Bomag BW 156 D-3 Manuel utilisateur

Service Training

Single Drum Rollers

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

008 098 14 Edition 04/2000

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 (51D110 + GFT17) DH/PDH versions D 23

Trouble shooting travel system DTr 1

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Vibration E 1

Vibration pump E 3

Control E 6

High pressure relief valves E 6

Charge pump E 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 G 1

Power supply G 2

Starting G 4

Fault monitoring board G 7

Function diagram fault indicator G 10

Brakes G 11

Travel speed range selector G 14

Vibration G 18

Service Training

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Foreword

This training manual was specially written for the new single drum rollers BW 156 D-3 to BW 179 PDH-

3 of generation 3. This range of single drum rollers is the consistent further development of the product

range BW 142 D-2 to BW 172 PD-2 and represents a perfect adaptation to the presently highest

technical standards.

Today single drum rollers of series BW 156 and BW 179 can be found on construction sites all over the

world. These machines are mainly used in earth construction, for the preparation and sealing of sanitary

landfill sites and, as AD-versions, for the compaction of bituminous wear courses.

During the development of this new generation of single drum rollers special attention was paid to the

necessities and requirements of customers and operating personnel.

Also in the future we will obviously undertake everything possible to increase the benefits 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 all

persons who are responsible for a trouble free service support for these products.

For this reason we have revised these training documents. They should help the trainer to pass the

necessary information on to the persons attending the training course in an easy to understand way.

This documentation is by no means complete. Technical data and details, which were not yet available

at the time this manual was written or which have changed since the introduction of this manual, must

be explained by the trainer during the training session.

These training documents are not subjected to a regular updating service. However, all important

changes to the machine will be included during a revision.

The chapter „Documentation“ contains notes on further documents, which are additionally available for

this machine. The currently valid operating and maintenance instructions and the latest electric and

hydraulic diagrams are part of this training manual.

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Documentation

For the single drum rollers BW 156 D-3 to BW 179 PDH-3 the following documents are available:

1. Operating and maintenance instructions

Machine type Catalogue-No.: from serial-number to serial-number

BW 156 D-3 008 140 20 101 580 00 0101

BW 156 DH-3 008 140 20 101 580 03 0101

BW 156 PDH-3 008 140 20 101 580 02 0101

BW 177 AD-3 008 140 20 101 580 11 0101

BW 177 D-3 008 140 20 101 580 10 0101

BW 177 DH-3 008 140 20 101 580 14 0101

BW 177 PDH-3 008 140 20 101 580 13 0101

BW 178 D-3 008 140 20 101 580 70 0101

BW 178 DH-3 008 140 20 101 580 73 0101

BW 178 PDH-3 008 140 20 101 580 72 0101

BW 179 D-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 156 D-3 008 153 00 101 580 00 0101

BW 165 DH-3 008 153 03 101 580 03 0101

BW 156 PDH-3 008 153 02 101 580 02 0101

BW 177 AD-3 008 153 11 101 580 11 0101

BW 177 D-3 008 153 10 101 580 10 0101

BW 177 DH-3 008 153 14 101 580 14 0101

BW 177 PDH-3 008 153 13 101 580 13 0101

BW 178 D-3 008 153 70 101 580 70 0101

BW 178 DH-3 008 153 73 101 580 73 0101

BW 178 PDH-3 008 153 72 101 580 72 0101

BW 179 D-3 008 153 80 101 580 80 0101

BW 179 DH-3 008 153 83 101 580 83 0101

BW 179 PDH-3 008 153 82 101 580 82 0101

3. Electric circuit diagram*

Drawing-No.: for machine

582 700 38 for single drum rollers with new control board

582 700 48 for single drum rollers with new control board from BJ 02/99

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4. Hydraulic diagram*

Machine type Catalogue-No.: from serial-number to serial-number

BW 156 D-3 058 120 124 101 580 00 0101

BW 156 DH-3 058 120 136 101 580 03 0101

BW 156 PDH-3 058 120 136 101 580 02 0101

BW 177 AD-3 058 120 124 101 580 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-3 058 120 136 101 580 73 0101

BW 178 PDH-3 058 120 136 101 580 72 0101

BW 179 D-3 058 120 187 101 580 80 0101

BW 179 DH-3 058 120 136 101 580 83 0101

BW 179 PDH-3 058 120 136 101 580 82 0101

5. Repair instructions

Catalogue-No.: Component Part-No.

6. Service Information

Remark:

* These documents are part of this training manual

Service Training

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General

The new single drum rollers BW 156 D-3 to BW 179 PDH-3 from BOMAG are mainly further

developments of their predecessors BW 142 D-2 to BW 172 DH-2.

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,wehavedecidedtousethesamesuccessfuldriveconceptwithdieselengine(watercooled)

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 board 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

offers clear vision to all sides.

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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

•multi-disc brakes in planetary gears as parking and emergency brakes

•high stability due to low 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 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 156 D-3 to BW 179 PDH-3 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.

Service Training

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BW 178/179 D-3/PD-3

List of components

1Drum

2Drum drive motor

3Front frame

4Articulated joint

5Operator’s stand

6Hydraulic oil tank

7Hydraulic oil cooler

8Radiator

9Engine 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

16 Accumulator for the absorption of vibrations in the steering

17 Fuel filter

18 Steering/charge pump

19 Colling blower

20 Operator’s seat

21 Steering wheel with steering valve

22 Vibration motor

23 Generator

24 Starter

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BW 156 D-3

Engine

Manufacturer Cummins

Type 4 B 3.9-C

Cooling Water

Rated power ISO 9249 kW 56

at nominal speed min-1 2200

Low idle speed min-1 700 - 950

High idle speed min-1 2280 - 2330

spec. fuel consumption g/kWh approx. 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 Axial piston

Control Swash plate

Displacement cm3/rev. 55

High pressure limitation bar 435 +/- 15

Charge pressure bar 25 +/- 1

Travel motor (drum)

Manufacturer Poclain

Type MSE 08

System Radial piston

Displacement cm3/rev. 1260

Operating pressure, max. bar 435 +/- 15

Leak oil quantity, max l/min 2

Ce manuel convient aux modèles suivants

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