BOMAG BW27 RH-4i Rubber Tire Roller Service Manual 00892289 – PDF Download

Description

BOMAG BW27 RH-4i Rubber Tire Roller Service Manual – Document 00892289

This is the full BOMAG service manual for the BW27 RH-4i rubber tire roller, published under document number 00892289. It is the workshop reference for repairing, adjusting and diagnosing this pneumatic tired roller, spanning mechanical overhaul of the front axle and travel gear through to EMR4 engine management fault code readouts and hydraulic circuit troubleshooting. Every section is written for the technician working on the machine, with tightening torques, component descriptions and system-level diagnostics throughout.

File Details

• Manual type: Service Manual
• Brand: BOMAG (Fayat Group)
• Model: BW27 RH-4i Rubber Tire Roller
• Document number: 00892289
• Language: English
• Page count: 706
• File format: PDF
• Serial numbers covered: S/N 101 538 12 … / S/N 861 538 23 … / S/N 861 538 24 … / S/N 861 538 25 …

Chapters Covered

• 1 General – Introduction, Safety regulations, General repair instructions, Tightening torques
• Pneumatic tires rollers – Technical data, Maintenance (general notes, fuels and lubricants, table of fuels and lubricants, running-in instructions, maintenance table)
• Electrics – Overview, battery service and main battery switch, starting with jump wires, level sensor in diesel tank (R03), differential pressure switches hydraulic oil filter (B21 and B22), brake oil temperature switch (B148), brake pressure switches (B12 and B102), float switch in water tank (B33), air filter vacuum switch, indicators and control elements, fuse assignment, overview of electric components
• Electronic modules – Module description A04, electric module A108, steering column locking module A100
• Speedometer Module
• Engine electrics – EMR4 system overview, EMR4 system components, exhaust gas after-treatment, fuel control unit (FCU), injector, crankshaft speed sensor, camshaft speed sensor, rail pressure sensor, EMR coolant temperature sensor, fuel pressure sensor, charge air temperature and charge air pressure sensor, oil pressure sensor, sensor for water in fuel, fuel pre-heating, heating flange on engine, charge control light and operating hour meter, system faults per flashing code
• List of EMR4 fault codes
• Engine – Overview, diesel engine, engine description TCD 4.1, lubrication oil circuit, coolant circuit, Common Rail System (CRS), exhaust gas after-treatment, adjust the valve clearance, check the engine oil level, changing engine oil and oil filter cartridge, check the coolant level, change the coolant, check anti-freeze concentration, clean the cooling fins, check/clean the water separator, replacing the fuel filter cartridge, change the fuel filter and bleed the fuel system, checking the ribbed V-belt, replacing ribbed V-belt and idler pulley, air filter maintenance, check the engine mounts, engine problems
• Hydraulics – Overview, hydraulic circuit, travel pumps A4VG105 DA, troubleshooting axial piston pumps, external gear pumps, travel motor A6VM 107HA2R1, troubleshooting variable displacement axial piston motor, steering valve, travel circuit, steering circuit, cooling and cross-flushing of the brake housing, edge cutter, check the hydraulic oil level, replace hydraulic oil and breather filter, replace hydraulic oil filter, replacing the bypass filter
• Brake – Overview, brake system, stopping the machine and operating the parking brake, driving and braking the machine, multi-disc brake function test, towing in case of an engine failure
• Pneumatics – Overview, pneumatic system, operating the tire inflation system, draining the air pressure vessel, change the air drier for the brake system, check the supply lines for the compressor
• Water sprinkling system – Overview, operating the pressure sprinkler system, service the water sprinkling system, maintenance in case of frost
• Air conditioning system – Overview, physical basics, refrigerant R134a, compressor oil, working principle, monitoring devices, description of components, measuring the compressor oil level, checking the magnetic clutch, inspection and maintenance work, servicing the V-belt, service the air conditioning, drying and evacuation, emptying in case of repair, leak test, filling instructions, troubleshooting in the refrigerant circuit
• Replacing the cab window panes
• Front axle – Repair overview, dismantling the front axle, assembling the front axle
• Suppliers documentation – Travel pump (Rexroth A4VG 71-180), travel motor (A6VM 28-200), travel gear (Bonfiglioli wheel drive 606Y), steering valve (OSPB/OSPC/OSPF)
• Circuit diagrams – Hydraulic diagram 538 110 00, pneumatic diagram 538 120 00, wiring diagram 216

The manual is organised so that each major system can be worked on independently. Hydraulic sections include both the closed-loop travel circuit and the open steering circuit, with the travel pump and bent-axis travel motor covered down to component-level troubleshooting. Engine electrics walks through the EMR4 management system sensor by sensor, and the fault code list gives blink codes and diagnostic paths for both the engine and the exhaust gas after-treatment. The front axle chapter is a step-by-step teardown and rebuild with bearing preload, shim measurement and toe-in adjustment values. Circuit diagrams at the back include hydraulic, pneumatic and full wiring schematics.

What This Manual Enables You To Do

• Diagnose EMR4 engine management faults using flashing codes and the full EMR4 diagnostic trouble code list.
• Service and repair the Deutz TCD 4.1 L4 engine, including valve clearance adjustment, fuel system bleeding and coolant changes.
• Troubleshoot and overhaul the Rexroth A4VG105 DA travel pump, A6VM 107HA2R1 travel motor and AZPF-22-016R gear pump.
• Repair the brake system, including the multi-disc brake function test, brake releasing valve and towing procedures.
• Dismantle and rebuild the front axle with correct bearing preload and toe-in values.
• Service the pneumatic system, water sprinkling system and air conditioning system.
• Replace cab window panes and repair the front axle using the illustrated step-by-step procedures.
• Reference tightening torques, fuel and lubricant specifications, and maintenance intervals.

Working without the correct procedures and specifications on a machine of this size and complexity is how small faults turn into major repairs. The BW27 RH-4i service manual gives you the torque values, pressure settings, clearance figures and diagnostic sequences that the manufacturer specifies, so that components are assembled correctly the first time and system faults are traced to their actual cause rather than replaced by guesswork.

This BOMAG BW27 RH-4i Rubber Tire Roller Service Manual is delivered as an instant PDF download after payment. There is no shipping and no waiting for a physical book. The file works on any device that reads PDFs, can be printed for workshop use, and can be kept on a laptop or tablet at the machine. Document 00892289 covers serial numbers S/N 101 538 12 … / S/N 861 538 23 … / S/N 861 538 24 … / S/N 861 538 25 … and is the reference to keep on hand for every service and repair job on this roller.