine is running the gene...

Page 148: ...Service Training BW 156 177 D 3 PD 3 G 7 BW 178 179 D 3 PD 3 Fault monitoring board Fig 3 Fault monitoring board...

Page 149: ...ecified time all sender signals must change to the corresponding potentail for the condition O K Otherwise the signal fields will light the warning buzzer is activated and the shut off relay is switch...

Page 150: ...tion group Colour of indication Shut off relay Hydraulic oil filter B21 red 2 minutes Coolant temperature B53 red 2 minutes Engine oil pressure B06 red 10 seconds Brake closed red Charge control MD ye...

Page 151: ...Service Training BW 156 177 D 3 PD 3 G 10 BW 178 179 D 3 PD 3 Function diagram fault indicator Fig 4 Fault indicator...

Page 152: ...Service Training BW 156 177 D 3 PD 3 G 11 BW 178 179 D 3 PD 3 Brakes Fig 5 Brake...

Page 153: ...lay K36 33 If the travel lever is in brake position the coil of relay K48 05 will not be excited Current flows from potential K11 via fuse F25 the contacts of relay K48 07 to the coil of relay K05 09...

Page 154: ...P switch S01 34 to solenoid valve Y04 34 The brake is released If the MD signal is missing e g because of a snapped V belt a defective generator or if the engine has been stalled e g on a slope to coi...

Page 155: ...Service Training BW 156 177 D 3 PD 3 G 14 BW 178 179 D 3 PD 3 Travel speed range selector Fig 6 Travel speed ranges...

Page 156: ...gh the closed contact K26 07 to the back up alarm buzzer H14 11 The back up alarm will sound Forward tavel In this position the proximity switch B14 05 closes Current flows from potential K11 via fuse...

Page 157: ...travel speed range selector switch S42 23 is in position 1 turtle none of the solenoid valves Y30 11 Y31 18 is supplied with current In this switch position all motors for drum and axle work with hig...

Page 158: ...th current In this switching condition both motors for drum and axle are switched to low displacement The machine drives with high speed range transport speed In this switch position current flows fro...

Page 159: ...Service Training BW 156 177 D 3 PD 3 G 18 BW 178 179 D 3 PD 3 Vibration Fig 7 Vibration...

Page 160: ...lay K04 05 When pressing the push button S13 05 the toggle relay will switch and the contact of toggle relay K04 05 will close Current flows to the selector switch for high low amplitude S35 29 Depend...

Page 161: ...7 582 700 71 Vibrationseinschaltung activation of vibration 008 582 700 71 Anti Schlupfregelung nur bei DH PDH Maschinen anti spin control only acc to DH PDH versions 009 582 700 71 Variocontrol vario...

Page 162: ...r gn gn Y14 Kraftstoffpumpe 1 2 Steuerger t Schalter Kabinenheizung max 20A nenn 2A 25A Au erhalb der Kabine montiert assembled outside of cabin innerhalb der Kabine Zusatzausr stung option inside of...

Page 163: ...cabin 17 K11 86 85 K32 86 85 F13 X18 2 1 X17 2 4 B 2 10 X17 2 3 X18 2 2 V08 1 2 V07 1 2 Y13 Hubmagnet 4BT3 9C HW AW ws sw rt K11 3 6 30 87 K22 4 12 30 87a 87 X18 1 7 X17 1 6 50A 4 12 Nur bei VARIOCON...

Page 164: ...gn bl gr br ge ge gn ws X18 1 5 X18 1 4 X17 1 8 X17 1 1 X18 2 3 X17 2 2 B55 K hlmittelvorrat Q 3 4 B21 Hydraulik lfilter P 2 3 K22 86 85 P01 Tankanzeige G P02 Hydraulik ltemperatur G P14 K hlmittelte...

Page 165: ...16 Tachographenmodul 4 3 2 1 6 7 8 9 5 P05 Frequenzanzeige 31 4 20 31 6 1 ZA Frequenzanzeige option frequency meter ZA Tachograph option tachograph F24 4 20 F24 X1 278 X1 282 X1 281 X1 285 X1 279 X1 2...

Page 166: ...tion front speed range selection rear max 1 67A Poclain max 1 23A speed range selection rear f r BW 156 177 D AD acc to BW 156 177 D AD switch speed range switch speed range V10 V11 V12 K26 6 5 30 87a...

Page 167: ...G 0 K F03 Standardvibration mit 2 Amplituden und ASC Notbetrieb emergency service module vibration push button travel lever S13 Taster Fahrhebel 3 4 X8 1 X8 2 K04 Modul Vibration 30 S 56a 56b 56 F03 V...

Page 168: ...onic motor drum motor axle potentiometer travel lever sensor drum speed sensor axle speed slope sensor connection diagnosis tool 0 5V 4 5V 1V 2 5V 4V 09 0 Signal 1 Gang Vibration 09 1 Signal und 08 0...

Page 169: ...1kOhm R24 R25 R26 amplitude indicator Fahrtrichtungserkennung vertikal 12V 5x0 75 Leistung S106 Automatik S AGND S107 Hand Pr fen S AGND 30A 10A 1x0 75 Elektronik 1x1 5 1x1 5 Z ndung 15 54 X11 7 X11...

Page 170: ...meter Ausr stungsumfang VM2 VM5 terra meter applications VM2 VM5 Omegameter Ausr stungsumfang VM1 omega meter application VM1 15 8 7 Stecker f r in Planung interface max 10A max 1A w out gnd r in w in...

Page 171: ...P07 Omegameter Bedieneinheit printer unit printer controller start stop print PD D test normal clear continue comp achieved illum omegameter illum frequency meter illum speedometer omegameter frequen...

Page 172: ...0 18A 0 18A 40A 15A sprinkler pump interval switch switch sprinkler system solenoid valve sprinkler 4s abschaltverz gert 1 83A solenoid valve sprinkler 31 10 20 31 13 1 M02 Berieselungspumpe K46 86 8...

Page 173: ...r indicator front LH contour indicator front RH contour indicator rear RH indicator relay bei ROPS Aufbau rotary beacon acc to ROPS A02 Blinkgeber 49 31 49a F08 15A K06 13 3 30 87a 87 BR 4 19 BL 4 19...

Page 174: ...1 F42 B 2 F43 C 3 F44 D 4 F31 E 5 F17 F 6 E29 Innenleuchte 1 2 S21 2 5 7 4 X28 2 6 X28 1 7 X28 2 7 X28 1 6 X28 2 8 X28 1 5 X28 2 5 X28 1 8 S20 2 5 7 4 X29 2 5 X29 1 8 X29 2 6 X29 1 7 X29 2 7 X29 1 6 X...

Page 175: ...Omegameter Illumination Omegameter E08 013 18 Blinkleuchte vorne links Indicator front lh MAX 1 75A E09 013 18 Blinkleuchte hinten links Indicator rear lh MAX 1 75A E10 013 19 Blinkleuchte vorne rech...

Page 176: ...12 14 Emulsionsberieselungspumpe Emulsion sprinkler pump MAX 7 2A M04 014 10 Scheibenwischermotor vorne Windscreen wiper motor front 4 7A M05 014 8 Scheibenwischermotor hinten Windscreen wiper motor r...

Page 177: ...de Diode L TZE V10 006 11 Diode Diode L TZE V11 006 14 Diode Diode L TZE V12 006 15 Diode Diode L TZE V13 007 4 Diode Diode VENTIL V13 007 9 Diode Diode VENTIL V14 007 5 Diode Diode VENTIL V14 007 10...

Page 178: ...GO E BOX X1 120 007 12 WAGO E KASTEN WAGO E BOX X1 120 007 17 WAGO E KASTEN WAGO E BOX X1 121 007 2 WAGO E KASTEN WAGO E BOX X1 121 007 7 WAGO E KASTEN WAGO E BOX X1 121 007 12 WAGO E KASTEN WAGO E BO...

Page 179: ...E KASTEN WAGO E BOX X1 188 004 18 WAGO E KASTEN WAGO E BOX X1 189 004 18 WAGO E KASTEN WAGO E BOX X1 18A 013 12 SIKA KLEMME fuse terminal X1 18E 013 12 SIKA KLEMME fuse terminal X1 190 006 9 WAGO E K...

Page 180: ...O E KASTEN WAGO E BOX X1 289 010 7 WAGO E KASTEN WAGO E BOX X1 28A 003 12 SIKA KLEMME fuse terminal X1 28E 003 12 SIKA KLEMME fuse terminal X1 290 010 7 WAGO E KASTEN WAGO E BOX X1 291 010 7 WAGO E KA...

Page 181: ...ARIOCONTROL variocontrol X2 20 009 6 VARIOCONTROL variocontrol X2 21 009 8 VARIOCONTROL variocontrol X2 22 009 9 VARIOCONTROL variocontrol X2 23 009 9 VARIOCONTROL variocontrol X2 24 009 9 VARIOCONTRO...

Page 182: ...9 Steckdose Socket X10 1 19 010 13 SCHALTBAU FAHRERSTAND SCHALTBAU operators platform X11 1 009 19 SCHALTBAU DIAGNOSE Schaltbau diagnosis X11 2 009 18 SCHALTBAU DIAGNOSE Schaltbau diagnosis X11 3 009...

Page 183: ...HLU LEUCHTE connector tail lights X27 2 013 7 STECKER SCHLU LEUCHTE connector tail lights X27 3 013 7 STECKER SCHLU LEUCHTE connector tail lights X30 1 014 9 WISCHER HINTEN connector wiper rear X30 2...

Page 184: ...6 10 Magnetventil Stufenumschaltung hinten Solenoid valve speed range sel rear MAX 1 23A Y31 006 15 Magnetventil Stufenumschaltung hinten Solenoid valve speed range sel rear MAX 1 23A Y31 008 9 Magnet...

Page 185: ...252 249 253 268 271 269 272 270 273 274 276 275 277 278 282 279 283 280 284 268 289 287 290 288 291 292 296 293 297 294 298 295 299 254 256 258 261 259 262 260 263 264 266 300 305 301 306 302 307 303...

Page 186: ...2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 X2 1 30...

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