Operating instructions

Maintenance instructions
Original operating instructions

BM 2000/60
S/N 821 836 26 ....> S/N 821 836 31 ....>

Cold Milling Machine

Catalogue No.
008 060 61 08/2011
 Foreword

BOMAG machines are products from the wide You should only operate the machine after you
F oreword

range of BOMAG compaction and road milling have been instructed and in compliance with these
equipment. instructions.

BOMAGs vast experience in connection with
state-of-the-art production and testing meth-
ods, such as lifetime tests of all important
components and highest quality demands
guarantee maximum reliability of your ma-
chine.
This manual comprises:
l Safety regulations
l Operating instructions
l Maintenance instructions
l Trouble shooting
Strictly observe the safety regulations.
Please observe the guidelines of the Civil Engi-
neering Liability Association "Road Milling Equip-
ment" and the applicable accident prevention
instructions.
For your own personal safety you should only
use original spare parts from BOMAG.
In the course of technical development we re-
serve the right for technical modifications
without prior notification.
These operating and maintenance instructions are
also available in other languages.

Using these instructions will Apart from that, the spare parts catalogue is avail-
able from your BOMAG dealer against the serial
l help you to become familiar with the machine. number of your machine.
l avoid malfunctions caused by unprofessional The above notes do not constitute an extension of
operation. the warranty and liability conditions specified in the
general terms of business of BOMAG GmbH.
Compliance with the maintenance instructions will
We wish you successful work with your BOMAG
l enhance the reliability of the machine on con- machine.
struction sites,
BOMAG GmbH
l prolong the lifetime of the machine,
Printed in Germany
l reduce repair costs and downtimes.
Copyright by BOMAG
BOMAG GmbH will not assume liability for the
function of the machine
l if it is handled in a way not complying with the
usual modes of use,
l if it is used for purposes other than those men-
tioned in these instructions.

No warranty claims can be lodged in case of dam-

age resulting from
l operating errors,
l insufficient maintenance and
l wrong fuels and lubricants.

Please note!
This manual was written for operators and mainte-
nance personnel on construction sites.
Always keep this manual close at hand, e.g. in the
tool compartment of the machine or in a specially
provided container. These operating and mainte-
nance instructions are part of the machine.

BM 2000/60 BOMAG 3
Foreword

Please fill in
............................
Machine type (Fig. 1)
............................
Serial number (Fig. 2 )
............................
Engine type (Fig. 3)
............................
Engine number (Fig. 3)

i Note Fig. 1
Supplement the above data together with the com-
missioning protocol.
During commissioning our organisation will in-
struct you in the operation and maintenance of the
machine.
Please observe strictly the safety regulations and
all notes on risks and dangers!

Fig. 2

Fig. 3

4 BOMAG BM 2000/60
 Table of Contents

Technical Data 9
Safety regulations 13
Indicators and Controls 27
3.1 View of operating console left, middle, right 28
3.2 General notes 30
3.3 Display and control elements operator's stand 30
3.4 View rear right hand control panel 44
3.5 Control elements on rear right hand control panel 45
3.6 View rear left hand control panel 46
3.7 Description of rear left hand control panel 47
3.8 View front right hand control panel 48
3.9 Description of front right hand control panel 49
3.10 View front left hand control panel 50
3.11 Description of front left hand control panel 51
3.12 Automatic levelling control 52
3.13 Description of levelling control 54
3.14 View of ultrasonic levelling system 56
3.15 View of water spray system 57
Operation 59
4.1 General notes 60
4.2 Tests before taking into operation 60
4.3 Starting the engine 61
4.4 Starting with jump wires 63
4.5 Shutting down the engine 63
4.6 Steering 64
4.7 Lifting / lowering the machine 65
4.8 Switching the milling drum on/off 66
4.9 Operating the scraper 67
4.10 Operation of loading and gathering conveyor belt 68
4.11 Driving the machine 71
4.12 Preparing for work 72
4.13 Work operation, setting the cutting depth 76
4.14 Automatic milling depth control 80
4.15 Milling depth control by means of ultrasound 83
4.16 Stopping/finishing work 85
4.17 Adjusting the seat 86
4.18 Operating the engine hood 86
4.19 Operating the protection roof on the operator's stand 87
4.20 In events of emergency 87
4.21 Preparing the machine for a longer rest 89
4.22 Operating the water spray system 90

BM 2000/60 BOMAG 5
Table of Contents

4.23 Folding / unfolding the loading conveyor belt 92

4.24 Loading, transport 93
4.25 Multi-function display 95
4.26 Scrapping the machine 97
Maintenance 99
5.1 General notes on maintenance 100
5.2 Fuels and lubricants 101
5.3 Table of fuels and lubricants 104
5.4 Running-in instructions 105
5.5 Maintenance table 106
5.6 Check the engine oil level 109
5.7 Check, clean the water separator 109
5.8 Check the fuel level 110
5.9 Checking the hydraulic oil level 111
5.10 Check water level, spray nozzles 112
5.11 Check/replace cutting tools, scraper 112
5.12 Checking the track plates 118
5.13 Check, tighten the conveyor belts 118
5.14 Checking the safety ropes 120
5.15 Lubricate the machine 120
5.16 Check the coolant level 123
5.17 Check the oil level in the pump drive gear 123
5.18 Retightening the track shoe fastening screws 124
5.19 Lubricate the machine 124
5.20 Clean the cooling fins on engine and hydraulic oil cooler 127
5.21 Cleaning the engine 128
5.22 Changing engine oil and oil filter cartridges 129
5.23 Checking, replacing the generator V-belt 130
5.24 Checking, replacing the milling drum V-belt 132
5.25 Checking the track drive 133
5.26 Lubricate the machine 135
5.27 Check, adjust the valve clearance 137
5.28 Change the fuel pre-filter cartridge 139
5.29 Change the fuel filter cartridge 140
5.30 Check fastening of engine / turbocharger / combustion air hoses 141
5.31 Checking the crankcase pressure 142
5.32 Intercooler, draining oil and condensation water 143
5.33 Change the hydraulic oil 143
5.34 Changing the hydraulic oil filter 145
5.35 Change the oil in the pump drive gear 146
5.36 Change the oil in the milling drum reduction gear 147
5.37 Oil change in milling drum bearing 148

6 BOMAG BM 2000/60
 Table of Contents

5.38 Oil change in track drive gear 149

5.39 Drain the sludge from the fuel tank 150
5.40 Battery maintenance 150
5.41 Changing the coolant 153
5.42 Changing the injection valve 155
5.43 Changing the coolant pump 157
5.44 Changing the pressure retaining valve on te injection pump 157
5.45 Changing the crankcase ventilation valve 158
5.46 Service the combustion air filter 161
5.47 Clean water tank and water filter 163
5.48 Water spray system, maintenance in case of frost 164
5.49 Clean the pressure cleaner water filter 165
5.50 Tightening torques 166
5.51 Engine conservation 166
Trouble shooting 167
6.1 General notes 168
6.2 Engine 169

BM 2000/60 BOMAG 7
Table of Contents

8 BOMAG BM 2000/60
 1 Technical Data

BM 2000/60 BOMAG 9
 Technical Data

Fig. 4

Dimensions in A B B2 H H2 H3 K L L1
mm
BM 2000/60 4720 2500 1870 2960 3990 4500 1120 14900 12000

*
BM 2000/60

Weights
Operating weight (CECE) kg 30300
Basic weight kg 28100
Max. operating weight kg 32500

Rotor
Milling depth mm 0-320
Milling width mm 2000
Diameter mm 1070
Number of teeth Pieces 168
Milling line distance mm 15
Rated speed rpm 108
Power per cutter kW 2.62

Travel characteristics
Working speed m/min 0 - 40
Travel speed km/h 0-5
Max perm. inclination % 100
Max perm. slope % 9
Inner track radius m 2.1

10 BOMAG BM 2000/60
 Technical Data

* BM 2000/60
Drive
Engine manufacturer Deutz
Type TCD 2015
Cooling Water
Number of cylinders 8V
Rated power ISO 3046 kW(HP) 440 (600)
Rated speed rpm 1900
Fuel Diesel

Crawler tracks
Dimensions LxWxH front mm 1700x300x640
Dimensions LxWxH rear mm 1700x300x640

Electric system
Voltage V 24
Batteries (2) Ah 2x155
Generator A 80

Conveyor system
Belt width, gathering belt mm 800x2400
Belt width, loading belt mm 800x7600

Filling capacities
Diesel fuel l 1200
Hydraulic oil l 230
Water l 3500
* The right for technical modifications remains reserved

BM 2000/60 BOMAG 11
Technical Data

The following noise and vibration data acc. to

- EC Machine Regulation edition 2006/42/EC

- the noise regulation 2000/14/EG, noise protection guideline 2003/10/EC

- Vibration Protection Regulation 2002/44/EC

were determined during conditions typical for this type of equipment and by application of harmo-
nized standards.

During operation these values may vary because of the existing operating conditions.

Noise value
Sound pressure level on the place of the operator:
LpA = 92 dB(A), determined acc. to ISO 11204 and EN 500

Guaranteed sound power level:

LWA = 114 dB(A), determined acc. to ISO 3744 and EN 500

! Danger
Wear your personal noise protection means (ear defenders) before starting operation.

Vibration value
Vibration of the entire body (drivers seat)
The weighted effective acceleration value determined acc. to ISO 7096, is 0.5 m/s2.

Hand-arm vibration values

The weighted effective acceleration value, determined acc. to EN 500/ISO 5349, is 2.5 m/s2.

12 BOMAG BM 2000/60
 2 Safety regulations

BM 2000/60 BOMAG 13
Safety regulations
General
This BOMAG machine has been built in com-
pliance with the latest technical standard and
complies with the applicable regulations and
technical rules. However, considerable dan-
gers for persons and property may arise from
this machine, if:
l it is used for purposes other than the ones it is
intended for
l it is operated by untrained personnel
l it is changed or converted in an unprofessional
way
l the safety instructions are not observed
Each person involved in the operation, mainte-
nance and repair of the machine must there-
fore read and comply with these safety
regulations. If necessary, this must be con-
firmed by obtaining the signature of the cus-
tomer.
Moreover, the following instructions and regula-
tions must obviously also be adhered to:
l applicable accident prevention instructions
l generally accepted safety and road traffic reg-
ulations
l country specific safety regulations. It is the
duty of the operator to be acquainted with
these instructions and to apply these accord-
ingly. This applies also for local regulations
concerning different types of handling work.
Should the recommendations in these instruc-
tions be different from the regulations valid in
your country, you must comply with the safety
regulations valid in your country.
The machine must only be operated and serv-
iced by persons:
l who have been instructed in operation/han-
dling of the machine,
l and who have read and understood the oper-
ating instructions with the safety regulations.
The machine operator is responsible with all work
related with the machine.
He should therefore check the operating/road traf-
fic safety of the machine before taking up work and
use the machine only for the purpose it is intended
for.
14
Intended use
This machine must only be used for the milling of
asphalt or concrete road surfaces.
The machine must only be used inside cordoned
off construction sites.
Intended use also includes the compliance with
the specified operating, maintenance and repair
measures.
Any other use is considered as unintended.
Have the machine inspected by an expert once
every year.
Unintended use
However, dangers may arise from the machine
l if the operator acts irresponsibly
l or if the machine is used inappropriately by un-
trained personnel or for purposes it is not in-
tended for
l if safety features have been removed or are
not used.
The machine must especially not be used:
l for the transport of persons, except the operat-
ing personnel
l to push vehicles by suing the conveyor belt
swinging function
l for towing or pushing other vehicles or ma-
chines
l as recovery vehicle or as towing machine for
transportation
l the conveyor belt as lifting gear
l the milling of railway tracks, pipes, manhole
covers or other objects in the carriage way
l height regulation by pulling on the rope sensor
l with single-man operation
l mixing soils with cement, lime and other soil
stabilizing substances
l in explosion endangered environments.
Regular safety inspections
Have the machine inspected by an expert (proper-
ly trained person) once every year.
BOMAG BM 2000/60

Who is allowed to work with the ma-
chine?
The machine must only be operated by trained
and authorized persons which are at least 18
years of age. The responsibilities for the operation
of the machine must be clearly specified and com-
plied with.
Persons under the influence of alcohol, medica-
tion or drugs must not operate, service or repair
the machine.
Maintenance and repair tasks require specific
knowledge and must therefore only be carried out
by trained and qualified personnel.
Changes and conversions to the ma-
chine
Unauthorized changes to the machine are prohib-
ited for safety reasons.
Original parts and accessories have been special-
ly designed for this machine. We wish to make ex-
plicitly clear that we have not tested or approved
any parts or accessories not supplied by us. The
installation and/or use of such products may have
an adverse effect on the active and/or passive
driving safety. The manufacturer explicitly ex-
cludes any liability for damage caused by the use
of non-original parts or accessories.
No additional parts must be bolted on, welded on
and no holes must be drilled.
Damage, deficiencies, misuse of safety
installations
Machines which are not safe to operate or in traffic
must be immediately taken out of service and shall
not be used, until these deficiencies have been
properly rectified.
Safety installations and switches must neither be
removed nor must they be made ineffective.
Safety notes in the operating and main-
tenance instructions:
! Danger
Sections marked like this point out possible
dangers for persons.
BM 2000/60
Safety regulations
Caution
!
Sections marked like this point out possible
dangers for the machine or for parts of the ma-
chine.
i Note
Sections marked like this provide technical infor-
mation concerning the optimal economical use of
the machine.
Environment
Sections marked like this highlight activities
for the safe and environmental disposal of fu-
els and lubricants as well as replaced parts.
Observe all environment protection regula-
tions.
Loading the machine
Use only stable loading ramps of sufficient load
bearing capacity. The ramp inclination must not
exceed 18.
Secure the machine on the transport vehicle
against rolling, slipping and turning over.
Lower all height adjustable parts, if necessary lock
their position
Make sure that persons are not endangered by the
machine tipping or sliding off. The instructing per-
son must stand within the view of the oeprator, but
outside the danger area.
Persons are highly endangered if
l they step or stand under loads being lifted
l they remain in the drive range of the machine
during an instruction and during loading.
The machine must not swing about when being lift-
ed.
Use only safe lifting gear of sufficient load bearing
capacity
Fasten the lifting gear only at the specified lifting
points.
When lifting the machine or parts of the machine
ensure sufficient load bearing capacity of the lifting
gear.
Towing the machine
You should generally use a tow bar.
BOMAG 15
Safety regulations
Max. towing speed 10 m/min (33 ftpm), max. tow-
ing distance 300 m (1640 ft).
Before releasing the parking brake secure the ma-
chine against unintended moving.
Starting the machine
Before starting work inform yourself about First Aid
equipment and rescue possibilities (medical emer-
gency service, fire brigade).
Make sure that a correctly equipped first aid kit is
available.
Before starting
The machine must only be operated from the driv-
ers station.
Use only machines which are serviced at regular
intervals.
Become acquainted with the equipment, the con-
trol elements, the working principle of the machine
and the working area.
Use your personal protective outfit (hard hat, safe-
ty boots, if necessary also goggles and ear de-
fenders).
Make sure that the machine is equipped with the
appropriate illumination according to the require-
ments of the application.
Check the condition and correct fit of safety ropes,
bolts, spring plugs and other safety elements.
Do not take any loose objects with you or fasten
them to the machine.
Before mounting the machine check whether:
l persons or obstructions are beside or under
the machine
l the machine is free of oily and combustible
material
l all grips, steps and platforms are free of obsta-
cles, grease, oils, fuel, dirt, snow and ice
l engine compartment door and all safety cov-
ers are closed and locked.
Use steps and grips to mount the machine.
Do not use control levers or hoses as hand grips
for accessing the machine.
Before starting the machine check whether:
l the machine shows any obvious faults
l all guards and safety elements are in place
16
l steering, brakes, control elements, light sys-
tem and warning horn work correctly
l the seat is correctly adjusted
l mirrors are clean and correctly adjusted.
Do not start the machine with defective gauges,
control lights or control elements.
Starting
Start and operate the machine only from the driv-
ers station.
Before starting and moving the machine make
sure that no person
l is under the machine
l is in the swinging range of the loading convey-
or belt
l or in the vicinity of track wheels or crawler
tracks.
Always sound the warning horn before starting the
machine
Check the function of the emergency stop buttons.
The engine must stop. The machine must not be
operated with damaged, missing or non-functional
safety installations.
For starting set all control levers to 'neutral posi-
tion'.
Do not use any starting aids like start pilot or ether.
After starting check all gauges and control lights.
Do not leave the machine with the engine running.
Starting with jump wires
Connect positive with positive and negative with
negative (ground cable) always connect the
ground strap last and disconnect it first! A wrong
connection will cause severe damage in the elec-
tric system.
Do not start the engine by shorting the electric ter-
minals on the starter motor, because the machine
may start to drive immediately.
Starting in closed rooms
Exhaust gases are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
in closed rooms!
BOMAG BM 2000/60

Driving the machine, milling operation
Persons in the danger area
Before taking up work, also after breaks, you
should always convince yourself that the danger
zone is free of persons or obstructions, especially
when driving in reverse.
Give warning signals, if necessary. Stop work im-
mediately if persons remain in the danger zone,
despite the warning.
Driving
In events of emergency and in case of danger ac-
tuate one of the emergency stop buttons immedi-
ately. Do not use the emergency stop switch as
service brake.
Restart the machine only after the danger that
caused the actuation of the emergency stop switch
has been eliminated.
When displacing/transporting the machine:
l Level the machine in transverse direction and
raise it completely
l Align the loading belt straight ahead
l Do not activate any work equipment
Always keep the machine horizontal when driving
into or out of the milling track.
Always keep a sufficient distance when passing
through subways, under bridges, tunnels, electric
power lines etc.
If the machine has contacted high-voltage power
lines:
l do not leave the operators stand
l warn others from coming close to or touching
the machine
l if possible drive the machine out of the danger
zone
l have the power switched off
Operate the machine only from the operators
stand.
Do not climb onto or off the machine while the ma-
chine is driving.
Change the travel direction only at standstill.
Do not use the machine to transport persons.
In case of unusual noises and development of
smoke perform trouble shooting and have the fault
corrected.
BM 2000/60 BOMAG
Safety regulations
Always keep a sufficient distance to excavation
walls and embankments and do not use working
methods that could impair the stability of the ma-
chine.
Check the load bearing capacity before driving
over bridges, cellar roof, vaults or similar.
Leave the machine in case of thunderstorms. Dan-
ger of lightning.
Milling operation
Danger
!
Health hazard!
When milling road covering layers harmful
dusts may be released.
In order to avoid any damage to health the ma-
chine operator and other persons, who have to
work in the immediate vicinity of the milling
machine, should wear breathing masks (half
mask with exhalation valve or respirator) to re-
duce the dust particles, when a development
of dust is noticed.
Contaminated parts of the body should be
thoroughly washed before breaks and at the
end of work. After work the dust covered work-
ing clothes should be replaced by normal
clothes. Working clothes and respiratory
equipment should not be stored together with
normal clothes. Dust covered working clothes
must be cleaned at regular intervals.
Special caution is required when lowering the mill-
ing drum into the ground and during the subse-
quent work process:
l During careless starting of a new milling track
the machine can suddenly make a sudden and
uncontrolled backwards move.
l There may be foreign objects (pipes, metal
parts or similar) in the milling range, which can
cause dangerous operating conditions.
l Worn cutting tools can also cause dangerous
operating conditions, worn cutting tools should
therefore be replaced in due time.
Keep a safety distance of at least 2 metres when
checking the milling depth.
Make sure that no persons are in the danger area
when operating the drum flap or the milling drum
drive.
17
 Safety regulations
Always chose the belt speed so that no milling ma-
terial is thrown out in an uncontrolled manner.
Never reach into the running conveyor system for
the purpose of cleaning.
Never swing the loading conveyor belt over per-
sons or the truck cabin
Inclination
Fig. 5
The tipping angle was measured on level, hard
ground with the machine stopped and not steering.
With loose soil, acceleration/deceleration, steering
operated or attached accessories the tipping an-
gle may be considerably lower.
Driving across slopes should therefore be strictly
avoided, because of the high risk of tipping over
and the related risk of severe or even fatal acci-
dents.
Driving on inclinations and slopes
Do not drive on gradients exceeding the maximum
gradability of the machine.
On slopes drive extremely careful and always di-
rectly up or down the slope. Change to a lower
gear before starting to drive.
Wet and loose soils considerably reduce the
ground adhesion of the machine on inclinations
and slopes. Higher risk of accident!
You should therefore always drive straight up or
down a slope.
Behaviour in traffic
Match the speed to the road conditions.
Switch the lights on if the visibility is poor.
Always keep a safe distance to edges and em-
bankments.
18
Parking the machine
Empty the conveyor belt from all milled material.
Do not park the machine in front of stairs or lad-
ders, water hydrants etc., if this would obstruct
their use.
Park the machine on horizontal, level, firm ground.
Before leaving the machine:
l shift all control levers to "Neutral position",
"OFF" or "0"
l apply the parking brake
l shut the engine down, pull the ignition key off
l secure the machine against unintended use.
Do not jump off the machine, but use hand grips
and access steps.
Mark machines, which could be in the way, with a
clearly visible sign.
Parking on slopes and inclinations
Always secure the machine against unintended
rolling.
Filling the fuel tank
Do not inhale fuel fumes.
Refuel only after shutting the engine and the aux-
iliary heater down.
Do not refuel in closed rooms.
No open fire, do not smoke.
Do not spill any fuel. Catch running out fuel, do not
let it seep into the ground.
Wipe off spilled fuel. Keep fuel free of dirt and wa-
ter.
Leaking fuel tanks can cause explosions. Ensure
tight fit of the fuel tank filling cover, replace it if nec-
essary.
Fire protection measures
Make yourself acquainted with the location and the
operation of fire extinguishers. Observe fire warn-
ing and fire fighting installations.
Maintenance work
Comply with the maintenance work described in
the operating and maintenance instructions, in-
cluding the information concerning the replace-
ment of parts.
BOMAG BM 2000/60

Support the engine hood for all maintenance and
repair work in the engine compartment.
Maintenance work must only be performed by
qualified and authorized persons.
For overhead maintenance and assembly work
use the access steps and working platforms pro-
vided or other secure means. Do not use machine
parts as access steps.
Keep unauthorized persons away from the ma-
chine.
Do not perform maintenance work while the ma-
chine is driving or the engine is running.
Park the machine on horizontal, level, firm ground.
Pull the key out of the ignition switch.
Secure the articulated joint with the articulation
lock.
Work on hydraulic lines
Relieve hydraulic pressures before working on hy-
draulic lines. Hydraulic oil escaping under pres-
sure can penetrate the skin and cause severe
injury. When being injured by hydraulic oil consult
a medical doctor immediately, as otherwise this
may cause severe infections.
Do not step in front of or behind the drums/wheels
when performing adjustment work in the hydraulic
system.
Do not change the setting of pressure relief valves.
Drain the hydraulic oil at operating temperature
danger of scalding!
Catch running out hydraulic oil and dispose of en-
vironmentally.
Always catch and dispose of hydraulic oils sepa-
rately.
Do not start the engine after draining the hydraulic
oil.
Once all work is completed (with the system still
depressurized!) check all connections and fittings
for leaks.
Changing hydraulic hoses
Hydraulic hoses must be visually inspected at reg-
ular intervals.
Hydraulic hoses must be immediately replaced if:
l the outer layer is damaged down to the inlay
(e.g. chafing, cuts, cracks)
BM 2000/60
Safety regulations
l the outer layer is brittle (formation of cracks in
the hose material)
l the hose shows deformations in pressurized
and depressurized condition, which do not
comply with the genuine shape of the hydrau-
lic hose
l the hose shows deformations in bends, e.g.
squeezing, buckling, layer separation, forma-
tion of blisters
l parts of the hose are leaking.
l hoses are not correctly installed.
l the hydraulic hose has separated from the fit-
ting
l the fitting shows corrosion that impairs both
function and strength.
l hoses are mixed up by mistake.
l fittings are damaged or deformed, whereby
the function and strength of the hose/hose
connection is impaired.
Only genuine BOMAG replacement hydraulic hos-
es ensure that the correct hose type (pressure
range) is used at the right location.
Working on the engine
Shut the engine down before opening the engine
hood.
Do not work on the fuel system while the engine is
running - danger to life due to high pressures!
l Wait another minute after the engine has
stopped.
l Keep out of the danger zone during the initial
test rung.
l In case of leaks return to the workshop imme-
diately.
l Make sure that the engine cannot be started
unintentionally during service and repair work.
Drain the engine oil at operating temperature
danger of scalding!
Wipe off spilled oil, catch running out oil and dis-
pose of environmentally.
Store used filters and other oil contaminated ma-
terials in a separate, specially marked container
and dispose of environmentally.
Do not leave any tools or other objects, that could
cause damage, in the engine compartment.
BOMAG 19
Safety regulations
The settings for idle speed and highest speed
must not be changed, since this would affect the
exhaust gas values and cause damage to engine
and power train.
Turbo chargers work with high speeds and high
temperatures. Keep hands, tools and materials
away from the intake and outlet openings of the
nturbo charger and do not touch any hot surfaces.
Check and change coolant only when the engine
is cold.
Catch coolant and dispose of environmentally.
Working on electric parts of the machine
Before starting to work on electric parts of the ma-
chine disconnect the battery and cover it with insu-
lating material.
Do not use fuses with higher ampere ratings and
do not repair fuses with a piece of wire. Fire haz-
ard!
Disconnect the battery before starting welding
work on the machine.
Working on the battery
When working on the battery do not smoke, do not
use open fire!
Do not let acid come in contact with hands or
clothes! When injured by acid flush off with clear
water and seek medical advice.
Metal objects (e.g. tools, rings, watch straps) must
not come in contact with the battery poles dan-
ger of short circuit and burning!
When recharging serviceable batteries remove all
plugs, to avoid the accumulation of explosive gas-
es.
Observe the applicable instructions when starting
with an auxiliary battery.
Dispose of old batteries according to regulations.
Switch off the charging current before removing
the charging clamps.
Ensure sufficient ventilation, especially if the bat-
tery is to be charged in a closed room.
Working on the fuel system
Do not inhale any fuel fumes.
Avoid open fire, do not smoke, do not spill any fuel.
Catch running out fuel, do not let it seep into the
ground and dispose off environmentally.
20
Working on wheels and tires
Explosion-like bursting of tires or parts of tires and
rims can cause most severe or even deadly inju-
ries.
Assembly of tires must only be performed with ap-
propriate experience and tools. If necessary have
tires assembled in a qualified workshop.
Always ensure the correct tire pressure and do not
exceed the specified maximum pressure.
Check tires and wheels every day for specified
pressure, cuts, bulges, damaged rims, missing
wheel studs or nuts. Do not drive with damaged
tires or wheels.
Ant-sticking emulsions for tires must only consist
of water and anti-sticking agent, in a concentration
in accordance with the specifications of the manu-
facturer of the anti-sticking agent. Observe appli-
cable environmental regulations.
Cleaning work
Do not perform cleaning work while the engine is
running.
Do not use gasoline or other easily inflammable
substances for cleaning.
When cleaning with steam cleaning equipment do
not subject electrical parts and insulation material
to the direct jet of water, or cover it beforehand.
l Do not guide the water jet into the exhaust and
into the air filter.
After maintenance work
After all maintenance work is completed reinstall
all guards and safety installations.
Repair
Mark a defective machine by attaching a warning
tag to the steering wheel.
Repair work must only be performed by qualified
and authorized persons. Use our repair instruc-
tions for this work.
Exhaust gases are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
in closed rooms!
Do not work on the fuel system while the engine is
running - danger to life!
The system is under high pressure! Keep away
from leakages in the high pressure system, be-
cause fuel squirting out may cause severe injury.
BOMAG BM 2000/60

After shutting down the engine wait for another
minute, until the pressure has dropped to a per-
missible level. In case of leakages you should con-
tact the Service Department of the engine
manufacturer and refrain from starting the engine.
Test
The safety of compaction equipment must be
checked by a specialist as required in dependence
on the application and the operating conditions,
however at least once every year.
Maintenance work
Comply with the maintenance work described in
the operating and maintenance instructions, in-
cluding the information concerning the replace-
ment of parts.
Maintenance work must only be performed by
qualified and authorized persons.
For overhead maintenance and assembly work
use the access steps and working platforms pro-
vided or other secure means. Do not use machine
and control parts as access steps and handles.
Keep unauthorized persons away from the ma-
chine.
Do not perform maintenance work while the ma-
chine is driving or the engine is running.
Park the machine on horizontal, level, firm ground.
Pull off the ignition key and attach a warning label.
Wear safety gloves when working on the hot en-
gine.
When removing the radiator cap hot coolant may
leak out, danger of scalding!
Anti-freeze agents can be toxic. Dispose of
drained off coolant environmentally.
Do not start the engine without engine oil or cool-
ant.
Dispose of old oil, oil filter and filter elements envi-
ronmentally.
Avoid sparks and open flames in the vicinity of bat-
teries.
Do not disconnect the batteries while the engine is
running.
Do not reach with your hands into the running con-
veyor system.
BM 2000/60
Safety regulations
Work on hydraulic lines
Relieve hydraulic pressures before working on hy-
draulic lines. Hydraulic oil escaping under pres-
sure can penetrate the skin and cause severe
injury. When being injured by hydraulic oil consult
a medical doctor immediately, as otherwise this
may cause severe infections.
Do not step in front of or behind the tracks when
performing adjustment work in the hydraulic sys-
tem.
Do not change the setting of pressure relief valves.
Drain the hydraulic oil at operating temperature
danger of scalding!
Catch running out hydraulic oil and dispose of en-
vironmentally.
Always catch and dispose of hydraulic oils sepa-
rately.
Do not start the engine after draining the hydraulic
oil.
Once all work is completed (with the system still
depressurized!) check all connections and fittings
for leaks.
Changing hydraulic hoses
Hydraulic hoses must be visually inspected at reg-
ular intervals.
Hydraulic hoses must be immediately replaced if:
l the outer layer is damaged down to the inlay
(e.g. chafing, cuts, cracks)
l the outer layer is brittle (formation of cracks in
the hose material)
l the hose shows deformations in pressurized
and depressurized condition, which do not
comply with the genuine shape of the hydrau-
lic hose
l the hose shows deformations in bends, e.g.
squeezing, buckling, layer separation, forma-
tion of blisters
l parts of the hose are leaking.
l hoses are not correctly installed.
l the hydraulic hose has separated from the fit-
ting
l the fitting shows corrosion that impairs both
function and strength.
BOMAG 21
Safety regulations
l hoses are mixed up by mistake.
l fittings are damaged or deformed, whereby
the function and strength of the hose/hose
connection is impaired.
Only genuine BOMAG replacement hydraulic hos-
es ensure that the correct hose type (pressure
range) is used at the right location.
Working on the engine
Shut the engine down before opening the engine
hood.
Do not work on the fuel system while the engine is
running - danger to life due to high pressures!
l Wait another minute after the engine has
stopped.
l Keep out of the danger zone during the initial
test rung.
l In case of leaks return to the workshop imme-
diately.
l Make sure that the engine cannot be started
unintentionally during service and repair work.
Drain the engine oil at operating temperature
danger of scalding!
Wipe off spilled oil, catch running out oil and dis-
pose of environmentally.
Store used filters and other oil contaminated ma-
terials in a separate, specially marked container
and dispose of environmentally.
Do not leave any tools or other objects, that could
cause damage, in the engine compartment.
Working on electric parts of the machine
Before starting to work on electric parts of the ma-
chine disconnect the battery and cover it with insu-
lating material.
Do not use fuses with higher ampere ratings and
do not repair fuses with a piece of wire. Fire haz-
ard!
Disconnect the battery before starting welding
work on the machine.
Working on the battery
When working on the battery do not smoke, do not
use open fire!
Do not let acid come in contact with hands or
clothes! When injured by acid flush off with clear
water and seek medical advice.
22
Metal objects (e.g. tools, rings, watch straps) must
not come in contact with the battery poles dan-
ger of short circuit and burning!
When recharging serviceable batteries remove all
plugs, to avoid the accumulation of explosive gas-
es.
Observe the applicable instructions when starting
with an auxiliary battery.
Dispose of old batteries according to regulations.
Switch off the charging current before removing
the charging clamps.
Ensure sufficient ventilation, especially if the bat-
tery is to be charged in a closed room.
Working on the fuel system
Do not inhale any fuel fumes.
Avoid open fire, do not smoke, do not spill any fuel.
Catch running out fuel, do not let it seep into the
ground and dispose off environmentally.
Cleaning work
Do not perform cleaning work while the engine is
running.
Do not use gasoline or other easily inflammable
substances for cleaning.
When cleaning with steam cleaning equipment do
not subject electrical parts and insulation material
to the direct jet of water, or cover it beforehand.
l Do not guide the water jet into the exhaust and
into the air filter.
Safety information for high pressure cleaning
equipment
Check hoses and fittings for leaks before use.
Do not use damaged high pressure hoses.
Use only hoses and connecting elements that
have been approved by the manufacturer.
Use only properly serviced and safe working
equipment.
Do not draw in solvent containing fluids like petrol,
paint thinner, diesel or similar. The spray mist is
highly inflammable, explosive and health threaten-
ing.
Always wear appropriate safety clothing.
Do not guide the water jet towards persons, ani-
mals, the high pressure cleaning unit or electrical
components.
BOMAG BM 2000/60
 Safety regulations

Jet wash vehicle tires and valves only with a mini-
mum distance of 30 cm. Damaged vehicle tires
and valves can be extremely dangerous.
Do not clamp the gun lever during operation.
Asbestos containing and health impairing sub-
stances must not be jet washed.
Use only permitted cleansing agents.
Do not run the unit unattended.
Information and safety stickers/decals
on the machine
Keep stickers/decals complete (see spare parts
catalogue) and fully legible and observe their
meaning.
Replace damaged or illegible stickers/decals im-
mediately.

After maintenance work

After all maintenance work is completed reinstall
all guards and safety installations.
If safety equipment had been dismantled for setup
or maintenance work, this equipment must be re-
assembled immediately after work has been com-
pleted.

Repair

Repair
Mark a defective machine by attaching a warning
tag to the steering wheel.
Repair work must only be performed by qualified
and authorized persons. Use our repair instruc-
tions for this work.
Exhaust gases are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
in closed rooms!
Do not work on the fuel system while the engine is
running - danger to life!
The system is under high pressure! Keep away
from leakages in the high pressure system, be-
cause fuel squirting out may cause severe injury.
After shutting down the engine wait for another
minute, until the pressure has dropped to a per-
missible level. In case of leakages you should con-
tact the Service Department of the engine
manufacturer and refrain from starting the engine.

Test
The safety of milling machines must be checked
by a specialist as required in dependence on the
application and the operating conditions, however
at least once every year.

BM 2000/60 BOMAG 23
 Safety regulations

Fig. 6 Fig. 9

Warning sticker - Warning of being crushed Warning sticker - Danger of injury - do not exit
the machine while driving

Fig. 7
Fig. 10
Warning sticker - Danger when passing over
rail chains Warning sticker - Danger of injury caused by
milling drum

Fig. 8
Fig. 11
Warning sticker - Danger of being run over
when reversing Warning sticker - Danger of collision with ro-
tating parts

24 BOMAG BM 2000/60
 Safety regulations

Fig. 12 Fig. 15

Warning sticker - Danger of electric shock Warning sticker - Danger of injury - Do not re-
when touching electric power lines move any safety installations during work

Fig. 13 Fig. 16

Warning sticker - Danger of collision in tunnels Warning sticker - Danger of injury - no mainte-
and under bridges nance work on moving parts

Fig. 14 Fig. 17

Warning sticker - Danger of tipping over on Warning sticker - Health hazard - no drinking
steep gradients water

BM 2000/60 BOMAG 25
Safety regulations

Fig. 18 Fig. 21

Warning sticker - Danger of accident - access Instruction sticker - Wear ear defenders
not permitted

Fig. 22
Fig. 19
Instruction sticker - Read the operating and
Instruction sticker - Keep access doors and maintenance instructions
flaps closed to prevent access to moving parts

Fig. 20

Instruction sticker - Operate warning horn be-

fore starting the machine

26 BOMAG BM 2000/60
 3 Indicators and Controls

BM 2000/60 BOMAG 27
Indicators and Controls

3.1 View of operating console

left, middle, right

Fig. 23

28 BOMAG BM 2000/60

1 Push button for warning horn
2 Control lever, loader conveyor belt
3 Control lever, rear steering
4 Control lever, rear steering mode
5 Control lever, height adjustment front left
6 Control lever for height adjustment, front right
7 Rotary button, total height adjustment
8 Control lever, rear height adjustment
9 Rotary switch for travel ranges
10 Rotary switch for engine anti-stall control
11 Rotary switch, differential lock
12 Rotary switch for conveyor belts
13 Rotary switch for water spray system
14 Rotary switch for milling drum
15 Rotary switch for gathering belt foot
16 Rotary button for scraper
17 Rotary switch work on/off
BM 2000/60
Indicators and Controls
18 Rotary switch for grade shoes
19 Steering lever
20 Travel lever
21 Emergency stop push button
22 General fault warning light and diagnostics
button
23 Multi-function display
24 Rotary momentary contact switch for protec-
tive roof
25 Rotary button, engine hood
26 Rotary switch for lighting
27 Rotary switch for flashing beacon
28 Ignition switch, engine
29 Rotary momentary contact switch for engine
speed
30 Rotary switch to fold the loading belt
31 Potentiometer for conveyor belt speed
32 Rotary switch for grade shoes
BOMAG 29
Indicators and Controls

3.2 General notes 3.3 Display and control ele-

ments operator's stand
Please read this section thoroughly before operat-
ing this machine if you are not yet conversant with
the indicators and control elements. All functions
are described in detail hereunder.
Paragraph 4 Operation contains only concise de-
scriptions of the individual operating steps.

Fig. 24
No. 1 = Push button for warning horn

Fig. 25
No. 2 = Control lever, loader conveyor belt
Position left = Swinging left
Position right = Swinging right
Position front = Lift
Position rear = Lower

30 BOMAG BM 2000/60
 Indicators and Controls

Position left = Rear steering automatically re-

turns to middle position
Position right = Manual, rear steering remains
at chosen position

Fig. 26
No. 3 = Control lever, rear steering
Position left = Machine steers to the left
Position right = Machine steers to the right
Fig. 28
No. 5 = Control lever for height adjustment
front left
Position rear = to lift the machine at front left
Position front = to lower the machine at front
left

Fig. 29
No. 6 = Control lever for height adjustment
front right
Position rear = to lift the machine at front right
Fig. 27 Position front = to lower the machine at front
No. 4 = Control lever, rear steering mode* right
Position front = Rear steering asynchronous No. 7 = Rotary button, total height adjust-
like front steering ment
Position rear = Crab walk, rear steering syn-
chronous with front steering

* Optional equipment

BM 2000/60 BOMAG 31
Indicators and Controls

Fig. 30
Momentary con-
tact position
right = Momentary contact position for
simultaneous lifting of the ma-
chine by all 4 posts, milling
drive, conveyor belt and water
spray system disabled
Momentary con-
tact position left = Momentary contact position for
simultaneous lifting of the ma-
chine by all 4 posts
No. 8 = Rotary button for height adjustment
at rear
Fig. 32
No. 9 = Momentary contact switch for travel
ranges
Momentary con-
tact position left = Working speed
Position right = Transport speed
No. 10 = Momentary contact switch for load
limit sensing control, travel system
Momentary con-
tact position left = Load limit sensing control with
working speed
Momentary con-
Fig. 31 tact position
Position rear = to lift the rear of the machine right = Manual, no load limit sensing
control
Position front = to lower the rear of the ma-
chine No. 11 = Momentary contact switch for differ-
ential lock

i Note
Only active in working speed mode

32 BOMAG BM 2000/60
 Indicators and Controls

Momentary con-
tact position left = Differential lock disabled
Momentary con-
tact position
right = Differential lock enabled

Fig. 34
No. 13 = Momentary contact switch for water
spray system
Momentary con-
tact position left = Pump switched off

Fig. 33 Momentary con-

tact position
No. 12 = Momentary contact switches for con-
right = Pump switched on, control
veyor belts
light lights

i Note
Can only be switched on after the loader conveyor
belt has been fully folded out and locked.
Momentary con-
tact position left = Disabled

i Note
If the switch is held in position "0", the conveyor
belts are operated with low speed in reverse.
Momentary con-
tact position
right = Switched on, control lamp Fig. 35
lights No. 14 = Momentary contact switch, milling
drum
Momentary con-
tact position left = Disabled
Momentary con-
tact position
right = Switched on, control lamp
lights, shifts automatically to
working speed

i Note
The milling drum can only be switched on at an en-
gine speed of < 850 rpm.

BM 2000/60 BOMAG 33
Indicators and Controls

Fig. 36 Fig. 38
No. 15 = Momentary contact switch for break- No. 17 = Momentary contact switch, work
er (mouldboard) gathering belt Momentary con-
Momentary con- tact position left = Travel drive stops, conveyor
tact position left = Floating position belt drive and water pump
the control lamp lights up. switched off, cutting depth
control switched off, engine
Momentary con- running in idle speed
tact position
right = to lift
! Danger
The milling drive stays on also in position "0"!
Momentary con-
tact position
right = The control lamp lights up, all
functions are restarted

Fig. 37
No. 16 = Momentary contact switch for scrap-
er
Momentary con-
tact position left = float position, control lamp
lights
Momentary con- Fig. 39
tact position No. 18 = Rotary switch for grade shoes left/
right = to lift right
Position "mid-
dle" = Floating position
Turn anti-clock-
wise = to lower

34 BOMAG BM 2000/60
 Indicators and Controls

Turn clockwise = to lift

i Note
The further the travel lever is shifted forward or
back, the faster the machine will drive.
When the travel lever is released, it will return to
middle position, however, the machine will drive
on with the selected speed.
To reduce the travel speed shift the travel lever to
the opposite direction.
To stop the machine operate the travel lever to the
opposite direction against the stop. The machine
will decelerate down to standstill and the parking
brake will be applied.

a Safety button in travel lever

Fig. 40
l Press and shift the travel lever to the desired
No. 19 = Steering lever
direction.
Position left = Steering left
The parking brake is released.
Position "mid-
dle" = Neutral, straight ahead
Position "right" = Steering right

i Note
The further the steering lever is operated, the fast-
er the steering will respond.

Fig. 42
No. 21 = Emergency stop push button
Shuts the engine down and closes the brake.

! Danger

Danger of accident!
Fig. 41 Actuate only in events of emergency during
No. 20 = Travel lever operation, do not use as service brake.
Position "I" = Forward travel Restart the machine only after the danger that
caused the actuation of the emergency stop
Position "mid-
switch has been eliminated.
dle" = Neutrals (braking position), to
start the diesel engine actuate = press the button completely
down, it automatically locks in
Position "II" = Backwards travel
fully pressed position.
unlock = turn the button clockwise and
let it go.

BM 2000/60 BOMAG 35
Indicators and Controls

to drive = return the travel lever first to

"neutral", then start the engine
i Note
The assignment of the individual function keys is
and actuate the travel lever
displayed on the corresponding screen page.
again.
For safety reasons the machine can only start to OK = Turn for menu selection, press OK to
drive after returning the travel lever to neutral po- confirm selection.
sition. F1 = ESC - back to the initial screen
F2 = extended functions
F3 = Function key
F4 = Scroll back in the screen
F5 = Scroll forward in the screen
F6 = Function key
See also "Multi-Function Display PLC" in the chap-
ter "Operation"

Fig. 43
No. 22 = General fault indication
flashes = Generic fault
Press the
push but-
ton = The error message is displayed on
the screen of the multi-function dis-
play
Fig. 45
No. 24 = Rotary button for protection roof
Turn anti-clock-
wise = Fold in
Turn clockwise = Fold out

Fig. 44
No. 23 = Multi-function display
The multi-function display serves the purpose of:
l displaying operation data
l indicating faults,
Fig. 46
l reading out work parameters,
No. 25 = Rotary button, engine hood
l and entering work parameters.

36 BOMAG BM 2000/60
 Indicators and Controls

Turn anti-clock-
wise = Lower
Turn clockwise = Lift

Fig. 49
No. 28 = Ignition switch
Position "0" = Ignition off, key can be pulled
Fig. 47
out, engine off.
No. 26 = Rotary switch for working lights Position "I" = Ignition on, all control and
warning lights in the fault mon-
Position "0" = Illumination off itoring board light up for a mo-
Position "mid- ment.
dle" = Lighting on, without cabin The "pre-heating" control lamp
lights (dazzle protection) lights up.
Position "right" = Lighting on with cabin lights The light system can be
switched on.

i Note
The engine can only be started if both travel levers
are in neutral.
The ignition switch is designed with a lock to pre-
vent repetitive starting. For a new starting attempt
the ignition key must first be turned back to posi-
tion "0".
Position "II" = turn further against spring
pressure, he engine starts,
turn the ignition key back to
position once the engine has
Fig. 48
started
No. 27 = Rotary switch for flashing beacon*
Position "0" = Flashing beacon off !Caution
Position "I" = Flashing beacon on Run the engine warm for a short while before
starting work. Do not allow the engine to run
longer than 10 minutes with idle speed.
Do not shut the engine down all of the sudden
from full speed, but let it idle for a while for
temperature equalization.

* Optional equipment

BM 2000/60 BOMAG 37
Indicators and Controls

Fig. 50 Fig. 52
No. 29 = Rotary momentary contact switch for No. 31 = Rotary switch for conveyor belt
engine speed speed
Turn anti-clock- Turn anti-clock-
wise = reduces the speed wise = Reduces the speed
Turn clockwise = Speed increase Turn clockwise = Increases the speed

Fig. 51 Fig. 53
No. 30 = Rotary button to fold in the loader No. 32 = Rotary switch for grade shoes
conveyor belt Position left = Floating position
Turn anti-clock- Momentary con-
wise = Folding in, transport position tact position
Turn clockwise = Fold out, work position right = both sides are lifted up and the
milling drum drive is automati-
cally disengaged

38 BOMAG BM 2000/60
 Indicators and Controls

F2 = 25A, EMR
F3 = 7.5A, EMR
F4 = 10A, converter 24V/12V
F5 = 1A, converter 24V/12V
F6 = 1A, control box front left
F7 = 1A, control box rear left
F8 = 1A, control box rear left
F9 = 1A, control box front right
F10 = 1A, control box rear right
F11 = 1A, control box rear right
Fig. 54 F12 = 1A, control cabinet
No. 33 = High pressure cleaner* F13 = 1A, control cabinet
a = High pressure pump F14 = 1A, control cabinet
b = Pressure gauge, shows the spray jet F15 = 1A, control cabinet
pressure
F16 = 7.5A, ECU
c = Connection for high pressure hose
F17 = 7.5A, ECU
d = Dirt filter
F18 = 7.5A, ECU
e = Water shut-off tap
F19 = 15A, I/O module
F20 = 4A, I/O module
i Note
F21 = 4A, I/O module
Operation requires running of the engine. To
switch on see front left hand control panel F22 = 15A, I/O module
F23 = 15A, I/O module
F24 = 4A, I/O module
F25 = 15A, I/O module
F26 = 4A, I/O module
F27 = 7.7A, Can-bus
F28 = 1A, engine
F29 = 1A, speed sensor
F30 = 7.5A, I/O levelling
F31 = 1A, control box, scraper plate
F32 = 1A, wire sensor
F33 = 1A, inclination sensor
Fig. 55
F34 = 1A, post transmitter
No. 34 = Fuses in electric installation box
F35 = 7.5A, external levelling

Danger
!
F36 = 7.5A, levelling system
Fire hazard! F37 = 7.5A, conveyor belt
F38 = 7.5A, water filling and cleaning
Do not use fuses with higher ampere ratings
system
and do not bridge fuses.
F39 = 7.5A, water spraying system
F1 = 15A, EMR
F40 = 1A, rope sensor, control
* Optional equipment

BM 2000/60 BOMAG 39
 Indicators and Controls

F41 = 7.5A, signal horn

F42 = 10A, working lights
F43 = 10A, working lights
F44 = 10A, working lights
F45 = 10A, working lights
F46 = 10A, working lights
F47 = 10A, working lights
F48 = 7.5A, flashing beacon
F49 = 25A, fuel lift pump
F50 = 1A, sensors
F51 = 1A, sensors Fig. 57

F52 = 7.5A, warning buzzer Main battery switch

F53 = 1A, display control panel Position "I" = Normal position, operation
F54 = 10A, working lights roof Position "II" = Separates batteries from the
F55 = 7.5A, milling drum drive* on-board electrics in case of
cable fire and fire in the engine
a Rotary switch 204.4 S1 compartment as well as pro-
Software update (only for service) tection against unauthorized
use.

! Caution
Pull out the main battery switch at the earliest
40 seconds after switching off the ignition, ex-
cept in cases of emergency.

Fig. 56
No. 35 = Fuses in battery compartment
F1 = 80A - Ignition
F2 = 25A - Emergency stop
F3 = 150A - Emergency hydraulic pump
F4 = 80A - Preheating of diesel engine Fig. 58
No. 36 = Scraper contact pressure

"a" pressure gauge

Shows the adjusted contact pressure

"b" rotary momentary contact switch

Momentary con-
tact position left = Pressure reduction
* Optional equipment

40 BOMAG BM 2000/60
 Indicators and Controls

Momentary con- "h" scraper pressure adjustment knob

tact position Turn anti-clock-
right = Pressure increase wise = Pressure reduction
Turn clockwise = Pressure increase

Fig. 59
No. 37 = Display and control panel operator's
Fig. 60
stand
No. 38 = Control console for auxiliary control
"a" pressure gauge
"a" Brake releasing pressure gauge
Shows the adjusted contact pressure of the scrap-
er. Shows the brake release pressure.

"b" spirit level "b" not used

Shows the transverse inclination of the machine. "c" Rotary switch for protective roof
"c" pressure gauge Momentary con-
tact position left = Fold in
Shows the adjusted contact pressure of the break-
er. Momentary con-
tact position
"d" pressure adjustment button for breaker right = Fold out
Turn anti-clock-
"d" Rotary switch to release parking brake in
wise = Pressure reduction
emergency
Turn clockwise = Pressure increase
Position left = Normal operation
"e" compressed air connection* Momentary con-
"f" 12 V-socket tact position
right = Emergency release with auxil-
12 V vehicle voltage when main battery switch is iary hydraulics activated
switched on.
"e" Rotary momentary contact switch for
emergency hydraulics
Caution
!
Position left = Switched off
Max. permanent amperage 2 A
Momentary con-
"g" service socket tact position
Only for BOMAG Customer Service. right = Switched on

"f" Ball valve

Bypass loading belt swing cylinder
* Optional equipment Turn valve clockwise for transport on low loader

BM 2000/60 BOMAG 41
Indicators and Controls

Fig. 61
No. 39 = Rotary button for steering correction,
rear
Turn anti-clock-
wise = The rear of the machine steers
to the left (max. 5 %)
Turn clockwise = The rear of the machine steers
to the right (max. 5 %)

42 BOMAG BM 2000/60
 Indicators and Controls

BM 2000/60 BOMAG 43
Indicators and Controls

3.4 View rear right hand control

panel

Fig. 62

1 Plug, external sensors for 3-point average lev- 6 Warning light

elling system 7 Rotary momentary contact switch, right hand
2 Warning horn grade shoe
3 Rotary momentary contact switch for height 8 Rotary momentary contact switch to raise the
adjustment, rear scraper shield
4 Rotary momentary contact switch, rear steer- 9 Rotary momentary contact switch to fold back
ing the scraper shield
5 Emergency stop push button 10 Plug, graphic display of levelling control

44 BOMAG BM 2000/60
 Indicators and Controls

Danger
!
3.5 Control elements on rear
Safety component
right hand control panel
Ensure correct function at all times
No. 1 = Plug, external sensors Flashes when raising the scraper shield or the
For connection of a 3-point average levelling con- grade shoe on the left hand side.
trol sensor* No. 7 = Rotary switch for right hand grade
No. 2 = Warning horn shoe

No. 3 = Rotary momentary contact switch for Position "mid-

height adjustment, rear dle" = Floating position

Turn anti- Turn anti-clock-

clock- wise = to lower
wise = Rear of machine is lowered Turn clockwise = to lift
Turn clock- No. 8 = Rotary momentary contact switch to
wise = Rear of the machine is raised raise the scraper shield
No. 4 = Rotary momentary contact switch, Turn anti-clock-
rear steering wise = Lift the scraper
Turn anti-clock- Turn clockwise = Floating position with the ad-
wise = Machine travels to the left justed contact pressure
Turn clockwise = Machine travels to the right No. 9 = Rotary momentary contact switch to
No. 5 = Emergency stop push button fold back the scraper shield
actuate = Press the button completely
down, it automatically locks in ! Danger
fully pressed position. This control serves the purpose of gaining
unlock = Turn the button clockwise and easier access when changing the cutting tools.
let it go. The diesel engine must be shut down after
to drive = return the travel lever first to opening.
"neutral", then start the engine Turn clockwise = Opens the shield
and actuate the travel lever
again. Turn anti-clock-
wise = Closes the shield
No. 10 = Plug, graphic display of levelling con-
Danger
!
trol
Danger of accident!
For connection of the electronic levelling control
Actuate only in events of emergency during unit
operation, do not use as service brake.
Restart the machine only after the danger that
caused the actuation of the emergency stop
switch has been eliminated.
For safety reasons the machine can only start to
drive after returning the travel lever to neutral po-
sition.
No. 6 = Warning light

* Optional equipment

BM 2000/60 BOMAG 45
Indicators and Controls

3.6 View rear left hand control

panel

Fig. 63

1 Emergency stop push button 6 Plug, graphic display of levelling control

2 Rear steering 7 Rotary momentary contact switch to fold back
3 Rotary momentary contact switch for height the scraper shield
adjustment, rear 8 Rotary momentary contact switch to raise the
4 Warning horn scraper shield
5 Plug, external sensors for 3-point average lev- 9 Rotary momentary contact switch, left hand
elling system grade shoe
10 Warning light

46 BOMAG BM 2000/60
 Indicators and Controls

For connection of the electronic levelling control

3.7 Description of rear left hand unit
control panel No. 7 = Rotary momentary contact switch to
fold back the scraper shield
No. 1 = Emergency stop push button
Shuts the engine down and closes the brake. ! Danger

Danger of accident!
Danger
! This control serves the purpose of gaining
Danger of accident! easier access when changing the cutting tools.
Actuate only in events of emergency during The diesel engine must be shut down after
operation, do not use as service brake. opening.
Restart the machine only after the danger that Turn anti-clock-
caused the actuation of the emergency stop wise = Opens the shield
switch has been eliminated. Turn clockwise = Closes the shield
actuate = Press the button completely No. 8 = Rotary momentary contact switch to
down, it automatically locks in raise the scraper shield
fully pressed position. Turn anti-clock-
unlock = Turn the button clockwise and wise = Lifting the scraper
let it go. Turn clockwise = Floating position with the ad-
to drive = return the travel lever first to justed contact pressure
"neutral", then start the engine No. 9 = Rotary button for left hand grade
and actuate the travel lever shoe
again.
Position "mid-
For safety reasons the machine can only start to dle" = Floating position
drive after returning the travel lever to neutral po-
Turn anti-clock-
sition.
wise = to lift
No. 2 = Rotary momentary contact switch,
rear steering Turn clockwise = to lower
No. 10 = Warning light
Turn anti-clock-
wise = Machine travels to the left
Turn clockwise = Machine travels to the right ! Danger
No. 3 = Rotary momentary contact switch for Safety component
height adjustment, rear Ensure correct function at all times
Turn anti- Flashes when raising the scraper shield or the
clock- grade shoe on the left hand side.
wise = Rear of machine is lowered
Turn clock-
wise = Rear of the machine is raised
No. 4 = Warning horn
No. 5 = Plug, external sensors
For connection of a 3-point average levelling con-
trol sensor*
No. 6 = Plug, graphic display of levelling con-
trol

* Optional equipment

BM 2000/60 BOMAG 47
Indicators and Controls

3.8 View front right hand con-

trol panel

Fig. 64

1 Warning horn 4 Rotary switch to fold/unfold the loader belt

2 not used 5 Rotary momentary contact switch, breaker
3 Plug, rope sensor (mouldboard)
6 Emergency stop push button

48 BOMAG BM 2000/60
 Indicators and Controls

3.9 Description of front right

hand control panel
No. 1 = Warning horn
No. 2 = not used
No. 3 = Plug, rope sensor
For connection of the 3-point average levelling
control sensor
No. 4 = Rotary switch to fold/unfold the load-
er belt
Turn anti-clock-
wise = Fold loader conveyor belt in for
transport
Turn clockwise = Unfold the loader conveyor
belt to working position
No. 5 = Rotary momentary contact switch,
breaker (mouldboard)
Turn anti-clock-
wise = to lift
Turn clockwise = Floating position to pick up
material, control lamp flashes
No. 6 = Emergency stop push button
Shuts the engine down and closes the brake.

! Danger
Danger of accident!
Actuate only in events of emergency during
operation, do not use as service brake.
Restart the machine only after the danger that
caused the actuation of the emergency stop
switch has been eliminated.
actuate = Press the button completely
down, it automatically locks in
fully pressed position.
unlock = Turn the button clockwise and
let it go.
to drive = return the travel lever first to
"neutral", then start the engine
and actuate the travel lever
again.
For safety reasons the machine can only start to
drive after returning the travel lever to neutral po-
sition.

BM 2000/60 BOMAG 49
Indicators and Controls

3.10 View front left hand control

panel

Fig. 65

1 Emergency stop push button 4 not used

2 Rotary momentary contact switch, breaker 5 Plug, rope sensor
(mouldboard) 6 Warning horn
3 Rotary button for water pump control

50 BOMAG BM 2000/60
 Indicators and Controls

3.11 Description of front left

hand control panel
No. 1 = Emergency stop push button
Shuts the engine down and closes the brake.

Danger
!

Danger of accident!
Actuate only in events of emergency during
operation, do not use as service brake.
Restart the machine only after the danger that
caused the actuation of the emergency stop
switch has been eliminated.
actuate = Press the button completely
down, it automatically locks in
fully pressed position.
unlock = Turn the button clockwise and
let it go.
to drive = return the travel lever first to
"neutral", then start the engine
and actuate the travel lever
again.
For safety reasons the machine can only start to
drive after returning the travel lever to neutral po-
sition.
No. 2 = Rotary momentary contact switch,
breaker (mouldboard)
Turn anti-clock-
wise = to lift
Turn clockwise = Floating position to pick up
material, control lamp lights
No. 3 = Rotary button for water pump control*
Position left = Water filling pump on
Position right = High pressure cleaner on
No. 4 = not used
No. 5 = Plug, rope sensor
For connection of the 3-point average levelling
control sensor
No. 6 = Warning horn

* Optional equipment

BM 2000/60 BOMAG 51
Indicators and Controls

3.12 Automatic levelling control

Fig. 66

52 BOMAG BM 2000/60
 Indicators and Controls

1 Graphic display 14 not used

2 Display of travel distance
3 Display, simultaneous adjustment on both
sides
4 Display of actual value for depth or inclination
right
5 Display of nominal value for depth or inclina-
tion right
6 Operating mode right hand side "A" Automatic,
"M" Manual
7 Display of control status, depth or inclination
right
8 Push button Automatic/Manual mode right
9 Button for depth/inclination sensor right
10 Button for depth/inclination value increase
right
11 Button for depth/inclination value reduction
right
12 Button "0"-calibration for depth/inclination right
13 not used
15 not used
16 Reset button, to reset to "0"
17 not used
18 not used
19 not used
20 Button "0"-calibration for depth/inclination left
21 Button for depth/inclination value reduction left
22 Button for depth/inclination value increase left
23 Button for depth/inclination sensor left
24 Button Automatic/Manual mode left
25 Operating mode left hand side "A" Automatic,
"M" Manual
26 Display of control status for depth or inclination
left
27 Display of nominal value for depth or inclina-
tion left
28 Display of actual value for depth or inclination
left
29 Speed display

BM 2000/60 BOMAG 53
Indicators and Controls
3.13 Description of levelling con-
trol
No. 1 = Graphic display
Display of actual and nominal values
No. 2 = Display of travel distance
Shows the travelled distance in metres/feet. Press
Reset (Pos. 16) for 5 seconds to reset to zero.
No. 3 = Display, simultaneous adjustment on
both sides
Display symbol in mode "identical setting on both
sides, for this button Pos. 16 with button Pos. 8 or
24.
No. 4 = Display of actual value for depth or in-
clination right
Shows the actual cutting depth value [mm/in] or in-
clination [%].
No. 5 = Display of nominal value for depth or
inclination right
Shows the adjusted cutting depth value [mm/in] or
inclination [%].
No. 6 = Levelling operating mode, right
Shows the levelling control mode on the left front
stand. "A" = Automatic; "M" = Manual. Select with
button Pos. 8.
No. 7 = Display of control status,depth or in-
clination right
Shows the selected control for depth or inclination.
Select with button Pos. 9.
No. 8 = Push button Automatic/Manual mode
right
To select operating mode Automatic or Manual.
The corresponding symbol appears in the display
(Pos. 6).
No. 9 = Button for depth/inclination sensor
right
To change the control to depth or inclination. The
corresponding symbol appears at Pos. 7 control
status.
No. 10 = Button for depth/inclination value in-
crease right
To increase the nominal value for depth or inclina-
tion. Display of the value in Pos. 5.
No. 11 = Button for depth/inclination value re-
duction right
54
To reduce the nominal value for depth or inclina-
tion. Display of the value in Pos. 5
No. 12 = Button "0"-calibration for depth/incli-
nation right
To set the actual value to zero in combination with
Pos. 16 Reset.
No. 13 = not used
No. 14 = not used
No. 15 = not used
No. 16 = Reset button
To reset the displayed travel distance to zero
press the button longer than 5 seconds. To "ze-
roize" actual values. In connection with buttons 12
or 20.
Press and hold the key for at least 20 seconds to
switch between metric and imperial units.
No. 17 = not used
No. 18 = Service menu
Service menu (parameter) call up in connection
with function key F1.
For service personnel only!
No. 19 = Function key F1
Service menu (parameter) call up in connection
with Pos. 18.
For service personnel only!
No. 20 = Button "0"-calibration for depth/incli-
nation left
To set the nominal value to zero in combination
with Pos. 16 Reset.
No. 21 = Button for depth/inclination value re-
duction left
To reduce the nominal value for depth or inclina-
tion. Display of the value in Pos. 5
No. 22 = Button for depth/inclination value in-
crease left
To increase the nominal value for depth or inclina-
tion. Display of the value in Pos. 5
No. 23 = Button for depth/inclination sensor
left
To change the control to depth or inclination. The
corresponding symbol appears at Pos. 26 control
status.
No. 24 = Push button Automatic/Manual mode
left
BOMAG BM 2000/60
 Indicators and Controls

To select operating mode Automatic or Manual.

The corresponding symbol appears in the display
(Pos. 25).
No. 25 = Levelling operating mode, left
Shows the levelling control mode on the left front
stand. "A" = Automatic; "M" = Manual. Select with
button (Pos. 24).
No. 26 = Display control status left
Shows the selected control for depth or inclination.
Select with button Pos. 23.
No. 27 = Display of nominal value for depth or
inclination left
Shows the adjusted cutting depth value [mm/in] or
inclination [%].
No. 28 = Display of actual value for depth or in-
clination left
Shows the actual cutting depth value [mm/in] or in-
clination [%].
No. 29 = Speed
Shows the current travel speed in [m/min] or in [ft/
min].

BM 2000/60 BOMAG 55
 Indicators and Controls

3.14 View of ultrasonic levelling

system*

* Optional equipment

Fig. 67

1 Crank handle for height adjustment 4 Connecting lead

2 Boom 5 Sensor head
3 Control unit 6 Fixation button

56 BOMAG BM 2000/60
 Indicators and Controls

3.15 View of water spray system

Fig. 68

1 Spray pressure control valve 5 Water filter

2 Pressure gauge for spraying pressure 6 Shut-off valve for gathering belt spray bar
3 Main shut-off valve 7 Shut-off valve for milling drum spray bar
4 Drain tap 8 Water pump

BM 2000/60 BOMAG 57
Indicators and Controls

58 BOMAG BM 2000/60
 4 Operation

BM 2000/60 BOMAG 59
Operation

4.1 General notes 4.2 Tests before taking into op-

eration
Please read section 3 Indicators and Control Ele-
ments thoroughly before operating the machine if
The following inspections must be carried out be-
you are not yet fully familiar with the indicators and
fore each working day or before a longer working
control elements of the machine.
period.
All indicators and control elements are described
in detail in this chapter.
! Danger
Danger of accident!
Please observe strictly the safety regulations
in chapter 2 of this instruction manual!
l Park the machine on ground as level as possi-
ble or adjust it horizontally.

Check:
l fuel tank and fuel lines for leaks
l screw joints for tight fit
l function of steering
l machine for cleanliness, damage
l Presence of the appropriate operating and
maintenance instructions
l check whether the machine has been properly
serviced
l leakages on transmissions and hydraulic com-
ponents
l function of emergency stop,

! Caution
If leakages are found on transmissions or hy-
draulic components check the oil level, replen-
ish oil if necessary.
Have leaks sealed as quickly as possible.

i Note
For a description of the following tasks refer to the
chapter "maintenance every 10 operating hours".
l Engine oil level
l Check the hydraulic oil level, top up if neces-
sary.
l Check the coolant level, top up if necessary.

! Danger
Fire hazard!

60 BOMAG BM 2000/60
 Operation

Do not refuel in closed rooms.

4.3 Starting the engine
l Check the fuel level, top up if necessary.
l Check the water level in the water spray sys-
tem, replenish if necessary. ! Caution
Do not accelerate the engine in cold condition
immediately from idle speed to full load speed.
Risk of damage to the exhaust turbocharger.
Warm the engine up by running it for about 30
seconds at low idle speed. The engine can
then be continuously accelerated or loaded

Fig. 69

l Check whether travel lever (Fig. 69) is in "Neu-

tral" position.
The control lamp lights up.

Fig. 70

l Check, whether all emergency stop switches

(Fig. 70) are unlocked.

BM 2000/60 BOMAG 61
Operation

Fig. 71 Fig. 73

l Switch on the ignition 24 (Fig. 71).
l Turn the ignition key to position "II" (Fig. 73),
the starter cranks the engine.
l As soon as the engine ignites return the igni-
tion key to position "I".
All warning and control lamps must go out.

Fig. 72
Wait until the initial screen (Fig. 72) of the multi-
function display appears.

Caution
!

Perform the starting process for maximum 20

seconds without interruption and pause for a
minute between starting attempts.
If the engine has not started after two attempts
perform trouble shooting.

62 BOMAG BM 2000/60
 Operation

4.4 Starting with jump wires 4.5 Shutting down the engine

! Caution
When using external starting aid two external
batteries (24 V system) are required, one for
each on-board battery.
A wrong connection will cause severe damage
in the electric system.
! Caution
Do not shut the engine down all of a sudden
from full speed, but let it idle for a while for
temperature equalization.

Fig. 75

l Set the throttle to idle speed (Fig. 75).

Fig. 74

l First connect the plus poles with the jump lead.

l Then connect the ground cable first to the mi-
nus pole of the current supplying auxiliary bat-
tery and then to engine or chassis ground, as
far away from the battery as possible (Fig. 74).
l Start as described under "Starting the engine".
l Once the engine is running switch on a power-
ful consumer (working light, etc.).

! Caution
If no powerful consumer is switched on volt-
age peaks may occur when separating the con-
necting cables between the batteries, which
could damage electrical components.
l After starting disconnect the negative poles
(ground cable) first and the positive poles af-
ter.
l Switch off the consumer.
Fig. 76
l Turn the ignition switch (Fig. 76) to position "0"
and pull the ignition key out.
! Caution
Secure the machine against unauthorized use,
pull the ignition key out, if necessary pull out
the battery disconnecting switch.

BM 2000/60 BOMAG 63
Operation

Rear steering
4.6 Steering
The front crawler track drive is controlled with the
steering lever. The rear crawler track drive can be
controlled in synchronized mode*, manually with
automatic centring or manually with fixed setting.

Steering

Fig. 77

l Steer the machine with the steering lever (Fig.

77).
Fig. 78

l Select the desired steering mode with the se-

lector lever (Fig. 78).

Fig. 79

l Make steering corrections with the steering le-

ver (Fig. 79).

64 BOMAG BM 2000/60
 Operation

Raising/lowering he machine at the

4.7 Lifting / lowering the ma- front left only
chine

Raising the machine completely

Fig. 82

l For lowering shift the lever (Fig. 82) forward,

for lifting pull it back.

Fig. 80
Raising/lowering the machine only at
l Turn switch (Fig. 80) anti-clockwise.
front right
The complete machine is raised at front and rear.
l Turn switch clockwise.
The complete machine is raised at front and rear.
Rotor drive, water spray system and conveyor belt
are automatically switched off.

Raising/lowering only the rear of the

machine

Fig. 83

l For lowering shift the lever (Fig. 83) forward,

for lifting pull it back.

Fig. 81

l For lifting shift the lever (Fig. 81) forward, for

lowering pull it back.

BM 2000/60 BOMAG 65
Operation

4.8 Switching the milling drum

on/off

Switch on

Danger
!

Life hazard!
Before switching on the milling drum make
sure that there are no persons in the danger ar-
ea.
Fig. 85
Operate the warning horn before switching on
the milling drum l Turn switch (Fig. 85) clockwise.
The milling drive clutch is closed and the milling
drum starts to rotate.
!Caution
Before switching on the milling drum check The control lamp in the switch lights up.
that there is no ground contact, if necessary
raise the machine.

i Note
The milling drum can only be switched on if:
- the engine runs with idle speed (below 750 rpm),
- the travel lever is in "Neutral",
- a low travel range (working speed) was selected
(will automatically change to working speed)
- and the scraper shield has been lowered.

Fig. 86

l After a short waiting time (5 seconds) increase

the engine speed (Fig. 86).

Switch off
l Shift the travel lever to "Neutral"
l Adjust the engine speed to "Idle speed"

Fig. 84

l Operate the horn (Fig. 84).

66 BOMAG BM 2000/60
 Operation

4.9 Operating the scraper

i Note
The scraper can also be operated from the control
panel on the operator's stand.

Work position (floating position)

Fig. 87

l Turn the switch (Fig. 87) to position "0".

The milling drive clutch is opened and the milling
drum stops..
The control lamp goes out.

Danger
!

Life hazard!
Wait until the drum has stopped before ac- Fig. 88
cessing the milling drum
l Turn switch (Fig. 88) anti-clockwise.
The scraper is pressed down with an adjustable
pre-pressure. The control lamp in the switch lights
up.

Fig. 89

l Adjust the contact pressure by the rotary but-

ton b (Fig. 89).
The adjusted contact pressure can be read on the
pressure gauge (a).

BM 2000/60 BOMAG 67
Operation

Lift the scraper

4.10 Operation of loading and
gathering conveyor belt

! Danger
Danger of injury!
Before switching on the conveyor belt make
sure that there are no persons in the loading
area.

Fig. 90
l Turn switch (Fig. 90) clockwise.
The scraper shield moves up as long as the
switch is operated.
The control lamp goes out.
The left and right warning lamps are flashing.
! Caution
If the machine is to be moved in transport
speed you should always lower the loading
conveyor belt and align it in middle position.
Only switch the conveyor belt on or off if there
is no material on the belt.
i Note
The conveyor belts can only be switched on when
the loading conveyor belt is fully extended.

Switching the conveyor belt on/off

Fig. 91

l To switch on turn the momentary contact

switch (Fig. 91) clockwise, until the control
lamp lights up.

68 BOMAG BM 2000/60
 Operation

Fig. 92 Fig. 94

l To switch off turn the momentary contact
switch (Fig. 92) anti-clockwise, until the control
lamp goes out.
Setting the speed
l Turn the selector switch (Fig. 94) to position
"0" and hold it for approx. 3 seconds.
The conveyor runs in reverse with low speed, until
the switch is released.
Lifting / lowering the loading conveyor
belt

Fig. 93

l If necessary adjust the belt speed with the ro-

tary button (Fig. 93). Fig. 95

l Shift the control lever (Fig. 95) forward or

Run the conveyor belt in reverse backward.
The loading conveyor belt moves up or down as
i Note long as the lever is operated.
Only for maintenance purposes

BM 2000/60 BOMAG 69
Operation

Swinging the loading conveyor belt

Fig. 98

l Turn switch (Fig. 98) anti-clockwise.

Fig. 96
l Shift the control lever (Fig. 96) to left or right.
The unloading belt swings to left or right, as long
as the lever is operated.
The gathering belt with mouldboard moves down,
as long as the button is operated (floating posi-
tion).
The control lamp lights up.

Lifting / lowering the gathering belt

(mouldboard)
i Note
When reversing, the mouldboard will automatically
be raised.
i Note
The gathering belt or mouldboard can also be op-
erated from the control panel on the operator's
stand

Fig. 97

l Turn switch (Fig. 97) clockwise.

The gathering belt with the foot skid moves up, as
long as the button is operated.

70 BOMAG BM 2000/60
 Operation

4.11 Driving the machine

! Danger
Life hazard!
Climbing onto or off the machine while driving
is prohibited.
Do not lean too far out of the vehicle, danger of
crushing!
Do not execute any extreme steering move-
ments at high speed and with the machine in
inclined position do not swing out the convey-
or belt to the same direction, danger of tipping
over!
To not allow protruding parts of the machine to
access into the public traffic, danger of acci-
dent!

Prerequisites
l The engine is running with max. speed.
l No warning lamps light up.
l Travel lever in "Neutral"
l The milling drum is switched off.
l The machine has been raised to highest posi-
tion. Fig. 99

l The scraper shield is folded down.
l Select transport or working speed 9 (Fig. 99).
The corresponding control lamp lights up.
l If working speed is selected, choose also the
engine anti-stall control mode (10).
l If necessary, activate the differential lock (11).

BM 2000/60 BOMAG 71
Operation
Driving forward/backward
Fig. 100
l Press button a (Fig. 100) and shift the travel le-
ver to the desired travel direction.
i Note
The further the travel lever is shifted forward or
back, the faster the machine will drive.
When the travel lever is released, it will return to
middle position, however, the machine will drive
on with the selected speed.
To reduce the travel speed shift the travel lever to
the opposite direction.
To stop the machine operate the travel lever to the
opposite direction against the stop. The machine
will decelerate down to standstill and the parking
brake will be applied.
72
4.12 Preparing for work
Check the condition of scraper, cutting
tools and holders
! Danger
Life hazard!
Shut down the engine and remove the ignition
key before accessing the milling drum
Attach a warning note to the control panel
Danger
!
Health hazard!
When milling road covering layers harmful
dusts may be released.
In order to avoid any damage to health the ma-
chine operator and other persons, who have to
work in the immediate vicinity of the milling
machine, should wear breathing masks (half
mask with exhalation valve or respirator) to re-
duce the dust particles, when a development
of dust is noticed.
Contaminated parts of the body should be
thoroughly washed before breaks and at the
end of work. After work the dust covered work-
ing clothes should be replaced by normal
clothes. Working clothes and respiratory
equipment should not be stored together with
normal clothes. Dust covered working clothes
must be cleaned at regular intervals.
!Caution
If necessary check the conditions of scraper,
cutting tools and holder seats several times
every day, in order to prevent damage to the
rotor.
l Start the engine.
BOMAG BM 2000/60
 Operation

Fig. 101 Fig. 103

l Raise the machine (Fig. 101) completely. l Operate rotary button 6 (Fig. 103), until the
scraper shield is fully folded open and the lock-
ing device has engaged.
Danger
!

Danger of accident! The control lamp lights up.

Always attach the safety supports before start-

ing work on the milling drum.

Fig. 104

l Turn the ignition switch (Fig. 104) to position

"0".
Fig. 102
l Pull off the ignition key and attach a warning
l Mount the safety supports to all four lift cylin-
label to the control panel.
ders (Fig. 102).

! Danger
i Note
For better access the rear track drives can even by Life hazard!
rotated, if necessary. Access the space under the machine only with
engine and milling drum stopped.

BM 2000/60 BOMAG 73
Operation

Before starting the engine make sure that no-

body is in the danger area.
l Restart the engine.

Fig. 105

l Turn the milling drum by hand and check con-

dition and fastening of cutting tools and hold-
ers (Fig. 105). Round shank cutting tools must
be free to turn in the sleeve. Fig. 107

l If necessary replace the cutting tools, see sec- l Move the scraper shield slightly up first 1 (Fig.
tion "Maintenance as required". 107).
l Disengage the lock (2) and fold the scraper
Caution
! shield completely off (3).
Cutting tools with missing hard metal must be
replaced immediately.
If cutting tools are not changed in time, milling
drum or tool holders may suffer severe dam-
age.

Fig. 108

l Switch the gathering conveyor foot to floating

position (Fig. 108).

Fig. 106

l Check condition and tight fit of the scraper

(Fig. 106).
l If necessary replace the scraper, see section
"Maintenance as required".

! Danger

Danger of injury!

74 BOMAG BM 2000/60
 Operation

Connecting the levelling control

Fig. 111

l Insert the stops (Fig. 111) into the receptacles

Fig. 109
on both sides.
l Connect the levelling control panel (Fig. 109)
at the operator's stand of the machine. Opening the shut-off valves of the wa-
ter spray system

Fig. 110

l Connect the levelling control panel (Fig. 110) Fig. 112

at the operator's stand on the side of the ma-
l Check the water tank (Fig. 112) filling level, re-
chine.
plenish as necessary.

Mounting the scraper plate stops

i Note
If the milled material is to remain in the milled
track, end stops for the scraper plate can be
mounted.
The scraper plate can in this case remain opened
against the stop.

BM 2000/60 BOMAG 75
Operation

4.13 Work operation, setting the

cutting depth
The following description applies to a standard
machine equipped with an electronic levelling con-
trol and wire rope sensors.
Machines with other sensors see section "Auto-
matic milling depth control"

Danger
!

Fig. 113
l Open the water pump drain cock (Fig. 113).
l Adjust the water quantity as necessary.
Switching on the flashing beacon
Danger of accident!
If the rotor is lowered too quickly into hard
ground, the crawler tracks may loose ground
contact. The machine will thereby move back-
wards.
Switch the milling drum off immediately or op-
erate the emergency stop switch.

Caution
!

Do not execute milling operations without the

water spray system switched on.

Aligning the machine

l Move the machine to the start position.

Fig. 114

l Switch on the flashing beacon (Fig. 114).

76 BOMAG BM 2000/60
 Operation

Fig. 116

l Use the reference rod to align the track at the

reference point (Fig. 116).

Determining cross slope and milling

depth

!Caution
Switch on milling drum and conveyor belt only
at low speed.
l Set the milling depth control PLC to the re-
quired depth for both sides or for one side and
the cross slope control for the other side. See
Fig. 115
following chapter.

l Set the rotary switch 9 (Fig. 115) for work and

transport stages to the working range for mill-
ing.
l Operate rotary switch (10) to proper speed lim-
itation, controlled by the engine anti-stall sys-
tem.
l Align the machine and stop at the starting
mark.
l Wait until the loading area of the truck is posi-
tioned under the loading conveyor belt.

Fig. 117

l switch on the conveyor belt (Fig. 117).

BM 2000/60 BOMAG 77
Operation

Fig. 118 Fig. 121

l Switch on the milling drive (Fig. 118). l Lower the rear of the machine, until the rear
reference rods just extend out of the upper
cover (Fig. 121).

Fig. 119

l Run the engine with max. speed (Fig. 119).

Fig. 122

l Switch on the water spray system (Fig. 122).

Danger
!

Danger of accident!
If the rotor is lowered too quickly into hard
ground, the crawler tracks may loose ground
contact. The machine will thereby move back-
wards.
l Calibrate the rope sensors to "0" (see follow-
ing section).

Fig. 120

l Lower the machine evenly at front and rear

(switches 5, 6, 8) (Fig. 120), until the cutting
tools touch the road surface.

78 BOMAG BM 2000/60
 Operation

Fig. 123

l Once the desired milling depth is reached

press the button on the travel lever and shift
the travel lever slowly forward (Fig. 123).

i Note
In this phase move the machine only very slowly,
to allow the rear track drive to enter slowly into the
milled track, so that the machine will remain hori-
zontal.
After this you may utilize the maximum possible
working speed.

During work
Fig. 125

l Select the engine load limit sensing control

"Manual mode" 10 (Fig. 125), if no high power
is demanded from the engine, e.g. shallow
milling depth or light breaking road surface.
l Activate the differential lock (11) only when
slipping to the side and only for the required
period of time.
l Check the water level at regular intervals and
replenish in due time

! Caution
Fig. 124
Do not perform milling operations without wa-
ter spraying.
l Use the steering lever of the rear steering sys-
tem to make slight steering corrections (Fig. l Arrange signals (warning horn) with the truck
124). driver to enable synchronous operation and
uniform loading of the truck.
Once the truck is fully loaded:
l Stop the machine,
l switch off the milling drum drive,

BM 2000/60 BOMAG 79
Operation
l once the conveyor belt is empty switch off the
conveyor belt drive,
l switch off the water spray system,
l Run the engine in idle speed.
i Note
The above operations can also be performed us-
ing the switch "Stopping work" (see section 4.18).
80
4.14 Automatic milling depth
control
! Caution
Shut down the machine before replacing the
sensors of one side from wire sensor to slope
sensor and vice versa.
Select the sensors, buttons 9 and 23 (Fig. 126).
After restarting the machine check whether the
cutting depth has changed.
i Note
The manual or automatic milling depth control con-
trols the front hydraulic cylinders of the posts.
Up to three depth sensors can be installed per
side. The computer detects these after they have
been connected. The computer compares the
measuring values with the nominal values of the
milling depth control. If a side has no depth sensor
installed, no value will be displayed.
!Caution
Do not try to clean the display with gloves or a
dirty cloth. Do not use solvents to clean!
Always close the protective covering and store
the unit safely after use.
Milling depth zero calibration
l Lower the machine evenly at front and rear,
until the cutting tools touch the road surface.
BOMAG BM 2000/60

Fig. 126
l Use buttons 9 and 23 (Fig. 126) to select
"DEPTH" mode for both sides.
l Press button 12 or 20 together with button 16
to zeroize the depth indication.
Calibration to zero of the slope
l Lower the machine evenly at front and rear,
until the cutting tools touch the road surface.
Fig. 127
l Use buttons 9 or 23 (Fig. 127) to select
"SLOPE" mode for both sides.
l Press button 12 or 20 together with button 16
to zeroize the depth indication.
BM 2000/60 BOMAG
Operation
Setting the cutting depth left/right
Fig. 128
l Use button 9 (Fig. 128) to select "DEPTH"
mode for the right hand side.
l Press button (10/11) to adjust the desired cut-
ting depth.
l Use button 23 to select "DEPTH" mode for the
left hand side.
l Press button (21/22) to adjust the desired cut-
ting depth.
Setting the cutting depth simultane-
ously for both sides
i Note
When using the depth sensor on both sides the
cutting depth can be simultaneously adjusted for
both sides to the same value.
Fig. 129
l Press button 16 (Fig. 129) together with button
8 or 24.
81
Operation

The "Lock" symbol (3) appears in the display, Adjusting the brightness of the screen
l Press button (10/11) or (21/22) to adjust the
desired cutting depth.

i Note
This adjustment is only possible if mode "A" for au-
tomatic or "M" for manual has been selected for
both sides on the control panel.
l Press button 16 together with button 8 or 24
again to deactivate the function.

Automatic levelling

Fig. 131

l Press button 16 together with button 22 (+) or

21 (-) (Fig. 131).

Copying a reference profile*

A feeler to copy a reference profile can be mount-
ed on one of the two sides.
In this case the slope sensor can control the oppo-
site side.

Fig. 130
i Note
Observe the documentation of the supplier.
l Press buttons 24 and 8 (Fig. 130) to activate
"Automatic" mode
Initial start-up
Symbol "A" (6 and 25) is displayed.
The machine approaches the adjusted values for i Note
cutting depth and cross slope.
To be able to work with two control units, each of
the units must have a different initial setting A or B.
i Note
The automatic cutting depth control performs cor-
rections if:
- the depth differs by 1 mm,
the cross slop deviates from the nominal value by
more than 0,1%.

* Optional equipment

82 BOMAG BM 2000/60

Fig. 132
l With the ignition switched off press buttons 11,
21 and 22 (Fig. 132) at the same time.
l Switch the ignition back on with the buttons
pressed (second person required).
A page with five symbols (A, B, C, D and X) is dis-
played.
l Release the buttons and select the desired
setting "A" or "B" under the symbol.
BM 2000/60
Operation
4.15 Milling depth control by
means of ultrasound*
i Note
The milling depth control uses five ultrasonic sen-
sors for height measurement. A sixth sensor is
used for temperature compensation. The sensor
enables contact free scanning of the ground, rope
or curb stone for height regulation. When scanning
the ground, from five simultaneously performed ul-
trasound measurements the three closest to the
original adjustment are used to form a mean value.
Inaccuracies or obstructions can thus be directly
excluded from the calculation of the mean value.
When scanning the rope the sensor always uses
the oscillation with the shortest distance to the
rope for the purpose of measurement.
The side with the sensor installed is height regulat-
ed by the ultrasonic sensor. The opposite side can
be controlled in Auto mode or manually.
l The engine runs with low idle speed,
l the machine has been fully raised.
Pre-setting
l Move the machine to the desired height or mill-
ing depth.
l Set the ultrasonic sensor so that the distance
to the ground is approx. 30 cm.
l Align the sensor in longitudinal direction or
across the travel direction (rope scanning).
l Switch the milling depth control on the oppo-
site side of the sensor to manual or automatic
mode.
* Optional equipment
BOMAG 83
Operation

Sensor zero position Setting the ultrasonic measuring mode

Fig. 133 Fig. 135

l On "Manual" mode press button 2 (Fig. 133),
until the display shows "0".
l Press button (1) A/M, until the control lamp
AUTO (a) lights up.
l If the milling depth is to be changed press but-
tons (3) or (4).
l To switch over press both buttons 3 and 4 (Fig.
135) together.
If the symbol (b) lights up, the rope scanning mode
is activated.

Adjusting the sensitivity of the sensor

Fig. 134

l Press both buttons 1 and 2 (Fig. 134) together.

l Change the sensitivity with the buttons (3) and
(4).

84 BOMAG BM 2000/60

4.16 Stopping/finishing work
Temporal interruption of work
i Note
Perform this work, if e.g. the truck is fully loaded.
Fig. 136
l Turn the momentary contact switch (Fig. 136)
to position "0".
The machine stops, water spray system and con-
veyor belt are shut down, the levelling system is
turned to "Manual". Run engine with idling speed.
l Inform the truck driver that the truck is fully
loaded by peeping the horn.
Fig. 137
l To resume work: Turn the momentary contact
switch (Fig. 137) to position "1".
Water spraying system and conveyor belt are au-
tomatically switched on again, the machine starts
travelling with the adjusted levelling values.
BM 2000/60
Operation
Stopping work and driving the ma-
chine out of the milling track
i Note
Perform the following steps after the milling drum
has reached the end of the surface to be milled:
l To stop the machine shift the travel lever to op-
posite travel direction.
l Run milling drum and conveyor belt until all
material has been transferred to the truck.
Fig. 138
l Raise the machine completely by all four posts
9 (Fig. 138).
Milling drum drive and conveyor belt as well as wa-
ter spray system are automatically switched off.
l Drive the machine slowly out of the milling
track and to the parking place or to the new
place of use.
Activities at the end of the day
l Clean the machine thoroughly.
l If the machine is not going to be used again
shortly, drain all water off.
l If necessary perform the required mainte-
nance work.
BOMAG 85
Operation

4.17 Adjusting the seat 4.18 Operating the engine hood

l Open the rear window.
! Danger l Switch the ignition on.
Danger of accident!
Do not adjust the drivers seat while driving.

Fig. 141

l To raise the engine hood turn the switch (Fig.

Fig. 139 141) clockwise.
l To adjust the seat in longitudinal direction dis-
engage lever 1 (Fig. 139) and push the seat
forward or back.
l To adjust the weight adjust lever (3) accord-
ingly.
l To adjust the inclination of the backrest oper-
ate lever (2) and tilt the backrest forward or
back.

Fig. 140

l To slide the seat in transverse direction, lift le-

ver (Fig. 140). Fig. 142

l Support the hood (Fig. 142).

86 BOMAG BM 2000/60
 Operation

4.19 Operating the protection 4.20 In events of emergency

roof on the operator's stand

Folding the protection roof in

i Note
The protection roof can be folded down with the
help of an auxiliary hydraulic pump for transport.

Fig. 145

l In events of emergency operate one of the

emergency stop push buttons (Fig. 145) on the
control panel of the operator's stand or on the
side of the machine.
The engine is shut down and the parking brake is
closed.

Fig. 143

l Turn the rotary switch (Fig. 143) anti-clockwise

to fold the protection roof in.

Folding out the protection roof

Fig. 146

l In events of emergency, e.g. in case of a cable

fire, disconnect the battery from the vehicle
network.

!Caution
Fig. 144
Pull out the main battery switch at the earliest
l Turn the rotary switch (Fig. 144) clockwise to 40 seconds after switching off the ignition, ex-
fold the protection roof out. cept in cases of emergency.

BM 2000/60 BOMAG 87
Operation

Towing the machine

! Caution
Tow the machine only in a case of emergency
or to avoid an accident.
Towing distance max. 300 m, towing speed
max. 10 m/min.
Make sure that:
- the power and weight of the towing vehicle is
sufficient for the machine to be towed,
- towing ropes, chains and fastening means
are able to withstand the load and are fastened Fig. 147
at the points provided for this purpose. l Securely fasten the towing vehicle with towing
- the milling drum is raised above the ground, ropes or chains to the front or rear towing
points (Fig. 147) of the machine.
- the machine is only towed by the towing
hooks provided for this purpose. l Open the engine compartment service flap.
Disregarding these notes will cause severe
damage to drive and crawler tracks!

! Danger
Danger of accident!
Be extremely careful throughout the entire
towing process.
Observe all safety measures as specified in
UNI-EN 500.
Before releasing the brake secure the machine
against unintended rolling.
During towing one operator on the operator's
Fig. 148
platform must watch the towing vehicle and
the instructing personnel. l Slacken the counter nuts on both high pres-
sure relief valves (Fig. 148) to create a by-
pass around the travel pump.
l Turn the threaded spindle in until it is flush with
the nut.
l Retighten the counter nut.

88 BOMAG BM 2000/60

Fig. 149
l Close the parking brake valve (Fig. 149) under
the left hand floor plate.
l Open the front right service flap.
Fig. 150
l In order to release the parking brake turn
switch e (Fig. 150) together with switch (d), un-
til the pressure gauge (a) shows a reading of
approx. 30 to 35 bar.
l If necessary raise the machine, so that the
milling drum comes free.
l During towing the operator's stand must be oc-
cupied, so that the driver can watch the towing
vehicle and the person giving instructions.
After towing
l Turn the threaded spindle of the high pressure
relief valves completely out again and tighten
the counter nuts.
l Open the parking brake valve again.
BM 2000/60
Operation
4.21 Preparing the machine for a
longer rest
If the machine is shut down for a longer period of
time, e.g. winter season, the following work must
be carried out.
l Fill the fuel tank with diesel fuel.
l Clean the machine thoroughly.
l Park the machine under a cover or cover it with
a tarpaulin.
l Pull off the main battery switch.
l Remove the batteries, check the acid level and
add distilled water, if necessary.
l Recharge the batteries at regular intervals.
l Drain the water tank completely.
l Completely drain the water circuit of the spray
system or fill it with a water/antifreeze mixture.
l Lower or support the loading conveyor belt, or
let it hang suspended by the safety ropes.
l Place square timber beams under the milling
drum and lower the machine until the drum
rests on the square timber.
l Grease the hydraulic cylinders of the posts.
l Lubricate the machine.
BOMAG 89
Operation

4.22 Operating the water spray

system

Fill the water tank

Fig. 153

l Check the filling levels (Fig. 153) of the water

tanks.

Switching on the water spray system

Fig. 151

l Fill the front water tank with clean water (Fig.

151).

Fig. 154

l Open the tap (Fig. 154) if water is to be taken

from the rear tank.

Fig. 152

l Fill the rear water tank with clean water (Fig.

152).

90 BOMAG BM 2000/60
 Operation

Fig. 155 Fig. 157

l Open the tap (Fig. 155) if water is to be taken l Switch on the water pump (Fig. 157).
from the front tank.

Fig. 158
Fig. 156
l Adjust the required water quantity on the valve
l Open the main shut-off valve (Fig. 156). (Fig. 158) and read the spraying pressure on
the pressure gauge.
Caution
! l Open the shut-off valves (2) for gathering belt
Do not allow the water pump to run dry. and (3) for milling drum.

BM 2000/60 BOMAG 91
Operation

Draining the water tank

4.23 Folding / unfolding the load-
ing conveyor belt

Folding the loading conveyor belt in

Fig. 159

l Open the shut-off valve (Fig. 159) and let all

water run out.

Additionally in case of frost

Fig. 160
Refer to the section "Maintenance as required".
l Raise the loading conveyor belt (Fig. 160).

Fig. 161

l Turn the momentary contact switch (Fig. 161)

anti-clockwise.

92 BOMAG BM 2000/60
 Operation

4.24 Loading, transport

! Danger
Life hazard!
During demonstration and when loading the
machine do not remain in the danger zone of
the machine.
Use only stable loading ramps of sufficient
load bearing capacity. Make sure that persons
are not endangered by the machine tipping or
Fig. 162 sliding off.
l Fold the conveyor belt in completely (Fig. Always switch off milling drum and conveyor
162). belt.
Lash the machine down, so that it is secured
against rolling, sliding and turning over. Al-
ways use shackles on the lifting points for
loading or tying the machine down.
Lift the machine only with suitable lifting gear.
Weights: see chapter "Technical Data".
Loading weight and dimensions see technical
data.

Transport by low loader

l Remove and stow away all milling depth sen-
sors.
Fig. 163 l Remove the display of the milling depth control
and stow it away.
l Insert the securing clamps (Fig. 163) on both
sides. l Drain remaining water from the tank.
l Disassemble working lights and flashing bea-
Unfolding the loading belt con and place them in the corresponding hold-
l Perform these steps in reverse order to unfold ers. Close the sockets with rubber plugs.
the conveyor belt. l Fold in the loading conveyor belt (refer to the
corresponding section).
l Close all doors and flaps.

BM 2000/60 BOMAG 93
Operation

Fig. 164 Fig. 166

l Swing the lock for conveyor belt 1 (Fig. 164)
out of the bracket and fasten it to the eye in the
cross strut. Secure the bolt (2) with the cotter
pin (3).
l If necessary open the bypass valve f (Fig. 166)
for the loader conveyor cylinders.
By opening the bypass valve the loader conveyor
can freely swing and follow the steering movement
of the low loader.

Loading by crane

Danger
!

Life hazard!
Do not step under suspended loads.
The crane must be of sufficient load bearing
capacity.
The four lifting ropes (steel ropes) or chains
must have a length of at least 6,5 m (22 ft) and
a load bearing capacity of 10 000 daN (kg).
Fig. 165

l Drive the machine onto the low loader (Fig.

165), the conveyor belt towards the truck cab.
l Support the frame of the conveyor belt.
l Lower the protection roof
l Place wooden beams under the milling drum
and lower the machine, until the milling drum
rests on the wooden beams.
l Strap the machine to the transport vehicle, use
the lashing eyes on the machine.

Fig. 167

l Use the marked lifting eyes for lifting (Fig.

167).

94 BOMAG BM 2000/60
 Operation

Loading by ramp
4.25 Multi-function display
! Danger
Life hazard! Switching on
The ramp must be free of grease, oil, snow and l Switch on the ignition.
ice.
The instructing personnel must keep a suffi-
cient distance to be safe should the machine
start to slip.
The max. permissible ramp inclination is 30%
(17).
l Make sure that no persons are in the danger
area.
l Lower the conveyor belt and select low speed
range.

Fig. 169
The initial screen is displayed (Fig. 169).

i Note
Always wait until the basic screen is displayed

Fig. 168

l Observe the max. permitted inclination (Fig.

168).
l Make sure that the ramp is able to carry the
weight of the machine.

Fig. 170

l The basic screen appears after approx. 10

seconds (Fig. 170).

i Note
The display shows engine speed, operating hours,
engine oil pressure, coolant temperature, travel
speed and fuel level.

BM 2000/60 BOMAG 95
Operation

Scroll through pages l 2 Coolant temperature

Page 2, hydraulic displays l 3 Temperature of air entering the engine, after

intercooler
l 4 Fuel consumption, current
l 5 Engine power with turbocharger
l 6 Engine oil pressure
l 7 Battery / supply voltage
l 8 Turbocharger boost pressure
l 9 Fuel temperature
l 10 Fuel filling level

Settings
Setting brightness, contrast
Fig. 171

l Press key F5 (Fig. 171).

The following information is displayed:
l 1 auxiliary hydraulics, current pressure
l 2 conveyor belt drive, current pressure
l 3 clutch pressure, current pressure
l 4 scraper flap, current pressure
l 5 Hydraulic oil temperature
l 6 travel drive, current pressure
l 7 fan drive, current pressure
l 8 mouldboard, current pressure Fig. 173
Page 3, engine displays l Press key F2 (Fig. 173).

Fig. 172

l Press key F5 (Fig. 172).

The following information is displayed:
l 1 Engine speed

96 BOMAG BM 2000/60
 Operation

4.26 Scrapping the machine

If the machine can no longer be used and needs to
be scrapped you must carry out the following work
and have the machine disassembled by an ap-
proved specilaist workshop.

Environment
Catch all fuels and lubricants, do not let them
seep into the ground and dispose of in compli-
ance with legal regulations.
Fig. 174 l Disassemble the batteries and dispose off ac-
l The menu ADVANCED FUNCTIONS (Fig. cording to legal regulations.
174) will appear. l Empty the fuel tank.
l Turn the (OK) selector switch choose the l Drain the hydraulic oil tank.
menu option DISPLAY AJUSTMENT. Press
l Drain coolant from engine and cooling system.
the switch to confirm.
l Drain off the milling drum cooling fluid.

i Note l Drain off engine and transmission oil

The other functions can be called up after entering
a password. ! Danger
Only for service purposes. Danger of explosion!
l Adjust the desired brightness with the rotary Parts that previously contained combustible
button (OK). fluids must not be cut with a cutting torch.
l The ESC - key (F1) brings you back to the ba-
sic screen.

BM 2000/60 BOMAG 97
Operation

98 BOMAG BM 2000/60
 5 Maintenance

BM 2000/60 BOMAG 99
Maintenance
5.1 General notes on mainte-
nance
When performing maintenance work always com-
ply with the appropriate safety regulations.
Thorough maintenance of the machine guaran-
tees far longer safe functioning of the machine and
prolongs the lifetime of important components.
The effort needed for this work is only little com-
pared with the problems that may arise when not
observing this rule.
The terms right/left correspond with travel direc-
tion forward.
l Always clean machine and engine thoroughly
before starting maintenance work.
l For maintenance work stand the machine on
level ground.
l Perform maintenance work only with the motor
switched off.
l Relieve hydraulic pressures before working on
hydraulic lines.
l Always remove the main battery switch for all
maintenance work.
Environment
During maintenance work catch all oils and fu-
els and do not let them seep into the ground or
into the sewage system. Dispose of oils, cool-
ant and fuels environmentally.
Notes on the fuel system
The lifetime of the diesel engine depends to a
great extent on the cleanliness of the fuel.
l Keep fuel free of contaminants and water,
since this will damage the injection elements
of the engine.
l Drums with inside zinc lining are not suitable to
store fuel.
l The fuel drum must rest for a longer period of
time before drawing off fuel.
l Do not let the hose stir up the slurry at the bot-
tom of the drum.
100
l Do not draw off fuel from near the bottom of
the drum.
l The rest in the drum is not suitable for the en-
gine and should only be used for cleaning pur-
poses.
Notes on the performance of the en-
gine
On diesel engines both combustion air and fuel in-
jection quantities are thoroughly adapted to each
other and determine power, temperature level and
exhaust gas quality of the engine.
If your engine has to work permanently in "thin air"
(at higher altitudes) and under full load, you should
consult the customer service of MARINI or the
customer service of the engine manufacturer.
Notes on the hydraulic system
During maintenance work on the hydraulic system
cleanliness is of major importance. Make sure that
no dirt or other contaminating substances can en-
ter into the system. Small particles can produce
flutes in valves, cause pumps to seize, clog noz-
zles and pilot bores, thereby making expensive re-
pairs inevitable.
l If, during the daily inspection of the oil level the
hydraulic oil level is found to have dropped,
check all lines, hoses and components for
leaks.
l Seal external leaks immediately. If necessary
inform the responsible customer service.
l Do not store drums with hydraulic oil outdoors,
or at least under a cover. Water can be drawn
in through the bunghole when the weather
changes.
l Clean fittings, filler covers and the area around
such parts before disassembly to avoid enter-
ing of dirt.
l Do not leave the tank opening unnecessarily
open, but cover it so that nothing can fall in.
Notes on the cooling system
For water-cooled engines the preparation and in-
spection of the coolant is of greatest importance,
as otherwise the engine may be damaged by cor-
rosion, cavitation and freezing.
BOMAG BM 2000/60

The coolant is prepared by mixing a cooling sys-
tem protection agent into the coolant.
The cooling system must be permanently moni-
tored. Besides the inspection of the coolant level
this includes also the inspection of the concentra-
tion of cooling system protection agent.
The concentration of cooling system protection
agent can be checked by means of commercial
testers (glycomat).
! Danger
Health hazard!
The mixing of nitrite based anti-freeze agents
with amine based agents results in the forma-
tion of health affecting nitrosamines.
Environment
Cooling system protection agents must be dis-
posed of environmentally.
BM 2000/60
Maintenance
5.2 Fuels and lubricants
Engine oil
Quality
Use oil according to ACEA-classification E4-99
(Deutz oil quality TLX-10W-40FE). This allows the
utilisation of the longest oil change intervals.
Lubrication oils are classified according to their
performance and quality class. Oils according to
other comparable specifications may be used.
Approved engine oils
ACAE* E4-99/E6-04
Deutz DQC III-05/DQC IV-05
The exact assignment of the approved oil qualities
and oil change intervals can be taken from the fol-
lowing section "Lubrication oil change intervals".
Consult your local service station if in doubt.
Oil viscosity
You should generally use multi-purpose oils of
quality SAE 10W/40.
Since lubrication oil changes its viscosity with the
temperature, the ambient temperature at the oper-
ating location of the engine is of utmost impor-
tance when choosing the viscosity class (SAE-
class) (see diagram).
Occasional falling short of the temperature limit
(e.g. use of SAE 10W/40 down to -20 C) may ef-
fect the cold starting ability of the engine, but will
not cause any engine damage.
Temperature related lubrication oil changes can
be avoided by using multi-purpose oils. The follow-
ing oil change intervals apply also when using mul-
ti-purpose oils.
Oil change intervals
The longest permissible time a lubrication oil
should remain in an engine is 1 year. If the follow-
ing oil change intervals are not reached over a pe-
riod of 1 year, the oil change should be performed
at least once per year, irrespective of the operating
hours reached.
BOMAG 101
 Maintenance
ACEA*
E4-99/E6-04 = 250 operating hours
!Caution
These intervals apply only when using a diesel
fuel with maximum 0.5 % sulphur by weight
and for ambient temperatures higher than -10
C.
When using fuels with a sulphur content of
more than 0.5% to 1% or under ambient tem-
peratures below -10 C the oil change intervals
specified in the table must be halved. For fuels
with a sulphur content of more than 1% you
should consult the responsible service agen-
cy.
Fuels
Quality
You should only use commercially available brand
diesel fuel with a sulphur content below 0.5% and
ensure strict cleanliness when filling in. A higher
sulphur content has a negative effect on the oil
change intervals. Use only winter-grade diesel fuel
under low ambient temperatures. The fuel level
should always be topped up in due time so that the
fuel tank is never run dry, as otherwise filter and in-
jection lines need to be bled.
When using fuels with a Cetan number < 49 poor
starting and white smoke can be expected, in par-
ticular in connection with low ambient tempera-
tures.
The following fuel specifications are permitted:
l DIN/EN 590
l BS 2869: A1 and A2
l ASTM D 975-88: 1-D and 2-D.
l Nato Codes: F-54, F-75;
Winter fuel
! Danger
Fire hazard!
Diesel fuels must never be mixed with gaso-
line.
For winter operation use only winter diesel fuel, to
avoid clogging because of paraffin separation. At
* Association des Constructeurs European dAutomobiles
102
very low temperatures disturbing paraffin separa-
tion can also be expected when using winter diesel
fuel.
In most cases a sufficient cold resistance can also
be achieved by adding flow enhancing fuel addi-
tives (fuel additive / petroleum). Consult the en-
gine manufacturer.
Coolant, anti-freeze agent
High performance diesel engines require a well
balanced coolant mixture of water, anti-freeze and
supplementary coolant additives.
For coolant mixtures use only soft tap water with a
water hardness between 3 and 20 dGH. The wa-
ter should not contain more than 100 mg/dm3 of
chlorine and sulphate. The ph-value should be be-
tween 6.5 and 8.5.
Prepare and check coolant with highest care,
since otherwise the engine may be damaged by
corrosion, cavitation and freezing.
As a protection against frost and boiling point anti-
freeze agents must be used under any climatic
conditions.
Mixing of coolant water and cooling system protec-
tion agent must be performed at a concentration
level of the cooling system protection agent of min-
imum 35% and maximum 45%.
Caution
!
Do not mix different coolants and additives of
any other kind.
Environment
Cooling system protection agents must be dis-
posed of environmentally.
Hydraulic oil
The hydraulic system is operated with hydraulic oil
HV 46 (ISO) with a kinematic viscosity of 46 mm2/
s at 40C. For topping up or for oil changes use
only high-quality hydraulic oil, type HVLP accord-
ing to DIN 51524, part 3, or hydraulic oils type HV
according to ISO 6743/3. The viscosity index (VI)
should be at least 150 (observe information of
manufacturer).
BOMAG BM 2000/60
 Maintenance

Bio-degradable hydraulic oil

On request the hydraulic system can also be filled
with ester based biodegradable hydraulic oil (Pan-
olin HLP Synth. 46). The biologically quickly de-
gradable hydraulic oil meets all demands of a
mineral oil based hydraulic oil according to DIN
51524.
In hydraulic systems filled with Panolin HLP Synth.
46 always use the same oil to top up. When
changing from mineral oil based hydraulic oil to an
ester based biologically degradable oil, you should
consult the lubrication oil service of the oil manu-
facturer for details.
Check the filter more frequently after this change.

! Caution
Oil change bio-degradable hydraulic oil:
Perform regular oil analyses for content of wa-
ter and mineral oil.
Replace the hydraulic oil filter element every
500 operating hours.

Oil for milling drum gear and milling

drum bearings
For the milling drum drive use only synthetic gear
oil on basis of POLY-ETHYLEN-GLYCOL acc. to
DIN 51502 or gear oil on basis of POLY-ALPHA-
OLEFIN (PAO) acc. to DIN 51517-3 of viscosity
class ISO VG 220.

! Caution
These two lubricants are not suitable for mix-
ing!

Oil for track drive gear and hydraulic

pump drive transfer box
For the drive gear use only multi-purpose trans-
mission oil of API-class GL5, viscosity class SAE
90 EP.

Lubrication grease
For lubrication use only EP-high pressure grease,
lithium saponified NLGI 2. The milling drive clutch
must be lubricated every 250 hours with 25 g of
special grease (BOMAG part-no.: 00996009).

BM 2000/60 BOMAG 103

Maintenance

5.3 Table of fuels and lubri-

cants

Assembly Fuel or lubricant Quantity approx.

Summer Winter Attention

Observe the level marks

Engine Engine oil SAE 10 W-40 ACEA: E4-99/E6-04 or approx. 47 litres incl. oil fil-
ter

Fuel

Diesel Winter diesel fuel approx. 1200 litres

Hydraulic system Hydraulic oil (ISO), HLP 46 approx. 230 litres

Milling drum drive reduc- Gear oil on basis of POLY-ETHYLEN-GLYCOL acc. approx. 18 litres
tion gear to DIN 51502 or gear oil on basis of POLY-ALPHA-
OLEFIN (PAO) acc. to DIN 51517-3G of viscosity
class ISO VG 220.

Milling drum bearings Gear oil on basis of POLY-ETHYLEN-GLYCOL acc. approx. 1 litres
to DIN 51502 or gear oil on basis of POLY-ALPHA-
OLEFIN (PAO) acc. to DIN 51517-3G of viscosity
class ISO VG 220.

Transfer case Gear oil SAE 90, API GL5 approx. 3,5 litres

Crawler track drive gear Gear oil SAE 90, API GL5 approx. 4 x 1.3 litres

Engine cooling system Water and cooling system protection agent approx. 100 litres

Milling drum Water and cooling system protection agent approx. 355 litres

Lubrication points: High pressure, lithium saponified EP NLGI 2) as required

Loading belt, supporting
rollers, swinging fork
Gathering belt, supporting
rollers
Steering linkage front and
rear
Steering linkage, front and
rear crawler tracks
Bushings of the 4 posts
Milling drum bearing

Lubrication points: High pressure, lithium saponified EP NLGI 3 25 g every 250 operating
Clutch, milling drive BOMAG part-no.: 00996009 hours

Water tank, spray system Water approx. 3300 litres

104 BOMAG BM 2000/60

 Maintenance

5.4 Running-in instructions

The following maintenance work must be per-

formed when running in new machines or
overhauled engines:

! Caution
Up to approx. 250 operating hours check the
engine oil level twice every day.
Depending on the load the engine is subjected
to, the oil consumption will drop to the normal
level after approx. 100 to 250 operating hours.

After a running-in time of 30 minutes

l Retighten the engine V-belts

After 50 operating hours

l Retighten bolted connections on intake and
exhaust tubes, oil sump and engine mounts.
l Retighten the bolted connections on the ma-
chine.
l Change engine oil and filter
l Oil change in milling drum reduction gear
l Oil change milling drum bearings
l Change the oil in the transfer box.

Maintenance after 500 operating hours

l Change the oil in the transfer box.

BM 2000/60 BOMAG 105

Maintenance

5.5 Maintenance table

every 50 operating hours, every week

every 10 operating hours, daily
after 50 operating hours
Running-in instructions

every 1000 oper. hours

every 2000 oper. hours

every 4000 oper. hours

every 6000 oper. hours

every 250 oper. hours
No. Maintenance work Comment

as required
5.6 Check the engine oil level Dipstick mark X
5.7 Check the water separator X
5.8 Check the fuel level X
5.9 Check the hydraulic oil level Inspection X
glass
5.10 Check water level, spray nozzles Inspection X
glass
5.11 Check/replace cutting tools, scraper several times X
5.12 Check the track plates X
5.13 Check, tighten the conveyor belts X
5.14 Check the safety ropes X
5.15 Lubricate the machine X
5.16 Check the coolant level Inspection X
glass
5.17 Check the oil level in the transfer box X
5.18 Retighten the track shoe fastening X
screws
5.19 Lubricate the machine X
5.20 Clean the cooling fins on engine and X
hydraulic oil cooler
5.21 Cleaning the engine X
5.22 Change engine oil and oil filter car- min. 1x per X X
tridge* year

106 BOMAG BM 2000/60

 Maintenance

every 50 operating hours, every week

every 10 operating hours, daily
after 50 operating hours
Running-in instructions

every 1000 oper. hours

every 2000 oper. hours

every 4000 oper. hours

every 6000 oper. hours

every 250 oper. hours
No. Maintenance work Comment

as required
5.23 Checking, replacing the generator V- X
belt
5.24 Check, replace the milling drum V-belt X
5.25 Check the track drive X
5.26 Lubricate the machine X
5.27 Check, adjust the valve clearance min. 1x per X
year
5.28 Change the fuel pre-filter element X
5.29 Replace the fuel filter cartridge X
5.30 Check fastening of engine/turbo pole grease X
charger/combustion air hoses
5.31 Checking the crankcase pressure X
5.32 Intercooler, draining off oil/condensa- min. 1x per X
tion water year
5.33 Change the hydraulic oil** min. 1x per X
year
5.34 Change the hydraulic oil filter** min. 1x per X
year
5.35 Transfer case oil change*** X X
5.36 Change the oil in the milling drum re- min. 1x per X X
duction gear year
5.37 Oil change in milling drum bearing min. 1x per X
year
5.38 Oil change in track drive gear min. 1x per X
year
5.39 Drain the fuel tank sludge X

BM 2000/60 BOMAG 107

Maintenance

every 50 operating hours, every week

every 10 operating hours, daily
after 50 operating hours
Running-in instructions

every 1000 oper. hours

every 2000 oper. hours

every 4000 oper. hours

every 6000 oper. hours

every 250 oper. hours
No. Maintenance work Comment

as required
5.40 Battery service pole grease X
5.41 Change the coolant at least every 2 X
years
5.42 Change the injection valves X
5.43 Replace the coolant pump X
5.44 Replace the pressure retaining valve X
5.45 Change the crankcase ventilation X
valve
5.46 Service the combustion air filter min. 1x per X
year
Safety car-
tridge at least
every 2 years
5.47 Clean water tank and water filter X
5.48 Water spray system, maintenance in X
case of frost
5.49 Clean the pressure cleaner water filter X
5.50 Tightening torques X
5.51 Engine conservation X
* Oil change intervals depend on quality of oil and fuel (sulphur content)
** Also in case of repair in the hydraulic system.
*** Also after 500 operating hours

108 BOMAG BM 2000/60

 Every 10 operating hours

Every 10 operating hou rs

5.6 Check the engine oil level 5.7 Check, clean the water sep-
arator
i Note
The machine must be in horizontal position. Just ! Danger
before testing run the engine approx. 2 minutes
Danger of injury!
with idle speed. Shut down the engine.
Support the engine hood for all maintenance
and repair work.

i Note
The service intervals for the water separator de-
pend on the water content in the fuel and can
therefore not be determined precisely. After taking
the engine into operation you should therefore
check the water separator every day for signs of
water.
If a to high quantity is drained off, the filter must be
refilled with fuel. See chapter "maintenance as re-
quired", bleeding the fuel system.
Fig. 175

l Pull the dipstick (Fig. 175) out, wipe it off with Environment
a lint-free, clean cloth and reinsert it until it bot-
Catch running out fuel and dispose of environ-
toms.
mentally.
l Pull the dipstick back out again.
l The oil level must be near the Max-mark.
l If the oil level is too low top up oil immediately.

For quality of oil refer to the table of fuels, lu-

bricants and filling capacities.

Fig. 176

l Slacken the drain plug (Fig. 176) for a few

turns and catch running out fuel / water.
l Tighten the drain plug again and check for
leaks, if necessary replace the seal ring.

BM 2000/60 BOMAG 109

Every 10 operating hours

Caution
!
5.8 Check the fuel level
Contaminated fuel can cause malfunction or
even damage of the engine.
! Danger If necessary, fill in fuel through a funnel with
Fire hazard! screen.

When working on the fuel system do not use l If necessary top up with fuel (diesel or winter
open fire, do not smoke, do not refuel in closed diesel).
rooms, do not inhale any fuel fumes. For quality of fuel refer to the table of fuels and
lubricants.

Fig. 177

l Check the fuel level on the fuel level gauge

(Fig. 177) with the ignition switched on.

i Note
Do not drive the fuel tank dry, as otherwise the fuel
system needs to be bled.
l Clean the area around the filler opening.

Fig. 178

l Open the fuel tank cover (Fig. 178).

110 BOMAG BM 2000/60

 Every 10 operating hours

5.9 Checking the hydraulic oil

level
l Open the service flap on the right hand side.

Fig. 180

l If necessary fill in hydraulic oil (Fig. 180)

through the filler neck.

For quality and quantity of oil refer to the table

of fuels and lubricants.
Fig. 179

l Check the hydraulic oil level in the inspection

glass (Fig. 179).

Normal level
approx. 3 cm below the top edge of the inspection
glass.

Minimum level
Middle of inspection glass.

! Caution
If, during the daily inspection of the oil level
the hydraulic oil level is found to have
dropped, check all lines, hoses and compo-
nents for leaks.
l Open the engine hood.

BM 2000/60 BOMAG 111

Every 10 operating hours

5.10 Check water level, spray 5.11 Check/replace cutting tools,

nozzles scraper

i Note i Note
Always fill the water tank before starting work. The cutting tools are mounted in replaceable hold-
ers.

Danger
!

Life hazard!
Shut down the engine and remove the ignition
key before accessing the milling drum.
Additionally attach a warning tag stating "Do
not start the engine!" to the dashboard.

Preparations without electro-hydraulic

drive
l Raise the machine completely.
Fig. 181

l Check the filling level in the inspection glass

(Fig. 181).
l For filling remove the filler cap, fill in clean wa-
ter and close the cap again.

! Caution
Do not run the water pump without water.

Fig. 183

l Unlock all four safety supports and fold them

down (Fig. 183).
l If necessary turn the rear track drives in "Man-
ual" mode fully to the right.

Fig. 182

l Run the spray system for a short while and

check the efficiency of the spray nozzles for
conveyor belt (Fig. 182) and milling drum.
l If necessary unscrew and clean the nozzles.

112 BOMAG BM 2000/60

 Every 10 operating hours

Fig. 184 Fig. 186

l Swing the scraper plate completely open, until
the safety hooks (Fig. 184) click into place.
The warning lamps on both sides are flashing.
l Fold out the seat (Fig. 186).
Preparations with electro-hydraulic
drive*
l Raise the machine completely.

Fig. 185

l Shut down the engine (Fig. 185) and pull out

the ignition key. Fig. 187
l Attach a warning tag "Do not start the engine, l Unlock all four safety supports and fold them
maintenance work" to the dashboard. down (Fig. 187).
l If necessary turn the rear track drives in "Man-
! Danger ual" mode fully to the right.
Life hazard!
Access the space under the machine only with
the milling drum stopped.

* Optional equipment

BM 2000/60 BOMAG 113

Every 10 operating hours

Fig. 188 Fig. 190

l Swing the scraper plate completely open, until l Fasten the control box on the opened scraper
the safety hooks (Fig. 188) click into place. plate (Fig. 190).
The warning lamps on both sides are flashing.
l Shut down the engine and switch on the igni-
tion.
l Attach a warning tag "Do not start the engine,
maintenance work" to the dashboard.

! Danger

Life hazard!
Access the space under the machine only with
the milling drum stopped.

Fig. 191

l Fold out the seat (Fig. 191).

Check the cutting tools

l Rotate the drum by hand and check cutting
tools and holders.
l Check whether the cutting tools rotate in their
holders.

Fig. 189

l Remove the control box for rotor drive (Fig.

189) (magnetic holder).

114 BOMAG BM 2000/60

 Every 10 operating hours

Fig. 192 Fig. 195

Cutting tool in good condition (Fig. 192). Cutting tool showing uneven wear (Fig. 195). The
cutting tool must be replaced immediately.

Fig. 193
Cutting tool with even wear (Fig. 193), must be re- Fig. 196
placed after short term use. Tool tip with eroded body (Fig. 196). The cutting
tool must be replaced immediately.

Fig. 194
If the cutting tool is in this condition (Fig. 194), the Fig. 197
holder must perhaps also be changed, because Tool tip broken off (Fig. 197). The cutting tool must
the cutting tool cannot rotate. This causes uneven be replaced immediately.
wear.

BM 2000/60 BOMAG 115

Every 10 operating hours

Replace the cutting tool Checking the tool holders

! Danger
Wear goggles and gloves when changing the
cutting tools. Injury by hard metal splinters!

Fig. 200
Tool holder in good condition (Fig. 200).

Fig. 198

l Knock out damaged or worn off cutting tools

with a hammer and a special tool (Fig. 198).

Fig. 201
If the tool holder is in such a condition (Fig. 201) it
must be replaced immediately.

Fig. 199

l Knock in the new cutting tool fully with a cop-

per or plastic hammer (Fig. 199) and check
whether it can rotate freely.

116 BOMAG BM 2000/60

 Every 10 operating hours

Replacing the tool holders Checking the scraper bars

Fig. 202 Fig. 204

l Knock out damaged or worn off cutting tool Check the condition of the scraper bars (Fig. 204),
holders with a hammer and a special tool (Fig. replace if necessary.
202). Replace the scraper bars when the edges are
blunt or broken.

Replacing the scraper bars

Fig. 203

l Knock in the new cutting tool holders fully with

a copper or plastic hammer (Fig. 203) and
check whether the cutting tool can rotate free- Fig. 205
ly.
Unscrew fastening screws 1 (Fig. 205) and take off
scraper bars (2).
Mount the new scraper bars and tighten the fas-
tening screws.

BM 2000/60 BOMAG 117

Every 10 operating hours

5.12 Checking the track plates 5.13 Check, tighten the conveyor
belts

! Danger
Danger of injury!
Keep a safe distance when the conveyor belt is
running.
Do not adjust the tension while the belt is run-
ning.

Check

Fig. 206

l Check the condition of the track plate coating

(Fig. 206), replace if necessary.

Fig. 207

l Check the condition of the conveyor belts (Fig.

207).
l Conveyor belts showing cracks and peel-offs
must be replaced immediately.
l Check supporting and reversing rollers for
cleanliness, clean if necessary.

i Note
Dirt deposits on the rollers cause the belt to run out
of centre.
l Check the conveyor belt tension.
With correct tension the belt does not touch the
supporting rollers.

i Note
Tension of gathering belt:
Compression depth in middle of conveyor belt 50
mm under a force of 100 - 150 N.

118 BOMAG BM 2000/60

 Every 10 operating hours

Tension of loading belt:

Compression depth in middle of conveyor belt 70
mm under a force of 100 - 150 N.

Tensioning loading and unloading

belts

i Note
Tension evenly on both sides.
Center the belt.
Increase the tension on the side to which the belt
is running off, or reduce the tension on the oppo- Fig. 209
site side. l For tensioning the loading belt loosen the
Run the conveyor belt a few minutes to check. counter nuts (Fig. 209) on both sides and ten-
sion the conveyor belt with the screw.

Checking the supporting rollers

Fig. 208

l For tensioning the gathering belt loosen the

counter nuts (Fig. 208) on both sides and ten-
sion the conveyor belt with the screw. Fig. 210

l Check the condition and movability of the roll-

ers (Fig. 210).
l If necessary remove any dirt deposits from the
rollers.
l Switch on the conveyor belt and check the
centring.

BM 2000/60 BOMAG 119

Every 10 operating hours

5.14 Checking the safety ropes 5.15 Lubricate the machine

Loading conveyor belt

Fig. 211

l Check the condition of the safety ropes (Fig.

211), replace if necessary. Fig. 212

l Lubricate the front roller bracket (Fig. 212) on

both sides with three strokes from the grease
gun.

Fig. 213

l Lubricate the roller bearings (Fig. 213) on both

sides with three strokes from the grease gun.

120 BOMAG BM 2000/60

 Every 10 operating hours

Gathering belt Milling drum

Fig. 214 Fig. 216

l Lubricate the front drive roller holders (Fig. l Lubricate the bearings (Fig. 216) with three
214) with three strokes from the grease gun. strokes from the grease gun.

Fig. 215 Fig. 217

l Lubricate the bearings (Fig. 215) with three l Lubricate the labyrinth seal bearings (Fig. 217)
strokes from the grease gun. with three strokes from the grease gun.

BM 2000/60 BOMAG 121

Every 10 operating hours

122 BOMAG BM 2000/60

 Every 50 operating hours

Every 50 operating hou rs

5.16 Check the coolant level 5.17 Check the oil level in the
pump drive gear
! Danger
Danger of scalding! i Note
Fill up coolant only when the engine is cold. Check the oil level only in cold condition and with
the engine shut down.

! Caution
If, during the daily inspection the coolant level
is found to have dropped, check all lines, hos-
es and engine for leaks.

Fig. 219

l Unscrew the plug (Fig. 219).

Fig. 218
l Unscrew the radiator cap (Fig. 218) and check
the coolant level.
l Fill in coolant up to the MAX mark to refill.
l Check the oil level on the dipstick.
l The oil level must be near the "Max"-mark.
l Top up oil, if necessary.
For quality of oil refer to the table of fuels, lu-
bricants and filling capacities.

For quality of coolant refer to the chapter 5.2,

fuels and lubricants.

BM 2000/60 BOMAG 123

Every 50 operating hours

5.18 Retightening the track shoe 5.19 Lubricate the machine

fastening screws

Fig. 221

Fig. 220 l Lubricate the articulation cylinder edge protec-

l Retighten all fastening screws for the track tion (Fig. 221) on both sides with three strokes
shoes (Fig. 220). from the grease gun.

Fig. 222

l Lubricate the scraper plate (Fig. 222) on both

sides with three strokes from the grease gun.

124 BOMAG BM 2000/60

 Every 50 operating hours

Steering

Fig. 225

l Lubricate the pin (Fig. 225) with three strokes

Fig. 223
from the grease gun.
l Lubricate the tie rods (Fig. 223) with three
strokes from the grease gun. Posts

Fig. 224
Fig. 226
l Lubricate the steering cylinder bearings (Fig. l Lubricate the bushings (Fig. 226) with three
224) with three strokes from the grease gun. strokes from the grease gun.

BM 2000/60 BOMAG 125

Every 50 operating hours

Folding linkage for unloading convey-

or belt

Fig. 227

l Lubricate all grease nipples (Fig. 227) with

three strokes from the grease gun.

126 BOMAG BM 2000/60

 Every 250 operating hours

Cleaning with cold cleansing agent

Every 250 oper ating hours

5.20 Clean the cooling fins on

engine and hydraulic oil ! Caution
cooler Protect electrical equipment such as genera-
tor, regulator and starter against the direct wa-
ter jet.
Danger
!
l Spray the engine with a suitable cleansing
Danger of injury! agent, e.g. cold cleanser, let it soak in for a
Perform cleaning work only after the engine while and spray it off with a strong water jet.
has cooled down and with the engine stopped. l Run the engine warm for a while to avoid cor-
rosion.
Caution
!

Do not damage any cooling fins on the cooler

core when cleaning.

i Note
Dirt on fan blades and oil cooler reduce the cooling
effect. Dirt deposits in these areas are substantial-
ly supported by oil and fuel on these surfaces. For
this reason you should always seal any oil or fuel
leaks in the vicinity of the cooling fan or the oil
cooler and clean the cooling surfaces after.

Cleaning with compressed air

Fig. 228

i Note
Start to blow out from the exhaust side.
l Blow the cooler (Fig. 228) out with com-
pressed air.

BM 2000/60 BOMAG 127

Every 250 operating hours

l After wet cleaning run the engine warm to

5.21 Cleaning the engine evaporate all water residues and to avoid cor-
rosion.
l Reinstall the service covers.
Caution
!

After cleaning the coolers it is mandatory to

clean the engine.
Cover all parts of the electrical system, do not
subject to the direct water jet.
l Blow the engine dry with compressed air.
Flush lose dirt with a water jet out of the V-
shaped space between the cylinders.

Fig. 229

l Drain bores 1 (Fig. 229) and 2 (Fig. 230) must

be free, remove blockage if necessary.
l In case of oily contamination spray the engine
with cold cleansing agent and spray it off with
a water jet after s sufficient soaking time.

Fig. 230

l Drain bores 2 (Fig. 230) and 1 (Fig. 229) must

be free, remove blockage if necessary.

128 BOMAG BM 2000/60

 Every 250 operating hours

5.22 Changing engine oil and oil

filter cartridges

i Note
Drain the engine oil only when the engine is warm.
Preferably use oils of ACEA-classification E4-99 -
SAE 10W / 40. This enables utilization of the long-
est oil change intervals.

Oil change intervals (operating hours) for

ACEA quality
Fig. 232
E4-99 = 250 operating hours
l Thoroughly clean the outside of both filter car-
tridges (Fig. 232).
Danger
!
l Unscrew the filter cartridges using an appro-
Danger of scalding!
priate filter wrench.
Danger of scalding when draining off hot oil!
l Clean the sealing face on the filter carrier from
any dirt.
Environment l Slightly oil the rubber seal on the new filter car-
Environmental damage! tridges.
Do not let old oil seep into the ground, but dis-
pose off environmentally.

Fig. 233

l Turn the new filter cartridges (Fig. 233) on by

Fig. 231
l Open the bottom cover (Fig. 231).
l Unscrew the drain plug and catch running out
oil.
l Turn the drain plug tightly back in.
hand, until the seal contacts.
l Tighten the filter cartridges for another half
turn.

BM 2000/60 BOMAG 129

Every 250 operating hours

5.23 Checking, replacing the

generator V-belt

! Danger
Danger of injury!
Work on the generator V-belt must only be per-
formed with the engine shut down.

Check the V-belt

Fig. 234

l Fill in new engine oil (Fig. 234).

For quality and quantity of oil refer to the table

of fuels and lubricants.
l Tighten the oil filler cap properly.

! Caution
Before starting crank the engine with the start-
er motor until the oil pressure warning light
goes out.
l After a short test run check the oil level on the
dipstick, if necessary top up to the top dipstick Fig. 235
mark. l Inspect the entire circumference of the V-belt
l Check filter cartridge and drain plug for leaks (Fig. 235) visually for damage and cracks. Re-
after a short test run. place damaged or cracked V-belts.

l Shut the engine down and wait for about 15
minutes, so that all oil can flow back into the oil
sump.
l Check the oil level again, if necessary fill up to
the Max.-mark.
l Check with thumb pressure whether the V-belt
can be depressed more than 5 to 10 mm be-
tween the V-belt pulleys, retighten if neces-
sary.

130 BOMAG BM 2000/60

 Every 250 operating hours

Retighten the V-belt

Fig. 238

l Unscrew the fastening screw 2 (Fig. 238) for

Fig. 236
l Slacken the fastening screws 3 and 4 (Fig.
236) slightly.
l Loosen the counter nut (2).
l Turn down tensioning screw (1) in direction of
arrow, until the correct V-belt tension is
reached.
l Retighten hexagon screws and counter nut.
the spacer disc (1).
l Unscrew clamping screws (4).
l Push the flexible coupling (3) to the side.
l Take the old V-belt off the V-belt pulley.
l Fit the new V-belt to the V-belt pulleys.
l Tension the V-belt as previously described.
l Reassemble the coupling.

Changing the V-belt

i Note
Retighten new V-belts after a running time of 15
minutes.

Fig. 237

l Slacken the fastening screws 3 and 4 (Fig.

237) slightly.
l Loosen the counter nut (2).
l Turn tensioning screw (1) in direction of arrow
to the stop.

BM 2000/60 BOMAG 131

Every 250 operating hours

Changing the V-belt

5.24 Checking, replacing the
l Start the engine and raise the machine to high-
milling drum V-belt est position.
l Shut down the engine.
! Danger l Open the side flap and remove the cover
Danger of accident!
Perform this work only with the engine shut i Note
down! Before loosening the stop screw measure the
length and write it down.
Check the V-belt

Fig. 241

Fig. 239
l Check the entire circumference of the V-belts
(Fig. 239) for damage and cracks. Replace
damaged or cracked V-belts.
l Loosen the counter nut 1 (Fig. 241) and tight-
en the stop screw (2).
l Take the old V-belt off.
l Fit the new V-belt to the V-belt pulleys.
l Return the idler pulley to its original position
and tighten the counter nut.
l Reassemble the cover.

Fig. 240

l Check the V-belt pulley for signs of wear (Fig.

240).

new V-belt pulley A=14.24 mm

Worn V-belt pulley A=15.24 mm

132 BOMAG BM 2000/60

 Every 250 operating hours

Checking the track links

5.25 Checking the track drive

! Danger
Danger of accident!
Perform this work only with the engine shut
down!

Checking the track tension

! Caution
A wrong track tension causes higher wear.
Fig. 243

l Measure the height of the track links (Fig.

243).

new track link A=70 mm

Replace the track if A=68.2 mm

Checking bolts and bushings

i Note
The inner wear of bolts and bushings cannot be
Fig. 242
checked as long as the track remains assembled.
Wear is characterized by an extension of the track.
l Check the track tension, if necessary adjust on
the track tensioner (Fig. 242).
l In order to tension the track clean the fitting
(arrow) and press in grease with a grease gun.

Fig. 244

l Measure the length over the centers of five

track link bolts with a tape measure (Fig. 244).

new track B=560 mm

Replace the track if B=566 mm

BM 2000/60 BOMAG 133

Every 250 operating hours

l Take off the track and remove the track plates.

l Clean the track plates, check their condition
and fit them to the new track.

Checking the supporting rollers

i Note
For easier measuring you may choose one sup-
porting roller each at the beginninga and the end
of the track drive.

Fig. 245

l Measure the outer diamter of the bush (Fig.

245).

new bush C=37 mm

Replace the track if C=34.3 mm

Replacing the track

Caution
!

Replace also the track drive wheel. Fig. 247

l Move the machine until the connecting bolt l Check the diameter of both running surfaces
with the notch is in top position. (Fig. 247).

l Shut down the engine and pull out the ignition

new supporting roller D=135 mm
key.
l Relieve the track. Replace the supporting roller if D=132.5 mm

Checking the track wheels

Fig. 246

l Press the connecting bolt (Fig. 246) out with

an hydraulic press. Fig. 248

l Check the height of the running surface to the

guiding (Fig. 248).

134 BOMAG BM 2000/60

 Every 250 operating hours

new track wheel E=16 mm 5.26 Lubricate the machine

Replace the track wheel if E=18 mm
Loading conveyor belt
Checking the track drive wheel

! Caution
Always replace the track drive wheel when re-
placing the crawler track.

Fig. 250

l Grease the threaded spindle (Fig. 250).

Gathering belt

Fig. 249

l Check the wear on the teeth (Fig. 249).

i Note
Replace when the depth of the wearijng is close to
the hardening depth.

Nominal value:
F=4,2 mm hardening depth

Fig. 251

l Grease the threaded spindle (Fig. 251).

BM 2000/60 BOMAG 135

Every 250 operating hours

Milling drum drive clutch

Fig. 252

l Lubricate the bearings (Fig. 252) with max. 25

g of special grease from the grease gun.

Caution
!

Use a special lubrication grease.

See section "Table of fuels and lubricants".

Hoods and covering flaps

l Lubricate hoods, doors and flaps.

136 BOMAG BM 2000/60

 Every 1000 operating hours

Every 1000 operating hours

5.27 Check, adjust the valve

clearance

! Caution
We recommend to have this work carried out
by trained personnel or our after sales service.
Before checking the valve clearance let the en-
gine cool down for at least 30 minutes. The en-
gine oil temperature must be less than 80 C.

Fig. 253 Fig. 254

l Remove all valve covers (Fig. 253). Adjustment schematic (Fig. 254)

Overlapping of valves adjustment

A1 B3
B4 A3
A4 B2
B1 A2
B3 A1
A3 B4
B2 A4
A2 B1

l Turn the crankshaft until the valves are over-

lapping.

Caution
!

This engine is equipped with an internal ex-

haust recirculation system. During the exhaust
cycle the intake valve opens for a short mo-
ment.
This must not be mistaken as overlapping of
valves!

BM 2000/60 BOMAG 137

Every 1000 operating hours

Check the valve clearance

Fig. 256

l Assemble all cylinder head covers with new

Fig. 255
gaskets (Fig. 256), tightening torque: 22 Nm.
Intake valves: 0,25 mm
l After a short test run check the engine for
Exhaust valves: 0,30 mm leaks.
l A feeler gauge of appropriate thickness (1)
must fit with little resistance between rocker
arm (2) (Fig. 255) and valve (3).
l If the gap is too narrow or too wide for the feel-
er gauge, the valve must be adjusted.

Adjusting the valve clearance

l Loosen counter nut (4) (Fig. 255) for 2 to 3
turns.
l Adjust the setscrew (5) with a screwdriver, un-
til the feeler gauge can be inserted and pulled
out with little resistance after retightening the
counter nut.
l Repeat the adjustment procedure on each cyl-
inder.

138 BOMAG BM 2000/60

 Every 1000 operating hours

5.28 Change the fuel pre-filter

cartridge

! Danger
Fire hazard!
When working on the fuel system do not use
open fire, do not smoke and do not spill any fu-
el.
Catch running out fuel, do not let it seep into
the ground.
Fig. 258
Do not inhale any fuel fumes.
l Unscrew the water separator from the filter
cartridge (Fig. 258).

Fig. 257

l Pull off the cable and unscrew the fuel filter
cartridge (Fig. 257) using an appropriate filter
wrench.
l Clean the sealing face on the filter carrier from
any dirt.
Fig. 259
l Apply a thin coat of oil to the rubber seal of the
water separator 1 (Fig. 259).
l Screw the water separator on by hand (2), until
the seal contacts.
l Tighten the water separator for another half
turn (3).
l Fill the filter cartridge with clean diesel fuel (4).
l Apply some oil to the rubber seal of the filter el-
ement (5) and screw it on by hand, until the
seal contacts.
l Tighten the filter element for another half turn
(6).
l Plug the water sensor cable back on.
l Check the filter cartridge for leaks after a short
test run.

BM 2000/60 BOMAG 139

Every 1000 operating hours

i Note
5.29 Change the fuel filter car-
Air in the fuel system causes irregular running of
the engine, a drop in engine power, stalls the en- tridge
gine and makes starting impossible.
Therefore bleed the fuel system after changing the
! Danger
fuel pre-filter.
Fire hazard!

Environment Avoid open fire, do not smoke, do not spill any

fuel.
Catch running out fuel and dispose of environ-
mentally. Do not inhale any fuel fumes.

Environment
Catch running out fuel, do not let it seep into
the ground.
l Open the left hand engine compartment doors.

Fig. 260

l Slacken the bleeding screw (Fig. 260) on the

fuel pre-filter for 2 to 3 turns.
l Operate the hand pump manually, until fuel
flows out of the slackened bleeding screw (Fig.
260) without air bubbles.
l Then tighten the bleeding screw while pump-
ing.
Fig. 261
l Loosen both fuel filters (Fig. 261) using a suit-
able filter wrench and screw it off.
l Clean the sealing face on the filter carriers
from any dirt.

140 BOMAG BM 2000/60

 Every 1000 operating hours

5.30 Check fastening of engine /

turbocharger / combustion
air hoses

Fig. 262

l Slightly oil the rubber seal on the new filter car-

tridges (Fig. 262).
l Fill the filter cartridge with clean diesel fuel.
l Turn the new filter cartridge on by hand, until
the seal contacts. Fig. 264
l Then tighten hand-tight. l Check charge air line (Fig. 264) and intercool-
er for tight fit and leaks.
l Check exhaust pipe and lubrication oil line to
and from the exhaust turbo charger for tight fit
and leaks.
l Check connecting sockets for tight fit.
l Check combustion air pipe and connecting
sockets for leak tightness and tight fit.

Fig. 263

l If necessary bleed the fuel system with the

help of the hand pump on the pre-filter (Fig.
263).
l Check the filter cartridge for leaks after a short
test run.

BM 2000/60 BOMAG 141

Every 1000 operating hours

5.31 Checking the crankcase

pressure Nominal value

high idle speed: max. 20 mm water col-

umn
! Caution
full load: max. 50 mm water col-
Excessive pressure in the crankcase can
umn
cause lubrication oil leaks on all seals.
This may be caused by a not correctly func-
tioning crankcase ventilation.
! Caution
If the pressure exceeds the permissible crank-
Moreover, too high crankcase pressure can
case pressure you should perform trouble-
also cause damage to the exhaust turbocharg-
shooting and rectify the fault.
er and the complete engine.
l Pull out the oil dipstick .

Fig. 265

l Connect the U-pipe pressure gauge (1) (Fig.

264) to the oil dipstick opening using hose and
hose clamps.
l Make sure that the connection is tightly
sealed!
l Fill half of the U-pipe pressure gauge with wa-
ter.
l Fasten the U-pipe pressure gauge at a quiet
location (e.g. on the wall).
l Run the engine up to operating temperature.
l Run the engine at high idle or under full load.
l Read the pressure on the fine measurement or
U-pipe pressure gauge.

142 BOMAG BM 2000/60

 Every 1000 operating hours

5.32 Intercooler, draining oil and 5.33 Change the hydraulic oil
condensation water
i Note
Environment See also chapter 5.1 "Notes on the hydraulic sys-
tem".
Catch running out substances, do not let them
seep into the ground.
Caution
!

Apart from the normal oil change intervals, the

hydraulic oil must also be changed after major
repairs in the hydraulic system.
Perform the oil change when the hydraulic oil
is warm.
Clean the area round hydraulic oil tank, filler
opening and breather filter.
Do not use any detergents to clean the system.
Do not start the engine after draining the hy-
draulic oil.
Replace the hydraulic oil filter element with
Fig. 266 every hydraulic oil change.
l Unscrew the plug (Fig. 266) and let oil or con-
densation water flow out. ! Danger

l Turn the plug tightly back on. Danger of scalding!

Danger of scalding by hot oil.

Environment
Catch running out oil and dispose of environ-
mentally.

i Note
Generally replace the hydraulic oil filter element
after the test run.

BM 2000/60 BOMAG 143

Every 1000 operating hours

Fig. 267 Fig. 269

l Unscrew the drain hose (Fig. 267) and drain l Check the oil level in the inspection glass (Fig.
off all hydraulic oil. 269).
l Reassemble the drain hose. Nominal value:
approx. 3 cm below the upper edge of the inspec-
tion glass

For quality and quantity of oil refer to the table

of fuels and lubricants.
l Close the tank with the filler cap.

Fig. 268

l Remove the filler cap (Fig. 268).

l Fill in new hydraulic oil through the screen.

144 BOMAG BM 2000/60

 Every 1000 operating hours

High pressure filter for charge and

5.34 Changing the hydraulic oil conveyor belt circuit
filter

! Danger
Danger of scalding!
Danger of scalding by hot oil when unscrewing
the oil filter.

! Caution
If the filter has to be changed together with the
hydraulic oil, the filter must only be changed
after the oil change and after the test run.
Do not use the oil in the filter bowl again. Fig. 270

l Unscrew the filter housing (Fig. 270) and re-

Environment move filter bowl with filter element.
Catch running out oil, dispose of oil and filter l Examine the surface of the filter element thor-
element environmentally. oughly for any visible dirt.
l Assemble the filter bowl with new filter ele-
i Note ment, check the condition of the seal rings, if
Filter elements and filter cartridges must also be necessary use new ones.
changed after each hydraulic oil change and after l After a short test run check the filter for leaks.
major repairs in the hydraulic system.
Return flow filter
! Caution
Visible dirt may be an early sign for the failure
of system components and indicate the possi-
ble failure of components. In this case deter-
mine the cause and replace or repair the
defective components, if necessary. Negli-
gence may cause destruction to the entire hy-
draulic system.
Do not clean or reuse the filter element.

Fig. 271

l Loosen and unscrew the fuel filter cartridge

(Fig. 271) using an appropriate filter wrench.
l Slightly oil the rubber seal on the new filter car-
tridge.
l Turn the new filter cartridge on by hand, until
the seal contacts.

BM 2000/60 BOMAG 145

Every 1000 operating hours

l Tighten the filter element for another half turn.

5.35 Change the oil in the pump
l Check the filter cartridge for leaks after a short
test run. drive gear

Breather filter on hydraulic oil tank

i Note
Drain oil only at operating temperature.

Danger
!

Danger of scalding!
Danger of scalding when draining off hot oil!

Environment
Environmental damage!
Catch old oil and dispose of environmentally.
l Remove the bottom cover.
Fig. 272

l Loosen and unscrew the fuel filter cartridge

(Fig. 272) using an appropriate filter wrench.
l Turn the new filter cartridge on by hand, until
the seal contacts.
l Tighten the filter element for another half turn.

Fig. 273

l Unscrew the drain hose (Fig. 273) from the

socket.
l Drain off and catch old oil.
l Once all old oil has run out remove the oil drain
hose.

146 BOMAG BM 2000/60


Fig. 274
l Fill in new oil (Fig. 274).
For quality and quantity of oil refer to the table
of fuels, lubricants and filling capacities.
Fig. 275
l Check the oil level on the dipstick (Fig. 275), if
necessary correct the filling level.
BM 2000/60
Every 1000 operating hours
5.36 Change the oil in the milling
drum reduction gear
! Danger
Life hazard!
Shut down the engine and remove the ignition
key before accessing the milling drum.
Additionally attach a warning tag stating "Do
not start the engine!" to the dashboard.
Environment
Catch the oil and dispose of environmentally.
l Park the machine so that milling drum is in hor-
izontal position.
Fig. 276
l Turn the milling drum with the crank handle 2
(Fig. 276) until the drain plug (3) is in bottom
position.
l Clean and unscrew plug (3).
l Drain and catch all oil.
l Turn drain plug (3) in and tighten it.
l Fill in oil through the oil level control bore (1),
until it has reached the bottom edge of the
bore.
For quality of oil refer to the table of fuels, lu-
bricants and filling capacities.
BOMAG 147
Every 1000 operating hours

5.37 Oil change in milling drum

bearing

! Caution
Drain oil only at operating temperature.

Environment
Catch old oil and dispose of environmentally.
l Park the machine horizontally.
Fig. 278

l Fill in oil through the oil level control bore, until

it reaches the bottom edge of the bore. (Fig.
278).
l Screw the level control plug back in and tight-
en it.

For quality of oil refer to the table of fuels, lu-

bricants and filling capacities.

Fig. 277

l Clean and unscrew the drain and level control

plugs (Fig. 277).
l Drain and catch all oil.
l Screw the drain plug back in and tighten it.

148 BOMAG BM 2000/60

 Every 1000 operating hours

5.38 Oil change in track drive

gear

! Caution
Drain oil only at operating temperature.

Environment
Catch old oil and dispose of environmentally.
l Park the machine horizontally.
Fig. 280

l Fill in oil through the oil level control bore, until

it reaches the bottom edge of the bore. (Fig.
280).
l Screw the level control plug back in and tight-
en it.

For quality of oil refer to the table of fuels, lu-

bricants and filling capacities.

Fig. 279

l Move the machine, until the drain plug (Fig.

279) is in lowest position.
l Clean and unscrew the drain and level control
plugs.
l Drain and catch all oil.
l Screw the drain plug back in and tighten it.

BM 2000/60 BOMAG 149

Every 1000 operating hours

5.39 Drain the sludge from the 5.40 Battery maintenance

fuel tank
! Danger
! Danger Danger of cauterisation ! Danger of explosion!
Fire hazard! When working on the battery do not use open
fire, do not smoke!
When working on the fuel system do not use
open fire, do not smoke. The battery contains acid. Do not let acid come
in contact with skin or clothes!
Do not spill any fuel.
Wear protective clothing!
Do not inhale any fuel fumes.
Do not lay any tools on the battery!

Environment
Catch running out fuel, do not let it seep into Environment
the ground. Dispose of the old battery environmentally.

i Note
Maintenance free batteries also need care. Main-
tenance free only means that the fluid level does
not need to be checked. Each battery suffers un-
der self-discharge, which may, in not checked oc-
casionally, even cause damage to the battery as a
result of exhaustive discharge.

The following therefore applies for the service

Fig. 281
l Unscrew the drain hose (Fig. 281) and drain
off approx. 5 litres of fuel.
l Reassemble the drain hose.
life:
l Switch off all consumers (e.g. ignition, light).
l Check open-circuit voltage of the battery at
regular intervals. At least once per month.
Reference values: 12.6 V = fully charged; 12.3 V =
50% discharged.
l Recharge the battery immediately after an
open-circuit voltage of 12.25 V or less is
reached. Do not perform boost charging.
The open-circuit voltage of the battery occurs ap-
prox. 10 hours after the last charging process or
one hour after the last discharge.
l After each charging process allow the battery
to rest for one hour before taking it into service.
l For resting periods of more than one month
you should always disconnect the battery. Do
not forget to perform regular open-circuit volt-
age measurements.

150 BOMAG BM 2000/60

 Every 1000 operating hours

!Caution
Exhausted batteries (batteries with formation
of sulphate on the plates are not covered un-
der warranty!
l Open the battery flap at the rear of the ma-
chine.

Fig. 282

l Remove the batteries (Fig. 282) and clean the

battery compartment.
l Clean the outside of the battery.
l Clean battery poles and pole clamps and
grease them with pole grease (Vaseline).
l Check the fastening of the battery.
l On serviceable batteries check the acid level,
if necessary top up to the filling mark with dis-
tilled water.

Charging voltage recommendation

Fig. 283

BM 2000/60 BOMAG 151

Every 1000 operating hours

152 BOMAG BM 2000/60

 Every 2000 operating hours

For quality of coolant refer to the chapter 5.2,

Every 2000 operating hours

5.41 Changing the coolant fuels and lubricants.

l Start the diesel engine and run it warm to op-
erating temperature.
! Danger
l Let the engine cool down and check the cool-
Danger of scalding!
ant level again, top up if necessary.
Change the coolant only when the engine is
cold.

Environment
Catch running out coolant and dispose of envi-
ronmentally.

Fig. 284

l Unscrew the plug, open the drain tap (Fig.

284), let the coolant run out and catch it.
l Screw the plug back in and close the drain tap
once all coolant has run out.

Fig. 285

l Open the radiator cap (Fig. 285) and fill in cool-

ant.

BM 2000/60 BOMAG 153

Every 2000 operating hours

154 BOMAG BM 2000/60

 Every 4000 operating hours

Every 4000 operating hours

5.42 Changing the injection

valve

i Note
This work must only be performed by authorized
service personnel.

BM 2000/60 BOMAG 155

Every 4000 operating hours

156 BOMAG BM 2000/60

 Every 6000 operating hours

Every 6000 operating hours

5.43 Changing the coolant pump 5.44 Changing the pressure re-
taining valve on te injection
i Note pump
This work must only be performed by authorized
service personnel.
i Note
This work must only be performed by authorized
service personnel.

BM 2000/60 BOMAG 157

Every 6000 operating hours

5.45 Changing the crankcase

ventilation valve

i Note
This work must only be performed by authorized
service personnel.

158 BOMAG BM 2000/60

 Every 6000 operating hours

BM 2000/60 BOMAG 159

Every 6000 operating hours

160 BOMAG BM 2000/60

 As required

Removing the main filter element

As r equired

5.46 Service the combustion air

filter

! Caution
Perform cleaning, maintenance and repair
work only with the engine shut down. Do not
start the engine after removing the filter ele-
ment.

Fig. 287

l Open the service flap 1 (Fig. 287) in front of the

air filter.
l Unscrew the wing nut from the air filter lid and
remove the lid.

Fig. 286
Maintenance of the dry air filter is due when the
general fault warning light flashes and the mes-
sage "Service air filter" appears in the fault mes-
sage screen (Fig. 286).
However, the filter cartridge must be replaced at
the latest after two years.
After completion of the filter service reset the indi-
cator piston back to "Zero" by pressing the button.
l Open the engine hood completely and secure Fig. 288
it. l Pull the main filter element (Fig. 288) with light
turning movements.

Cleaning the main filter element

! Caution
If necessary, the main filter element may be
cleaned up to five times. It must be renewed at
the latest after a maximum utilization period of
two years.
The number of cleaning intervals of the main
filter element can be marked on the safety ele-
ment with a ball pen or a felt pen.

BM 2000/60 BOMAG 161

As required
Cleaning does not make sense if the main filter
element is covered with a sooty deposit. Use a
new filter cartridge.
Incorrectly handled inserts may be ineffective
because of damage (e.g. cracks) and cause
damage to the engine.
Replace the safety cartridge if the main filter el-
ement is defective!
Additional cleaning intervals between two fil-
ter services signalized by the fault monitoring
board are not necessary.
Fig. 289
l Blow the cartridge out with compressed air
(max. 5 bar) from inside to outside by moving
the tube up and down inside the cartridge, until
it if free of dust (Fig. 289).
Fig. 290
l Examine the filter cartridge with a torch for
cracks and holes in the paper bellows (Fig.
290).
162
Caution
!
Do not continue to run the machine with a
damaged main filter element. If in doubt use a
new main filter element.
Installing the main filter element
l Slide the main filter element carefully into the
housing.
When closing the housing cover the main filter el-
ement is automatically forced in the correct posi-
tion.
Changing the safety filter element
Caution
!
The safety filter element must not be cleaned
and should not be used again after it has been
removed.
Break the seal only to replace the safety filter
element.
The safety filter element must be replaced:
if the main filter element is defective,
after five service intervals of the filter car-
tridge,
at the latest after 2 years,
if the warning light comes on again after serv-
icing the main filter cartridge.
l Remove the housing cover and pull the main
filter element off.
Fig. 291
l Unscrew the wing nut and pull the safety ele-
ment (Fig. 291) out by turning it lightly.
BOMAG BM 2000/60
 As required

l Install the new safety cartridge and fasten it

with the wing nut. 5.47 Clean water tank and water
l Reassemble main filter element and cover. filter

Caution
!

Make sure that the cover locks engage correct-

ly.

Fig. 292

l Open the shut-off valve (Fig. 292) and let all

water run out.

Fig. 293

l Unscrew the lid from the water tank (Fig. 293).

l Flush the water tank out with a strong water
jet.
l Let all water with dirt run out, close the shut-off
valve again.

BM 2000/60 BOMAG 163

As required

5.48 Water spray system, main-

tenance in case of frost

! Caution
If there is a risk of frost the water spray system
must be completely emptied or filled with an
anti-freeze mixture (radiator protection agent).
In this case frost protection measures are of
greatest importance in order to avoid freezing
of sensitive components like pump, solenoid
Fig. 294 valve and water filter.
l Unscrew the filter bowl (Fig. 294).
Draining the water spray system
l Take out the screen insert.
l Clean filter bowl and screen insert.
l Check the seal ring, replace if necessary.
l Reassemble the filter bowl with the screen in-
sert.
l Fill the water tank with clean water.

Fig. 296

l Open the shut-off valve (Fig. 296) and let all

water run out.
l Close the drain tap .

Fig. 295

l Unscrew the caps (Fig. 295) from the spray

bars for milling drum and gathering belt.
l Unscrew all nozzles.
l Activate the sprinkler system for a short while
so that all lines are flushed out.
l Screw all nozzles back on.
l Screw the caps back on again.
l Tighten the end caps.

164 BOMAG BM 2000/60

 As required

5.49 Clean the pressure cleaner

water filter

Fig. 297

l Unscrew the water filter (Fig. 297) and pour

out the water.
l Reassemble the filter.
Fig. 299

l Close the shut-off valve 2 (Fig. 299).

l Unscrew the filter bowl (2).
l Take out the screen insert.
l Clean filter bowl and screen insert.
l Check the seal ring, replace if necessary.
l Reassemble the filter bowl with the screen in-
sert.

Fig. 298

l Open the drain taps (Fig. 298) and drain off all
water.
l Close the shut-off valves again

Filling the water spray system with

anti-freeze
l Fill approx. 10 litres of anti-freeze mixture into
the water tank.
l Switch the sprinkler system on, until anti-
freeze mixture comes running out of the sprin-
kler tubes.

Environment
After the frost period drain off the anti-freeze
mixture and dispose of environmentally.

BM 2000/60 BOMAG 165

As required

5.50 Tightening torques 5.51 Engine conservation

If the engine is to be shut down for a longer period
of time (e.g. over winter), please consult the serv-
ice department of the engine manufacturer for fur-
ther details.

Fig. 300
* Strength classes for screws with untreated, non-
lubricated surface. Screw quality designations are
stamped on the screw heads.
8.8 = 8G
10.9 = 10K
12.9 = 12K
The values result in a 90% utilization of the screw
yield point at a coefficient of friction total = 0,14.
When using lubricant MOS2 the specified tighten-
ing torques do not apply.

i Note
Self-locking nuts must always be replaced once
they have been unscrewed.

166 BOMAG BM 2000/60

 6 Trouble shooting

BM 2000/60 BOMAG 167

Trouble shooting

6.1 General notes

The following work must only be carried out by

qualified and trained personnel or by the sales
service.

Please observe strictly the safety regulations

in chapter 2 of these operating and mainte-
nance instructions.
Faults occur frequently due to the fact, that the
machine has not been properly operated or serv-
iced. Therefore, whenever a fault occurs, read
through these instructions on correct operation
and maintenance. If you cannot locate the cause
of the fault or eliminate it yourself by following the
trouble shooting charts, you should contact our
customer service departments at our branch office
or dealers.

! Danger

Danger of injury!
Keep away from rotating parts of the engine.

168 BOMAG BM 2000/60

 Trouble shooting

6.2 Engine

Faults Possible cause Remedy

The engine Starter defective or pinion not engaging Have examined by a specialist
does not start
Fuel tank empty Fill and bleed the tank

Temperature below starting limit Use winter fuel and engine oil acc. to the
ambient temperature.

Fuel filter clogged, in winter due to paraf- Change the filter. use winter fuel
fin separation.

Fuel lines leaking Check all line connections for leakages

and tighten the fittings.

Battery discharged or not connected Tighten the pole clamps, check the cable
connections

Injection valves or injection pump defec- Have examined by a specialist

tive

The engine Battery power too low, battery clamps Have the battery checked, clean the ter-
starts poorly and loose or oxidized, causing the starter to minal clamps, tighten them and cover
works irregularly turn too slowly them with acid free grease
with poor power
Especially during winter: the use of too Use engine oil suitable for the ambient
viscous engine oil temperature

Fuel supply restricted, in winter fuel sys- Change the fuel filter. Check the line con-
tem clogged due to paraffin separation nections for leaks and tighten the fittings.
Use winter fuel in the cold season.

Incorrect valve clearance Adjust the valve clearance

Injection valve defective Have examined by a specialist

Injection lines leaking Check the lines for leakages

Turbo charger defective Have examined by a specialist

Dry air filter dirty clean, replace if necessary

Excessive play in the throttle cable Adjust the throttle cable, change it if nec-
essary

BM 2000/60 BOMAG 169

Trouble shooting

Faults Possible cause Remedy

Excessive ex- Engine oil level too high Drain the oil to the upper dipstick mark
haust smoke
Dry air filter dirty clean, replace if necessary

Exhaust gas turbo-charger defective Have examined by a specialist

Poor compression due to burned or bro- Have compression rings and pistons ex-
ken compression rings or incorrect valve amined by a specialist, adjust the valve
clearance clearance

Incorrect valve clearance Adjust the valve clearance

Engine over- Cooling fins on radiator extremely soiled Clean the cooling fins
heats, shut (the warning light "engine oil temperature"
down immedi- lights)
ately!
Injection valve defective Have examined by a specialist

Engine oil level too low Top up engine oil to the upper dipstick
mark

Filling capacity of the injection pump not Have adjusted by a specialist

correctly adjusted

Cooling air flow restricted Clean the cooling air duct

V-belt loos or broken Tension or replace the V-belt

Poor engine Engine oil level too high Drain the engine oil down to the upper dip-
power stick mark

Dry air filter dirty clean, change if necessary

Exhaust gas turbo-charger defective Have examined by a specialist

Charge air hose leaking Check fastening and connections

Incorrect valve clearance Adjust the valve clearance

Injection valve defective Have examined by a specialist

Engine oil pres- Engine oil level too low (control light "en- Top up oil
sure too low gine oil pressure" lights, the warning
buzzer sounds)

Leakages in the lubrication system Shut the engine down immediately, check
fittings on oil lines, lubrication oil filter and
oil cooler for leaks, if necessary tighten
the fittings.

The charge con- Generator speed too low Check the V-belt tension, replace the V-
trol light lights belt if necessary
during opera-
tion, the warning The generator does not charge the bat- Have examined by a specialis
buzzer sounds tery, because generator or regulator is de-
fective

170 BOMAG BM 2000/60

 Trouble shooting

BM 2000/60 BOMAG 171

Trouble shooting

172 BOMAG BM 2000/60