Bomag BW 156 D-3 Service Manual
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Bomag BW 156 D-3 Service Manual

Bomag BW 156 D-3 Service Manual

Single drum roller
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Service Training
Single Drum Rollers
BW 156/177 D-3/DH-3/PDH-3
BW 156/177 D-3/DH-3/PDH-3
Edition 04/2000
008 098 14

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Summary of Contents for Bomag 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 Edition 04/2000 008 098 14...

  • Page 2: Table Of Contents

    Service Training Table of contents Foreword Documentation General List of components Technical data Maintenance B 26 Maintenance table B 27 Cummins Diesel engine External engine parts Cummins 4B 3.9-C External engine parts Cummins 4BT 3.9-C Adjusting the valve clearance C 11 Changing the injection pump C 12 Travel system...
  • Page 3 Service Training Vibration Vibration pump Control High pressure relief valves Charge pump Vibration motor Drum E 11 Trouble shooting vibration system ETr 1 Steering Steering pump Steering valve Articulated joint Trouble shooting steering system FTr 1 Electrical system Power supply Starting Fault monitoring board Function diagram fault indicator...

  • Page 4: Foreword

    Service Training 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.

  • Page 5: Documentation

    Service Training 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...
  • Page 6 Service Training 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...

  • Page 7: General

    Service Training 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.
  • Page 8 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.

  • Page 9: List Of Components

    Operator’s stand Hydraulic oil tank Hydraulic oil cooler Radiator Engine oil filter Cummins engine 4B3.9 (BW 156 D-3/PD-3); 4BT 3.9 (BW 179 D-3/PD-3) Wheels (with axle and axle drive motor) Vibration pump Travel pump Hydraulic oil filter Hand pump for hood...
  • Page 10 Service Training BW 156 D-3 Engine Manufacturer Cummins Type 4 B 3.9-C Cooling Water Rated power ISO 9249 at nominal speed 2200 Low idle speed 700 - 950 High idle speed 2280 - 2330 spec. fuel consumption g/kWh approx. 246...
  • Page 11 Service Training BW 156 D-3 Travel motor (axle) Manufacturer Sauer Type 51 D 110 System Axial piston Displacement, range 1 /rev. Displacement, range 2 /rev. 55,3 Operating pressure, max. 435 +/- 15 Leak oil quantity, max l/min Axle Manufacturer Clark-Hurth...
  • Page 12 Service Training BW 156 D-3 Steering pump Manufacturer Bosch Type HY/ZFS11/22,5 System Gear pump Displacement /rev. 22,5 max. steering pressure 435 +/- 15 Steering valve Manufacturer Danfoss Type OSPC 500 ON System Rotary spool valve Filling capacities Coolant (50% water/50% anti-freeze)
  • Page 13 Service Training BW 156 DH-3 BW 156 PDH-3 Engine Manufacturer Cummins Cummins Type 4 B 3.9-C 4 B 3.9-C Cooling Water Water Rated power ISO 9249 at nominal speed 2200 2200 Low idle speed 700 - 950 700 - 950 High idle speed 2280 - 2330 2280 - 2330...
  • Page 14 Service Training BW 156 DH-3 BW 156 PDH-3 Reduction gear (drum) Manufacturer Lohmann + Stolterfoth Lohmann + Stolterfoth Type GFT 17 GFT 17 Reduction ratio i = 53,95 i = 53,95 Travel motor (axle) Manufacturer Sauer Sauer Type 51 D 110 51 D 110 System Axial piston...
  • Page 15 Service Training BW 156 DH-3 BW 156 PDH-3 Steering pump Manufacturer Bosch Bosch Type HY/ZFS11/22,5 HY/ZFS11/22,5 System Gear pump Gear pump Displacement /rev. 22,5 22,5 max. steering pressure 200 +/- 10 200 +/- 10 Steering valve Manufacturer Danfoss Danfoss Type OSPC 500 ON OSPC 500 ON System...
  • Page 16 Service Training BW 177 AD-3 Engine Manufacturer Cummins Type 4 B 3.9-C Cooling Water Rated power ISO 9249 at nominal speed 2200 Low idle speed 700 - 950 High idle speed 2280 - 2330 spec. fuel consumption g/kWh Starter voltage/power V/kW 12/2,9 Valve clearance (inlet)
  • Page 17 Service Training BW 177 AD-3 Travel motor (axle) Manufacturer Sauer Type 51 D 110 System Axial piston Displacement, range 1 /rev. Displacement /rev. 59,6 Operating pressure, max. 435 +/- 15 Leak oil quantity, max l/min Axle Manufacturer Clark-Hurth Type Transmission ratio i = 27 Vibration pump Manufacturer...
  • Page 18 Service Training BW 177 AD-3 Steering pump Manufacturer Bosch Type HY/ZFS11/22,5 System Gear pump Displacement /rev. 22,5 max. steering pressure 200 +/- 10 Steering valve Manufacturer Danfoss Type OSPC 500 ON System Rotary spool valve Filling capacities Coolant (50% water/50% anti-freeze) Engine oil 15W/40 10,9 Hydraulic oil HV46...
  • Page 19 Service Training BW 177 DH-3 BW 177 PDH-3 Engine Manufacturer Cummins Cummins Type 4 B 3.9-C 4 B 3.9-C Cooling Water Water Rated power ISO 9249 at nominal speed 2200 2200 Low idle speed 700 - 950 700 - 950 High idle speed 2280 - 2330 2280 - 2330...
  • Page 20 Service Training BW 177 DH-3 BW 177 PDH-3 Reduction gear (drum) Manufacturer Lohmann + Stolterfoth Lohmann + Stolterfoth Type GFT17 GFT17 Reduction ratio i = 53,95 i = 53,95 Travel motor (axle) Manufacturer Sauer Sauer Type 51 D 110 51 D 110 System Axial piston Axial piston...
  • Page 21 Service Training BW 177 DH-3 BW 177 PDH-3 Steering pump Manufacturer Bosch Bosch Type HY/ZFS11/22,5 HY/ZFS11/22,5 System Gear pump Gear pump Displacement /rev. 22,5 22,5 max. steering pressure 200 +/- 10 200 +/- 10 Steering valve Manufacturer Danfoss Danfoss Type OSPC 500 ON OSPC 500 ON System...
  • Page 22 Service Training BW 178 D-3 Engine Manufacturer Cummins Type 4 BT 3.9-C Cooling Water Rated power ISO 9249 at nominal speed 2200 Low idle speed 700 - 950 High idle speed 2280 - 2330 spec. fuel consumption g/kWh Starter voltage/power V/kW 12/2,9 Valve clearance (inlet)
  • Page 23 Service Training BW 178 D-3 Travel motor (axle) Manufacturer Sauer Type 51 D 110 System Axial piston Displacement, range 1 /rev. Displacement, range 2 /rev. 55,3 Operating pressure, max. 435 +/- 15 Leak oil quantity, max l/min Axle Manufacturer Clark-Hurth Type Transmission ratio i = 27...
  • Page 24 Service Training BW 178 D-3 Steering pump Manufacturer Bosch Type HY/ZFS11/22,5 System Gear pump Displacement /rev. 22,5 max. steering pressure 435 +/- 15 Steering valve Manufacturer Danfoss Type OSPC 500 ON System Rotary spool valve Filling capacities Coolant (50% water/50% anti-freeze) Engine oil 15W/40 10,9 Hydraulic oil HV46...
  • Page 25 Service Training BW 178 DH-3 BW 178 PDH-3 Engine Manufacturer Cummins Cummins Type 4 BT 3.9-C 4 BT 3.9-C Cooling Water Water Rated power ISO 9249 at nominal speed 2200 2200 Low idle speed min 700 - 950 700 - 950 High idle speed 2280 - 2330 2280 - 2330...
  • Page 26 Service Training BW 178 DH-3 BW 178 PDH-3 Reduction gear (drum) Manufacturer Lohmann + Stolterfoth Lohmann + Stolterfoth Type GFT 17 GFT 17 Reduction ratio i = 53,95 i = 53,95 Axle Manufacturer Clark-Hurth Clark-Hurth Type Reduction ratio i = 27 i = 27 Travel motor (axle) Manufacturer...

  • Page 27: Manufacturer Type System

    Service Training BW 178 DH-3 BW 178 PDH-3 Steering pump Manufacturer Bosch Bosch Type HY/ZFS11/22,5 HY/ZFS11/22,5 System Gear pump Gear pump Displacement /rev. 22,5 22,5 max. steering pressure 200 +/- 10 200 +/- 10 Steering valve Manufacturer Danfoss Danfoss Type OSPC 500 ON OSPC 500 ON System...

  • Page 28: Displacement

    Service Training BW 179 D-3 Engine Manufacturer Cummins Type 4 BT 3.9-C Cooling Water Rated power ISO 9249 at nominal speed 2200 Low idle speed 700 - 950 High idle speed 2280 - 2330 spec. fuel consumption g/kWh Starter voltage/power V/kW 12/2,9 Valve clearance (inlet)
  • Page 29 Service Training BW 179 D-3 Travel motor (axle) Manufacturer Sauer Type 51 D 110 System Axial piston Displacement, range 1 /rev. Displacement, range 2 /rev. 55,3 Operating pressure, max. 435 +/- 15 Leak oil quantity, max l/min Axle Manufacturer Clark-Hurth Type Transmission ratio i = 27...

  • Page 30: Hydraulic Oil Hv46

    Service Training BW 179 D-3 Steering pump Manufacturer Bosch Type HY/ZFS11/22,5 System Gear pump Displacement /rev. 22,5 max. steering pressure 435 +/- 15 Steering valve Manufacturer Danfoss Type OSPC 500 ON System Rotary spool valve Filling capacities Coolant (50% water/50% anti-freeze) Engine oil 15W/40 10,9 Hydraulic oil HV46...
  • Page 31 Service Training BW 179 DH-3 BW 179 PDH-3 Engine Manufacturer Cummins Cummins Type 4 BT 3.9 C 4 BT 3.9 C Cooling Water Water Rated power ISO 9249 at nominal speed 2200 2200 Low idle speed 700 - 950 700 - 950 High idle speed 2280 - 2330 2280 - 2330...
  • Page 32 Service Training BW 179 DH-3 BW 179 PDH-3 Reduction gear (drum) Manufacturer Lohmann + Stolterfoth Lohmann + Stolterfoth Type GFT 17 GFT 17 Reduction ratio i = 53,95 i = 53,95 Axle Manufacturer Clark-Hurth Clark-Hurth Type Reduction ratio i = 27 i = 27 Travel motor (axle) Manufacturer...
  • Page 33 Service Training BW 179 DH-3 BW 179 PDH-3 Steering pump Manufacturer Bosch Bosch Type HY/ZFS11/22,5 HY/ZFS11/22,5 System Gear pump Gear pump Displacement /rev. 22,5 22,5 max. steering pressure 200 +/- 10 200 +/- 10 Steering valve Manufacturer Danfoss Danfoss Type OSPC 500 ON OSPC 500 ON System...

  • Page 34: Maintenance

    Service Training Maintenance Single drum rollers of series BW 156 D-3 to BW 179 PDH-3 are heavy-duty machines for extremely difficult applications in earth work. To be able to meet these demands the machine must always be ready to be loaded up to its limits. Apart from this all safety installations must always be fully functional.

  • Page 35: Maintenance Table

    Service Training Maintenance table Maintenance work Comment Tighten all bolted connections on air intake, exhaust, oil sump and engine mounts Retighten the bolted connections on the machine Retighten the wheel studs Change the oil in the axle Change the oil in the planetary drives Change the oil in the axle reduction gear Change the oil in the drum drive reduction gear...
  • Page 36 Service Training Maintenance work Comment Adjust the scrapers Change engine oil and oil filter min. 1 x per year Clean the cooling fins on engine oil and hydraulic oil cooler Check the oil level in the axle Check the oil level in the planetary gear of the axle Check the oil level in the vibrator housings Check the oil level in the drum drive gear...
  • Page 37 Service Training Maintenance work Comment Check and adjust the valve clearance intake = 0.254 mm (on cold engine) CUMMINS exhaust = 0.508 Change hydraulic oil and breather filter min. every 2 years Change the hydraulic oil filter min. every 2 years and after repairs in the hydraulic system...
  • Page 38 Service Training 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. 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 preventive measure against corrosion and cavitation.
  • Page 39 • low noise development, • low exhaust emissions, • simple, but effective constructive design with simple installation characteristics. The engines used in these single drum rollers have the following designations: • BW 156 D-3/PD-3 4B3.9 • BW 179 D-3/PD-3 4BT3.9 The engine 4B3.9 is an aspirating engine with a power of 56 kW.
  • Page 40 Service Training The crankshaft is made of forged steel and has inductively hardened transition radii at the bearing journals. The crankshaft is designed for considerably higher loads. Due to the use of modern design methods the number of individual engine elements could be considerably reduced.

  • Page 41: External Engine Parts Cummins 4B 3.9-C

    Service Training External 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 Fuel filter Water separator Oil dipstick Fuel lift pump Oil filler neck Injection pump Engine solenoid (behind injection pump)
  • Page 42 Service Training Fig. 2 View starter side 4B 3.9-C Generator Coolant temperature sensor Water pump Coolant inlet port Engine oil filter Starter BW 156/177 D-3/PD-3 - C 4 - BW 178/179 D-3/PD-3...

  • Page 43: External Engine Parts Cummins 4Bt 3.9-C

    Service Training External 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 Fuel filter Water separator Oil dipstick Fuel lift pump Oil filler neck Injection pump Engine solenoid (behind injection pump) BW 156/177 D-3/PD-3 - C 5 - BW 178/179 D-3/PD-3...
  • Page 44 Service Training Fig. 4 View starter side 4BT 3.9-C Exhaust outlet turbo charger Turbo charger Lubrication oil line to turbo charger Fresh air intake Coolant outlet port Generator Coolant inlet Lubrication oil filter Lubrication oil return from turbo charger Starter BW 156/177 D-3/PD-3 - C 6 - BW 178/179 D-3/PD-3...
  • Page 45 Service Training Fig. 5 Fuel system Fuel from fuel tank Fuel lift pump Fuel line to fuel filter Fuel-water separator Fuel filter Low pressure supply line Additional turbo charger control line Injection pump Fuel return line High pressure line Injection nozzle Fuel return to fuel tank BW 156/177 D-3/PD-3 - C 7 -...
  • Page 46 Service Training Filter By-Pass Valve to filter from Filter Main flow filter, oil cooler Main closed oil channel open closed sump Pump Lub. oil open cooler pump Filter-by-pass Pressure control valve valve Oil supply Oil drain Fig. 6 Lubrication system BW 156/177 D-3/PD-3 - C 8 - BW 178/179 D-3/PD-3...
  • Page 47 Service Training to the valves from main oil channel Main oil channel to cam shaft to piston cooling nozzle from oil cooler to conrod bearing Rocker arm block Oil slot Crank journal Crankshaft Main journal Head gasket Trough Rocker arm Rocker arm shaft Rocker arm...
  • Page 48 Service Training Fig. 8 Cooling system Coolant inlet (from radiator) Coolant pump Coolant flow along oil cooler Coolant flow around cylinder Coolant to cylinder head Coolant to thermostat housing Coolant to cylinder block Thermostat Coolant flow along injection nozzle Coolant diversion, by-pass to radiator closed Coolant flow to pump inlet Coolant return to radiator By-pass to radiator open...

  • Page 49: Adjusting The Valve Clearance

    Service Training Adjusting the valve clearance Nominal value: Inlet valve: 0,25 mm Outlet valve: 0,51 mm • Set cylinder 1 to injection TDC Out In Flywheel side Fig. 9 • Turn the crankshaft 360° further Flywheel side Fig. 10 BW 156/177 D-3/PD-3 - C 11 - BW 178/179 D-3/PD-3...

  • Page 50: Changing The Injection Pump

    Service Training Changing the injection pump Preparation: • Thoroughly clean the area around the injection pump. • Disconnect the fuel line to the pump. • Disassemble the control linkage. • Disassemble the control air line for the fuel-air mix. • Remove the oil lines. Note: Dirt or water in the fuel system can lead to engine damage.
  • Page 51 Service Training 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 shaft. BW 156/177 D-3/PD-3 - C 13 - BW 178/179 D-3/PD-3...
  • Page 52 Service Training • Pull the injection pump drive gear from the shaft. • Unscrew the four fastening nuts from the injection pump. • Take the injection pump off. BW 156/177 D-3/PD-3 - C 14 - BW 178/179 D-3/PD-3...
  • Page 53 Service Training Assembly Note: Make sure that cylinder 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 installation of the pump this pin must be turned around and inserted into the housing (2).
  • Page 54 Service Training • Unscrew the plug. • Take the adjustment pin out. BW 156/177 D-3/PD-3 - C 16 - BW 178/179 D-3/PD-3...
  • Page 55 Service Training Note: If the adjustment 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 adjustment tooth in the pump.
  • Page 56 Service Training Note: If the O-ring of the fastening flange has a coloured stripe it can no longer be used. Replace it by a new one. Do not cover the new O-ring with lubricant. Lubricate the seat area in the timing gear housing. •...
  • Page 57 Service Training • Tighten the fastening nuts. Tightening torque: Fastening nuts: 44 Nm BW 156/177 D-3/PD-3 - C 19 - BW 178/179 D-3/PD-3...
  • Page 58 Service Training • Screw the fastening nut for the injection pump drive gear 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. •...
  • Page 59 Service Training Tightening 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 control lines for fuel-air mix, control linkage and engine shut- down solenoid.
  • Page 60 Service Training Tightening torques High pressure fuel lines 30 Nm Low pressure fuel fittings 15 Nm • Bleed fuel injection pump and high pressure lines (see operating instructions) BW 156/177 D-3/PD-3 - C 22 - BW 178/179 D-3/PD-3...

  • Page 61: Travel System

    Service Training Travel system 1 Travel pump 2 Axle drive motor 3 Drum drive motor (Poclain) Fig. 1 Hydraulic diagram travel system BW 156 D-3, 177 D-3/AD-3 BW 156/177 D-3/PD-3 - D 1 - BW 178/179 D-3/PD-3...
  • Page 62 Service Training Travel pump Axle drive motor Drum drive motor (Sauer 51D) Fig. 2 Hydraulic diagram travel system BW 156/177/178/179 DH-3/PDH-3 BW 156/177 D-3/PD-3 - D 2 - BW 178/179 D-3/PD-3...
  • Page 63 Service Training The travel system of the single drum roller product range BW 156/177/178/179 D/PD-3 and DH/PDH-3 is a closed hydrostatic circuit. The circuit consists mainly of • the travel pump with control and safety elements, • the drum drive motor with integrated multi-disc brake, •...
  • Page 64 Service Training Brake control During operation the closed hydrostatic travel circuit has the function of a service brake. When moving the travel lever from full forward or reverse position towards neutral, the travel pump will follow towards zero position relative to the movement of the travel lever. The oil flow is thereby reduced and the machine is hydraulically braked.
  • Page 65 Service Training Travel pump The travel pump is a swash plate operated Sauer-Sundstrand axial piston pump with variable displacement for hydrostatic power transmission in a closed hydraulic circuit. from charge pressure filter to vibration circuit charge port brake, travel speed range selector Fig.
  • Page 66 Service Training The pump flow is proportional to the drive speed (engine speed) and the infinitely adjustable displacement. By altering the position of the swash plate the pump flow can be adjusted from “0" to maximum pump displacement. When changing the swash plate position through neutral both the oil flow direction and the travel direction of the machine will change.
  • Page 67 Holder for swashing cradle Sliding block Servo piston Servo lever Servo valve Feed-back device Bearing for swashing cradle Guide for swashing cradle Swashing cradle Swashing lever Charge pump (not for Bomag) BW 156/177 D-3/PD-3 - D 7 - BW 178/179 D-3/PD-3...
  • Page 68 Service Training Fig. 6 Travel pump, rotating assembly BW 156/177 D-3/PD-3 - D 8 - BW 178/179 D-3/PD-3...
  • Page 69 Service Training Fig. 7 Cross-section of travel pump, function Drive shaft Drive shaft bearing Swashing cradle Pistons with slipper pads Cylinder block Multi-function valves Charge pump (not for Bomag) Valve plate BW 156/177 D-3/PD-3 - D 9 - BW 178/179 D-3/PD-3...
  • Page 70 Service Training Description of function The drive shaft (1) is directly driven by the diesel engine via an elastic coupling and transfers the rotary motion to the cylinder block (5) via a splined connection. The cylinder block rotates with the drive shaft (1), thereby carrying the working pistons (4). The pistons rest with their slipper pads on the sliding face of the swashing cradle (3).
  • Page 71 Service Training Mechanical-hydraulic displacement control MA The mechanical – hydraulic displacement control (servo control) converts the mechanical input signal on the control lever (1) into a position controlling output signal. This position controlling signal determines the swashing angle of the swash plate (8) and thereby the displacement of the travel pump as well as the swashing direction and obviously also the flow direction of the pressure fluid.
  • Page 72 Service Training Servo cylinder Control piston Sliding block Servo arm Fig. 9 Control piston Due to the spring-type centering 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: •...
  • Page 73 Service Training Multi-function valve High pressure limitation Pumps of series 90 are equipped with a follower valve, which activates a pressure override and a pressure relief valve, one after the other. When the adjusted pressure value is reached, the pressure override will return the pump very quickly back towards neutral, thereby limiting the system pressure.
  • Page 74 Service Training The pressure override function limits the pressure without overheating the system, whereas the high pressure relief valve eliminates suddenly appearing pressure peaks. Since the pressure relief valve responds only in case of a very quick pressure increase, the heat development is only limited a relatively short period of time.
  • Page 75 Service Training Charge pressure relief valve The charge pressure relief valve is a direct acting valve with a fixed adjustment and belongs to the group of safety elements in the closed circuit. This valve limits the pressure in the charge circuit to the value determined by the setting of the valve (approx.
  • Page 76 Service Training Flushing valve Fig. 11 Cross-section of flushing valve 1 Flushing spool 2 Flushing pressure relief valve The flushing valves are integrated in the axle drive motor, or on DH/PDH machines, also in the drum drive motor. In case of a pressure increase in one of the two sides of the closed circuit the flushing valves have the function to flush a certain quantity of oil out of the low pressure side.
  • Page 77 Service Training Drum drive motor On single drum rollers of generation “3" both the drive wheels as well as the drums are driven by hydraulic motors. Fig. 12 Radial piston motor (Poclain) Drive shaft with output flange Piston with roller Oil distributor Brake piston Multi-disc brake...
  • Page 78 Service Training The motor consists of • the outer three-piece housing, • the flat distributor, • the cylinder block with the working pistons, • the output shaft and • the brake. The motor housing consists of • the bearing section (drive shaft bearings), •...
  • Page 79 Service Training Fig. 13 Function of radial piston motor Piston position 1: The oil enters into the oil distributor under pressure, flows through the distributor and presses against the piston. 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.
  • Page 80 Service Training Piston position 3: Once the piston has reached the deepest point the oil flow to the piston is cut off. The piston is no longer driven. It has reached its dead centre. Another piston must now be driven to move the previous piston out of dead centre position.
  • Page 81 Service Training Axle drive motor and drum drive motor DH/PDH-versions The wheel drive motor is a swash plate controlled Sauer-Sundstrand axial piston 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).
  • Page 82 Service Training The motor can be adjusted to two fixed displacements. This is accomplished by changing the angle position of the cylinder block to the output shaft. With a large angle position the motor works with maximum displacement, slow speed and high torque. When swashing the cylinder block to minimum angle the motor will work with minimum displacement, high speed and low torque.
  • Page 83 Service Training Drum drive (51D110 + GFT17) DH/PDH-versions On the DH/PDH-versions the drum is driven by a fast rotating axial piston motor 51D110 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 explained in detail.
  • Page 84 Service Training Fastening to front frame Fixed housing section = planet carrier stage 2 Fastening to drum Ball bearing Locating pin for bearing Planet gear stage 2 Rotating housing = hollow wheel stages 1 and 2 Planet carrier stage 1 Planet gear stage 1 Drive shaft = sun gear stage 1 Hollow shaft = receptacle for motor output and brake shaft...
  • Page 85 Service Training Trouble shooting travel circuit The following description of trouble shooting steps contains a small selection of possible faults, which may occur during operation of the machine. This list is by no means complete, however, the description should help you to become acquainted with a systematic trouble shooting procedure. The problems and trouble 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.
  • Page 86 Service Training Machine drives with travel lever in „NEUTRAL“ Check neutral position Fig. F1 Adjust the travel OK ? cable Fig. F2 Check mechanical ‚0‘- position Fig. F3 Adjust the mechanical OK ? 0-position Fig. F4 Check the servo control Fig.
  • Page 87 Service Training Machine does not drive (to both directions) Check the control cable (torn/ detached) Replace / attach the OK ? OK ? OK ? travel cable Check charge pressure Fig. F6 Check function of steering OK ? and moveability Replace the Check high steering/charge...
  • Page 88 Service Training Testing of individual components Check the drum drive motor Fig. F12 Check flushing valve on drum Pressures drive motor (axial piston OK ? motor), Fig. F14 Check axöle drive motor / travel pump Fig. F13 OK ? Replace the flushing valve Check the flushing valve Pressures...
  • Page 89 Service Training Insufficient travel power, max. speed is not reached Check the engine speed Fig. F15 Perform trouble shooting OK ? on diesel engine Check travel cable for play and wear Adjust / replace the OK ? travel cable Continue with „machine does not drive“...
  • Page 90 Service Training Fig. F1: Checking the neutral position With the travel lever in neutral position the machine must not move, even when the engine is running. In this condition the travel pump is centred in neutral position and both sides of the closed circuit have identical pressure (charge pressure).
  • Page 91 Service Training 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 in line) is reached • tighten the counter nut again BW 156/177 D-3/PD-3 BW 178/179 D-3/PD-3 - DTr 3 -...
  • Page 92 Service Training Fig. F3: Checking the mechanical neutral position The mechanical neutral position determines the mechanical position of the pump control piston. This 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 is being pumped to the travel motors.
  • Page 93 Service Training Fig. F4: Adjusting the mechanical neutral position If the machine still moves after connecting both control chambers, the mechanical neutral position of the travel pump needs to be adjusted: • Connect 600 bar pressure gauges to the high pressure test ports •...
  • Page 94 Service Training 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 defective servo control immediately. BW 156/177 D-3/PD-3 BW 178/179 D-3/PD-3 - DTr 6 -...
  • Page 95 Service Training 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 value: 25 +/-1 bar BW 156/177 D-3/PD-3 BW 178/179 D-3/PD-3 - DTr 7 -...
  • Page 96 Service Training Fig. F7: Checking the charge pressure relief valve • Unscrew the valve and check for dirt and damage Replace a defective charge pressure relief valve immediately. BW 156/177 D-3/PD-3 BW 178/179 D-3/PD-3 - DTr 8 -...
  • Page 97 Service Training Fig. F8: Checking the leakage of the brake A leakage in the brake housings can cause a drop in charge pressure, the brake cannot be released. • Release the brake by shifting the travel lever out of braking position •...
  • Page 98 Service Training Fig. F9: Checking high pressure • Connect 600 bar pressure gauges to the high pressure test ports • Connect a 60 bar pressure gauge to the charge pressure test port • Pull the plug off the brake solenoid valve and block the drum •...
  • Page 99 Service Training Fig. F10: Checking the magnetic coil of the brake valve • Start the engine and 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 178 / 179 D-3:12 V / 1,8 A;...
  • Page 100 Service Training Fig. F11: Checking the brake releasing pressure If the brake valve does not open, no oil from the charge circuit will be guided to the brakes and the brake discs cannot open. • Install a pressure test port with a 60 bar pressure gauge to the brake releasing line •...
  • Page 101 Service Training Fig. F12: Checking the drum drive motor • Unscrew the high pressure hoses from the drum drive motor and 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 motor was still connected, the drum drive motor is defective.
  • Page 102 Service Training Fig. F13: Checking axle drive motor / travel pump • Disconnect the high 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 is OK, the fault must be in the axle drive motor.
  • Page 103 Service Training Fig. F14: Checking the flushing valves on axle drive and drum drive motor (only axial piston motor) In 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.
  • Page 104 Service Training 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) Nominal value: 2300 rpm (high idle speed) BW 156/177 D-3/PD-3 BW 178/179 D-3/PD-3 - DTr 16 -...
  • Page 105 Service Training Fig. F16: Checking the thermostat valve If the hydraulic oil heats up to a too high temperature it will loose its lubrication properties, which may cause damage to important components in the hydraulic system. In case of a too high hydraulic oil temperature shut the engine down immediately, let the system cool down and perform trouble shooting.
  • Page 106 Service Training Fig. F17: Checking the multi-function valves The opening cross-sections of the high pressure relief valves, which are part of the multi-function valves, are very small. Hydraulic oil escaping from the high pressure side through the high pressure relief valves (e.g.
  • Page 107 Service Training Vibration The vibration system of the single drum roller product ranges BW 156/177 D-3/PD-3 and BW 178/179 D-3/PD-3 works with two different frequencies and amplitudes. This enables a perfect adaptation of the machine to various types of soil and application profiles. The vibratio drive is a closed hydraulic circuit.
  • Page 108 Service Training Vibration pump and travel pump are joined together to a tandem pump unit. This tandem unit is directly driven by the diesel engine. When switching the 4/3-way solenoid valve on the pump control from neutral position to one of the two possible directions pilot oil will flow from the charge circuit to one of the control piston sides.
  • Page 109 Service Training Vibration pump Similar to the travel pump, the vibration pump is also a swash plate operated Sauer-Sundstrand axial piston pump with variable displacement for operation in a closed hydraulic circuit. The displacement of the pump is proportional to the engine speed and the chosen displacment. When actuating the swash plate out of neutral position the displacement for the chosen travel direction will increase from “0"...
  • Page 110 Service Training Function Fig. 4 Cross-section of vibration pump Servo piston Working pistons Charge pump Valve plate Roller bearing Swash plate BW 156/177 D-3/PD-3 - E 4 - BW 178/179 D-3/PD-3...
  • Page 111 Service Training Fig. 5 Cross-section of vibration pump Control Servo piston Friction free swash plate bearing Attachment plate Spool valve The engine drives the drive shaft with the cylinder block. The cylinder block carries the working pistons. The slipper pads rest against the sliding surface of the swash plate and are at the same time held on the sliding surface by a retaining device.
  • Page 112 Service Training During the suction stroke the oil is drawn into the piston chamber, i.e. the charge pressure forces it into the piston chamber. On the opposite side the piston presses the oil out into the high pressure side of he closed circuit.
  • Page 113 Service Training Since the heavy mass of the vibrator shaft must be set into motion during the acceleration of the vibration, very high pressure peaks will occur in the high pressure side of the closed circuit during this phase. The high pressure relief valve reduces these pressure peaks to a value of max. 374 bar (pressure difference between high and low pressure side = 345 bar + charge pressure = 29 bar).
  • Page 114 Service Training Vibration motor The vibration motor is a swash plate type axial piston motor with fixed displacement of series MMF 052 from Sauer-Sundstrand. Since the motor can be subjected to pressure from 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.
  • Page 115 Service Training The output torque raises with increasing pressure difference between low and high pressure side in the closed circuit. Changing the flow direction of the oil will also change the sense of rotation of the vibration motor. When switching the vibration on the motor must first start to move the resting vibration shaft. This resistance causes a hydraulic starting pressure, which is limited to 365 bar by the corresponding high pressure relief valve.
  • Page 116 Service Training The vibration motor is equipped with an integrated flushing valve. When switching the vibration on a pressure difference will appear between the two sides of the closed circuit. The higher pressure moves the valve spool of the flushing valve against the neutral setting spring, so that oil can flow out of the low pressure side.
  • Page 117 Service Training Drum Fig. 10 Drum cross section Drum shell Change-over weight Vibration bearing Coupling vibrat. motor - vibrat. shaft Basic eccentric weight Tavel bearing Vibrator housing Travel bearing housing Cooling fan Rubber buffer Vibrator shaft Vibration motor Elastic coupling between shafts Flanged housing BW 156/177 D-3/PD-3 - E 11 -...
  • Page 118 Service Training Trouble shooting vibration circuit The following description of trouble shooting steps contains a small selection of possible faults, which may occur during operation of the machine. This list is by no means complete, however, the description should help you to become acquainted with a systematic trouble shooting procedure. The problems and trouble 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.
  • Page 119 Service Training No vibration (travel system OK) Check vibration pressures Fig. V1 Charge pressure OK Charge pressure OK Start pressure too low Start pressure zero Check magnetic Check coupling on OK ? coil of vibration vibration motor valve Fig. V4 Fig.
  • Page 120 Service Training Vibration works only with high or low amplitude Check magnetic oil on vibration valve Fig. V4 Perform trouble Voltage / shooting in electric current OK ? system Check the solenoid valve Replace the solenoid OK ? valve Check the high pressure relief valve for the side with the not working amplitude, clean / replace if necessary...
  • Page 121 Service Training Vibration frequency too low (travel system OK) Check the engine speed Fig. F15 Perform trouble shooting OK ? on the diesel engine Drop in Adjust the speed for high or speed >10%? low frequency Fig. V5 Check the vibration pressures Fig.
  • Page 122 Service Training Fig. V1 Checking the vibration pressures A too low charge pressure is an early indicator for a fault (leakage) in the closed vibration circuit (if travel system is OK). The pump cannot be operated correctly. A too low starting pressure is an indicator for extreme leaks in the closed circuit or a defective vibration motor coupling.
  • Page 123 Service Training Fig. V2: Checking the coupling on the vibration motor • Disassemble the vibration motor • Check the coupling parts between motor and shaft • Replace defective parts BW 156/177 D-3/PD-3 BW 178/179 D-3/PD-3 - ETr 3 -...
  • Page 124 Service Training Fig. V3: Checking the vibration pump • Close the high 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, the vibration motor must be faulty.
  • Page 125 Service Training 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 current draw with an appropriate meter Nominal values: 12V / 2,5 A BW 156/177 D-3/PD-3 BW 178/179 D-3/PD-3...
  • Page 126 Service Training Fig. V5: Adjusting high and low frequency If the engine speed is correct and the drop in vibrator 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 •...
  • Page 127 Service Training Fig. V6; Checking the vibrator shaft bearings • Disassemble the vibration motor • Check the moveability of the vibration bearings • Replace defective parts BW 156/177 D-3/PD-3 BW 178/179 D-3/PD-3 - ETr 7 -...
  • Page 128 Service Training 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 • Replace a defective flushing valve BW 156/177 D-3/PD-3 BW 178/179 D-3/PD-3 - ETr 8 -...
  • Page 129 Service Training Steering The single drum rollers of product ranges BW 156/177 D-3/DH-3/PDH-3 and BW 178/179 D-3/DH-3/ PDH-3 are equipped with a hydraulically operated articulated steering. The steering system consists mainly of: • the steering/charge pump, • the steering valve, •...
  • Page 130 Service Training When turning the steering wheel the oil flow is guided through the distributor valve to the steering cylinder. A measuring pump in the steering unit measures the exact oil quantity corresponding to the turning angle of the steering wheel and delives this oil to the steering cylinders. The steering cylinders extend or retract and articulate the machine.
  • Page 131 Service Training Steering/charge pump The steering/charge pump is a gear pump with constant displacement. It is driven by the auxiliary drive of the diesel engine and draws the hydraulic oil directly out of the oil tank. The oil flows then through the steering valve and the fine filter to the charge system for travel and vibration drives or, when operating the steering, first to the steering cylinders.
  • Page 132 Service Training Outer gear pumps are fitted with gap seals. In dependence on the operating pressure there will 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 quantity of oil will leak from the pressure side to the suction side when the pressure increases.
  • Page 133 Service Training Steering valve The steering valve block consists mainly of: • the distributor valve, • the rating pump, • the steering pressure relief valve and • the shock valves Fig. 3 Steering valve Neutral setting springs Ring gear Housing Gear Inner spool Check valve...
  • Page 134 Service Training When turning the steering wheel the oil flow from the pump is guided through the distributor valve to the rating pump and from there to the respective steering cylinders. The rating pump determines the exact oil quantity in dependence on the turning angle of the steering wheel.
  • Page 135 Service Training Articulated joint The articulated joint is the connecting link between the front frame with the drum and the rear frame with operator’s stand, diesel engine and drive wheels. Fig. 4 Articulated joint The rear console is tightly bolted to the rear frame. The front console is fastened with screws to the rear cross-member of the front frame.
  • Page 136 Service Training The fastening eyes for the steering cylinders are welded to 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 articulates and steers. All bearing points on the articulated joint are maintenance free and do not require and lubrication.
  • Page 137 Service Training Trouble shooting steering The following description of trouble shooting steps contains a small selection of possible faults, which may occur during operation of the machine. This list is by no means complete, however, the description should help you to become acquainted with a systematic trouble shooting procedure. The problems and trouble 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.
  • Page 138 Service Training No steering / steering sticky / end stops are not reached (travel system OK) Check the steering pressure Fig. L1 Check moveability of articulated joint and OK ? steering cylinders Check steering/ charge pump Fig. L2 Replace/repair the steering/charge OK ? pump...
  • Page 139 Service Training Fig. L1: Checking 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 wheel in this position while reading the pressure gauge Nominal value: 225 +/- 15 bar BW 156/177 D-3/PD-3...
  • Page 140 Service Training Fig. L2: Checking the steering/charge pump • Install a 200 bar pressure relief 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 (adjustment value of the integrated pressure relief valve) If the pressure is not reached, replace or repair the steering/charge pump.
  • Page 141 Service Training Fig. L3: Checking the steering cylinders • as a measure to check whether a steering cylinder is defective, i.e. if it has internal leakage, the hydraulic hoses “L” and “R” can be disconnected from the steering cylinders and closed with plugs. •...
  • Page 142 Service Training Electric system The new single drum rollers of generation 3 are, for the first time, fitted with easy to replace logic control modules. Simple trouble shooting can be performed by bridging the input and output potentials. The control cabinet contains the following modules: •...
  • Page 143 Service Training Supply Fig. 1 Power supply BW 156/177 D-3/PD-3 - G 2 - BW 178/179 D-3/PD-3...
  • Page 144 Service Training Battery When the engine is at rest the voltage for the vehicle electrics is supplied by one or two parallel rechargeable and low-maintenance 12 V lead batteries. The minus pole of the battery (G01:05) is connected with vehicle ground (potential 31). The plus pole of the battery (G01:02) is connected with potential 30 via the main fuse (F00:02).
  • Page 145 Service Training Starting Fig. 2 Ignition and starting circuit BW 156/177 D-3/PD-3 - G 4 - BW 178/179 D-3/PD-3...
  • Page 146 Service Training Ignition switch (S00) in position "0" (ignition off) The ignition switch (S00:04) is permanently supplied with current from the battery (G01) (Fig. 1) via main fuse (F00) (potential 30) and fuse (F13:05). In this position the connection to the coil of relay (K11:28) is interrupted and the relay drops off. The solenoid valves (Y58:32) for fuel shut-off or (Y13:37) engine solenoid (depending on engine version) are no longer supplied with current and the diesel engine will stop.
  • Page 147 Service Training Note: The starter (M01) is directly supplied with current by potentials B+ and 31. After releasing the ignition key the ignition switch will automatically return to position "1". During the starting process a signal 50a is transmitted to the fault monitoring board (A15) (Fig. 3). During the starting process this signal avoids sounding of the warning buzzer and activation of the automatic engine shut-down (see description of the fault monitoring unit).
  • Page 148 Service Training Fault monitoring board Fig. 3 Fault monitoring board BW 156/177 D-3/PD-3 - G 7 - BW 178/179 D-3/PD-3...
  • Page 149 Service Training Ignition on, with engine at rest When switching the ignition on the program is set to a defined initial condition. For self-testing all warning and control lights are switched on for a short moment. If a fault should occur already at this state, the corresponding control light would stay on. However, warning buzzer (H07:27) and shut-off relay (K22:44) (Fig.
  • Page 150 Service Training Table of fault indications Function group Colour of indication Shut-off relay Hydraulic oil filter (B21) 2 minutes Coolant temperature 2 minutes (B53) Engine oil pressure 10 seconds (B06) Brake closed Charge control (MD+) yellow Air filter (B03) yellow Hazard light Indicator on green...
  • Page 151 Service Training Function diagram fault indicator Fig. 4 Fault indicator BW 156/177 D-3/PD-3 - G 10 - BW 178/179 D-3/PD-3...
  • Page 152 Service Training Brakes Fig. 5 Brake BW 156/177 D-3/PD-3 - G 11 - BW 178/179 D-3/PD-3...
  • Page 153 Service Training With the engine at standstill no hydraulic pressure is available, the brake discs cannot be relieved, the brake is automatically closed. Travel lever in position „brake“ with the engine running When the engine is running and the generator is intact, the generator (G02:15) (Bild 1) will transmit a D+ signal or the generator module (A23:24) (Fig.
  • Page 154 Service Training If the diesel motor is running and the generator is intact • the coil of relay (K36:34) is excited, • the contact closes. Current can now flow • from potential K11, • via the contacts of relay (K48:07) •...
  • Page 155 Service Training Travel speed range selector Fig. 6 Travel speed ranges BW 156/177 D-3/PD-3 - G 14 - BW 178/179 D-3/PD-3...
  • Page 156 Service Training Reverse travel When moving the travel lever to reverse while driving on level ground, the coil of relay (K26:05) is not supplied with current. Current flows • from potential K11, • via fuse (F26:23), • through the closed contact (K26:07) •...
  • Page 157 Service Training Travel speed ranges Depending on the position of the travel speed range (S42:23) the solenoid valves (Y30:19, Y31:29) • for both travel motors (drum and axle), • only for the front travel motor (drum), • only for the rear travel motor (axle), •...
  • Page 158 Service Training If the travel speed range selector switch (S42:23) is in position 4 „rabbit“ both solenoid valves (Y30:11/ Y31:18) are supplied with 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 •...
  • Page 159 Service Training Vibration Fig. 7 Vibration BW 156/177 D-3/PD-3 - G 18 - BW 178/179 D-3/PD-3...
  • Page 160 Service Training Switching the vibration on Current flows from potential K11 via fuse (F03:05) to toggle relay (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). Depending on the switch position current flows to the solenoid valve (Y07:29) for high amplitude or (Y08:34) for low amplitude.
  • Page 161 BW 156...178−3 mit X−COM Klemmen Inhaltsverzeichnis: table of contents: BW 156...178−3 with X−COM terminals Blatt Nr.: Zeichnungsnummer Funktionsgruppe function unit sheet no.: drawing − no. 582 700 71 Stromlaufplan Circuit Diagram 582 700 71 Versorgung, Heizung, Steckdosen supply, heating unit, sockets 582 700 71 Starten (je nach Motorausstattung) starting unnit (acc.
  • Page 162 K32:30 K32:30 3:1 K11:30 K11:30 3:6 30 3:1 B+ 3:7 X1:19E X1:21E 15/54 X1:61/2 X1:61/1 X1:19A X1:21A Zusatzausrüstung innerhalb der Kabine X1:43 option inside of cabin F05 9:19 Steuergerät control unit Heizgerät heating unit max.20A nenn.2A X1:60 4:12 4x4qmm 1x6qmm X1:106 X18−1:2 125A...
  • Page 163 30 12:1 2:20 K32:30 K11:30 K11:30 9:12 2:20 2:20 X1:22E 3x1,5 X1:9 K11:87 X1:112 X1:108 X1:22A X1:28E X18−2:7 X18−2:8 X18−2:5 X1:10 X1:8 X1:10 X17−2:6 X17−2:5 X17−2:8 14:2 X1:28A X1:47 P 0 1 2 3 X1:168 15/54 X1:176 Startschalter Not−Aus Schalter Taster Signalhorn ignition switch emergancy shut off...
  • Page 164 K11:87 K11:87 6:1 3:20 X1:29E X1:29A X1:45 X1:46 ASC ERROR BREMSE 6:5 WARNBLINK 13:11 X1:145 X1:97 X1:85 X1:82 X1:92 Sammelstöranzeige monitoring module X1:81 ws/ge X1:84 ws/bl P12 + − − − − − − X1:90 X1:91 X1:80 X1:96 X1:83 X1:148 X1:113 X1:109 X18−1:6...
  • Page 165 4:20 13:11 X1:72 X1:278 X1:282 X1:292 Tachographenmodul X1:293 module, tachograph A2+A3 Klemmen X1:282−285 alternativ X1:283 für Tachograph oder X1:294 Geschwindigkeitsanzeige! X1:284 terminals X1:282−285 for 7,8,9 X1:279 X1:295 assembling tachograph or speedometer X1:280 A5+A6 X1:296 Anzeige indicator X1:297 X1:283 X1:284 P05 − Elektronik transducer Elektronik...
  • Page 166 K11:87 K11:87 7:1 4:20 X1:30E X1:30A X1:48 X1:49 X1:171 X1:171 Lenkhebel X1:116 X1:119 steering lever L N R BR/BN BR/BN 1 2 3 4 PVREL Schalter Fahrstufen switch, speed range 1 5 7 3 BL/BU SW/BK BL/BU SW/BK N S N − X1:114 X1:115 X1:117 X1:118 X1:330...
  • Page 167 K11:87 K11:87 8:1 6:20 X1:31E X1:31E X1:31E X1:31E X1:31A X1:31A X1:31A X1:31A X1:50 X1:50 X1:50 X1:50 VERS1 9:1 VERS2 9:1 Modul Vibration Modul Vibration Modul Vibration Modul Vibration module vibration module vibration module vibration module vibration X1:173 X1:173 1 2 3 1 2 3 X1:174 X1:174...
  • Page 168 K11:87 10:1 K11:87 7:20 X1:34E X1:34A X1:62 X1:171 +45_G=4,5V 18: Analogsignal Neigungssensor X1:180 −45_G=0,5V 27: 1− Signal bei Fahrhebel in 0− Raste 09: 0− Signal = 1.Gang + Vibration 09: 1−Signal und 08: 1−Signal = 2.Gang + Vibration 1 2 3 09: 1−Signal und 08: 0−Signal = Transportgeschw.
  • Page 169 X2:47 VERS1 7:15 K11:30 F05 10:3 VERS2 X2:6 Aufnehmer Verstellmotor Beschleunigungssensoren 3:20 2:20 7:19 sensor, adjustable notor acceleration sensors Automatik/Manuell/Prüfen Hand/Prüfen Automatik X1:43 X2:7 automatic/manuell/test manuell/test automatic 8,5V 1x1,5 1x1,5 X1:237 AGND X1:182 X2:48 X3:2 S13:2 X2:72 X2:71 X2:72 10:14 X2:37 X2:55 S13:8...
  • Page 170 K11:87 K11:87 12:1 8:20 X1:35E NEUT"0" F05 14:1 Stecker für in Planung 9:20 befindliche Zusatzanwendungen B60:3 X1:43 5:19 connectors for additional equipment, not jet available X1:35A X1:71 − X2:50 X2:9 AGND A44:2,3 S13:9 Kopplung Komponenten Terrameter S13:8 connector board, terra meter components S13:2 S13:1 S2:1...
  • Page 171 Druckereinheit printer−unit ST21 Druckercontroller printer−controller S153 S131 S132 S133 S152 S140 S134 − − − START DRUCKEN TEST−NORMAL WEITER Bel. Omegameter Omegameter Geschwindigkeitsanzeige start print test−normal continue illum. omegameter omegameter speedometer STOP PD−D LÖSCHEN FERTIG Bel. Frequenzanzeige Frequenzanzeige stop PD−D clear comp.
  • Page 172 K11:87 K11:87 13:1 10:20 30 13:1 3:20 X1:33E X1:20E X1:20A X1:33A X1:70 X1:258 X1:259 4s abschaltverzögert 0 1 2 15 in − − 12:12 Schalter Berieselung switch, sprinkler system 1s 2s Zeitrelais timing relay X1:262 X1:261 15 out St− − 12:6 X1:264 X1:264...
  • Page 173 K11:87 K11:87 12:20 12:5 X1:18E X1:36E X1:17E X1:40 X1:40 X1:32E X1:18A X1:36A X1:32A X1:72 X1:17A WARNBLINK 4:19 Schalter StvZO Schalter Blinker Anschluß Arbeitsschein− X1:303 switch, StvZO X1:300 switch indicator werfer ohne StvZO connection working head L 0 R 0 1 2 lights without StvZO 13:3 Warnblinkschalter...
  • Page 174 X1:10 X29/1:5 X29/2:8 STV2 13:19 STV1 10:7 13:19 X1:44 14:5 X32:1 X1:270 X34:1 0 1 W 0 1 W 0 1 2 0 1 2 3 Schalter Klimaanlage S102 switch, air conditioning L M H − − − − Thermostat thermostat Lüfter blower...
  • Page 175 Name Benennung title 012 6 Intervallschalter Berieselungssystem Interval switch, sprinkler system 013 17 Blinkrelais Indicator relay 005 15 Elektronik Geschwindigkeitsanzeige Electronic system, speedometer MODUL 005 3 Elektronik Frequenzanzeige vorne Electronic system, frequency meter, fr. 010 18 Elektronik Omegameter Electronic system, Omegameter 014 17 Radio Radio...
  • Page 176 Name Benennung title 004 2 Sicherung Ueberwachungsmodul Fuse, monitoring module 006 3 Sicherung Magnetv. Fahren u. Bremse Fuse, sol. valve, travel and brake 014 13 Sicherung Kabinenluefter Fuse, cabin ventilator 012 4 Sicherung Berieselungspumpe Fuse, sprinkler pump 010 2 Sicherung Terrameter Fuse, terrameter 002 12 Sicherung Kabinenheizung...
  • Page 177 Name Benennung title 013 16 Schalter Blinker Switch, indicator 013 9 Schalter Kennleuchte Switch, warning light 014 20 Schalter Kennleuchte Switch, warning light 006 10 Stufenumschalter schnell−langsam Speed range selector, fast−slow 006 14 Stufenumschalter schnell−langsam Speed range selector, fast−slow 007 10 Stufenumschalter schnell−langsam Speed range selector, fast−slow 007 19...
  • Page 178 Name Benennung title X1:70 012 10 WAGO, E−KASTEN WAGO, E−BOX X1:71 010 2 WAGO, E−KASTEN WAGO, E−BOX X1:72 005 9 WAGO, E−KASTEN WAGO, E−BOX X1:72 013 12 WAGO, E−KASTEN WAGO, E−BOX X1:80 004 12 WAGO, E−KASTEN WAGO, E−BOX X1:81 004 12 WAGO, E−KASTEN WAGO, E−BOX X1:82...
  • Page 179 Name Benennung title X1:161 007 6 WAGO, E−KASTEN WAGO, E−BOX X1:161 007 11 WAGO, E−KASTEN WAGO, E−BOX X1:162 007 4 WAGO, E−KASTEN WAGO, E−BOX X1:162 007 10 WAGO, E−KASTEN WAGO, E−BOX X1:162 007 14 WAGO, E−KASTEN WAGO, E−BOX X1:162 007 19 WAGO, E−KASTEN WAGO, E−BOX X1:163...
  • Page 180 Name Benennung title X1:236 009 2 WAGO, E−KASTEN WAGO, E−BOX X1:237 009 20 WAGO, E−KASTEN WAGO, E−BOX X1:238 009 6 WAGO, E−KASTEN WAGO, E−BOX X1:239 009 7 WAGO, E−KASTEN WAGO, E−BOX X1:23A 013 14 SIKA − KLEMME fuse terminal X1:23E 013 14 SIKA −...
  • Page 181 Name Benennung title X1:331 006 19 WAGO, E−KASTEN WAGO, E−BOX X1:332 006 19 WAGO, E−KASTEN WAGO, E−BOX X1:333 006 19 WAGO, E−KASTEN WAGO, E−BOX X1:335 006 18 WAGO, E−KASTEN WAGO, E−BOX X1:336 006 18 WAGO, E−KASTEN WAGO, E−BOX X1:337 006 18 WAGO, E−KASTEN WAGO, E−BOX X1:338...
  • Page 182 Name Benennung title X2:67 009 10 VARIOCONTROL variocontrol X2:68 009 7 VARIOCONTROL variocontrol X2:69 009 4 VARIOCONTROL variocontrol X2:70 009 4 VARIOCONTROL variocontrol X2:71 009 7 VARIOCONTROL variocontrol X2:72 009 6 VARIOCONTROL variocontrol X2:72 009 10 VARIOCONTROL variocontrol X2:73 009 14 VARIOCONTROL variocontrol X2:74...
  • Page 183 Name Benennung title X17−1:1 004 16 MOTORSTECKER MOTOR engine plug, engine side X17−1:2 004 9 MOTORSTECKER MOTOR engine plug, engine side X17−1:3 002 5 MOTORSTECKER MOTOR engine plug, engine side X17−1:4 002 5 MOTORSTECKER MOTOR engine plug, engine side X17−1:6 003 12 MOTORSTECKER MOTOR engine plug, engine side...
  • Page 184 Name Benennung title 009 10 Magnetventil Vibration Solenoid valve, vibration 006 13 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front 1,23A/1,67A 008 7 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front 1,23A/1,67A 006 10 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear MAX.
  • Page 185 blaue Klemme, d.h. obere u. untere Ebene sind intern gebrückt! blue terminal, upper and lower flat are internaly connected! Bereich für ZA 057 556 55 057 543 05 057 664 33 options area 872 801 41 Neigungssensor 057 664 01 057 268 42 Bereich für ZA Bereich für ZA...
  • Page 186 057 563 57 057 563 56 057 563 58 057 563 55 Anschlußstecker ESX 7265 connector ESX 7265 10 11 12 13 14 15 16 18 19 20 21 22 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 42 43 44 45 47 48 49 50 51 52...

This manual is also suitable for:

Bw 156 dh-3Bw 156 pdh-3Bw 177 d-3Bw 177 dh-3Bw 177 pdh-3

Table of Contents