BOMAG BW 24 RH Service Training Manual PDF – Pneumatic Tire Roller Repair, Hydraulics & Wiring Diagrams

Description

BOMAG BW 24 RH Service Training Manual – The Complete Pneumatic Tire Roller Repair File

This is the BOMAG factory service training documentation for the BW 24 RH pneumatic tire roller, written for machines in the serial number range S/N 101 538 01 … S/N 101 538 30 …. It is the same material BOMAG used to bring its own service technicians up to speed on the hydrostatic travel drive, the A4VG105 DA travel pump, the A6VM bent-axis travel motors, the multi-disc brake, the compressed-air system, the Deutz TCD 2012 L04 2V engine and the entire electrical architecture of the roller. Everything is delivered as one fully illustrated BOMAG BW 24 RH service training manual PDF, ready to open on any device in your workshop.

File Details

• Manual type: Service training / workshop documentation
• Brand: BOMAG
• Model: BW 24 RH (also covers BW 27 RH and BW 24 RHI references)
• Covered serial range: S/N 101 538 01 … S/N 101 538 30 … ; wiring diagram section also lists S/N 101 538 011 … and S/N 101 538 301 001 …
• Language: English
• Page count: 346 pages
• File format: PDF

Chapters Covered

• 1 General
• 2 Pneumatic tires rollers
• 3 Technical data
• 4 Maintenance
• 5 E-Plan wiring diagrams
• 6 Electrics
• 7 Electronic modules
• 8 Module description A100
• 9 Speedometer Module
• 10 Hydraulics
• 11 Brake
• 12 Pneumatics
• 13 Engine
• 14 Air conditioning system
• 15 Front axle
• 16 Circuit diagrams

General, Safety and General Repair Instructions

The opening chapter explains how to use the manual and lays out BOMAG’s safety regulations for repair work – welding precautions, hydraulic system pressurisation, fuel handling, battery servicing, old-oil disposal, pressure-vessel handling and the air-conditioning refrigerant rules. The general repair section covers marking of parts before disassembly, radial seal and gasket assembly, feather keys, ball and roller bearing handling, screw strength classes and the correct installation of cotter pins. A separate chapter gathers all tightening torques for metric, metric-fine, UNC, UNF and Whitworth threads, plus wheel nuts and anti-seizure-paste values.

Technical Data and Maintenance

The technical data chapter lists dimensions in mm and inches, operating weights, wheel loads, travel speeds, gradability, tire size and air-pressure range, filling capacities for water, fuel, ballast compartment, engine oil, hydraulic oil and coolant, plus the Deutz engine data and the hydrostatic component specifications. The maintenance chapter provides a full maintenance table with daily, 250-hour, 500-hour, 1000-hour, 2000-hour, 3000-hour and 6000-hour intervals, running-in instructions, the fuel and lubricant table and the correct oils, greases and coolants for every assembly on the machine.

Electrics, E-Plan Wiring Diagrams and Electronic Modules

The electrical section explains how to read the BOMAG E-plan wiring diagrams – structuring symbols, relay and potential cross-references, terminal designations to DIN 72552, plug and pin overviews, and the component designation table used throughout the file. Every sensor and switch on the BW 24 RH is described individually: diesel tank level sensor R03, hydraulic oil filter differential pressure switches B21 and B22, brake oil temperature switch B148, brake pressure switches B12 and B102, water tank float switch B33, oil pressure switch B06, coolant temperature switch B152, water-in-fuel sensor B124, air filter vacuum switch B03 and the glow plug circuit. The electronic modules chapter documents module A04 (sprinkling module UPM1), module A72 (air conditioning control KS20.01 / KS20.02), module A108, module A100 (steering column locking module UPM03, 538 380 06 and 538 380 12) and the speedometer module with its self-teaching procedure.

Hydraulics – Travel, Steering and Brake Circuits

The hydraulic chapter covers the closed travel circuit, the open steering circuit, the charge and cross-flushing circuits and the cooling circuit. The A4VG105 DA variable displacement axial piston pump is documented with a colour cutaway, hydraulic diagram, port labels and individual treatment of the high-pressure relief valves with boost check valves and bypass function, the charge pressure relief valve, the pressure override valve, the DA-control valve, the inching valve and the auxiliary pump. The A6VM107HA2R1 bent-axis travel motor is shown with its HA2R high-pressure-dependent displacement control and flushing valve. The OSPF steering valve is covered as an exploded assembly with shock valves, anti-cavitation valves and check valve. The travel circuit chapter also lists pressure test points, filter differential-pressure settings and the procedure for checking and replacing hydraulic oil and both hydraulic oil filters.

Brake System and Pneumatics

The brake chapter describes the two brake systems on the roller: the spring-applied, hydraulically released parking brake with solenoid valve Y04, and the hydro-dynamic service brake with membrane cylinder, master brake cylinder, shuttle valve and multi-disc brakes in the travel gears. You get the function test for the multi-disc brake, the brake housing cooling and cross-flushing circuit, and the towing procedure for an engine failure including releasing the parking brake and re-tightening the high-pressure relief valves to 100 Nm. The pneumatics chapter documents the compressor, air drier, air tank, overflow valve, check valve, 3/2-way valve, tire inflation system and the drain procedure for the air pressure vessel.

Deutz TCD 2012 L04 2V Engine Service

The engine chapter is built around the Deutz TCD 2012 L04 2V water-cooled four-cylinder diesel rated 74.9 kW / 100.4 hp at 2300 rpm. It covers the lubrication oil circuit and coolant circuit for TCD 2012 / 2013, internal exhaust gas recirculation, valve clearance adjustment using the rotation angle disc method (intake 75° +10°, exhaust 120° +10°), engine oil and filter change, fuel filter replacement and fuel-system bleeding, water separator service, coolant replacement, cooling fin cleaning, ribbed V-belt and compressor V-belt checks, air filter maintenance and crankcase ventilation valve replacement. A general troubleshooting chart for the TCD 2012 / 2013 engine lists symptoms, causes and remedies, and a special-tools section identifies the required Deutz workshop tooling.

Air Conditioning System and Front Axle

The air conditioning chapter explains the physical basics, refrigerant R134a, PAG compressor oil, the working principle of the circuit, the pressure switch, thermostat and monitoring chain, and walks through component-level service: compressor oil level measurement, magnetic clutch testing, V-belt service, condenser cleaning, drier / collector unit replacement, evacuation and drying, leak testing, filling instructions and a full refrigerant-circuit troubleshooting procedure with pressure / temperature reference values. The front axle chapter provides a repair overview of the joint carrier, body bolster, steering leg, wheel bearing, steering cylinder, tie rods, rotation joint and steering axle bearings.

Circuit Diagrams – Hydraulic, Pneumatic and Wiring

The final chapter contains the complete circuit diagrams: hydraulic diagram 538 110 00, pneumatic diagram 538 120 00 and wiring diagram 25. The wiring diagram pages are reproduced straight from the BOMAG E-plan, with current paths, potential cross-references, relay cross-references, the fuse list for the cabin, ROPS and electric junction box, the 125 A main battery fuse F00 and the complete overview of electric components on monitoring board A15.

Who This BOMAG BW 24 RH Service Training Manual Is For

If you run a BW 24 RH or BW 27 RH pneumatic tired roller in a fleet, this is the file that lets your workshop diagnose the hydrostatic travel drive, trace a fault through the E-plan wiring diagram, adjust the valve clearance on the Deutz TCD 2012 correctly, service the multi-disc brake without damaging the discs, evacuate and recharge the R134a air conditioning circuit properly, and set every tightening torque on the machine to BOMAG specification. It is equally suited to an independent heavy-equipment shop that has taken on a BOMAG rubber tire roller and now needs the same level of documentation the dealer technician works from.

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Instant PDF Delivery

Your BOMAG BW 24 RH service training manual PDF is delivered immediately after checkout. There is no shipping, no waiting for a printed book, and no restriction on how you use it – open it on a laptop in the workshop, on a tablet next to the machine, or print the chapter you need and take it into the field. Because this is a training document that spans the entire machine rather than a single subsystem, keeping a copy on the workshop network means the next BW 24 RH repair, service interval or fault code diagnosis starts with the correct procedure instead of a guess.