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  9. Fayat Group BOMAG BW 27 RH-4i User manual

Fayat Group BOMAG BW 27 RH-4i User manual

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Service - Manual
Catalogue number.
008 922 89 09/2014
BW 27 RH-4i
S/N 101 538 12 .... S/N 861 538 23 .... / S/N 861 538 24 .... / S/N 861 538 25 ....
Rubber tire roller
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Table of Contents
BOMAG 3008 922 89
General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 14
1.4 Tightening torques 28
Pneumatic tires rollers 33
2.1 Rubber tire roller 34
Technical data 37
3.1 Technical data 38
Maintenance 43
4.1 General notes on maintenance 44
4.2 Fuels and lubricants 45
4.3 Table of fuels and lubricants 48
4.4 Running-in instructions 49
4.5 Maintenance table 50
Electrics 53
5.1 Overview 54
5.2 Service the battery, check the main battery switch 57
5.3 Main battery switch 58
5.4 Starting with jump wires 59
5.5 Level sensor in diesel tank (R03) 59
5.6 Differential pressure switches hydraulic oil filter, B21and B22 60
5.7 Brake oil temperature switch, B148 60
5.8 Brake pressure switches, B12 and B102 61
5.9 Float switch in water tank, B33 62
5.10 Air filter vacuum switch 63
5.11 Description of indicators and control elements 64
5.12 Fuse assignment 67
5.13 Overview of electric components 71
Electronic modules 87
6.1 Module description A04 89
6.2 Electric module A108 99
Module description A100 103
7.1 Steering column locking module, A100 104
Speedometer Module 107
8.1 Speedometer module 108
Engine electrics 111
9.1 EMR4 system overview 113
9.2 EMR4 system components 117
9.3 Exhaust gas after-treatment 119
9.4 Fuel control unit (FCU) 122
9.5 Injector 123
9.6 Crankshaft speed sensor 124
9.7 Camshaft speed sensor 124
9.8 Rail pressure sensor 125
9.9 EMR coolant temperature sensor 127
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Table of Contents
BOMAG4008 922 89
9.10 Fuel pressure sensor 127
9.11 Charge air temperature - charge air pressure sensor 128
9.12 Oil pressure sensor 128
9.13 Sensor, water in fuel 130
9.14 Fuel pre-heating 131
9.15 Heating flange on engine 131
9.16 Charge control light, operating hour meter 132
9.17 System faults per flashing code 133
List of EMR4 fault codes 137
10.1 List of EMR4 fault codes 139
Engine 243
11.1 Overview 244
11.2 Diesel engine 246
11.3 Engine description TCD 4.1 247
11.4 Lubrication oil circuit TCD 4.1 / 6.1 251
11.5 Coolant circuit TCD 4.1 / 6.1 252
11.6 Common Rail System (CRS) TCD 4.1 / 6.1 254
11.7 Exhaust gas after-treatment 261
11.8 Adjust the valve clearance 264
11.9 Check the engine oil level 265
11.10 Changing engine oil and oil filter cartridge 266
11.11 Check the coolant level 267
11.12 Change the coolant 267
11.13 Check the anti-freeze concentration and the condition of the coolant 269
11.14 Clean the cooling fins on engine and hydraulic oil cooler 270
11.15 Check, clean the water separator 270
11.16 Replacing the fuel filter cartridge 271
11.17 Change the fuel filter, bleed the fuel system 272
11.18 Checking the ribbed V-belt 273
11.19 Replacing ribbed V-belt and idler pulley 274
11.20 Air filter maintenance 274
11.21 Check the engine mounts 276
11.22 Engine problems 277
Hydraulics 281
12.1 Overview 282
12.2 Hydraulic circuit 284
12.3 Travel pumps, A4VG105 DA 286
12.4 Troubleshooting axial piston pumps 295
12.5 External gear pumps 298
12.6 Travel motor, A6VM 107HA2R1 300
12.7 Trouble shooting, variable displacement axial piston motor 303
12.8 Steering valve 305
12.9 Travel circuit 306
12.10 Steering circuit 312
12.11 Cooling and cross-flushing of the brake housing 315
12.12 Edge cutter 317
12.13 Check the hydraulic oil level 319
12.14 Replace hydraulic oil and breather filter. 320
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Table of Contents
BOMAG 5008 922 89
12.15 Replace hydraulic oil filter 321
12.16 Replacing the bypass filter 322
Brake 323
13.1 Overview 324
13.2 Brake system 325
13.3 Stopping the machine, operating the parking brake 332
13.4 Driving the machine / braking the machine 333
13.5 Multi-disc brake, function test 336
13.6 Towing in case of an engine failure 337
Pneumatics 339
14.1 Overview 340
14.2 Pneumatic system 341
14.3 Operating the tire inflation system 349
14.4 Draining the air pressure vessel 350
14.5 Change the air drier for the brake system 351
14.6 Check the supply lines for the compressor 351
Water sprinkling system 353
15.1 Overview 354
15.2 Operating the pressure sprinkler system 355
15.3 Service the water sprinkling system 355
15.4 Maintenance in case of frost 356
Air conditioning system 359
16.1 Overview 360
16.2 Physical basics 362
16.3 Refrigerant R134a 365
16.4 Compressor oil / refrigeration oil 366
16.5 Working principle of the air conditioning system 367
16.6 Monitoring devices 367
16.7 Description of components 368
16.8 Measuring the compressor oil level 374
16.9 Checking the magnetic clutch 374
16.10 Inspection and maintenance work 375
16.11 Servicing the V-belt for the refrigerant compressor 376
16.12 Service the air conditioning 377
16.13 Drying and evacuation 379
16.14 Emptying in case of repair 380
16.15 Leak test 380
16.16 Filling instructions 381
16.17 Trouble shooting in refrigerant circuit, basic principles 383
16.18 Trouble shooting, refrigerant circuit diagram 387
16.19 Trouble shooting procedure 388
16.20 Steam table for R134a 398
Replacing the cab window panes 403
17.1 Assembly of window panes 404
17.2 Special tools, cabin windows 405
17.3 Auxiliary materials 406
17.4 Removing and installing the window pane 408
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Table of Contents
BOMAG6008 922 89
Front axle 413
18.1 Repair overview for front axle 414
18.2 Dismantling the front axle 415
18.3 Assembling the front axle 422
Suppliers documentation 445
19.1 Travel pump 447
19.2 Travel motor 489
19.3 Travel gear 543
19.4 Steering valve 617
Circuit diagrams 651
20.1 Hydraulic diagram 538 110 00 653
20.2 Pneumatic diagram 538 120 00 657
20.3 Wiring diagram 216 661
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BOMAG 7008 922 89
1 General
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1.1 Introduction
BOMAG8008 922 89
1.1 Introduction
This manual addresses the professionally qualified
personnel or the after sales service of BOMAG, and
should be of help and assistance in correct and effi-
cient repair and maintenance work.
This manual describes the disassembly, dismantling,
assembly, installation and repair of components and
assemblies. The repair of components and assem-
blies is only described as this makes sense under due
consideration of working means and spare parts sup-
ply.
Documentation
For the BOMAG machines described in this manual
the following documentation is additionally available:
1 Operating and maintenance instructions
2 Spare parts catalogue
3 Service information
4 Fundamental electrics
Use only genuine BOMAG spare parts.
Spare parts needed for repairs can be taken from the
spare parts catalogue for the machine.
This manual is not subject of an updating service; for
this reason we would like to draw your attention to our
additional "Technical Service Bulletins".
In case of a new release all necessary changes will be
included.
In the course of technical development we reserve the
right for technical modifications without prior notifica-
tion.
Information and illustrations in this manual must not
be reproduced and distributed, nor must they be used
for the purpose of competition. All rights according to
the copyright law remain expressly reserved.
!Danger
These safety regulations must be read and ap-
plied by every person involved in the repair /main-
tenance of this machine. The applicable accident
prevention instructions and the safety regulations
in the operating and maintenance instructions
must be additionally observed.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG
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Safety regulations
BOMAG 9008 922 89
1.2
1.2 Safety regulations
Important notes
These safety regulations must be read and ap-
plied by every person involved in the repair /main-
tenance of this machine. The applicable accident
prevention instructions and the safety regulations
in the operating and maintenance instructions
must be additionally observed.
Repair work shall only performed by appropriately
trained personnel or by the after sales service of
BOMAG.
Workshop equipment and facilities as well as the
use and waste disposal of fuels and lubricants,
cleaning agents and solvent as well as gases and
chemicals are subject to legal regulations, which
are intended to provide a minimum on safety. It is
obviously your own responsibility to know and
adhere to these regulations.
This manual contains headers like "Note", "Attention",
"Danger" and "Environment", which must be strictly
complied with in order to inform about and avoid dan-
gers to persons, property and the environment.
i
Note
Paragraphs marked like this contain technical infor-
mation for the optimaleconomical use of the machine.
!
Caution
Paragraphs marked like this highlight possible
dangers for machines or parts of the machine.
!Danger
Paragraphs marked like this highlight possible
dangers for persons.
Environment
Paragraphs marked like this point out practices
for safe and environmental disposal of fuels and
lubricants as well as replacement parts.
Observe the regulations for the protection of the
environment.
General
lFor repair and maintenance work move the ma-
chine on a firm base and shut it down.
lAlways secure the machine against unintended roll-
ing.
lSecure the engine reliably against unintentional
starting.
lMark a defective machine and a machine under re-
pair by attaching a clearly visible warning label to
the dashboard.
lBlock the articulated joint with the articulation lock.
lUse protective clothes like hard hat, safety boots
and gloves.
lKeep unauthorized persons away from the machine
during repair work.
lTools, lifting gear, lifting tackle, supports and other
auxiliary equipment must be fully functional and in
safe condition.
lUse only safe and approved lifting gear of sufficient
load bearing capacity to remove and install parts or
components from and to the machine.
lDo not use easily inflammable or harmful substanc-
es, such as gasoline or paint thinners for cleaning.
lDo not smoke or use open fire and avoid sparks
when cleaning or repairing a tank.
lWhen performing welding work strictly comply with
the respective welding instructions.
Transport work with cranes and lifting
tackle
i
Note
Cranes must only be operated by instructed persons
who had been trained in handling cranes.
lFollow the operating instructions of the manufactur-
er when working with cranes.
lFollow the operating instructions of the operator
when working with cranes.
lAlways comply with the applicable accident preven-
tion instructions when working with cranes and lift-
ing tackle.
Precautions and codes of conduct for
welding work
Welding work must only be carried out by properly
trained personnel.
!Danger
Electric shock!
Sparks, fire hazard, burning of skin!
Infrared or ultraviolet radiation (arc), flashing of
eyes!
Health hazard caused by welding work on highly
alloyed work pieces, metal coatings, paint coat-
ings, plastic coatings, oil containing dirt deposits,
grease or solvent residues, etc.!
lCheck welding equipment and cables for damage
before use (also the validity of inspection stickers).
lEnsure good conductivity between ground cable
and workpiece, avoid joints and bearings.
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1.2 Safety regulations
BOMAG10 008 922 89
lStart the extraction fan before starting work and
guide with the progressing work as required.
lAlways isolate the burner when laying it down (re-
move possible electrode residues).
lProtect cables from being damaged, use cables
with insulated couplings.
lEnsure sufficient fire protection, keep a fire extin-
guisher at hand.
lWelding work in areas where there is a risk of fire or
explosion, must only be carried out with welding
permission.
lRemove any combustible materials from the weld-
ing area or cover such items appropriately.
lName a fire watch during and after welding work.
lPlace welding rod holders and inert gas welding
guns only on properly insulated bases.
lPlace the inert gas bottles in a safe place and se-
cure them against falling over.
lUse a protective screen or hand shield with welding
filter, wear welding gloves and clothes.
lSwitch the welding unit off before connecting weld-
ing cables.
lCheck electrode holders and electric cables at reg-
ular intervals.
Behaviour in case of faults
lIn case of faults on the welding unit switch of the
welding unit immediately and have it repaired by ex-
pert personnel.
lIn case of failure of the extraction system switch the
system off and have it repaired by expert personnel.
Maintenance; waste disposal
lReplace damaged insulating jaws and welding rod
holders immediately.
lReplace the welding wire reels only in de-energized
state.
What to do in case of accidents; First Aid
lKeep calm.
lCall first air helpers.
lReport the accident.
lIn case of an electric accident: Interrupt the power
supply and remove the injured person from the
electric circuit. If breathing and heart have stopped
apply reactivation measures and call for an emer-
gency doctor.
Operation of high-voltage systems
i
Note
The rules and statutory regulations valid in the corre-
sponding do apply in addition to the notes given here.
!
Caution
The high-voltage system must only be operated
and serviced by qualified and authorized person-
nel.
Before starting operation the operator must check
the proper condition of the system.
!Danger
Possibility of injury or even death caused by elec-
tric shock:
lif persons come into contact with live parts,
lin case of faulty insulation of live parts,
linadequate, unsuitable insulation,
lif melted parts flake off in case of short circuits.
Old oils
Prolonged and repetitive contact with mineral oils will
remove the natural greases from the skin and causes
dryness, irritation and dermatitis. Moreover, used en-
gine oils contain potentially hazardous contaminants,
which could cause skin cancer. Appropriate skin pro-
tection agents and washing facilities must therefore
be provided.
lWear protective clothes and safety gloves, if possi-
ble.
lIf there is a risk of eye contact you should protect
your eyes appropriately, e.g. chemistry goggles or
full face visor; a facility suitable for rinsing the eyes
should also be available.
lAvoid longer and repetitive contacts with oils. In
case of open incisionsand injuries seek medical ad-
vice immediately.
lApply protective cream before starting work, so that
oil can be easier removed from the skin.
lWash affected skin areas with water and soap (skin
cleansers and nail brushes will help). Lanolin con-
taining agents will replace natural skin oils that were
lost.
lDo not use gasoline, kerosene, diesel, thinner or
solvents to wash the skin.
lDo not put oil soaked cloths into your pockets.
lAvoid clothes getting soiled by oil.
lOveralls must be washed at regular intervals. Dis-
pose of non-washable clothes environmentally.
lIf possible degrease components before handling.
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