Built for the Bomag BW 27 RH-4i rubber tire roller, this 706-page Service Manual PDF (OEM ID 008 922 89) provides the factory repair data required to keep your compaction equipment moving on the mat. Detailed hydraulic schematics map out the closed-loop travel pumps and A6VM travel motors, and dedicated troubleshooting sections isolate faults fast. The documentation also unpacks complete EMR4 fault code lists, pneumatic diagrams for the tire inflation system, and full electrical wiring schematics. The text lays out exact factory measurements, such as the 6 bar fuel pump operating pressure and the 0.17 to 1.45 mm gap clearance for the crankshaft speed sensor. When the paving train is waiting and the machine stalls mid-pass for want of a single sensor value, this bookmarked, text-searchable file gets you to the correct specification the first time.
What's Inside This Bomag BW 27 RH-4i Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 7-32 | Introduction, Safety Regulations, General Repair Instructions |
| Pneumatic Tires Rollers | 33-36 | Rubber Tire Roller |
| Technical Data | 37-42 | Weights, Travel Characteristics, Drive, Brakes, Steering, Tires |
| Maintenance | 43-52 | Fuels and Lubricants, Table of Fuels and Lubricants, Running-In Instructions, Maintenance Table |
| Electrics | 53-86 | Overview, Service the Battery, Check the Main Battery Switch, Main Battery Switch, Starting with Jump Wires, Level Sensor in Diesel Tank |
| Electronic Modules | 87-102 | Module Description A04, Electric Module A108 |
| Module Description A100 | 103-106 | Steering Column Locking Module |
| Speedometer Module | 107-110 | Manual Testing, Teaching the Module |
| Engine Electrics | 111-136 | EMR4 System Overview, EMR4 System Components, Exhaust Gas After-Treatment, Fuel Control Unit, Injector, Crankshaft Speed Sensor, Camshaft Speed Sensor, Rail Pressure Sensor |
| List of EMR4 Fault Codes | 137-242 | Diagnostic Trouble Code List, EMR4 Fault Codes, Fault Code Descriptions |
| Engine | 243-280 | Overview, Diesel Engine, Engine Description Tcd 4.1, Lubrication Oil Circuit Tcd 4.1 / 6.1, Coolant Circuit Tcd 4.1 / 6.1, Common Rail System Tcd 4.1 / 6.1 |
| Hydraulics | 281-322 | Overview, Hydraulic Circuit, Travel Pumps, A4VG105 Da, Troubleshooting Axial Piston Pumps, External Gear Pumps, Travel Motor, A6VM 107HA2R1 |
| Brake | 323-338 | Overview, Brake System, Stopping the Machine, Operating the Parking Brake, Driving the Machine / Braking the Machine, Multi-Disc Brake, Function Test |
| Pneumatics | 339-352 | Overview, Pneumatic System, Operating the Tire Inflation System, Draining the Air Pressure Vessel, Change the Air Drier for the Brake System |
| Water Sprinkling System | 353-358 | Overview, Operating the Pressure Sprinkler System, Service the Water Sprinkling System, Maintenance in Case of Frost |
| Air Conditioning System | 359-402 | Overview, Physical Basics, Refrigerant R134a, Compressor Oil / Refrigeration Oil, Working Principle of the Air Conditioning System, Monitoring Devices, Components |
| Replacing the Cab Window Panes | 403-412 | Assembly of Window Panes, Special Tools, Cabin Windows, Auxiliary Materials, Removing and Installing the Window Pane |
| Front Axle | 413-444 | Repair Overview for Front Axle, Dismantling the Front Axle, Assembling the Front Axle |
| Suppliers Documentation | 445-650 | Travel Pump, Travel Motor, Travel Gear, Steering Valve |
| Circuit Diagrams | 651-706 | Hydraulic Diagram, Pneumatic Diagram, Wiring Diagram |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Drift punch diameter for seal assembly | 0.4 mm smaller than the outer diameter of the seal | p. 22 |
| F154 Amperage | 10 A | p. 67 |
| F13 Amperage | 10 A | p. 67 |
| Crankshaft speed sensor gap measurement | 0.17 - 1.45 mm | p. 124 |
| Fuel pump operating pressure | 6 bar | p. 255 |
| Tightening torque for threaded rod M12-8.8 | 77 Nm | p. 427 |
| F93 | 30A | p. 665 |
| F164 | 125A | p. 665 |
| Engine Oil Capacity | 11.5 L | p. 48 |
| Fuel Tank Capacity | 250 L | p. 39 |
| Water Tank Capacity | 400 L | p. 39 |
| Engine Oil Change Interval | 500 hours | p. 45 |
Bomag BW 27 RH-4i Common Problems This Manual Covers
Bomag BW 27 RH-4i engine stalls during rolling passes and throws EMR4 fault codes on the display
Inspect the crankshaft speed sensor gap before replacing components. Measure the clearance between the sensor and tone wheel. Adjust the bracket to achieve a gap of 0.17 - 1.45 mm as shown on page 124. Clear the faults and restart the machine to keep the paving train moving.
Manual Section: Engine Electrics p. 124Engine cranks over rapidly but refuses to fire up when restarting on a hot asphalt mat
Test the fuel pump operating pressure using an inline gauge. Verify the system maintains 6 bar during cranking as detailed on page 255. If pressure drops, check for a clogged filter or a vacuum reading exceeding -0.5 bar before pulling the pump off the block.
Manual Section: Engine p. 255Tires pick up asphalt because the water spray system suddenly stops spraying across all the nozzles
Check the electrical circuit for the pressure sprinkler system. Inspect fuse F06 on the main board and replace it with a 5A fuse if blown, referencing the wiring diagram on page 667. Clean the tank strainer before refilling the 400 L water tank to prevent pump cavitation.
Manual Section: Water Sprinkling System p. 667Machine completely loses travel drive in both directions and parking brake stays locked on the grade
Locate the travel and brake solenoid valve fuse in the main electrical box. Verify fuse F25 is intact and replace it with a 10A fuse if blown, using the diagram on page 668. Check the wiring harness for rub-throughs before returning the 27000 kg roller to the pass.
Manual Section: Circuit Diagrams p. 668Frequently Asked Questions
What are the torque specifications for the BOMAG BW 27 RH-4i wheel bolts?
Wheel nut torque (fine thread) on the BOMAG BW 27 RH-4i depends on the thread diameter. For an M12x1.5 thread, the torque is 100 Nm; for M14x1.5, it is 150 Nm; for M18x1.5, it is 300-350 Nm; for M20x1.5, it is 400-500 Nm; and for M22x1.5, it is 500-600 Nm. p. 29
How do I clear a fault code on the EMR4 engine control system?
To delete passive faults from fault log 1, turn the ignition OFF and keep the diagnostics button depressed. Switch the ignition ON, and release the diagnose button only after approximately 10 seconds. The deleting process is confirmed by three short flashing pulses. p. 135
What is the valve clearance adjustment angle on the TCD 4.1 engine in the Bomag BW 27 RH-4i?
Valve clearance adjustment angle for the TCD 4.1 engine is 75° ±15° for the intake valve and 120° ±15° for the exhaust valve. p. 264
What is the oil change interval for the engine oil on the BW 27 RH-4i?
The engine oil change interval is 500 operating hours for DQC III-LA and DQC IV-LA oils. Regardless of operating hours, the oil must be changed at least once per year. p. 45
What is the tightening torque for the high pressure relief valves on the Bomag BW 27 RH-4i travel pump?
When re-tightening the high pressure relief valves on the travel pump after towing, they must be tightened to 100 Nm (74 ft.lbs). p. 337
How quickly can I access this Bomag BW 27 RH-4i manual after buying?
Instant PDF download. You get the full 706-page searchable Service Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Can I print this Bomag BW 27 RH-4i manual?
You can. The PDF is unlocked and carries no copy protection, so print the sections you want and keep the file as your backup.
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