Bomag BW 156 D-3 User manual

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

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

Service Training
BW 156/177 D-3/DH-3/PDH-3
BW 178/179 D-3/DH-3/PDH-3
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
BW 156/177 D-3/DH-3/PDH-3 - A 1 -
BW 178/179 D-3/DH-3/PDH-3
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.

Service Training
BW 156/177 D-3/DH-3/PDH-3 - A 2 -
BW 178/179 D-3/DH-3/PDH-3
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

Service Training
BW 156/177 D-3/DH-3/PDH-3 - A 3 -
BW 178/179 D-3/DH-3/PDH-3
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
BW 156/177 D-3/DH-3/PDH-3 - A 4 -
BW 178/179 D-3/DH-3/PDH-3
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.

Service Training
BW 156/177 D-3/DH-3/PDH-3 - A 5 -
BW 178/179 D-3/DH-3/PDH-3
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
BW 156/177 D-3/PD-3 - B 1 -
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

Service Training
BW 156/177 D-3/PD-3 - B 2 -
BW 178/179 D-3/PD-3
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

Service Training
BW 156/177 D-3/PD-3 - B 3 -
BW 178/179 D-3/PD-3
BW 156 D-3
Travel motor (axle)
Manufacturer Sauer
Type 51 D 110
System Axial piston
Displacement, range 1 cm3/rev. 110
Displacement, range 2 cm3/rev. 55,3
Operating 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
Displacement cm3/rev. 28
High pressure limitation/
vibration starting pressre bar 365 +/- 35
Vibration motor
Manufacturer Sauer
Type MMF 025
System Swash plate
Displacement cm3/rev. 25
Frequency Hz 30/41
Amplitude mm 1,75/0,90

Service Training
BW 156/177 D-3/PD-3 - B 4 -
BW 178/179 D-3/PD-3
BW 156 D-3
Steering pump
Manufacturer Bosch
Type HY/ZFS11/22,5
System Gear pump
Displacement cm3/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) l15
Engine oil 15W/40 l10,9
Hydraulic oil HV46 l60
Axle SAE 90 l5,5
Planetary gear (axle) SAE 90 l/side 1
Vibrator housing 15W/40 l/side 2,3

Service Training
BW 156/177 D-3/PD-3 - B 5 -
BW 178/179 D-3/PD-3
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 kW 56 56
at nominal speed min-1 2200 2200
Low idle speed min-1 700 - 950 700 - 950
High idle speed min-1 2280 - 2330 2280 - 2330
spec. fuel consumption g/kWh 246 246
Starter voltage/power V/kW 12/2,9 12/2,9
Valve 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 piston Axial piston
Control Swash plate Swash plate
Displacement cm3/rev. 55 55
High pressure limitation bar 435 +/- 15 435 +/- 15
Charge pressure bar 25 +/- 1 25 +/- 1
Travel motor (drum)
Manufacturer Sauer Sauer
Type 51 C 060 51 C 060
System Axial piston Axial piston
Displacement, range 1 cm3/rev. 60 60
Displacement, range 2 cm3/rev. 15 15
Operating pressure, max. bar 435 +/- 15 435 +/- 15
Leak oil quantity, max l/min 2 2

Service Training
BW 156/177 D-3/PD-3 - B 6 -
BW 178/179 D-3/PD-3
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 Axial piston
Displacement, range 1 cm3/rev. 110 110
Displacement, 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
Manufacturer Sauer Sauer
Type 42 R 028 42 R 028
System Axial piston Axial piston
Displacement cm3/rev. 28 28
High pressure limitation/
Vibration starting pressure bar 365 +/- 35 365 +/- 35
Vibration motor
Manufacturer Sauer Sauer
Type MMF 025 MMF 025
System Swash plate Swash plate
Displacement cm3/rev. 25 25
Frequency Hz 30/41 30/41
Amplitude mm 1,75/0,90 1,65/0,80

Service Training
BW 156/177 D-3/PD-3 - B 7 -
BW 178/179 D-3/PD-3
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 cm3/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 (50% water/50% anti-freeze) l15 15
Engine oil 15W/40 l10,9 10,9
Hydraulic oil HV46 l60 60
Axle SAE 90 l5,5 5,5
Planetary gear (axle) SAE 90 l/side 1 1
Reduction gear (drum) SAE 90 lapprox. 2,5 approx. 2,5
Vibrator housing 15W/40 l/side 3,2 3,2

Service Training
BW 156/177 D-3/PD-3 - B 8 -
BW 178/179 D-3/PD-3
BW 177 AD-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 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

Service Training
BW 156/177 D-3/PD-3 - B 9 -
BW 178/179 D-3/PD-3
BW 177 AD-3
Travel motor (axle)
Manufacturer Sauer
Type 51 D 110
System Axial piston
Displacement, range 1 cm3/rev. 110
Displacement cm3/rev. 59,6
Operating 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
Displacement cm3/rev. 28
High pressure limitation/
Vibration starting pressure bar 365 +/- 35
Vibration motor
Manufacturer Sauer
Type MMF 025
System Swash plate
Displacement cm3/rev. 25
Frequency Hz 30/38
Amplitude mm 0,45/0,90

Service Training
BW 156/177 D-3/PD-3 - B 10 -
BW 178/179 D-3/PD-3
BW 177 AD-3
Steering pump
Manufacturer Bosch
Type HY/ZFS11/22,5
System Gear pump
Displacement cm3/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) l15
Engine oil 15W/40 l10,9
Hydraulic oil HV46 l60
Axle SAE 90 l5,5
Planetary gear (axle) SAE 90 l/side 1
Vibrator housing 15W/40 l/side 3,2

Service Training
BW 156/177 D-3/PD-3 - B 11 -
BW 178/179 D-3/PD-3
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 kW 56 56
at nominal speed min-1 2200 2200
Low idle speed min-1 700 - 950 700 - 950
High idle speed min-1 2280 - 2330 2280 - 2330
spec. fuel consumption g/kWh 246 246
Starter voltage/power V/kW 12/2,9 12/2,9
Valve 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 piston Axial piston
Control Swash plate Swash plate
Displacement cm3/rev. 55 55
High pressure limitation bar 435 +/- 15 435 +/- 15
Charge pressure bar 25 +/- 1 25 +/- 1
Travel motor (drum)
Manufacturer Sauer Sauer
Type 90 RO 55 90 RO 55
System Axial piston Axial piston
Displacement, range 1 cm3/rev. 60 60
Displacement, range 2 cm3/rev. 15 15
Operating pressure, max. bar 435 +/- 15 435 +/- 15
Leak oil quantity, max l/min 2 2

Service Training
BW 156/177 D-3/PD-3 - B 12 -
BW 178/179 D-3/PD-3
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
Displacement, range 1 cm3/rev. 110 110
Displacement, 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
Manufacturer Sauer Sauer
Type 42 R 028 42 R 028
System Axial piston Axial piston
Displacement cm3/rev. 28 28
High pressure limitation/
Vibration starting pressure bar 365 +/- 35 365 +/- 35
Vibration motor
Manufacturer Sauer Sauer
Type MMF 025 MMF 025
System Swash plate Swash plate
Displacement cm3/rev. 25 25
Frequency Hz 30/38 30/38
Amplitude mm 1,25/2,0 1,7/1,2