Bomag BW 27RH-4i Service Manual (Ver. September 2014)

Bomag BW 27RH-4i Rubber tire roller Service Manual
S/N 101 538 12 ….
S/N 861 538 23 ….
S/N 861 538 24 ….
S/N 861 538 25 ….

Type of machine: Rubber tire roller
Print No: 008 922 89, September 2014
Language and Format: English/PDF
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Table of contents:
General
1.1 Introduction
1.2 Safety regulations
1.3 General repair instructions
1.4 Tightening torques

Pneumatic tires rollers
2.1 Rubber tire roller

Technical data
3.1 Technical data

MAINTENANCE
4.1 General notes on maintenance
4.2 Fuels and lubricants
4.3 Table of fuels and lubricants
4.4 Running-in instructions
4.5 Maintenance table

ELECTRICS
5.1 Overview
5.2 Service the battery, check the main battery switch
5.3 Main battery switch
5.4 Starting with jump wires
5.5 Level sensor in diesel tank (R03)
5.6 Differential pressure switches hydraulic oil filter, B21and B22
5.7 Brake oil temperature switch, B148
5.8 Brake pressure switches, B12 and B102
5.9 Float switch in water tank, B33
5.10 Air filter vacuum switch
5.11 Description of indicators and control elements
5.12 Fuse assignment
5.13 Overview of electric components

ELECTRONIC MODULES
6.1 Module description A04
6.2 Electric module A108

MODULE DESCRIPTION A100
7.1 Steering column locking module, A100

SPEEDOMETER MODULE
8.1 Speedometer module

ENGINE ELECTRICS
9.1 EMR4 system overview
9.2 EMR4 system components
9.3 Exhaust gas after-treatment
9.4 Fuel control unit (FCU)
9.5 Injector
9.6 Crankshaft speed sensor
9.7 Camshaft speed sensor
9.8 Rail pressure sensor
9.9 EMR coolant temperature sensor
9.10 Fuel pressure sensor
9.11 Charge air temperature – charge air pressure sensor
9.12 Oil pressure sensor
9.13 Sensor, water in fuel
9.14 Fuel pre-heating
9.15 Heating flange on engine
9.16 Charge control light, operating hour meter
9.17 System faults per flashing code

List of EMR4 fault codes
10.1 List of EMR4 fault codes

ENGINE
11.1 Overview
11.2 Diesel engine
11.3 Engine description TCD 4.1
11.4 Lubrication oil circuit TCD 4.1 / 6.1
11.5 Coolant circuit TCD 4.1 / 6.1
11.6 Common Rail System (CRS) TCD 4.1 / 6.1
11.7 Exhaust gas after-treatment
11.8 Adjust the valve clearance
11.9 Check the engine oil level
11.10 Changing engine oil and oil filter cartridge
11.11 Check the coolant level
11.12 Change the coolant
11.13 Check the anti-freeze concentration and the condition of the coolant
11.14 Clean the cooling fins on engine and hydraulic oil cooler
11.15 Check, clean the water separator
11.16 Replacing the fuel filter cartridge
11.17 Change the fuel filter, bleed the fuel system
11.18 Checking the ribbed V-belt
11.19 Replacing ribbed V-belt and idler pulley
11.20 Air filter maintenance
11.21 Check the engine mounts
11.22 Engine problems

HYDRAULICS
12.1 Overview
12.2 Hydraulic circuit
12.3 Travel pumps, A4VG105 DA
12.4 Troubleshooting axial piston pumps
12.5 External gear pumps
12.6 Travel motor, A6VM 107HA2R1
12.7 Trouble shooting, variable displacement axial piston motor
12.8 Steering valve
12.9 Travel circuit
12.10 Steering circuit
12.11 Cooling and cross-flushing of the brake housing
12.12 Edge cutter
12.13 Check the hydraulic oil level
12.14 Replace hydraulic oil and breather filter.
12.15 Replace hydraulic oil filter
12.16 Replacing the bypass filter

BRAKE
13.1 Overview
13.2 Brake system
13.3 Stopping the machine, operating the parking brake
13.4 Driving the machine / braking the machine
13.5 Multi-disc brake, function test
13.6 Towing in case of an engine failure

PNEUMATICS
14.1 Overview
14.2 Pneumatic system
14.3 Operating the tire inflation system
14.4 Draining the air pressure vessel
14.5 Change the air drier for the brake system
14.6 Check the supply lines for the compressor

WATER SPRINKLING SYSTEM
15.1 Overview
15.2 Operating the pressure sprinkler system
15.3 Service the water sprinkling system
15.4 Maintenance in case of frost

AIR CONFITIONING SYSTEM
16.1 Overview
16.2 Physical basics
16.3 Refrigerant R134a
16.4 Compressor oil / refrigeration oil
16.5 Working principle of the air conditioning system
16.6 Monitoring devices
16.7 Description of components
16.8 Measuring the compressor oil level
16.9 Checking the magnetic clutch
16.10 Inspection and maintenance work
16.11 Servicing the V-belt for the refrigerant compressor
16.12 Service the air conditioning
16.13 Drying and evacuation
16.14 Emptying in case of repair
16.15 Leak test
16.6 Filling instructions
16.17 Trouble shooting in refrigerant circuit, basic principles
16.18 Trouble shooting, refrigerant circuit diagram
16.19 Trouble shooting procedure
16.20 Steam table for R134a

REPLACING THE CAB WINDOW PANES
17.1 Assembly of window panes
17.2 Special tools, cabin windows
17.3 Auxiliary materials
17.4 Removing and installing the window pane

FRONT AXLE
18.1 Repair overview for front axle
18.2 Dismantling the front axle
18.3 Assembling the front axle

Suppliers documentation
19.1 Travel pump
19.2 Travel motor
19.3 Travel gear
19.4 Steering valve

Circuit diagrams
20.1 Hydraulic diagram 538 110 00 653
20.2 Pneumatic diagram 538 120 00 657
20.3 Wiring diagram