The Bomag BW 154 AD-4 AM service manual PDF, OEM 008 917 53, takes this tandem vibratory roller apart across 886 pages, from drum drive to Asphalt Manager II. Factory wiring diagram 920 100 09 and hydraulic diagram 920 100 64 anchor the back of the book, and a long electrics section walks you through the BAM and A03 modules, sensors, and the MESX control unit. Drum repair gets its own chapter: pulling the AD-drum, dismantling the exciter unit, reassembly, plus the oscillating articulated joint and flushing procedures for the travel and vibration circuits. Torque the fuel filter cartridge to 10 to 12 Nm, and plan your lift around the 9900 kg CECE operating weight with ROPS cab. Guess at an exciter fit and you buy the teardown twice. Print what you need; these pages can take grease on the bench, and bookmarks put each system one click away.
What's Inside This Bomag BW 154 AD-4 AM Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 9-32 | Introduction, Safety Regulations, General Repair Instructions |
| Pivot Steered Tandem Rollers | 33-36 | Heavy Vibratory Rollers, Articulated |
| Technical Data | 37-42 | Weights, Dimensions, Travel Characteristics, Drive, Brake, Steering |
| Maintenance | 43-52 | Fuels and Lubricants, Table of Fuels and Lubricants, Running-In Instructions, Maintenance Table |
| Electrics | 53-180 | Understanding Circuit Diagrams, Designation of Components in the Wiring Diagram, Terminal Designations in Wiring Diagram, Circuit Symbols in the Circuit Diagram |
| Electronic Modules | 181-288 | Electrics Bam, Electrics Module A03, Electrics Module A68, Electrics Module A71, Electric Module A72 |
| Asphalt Manager | 289-328 | Asphalt Manager Ii, Function, Control Circuit and Mesx, Block Diagram, Asphalt Temperature, Acceleration Transducer, Potentiometer on Slewing Motor, B97 |
| Hydraulics | 329-384 | Hydraulic Circuit, Travel Pump, A4VG56 Hw, Vibration Pump, A10VG45 Ez, Overview of Travel/Vibration Pump Connections, Travel Circuit, Drum Drive Gft 7 G2091 / G2093 |
| Tests and Adjustments | 385-406 | Special Tools, Checking the Rotation Speeds, Pressure Tests in the Travel Circuit, Checking / Adjusting the Neutral Positions of the Travel Pump |
| Trouble Shooting | 407-426 | Travel System, No Vibration, Steering System, Axial Piston Pumps, Flow Divider, Engine Problems |
| Flushing and Bleeding | 427-452 | Special Tools for Flushing, Flushing - General, Flushing Schematic for Travel System, Flashing the Travel Circuit, Flushing Schematic for Vibration Drive on AD-machines |
| Engine | 453-492 | Diesel Engine, Lubrication Oil Circuit, Fuel System, Coolant Diagram, Exhaust Gas Recirculation, Check, Adjust the Valve Clearance, Check the Engine Oil Level |
| Air Conditioning System | 493-536 | Physical Basics, Refrigerant R134a, Compressor Oil / Refrigeration Oil, Working Principle of the Air Conditioning System, Monitoring Devices, Components |
| Replacing the Cab Window Panes | 537-546 | Assembly of Window Panes, Special Tools, Cabin Windows, Auxiliary Materials, Removing and Installing the Window Pane |
| Replacing the Travel Control Cable | 547-564 | Special Tools, Driver's Stand, Wiring Loom, Travel Control Cable |
| Drum | 565-630 | Special Tools, Repair Overview AD-drum, Removing and Installing the Drum, Dismantling the AD-drum, Ad/Ap Disassembling, Assembling the Exciter Unit, Assembling the AD-drum |
| Oscillating Articulated Joint | 631-654 | Repair Overview Oscillating Articulated Joint, Removing - Disassembling the Oscillating Articulated Joint, Assembling the Oscillating Articulated Joint |
| Suppliers Documentation | 655-838 | Travel Pump, Vibration Pump, Travel Motor, Vibration Motor, Steering Valve |
| Circuit Diagrams | 839-886 | Hydraulic Diagram 920 100 64, Wiring Diagram 920 100 09 |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Tighten the fuel filter cartridge | 10 - 12 Nm | p. 467 |
| Operating weight (CECE) with ROPS-cabin | 9900 kg | p. 38 |
| Max. operating weight | 11300 kg | p. 38 |
| Rated power ISO 14396 | 63 kW | p. 38 |
| Rated power SAE J 1995 | 84.4 hp | p. 38 |
| Fuel (diesel) filling capacity | approx. 160 l | p. 39 |
| Water filling capacity | approx. 800 l | p. 39 |
| Hydraulic oil filling capacity | approx. 60 l | p. 39 |
| Engine oil filling capacity | approx. 10,5 l | p. 39 |
| Coolant filling capacity | approx. 16 l | p. 39 |
| Valve clearance intake | 0.3 mm | p. 39 |
| Valve clearance exhaust | 0.5 mm | p. 39 |
Bomag BW 154 AD-4 AM Common Problems This Manual Covers
Bomag BW 154 AD-4 AM creeps forward with travel lever in neutral, won't drive in either direction
Check the charge pressure first; low charge pressure locks out travel on both drums. If the machine creeps in neutral, adjust the travel pump neutral position using the procedure on page 409. Run the travel circuit pressure tests starting page 385, and top the hydraulic tank to its full 60 liter capacity before retesting.
Manual Section: Travel System Troubleshooting p. 409No vibration on either drum, or only one amplitude works at full throttle
Test the vibration circuit pressures using the procedures starting on page 385 before pulling a drum. Check the vibration pump and shut-off valve lines against the hydraulic schematic. If pressure readings point to a seized exciter, follow the drum service procedures beginning on page 565, then refill the system to its 60 liter capacity.
Manual Section: Tests and Adjustments p. 385Engine runs hot and loses power under load when working in dusty conditions
Clean the cooling package with compressed air before anything else; dust-caked cores cause most heat complaints on base and landfill work. Check the coolant level and top up toward the full 16 liter capacity. Verify valve clearance at 0.3 mm intake and 0.5 mm exhaust, following the engine procedures starting page 453.
Manual Section: Engine p. 453Engine cranks but won't start, or stalls repeatedly after fuel filter service
Torque the fuel filter cartridge to 10-12 Nm per the spec on page 467, then bleed the fuel system completely; air-bound lines cause the crank-no-start. Verify the 160 liter tank isn't drawn down far enough for the pickup to suck air, and check the water separator before condemning the injection pump.
Manual Section: Engine p. 467Complete electrical shutdown with no ignition, gauges, or lights when turning the key
Start with the 125 A main fuse, spec listed on page 114; one blown fuse kills the whole machine. Inspect the battery terminals and ground strap for corrosion, then trace the ignition feed through the wiring diagram. Test module connectors for backed-out pins before replacing any components.
Manual Section: Electrics p. 114Frequently Asked Questions
What are the torque specifications for M10 screws with strength class 8.8 on the Bomag BW 154 AD-4 AM?
For screws with a metric unified thread and a strength class of 8.8, the tightening torque for an M10 screw is 50 Nm. p. 28
What is the valve clearance for the intake and exhaust valves on the Bomag BW 154 AD-4 AM engine?
The intake valve clearance is 0.3 mm and the exhaust valve clearance is 0.5 mm. p. 39
What is the engine oil change interval for the Bomag BW 154 AD-4 AM?
The engine oil should be changed every 500 operating hours. p. 45
What is the correct procedure for bleeding the vibration circuit?
To bleed the vibration circuit, connect a pressure test hose to the charge pressure test port and high pressure test ports, actuate the emergency stop switch, and crank the engine for approximately 10 seconds with the starter motor. Repeat this procedure until oil runs out of the test hoses. p. 450
What is the tightening torque for the drum drive shaft nut on the Bomag BW 154 AD-4 AM?
The tightening torque for the shaft nut on the drum drive is 4175 Nm. p. 358
Is this Bomag BW 154 AD-4 AM Service Manual a digital download?
You download the Service Manual yourself: an 886 page PDF, available immediately. Keep a copy on every device you use.
Am I free to print this Bomag BW 154 AD-4 AM Service Manual?
Print away. There is no DRM and no page limit. Many buyers print one chapter at a time and leave the rest on a tablet.
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