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Maintenance instructions
Original operating instructions
BM 2000/60
S/N 821 836 26 ....> S/N 821 836 31 ....>
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 Strictly observe the safety regulations.
state-of-the-art production and testing meth- Please observe the guidelines of the Civil Engi-
ods, such as lifetime tests of all important neering Liability Association "Road Milling Equip-
components and highest quality demands ment" and the applicable accident prevention
guarantee maximum reliability of your ma- instructions.
chine.
For your own personal safety you should only
This manual comprises: use original spare parts from BOMAG.
l Safety regulations In the course of technical development we re-
l Operating instructions serve the right for technical modifications
without prior notification.
l Maintenance instructions
These operating and maintenance instructions are
l Trouble shooting 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.
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
6 BOMAG BM 2000/60
Table of Contents
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
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
! 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.
12 BOMAG BM 2000/60
2 Safety regulations
BM 2000/60 BOMAG 13
Safety regulations
14 BOMAG BM 2000/60
Safety regulations
BM 2000/60 BOMAG 15
Safety regulations
Max. towing speed 10 m/min (33 ftpm), max. tow- l steering, brakes, control elements, light sys-
ing distance 300 m (1640 ft). tem and warning horn work correctly
Before releasing the parking brake secure the ma- l the seat is correctly adjusted
chine against unintended moving.
l mirrors are clean and correctly adjusted.
Starting the machine Do not start the machine with defective gauges,
control lights or control elements.
Before starting work inform yourself about First Aid
equipment and rescue possibilities (medical emer- Starting
gency service, fire brigade). Start and operate the machine only from the driv-
Make sure that a correctly equipped first aid kit is ers station.
available. Before starting and moving the machine make
sure that no person
Before starting
l is under the machine
The machine must only be operated from the driv-
ers station. l is in the swinging range of the loading convey-
or belt
Use only machines which are serviced at regular
intervals. l or in the vicinity of track wheels or crawler
tracks.
Become acquainted with the equipment, the con-
trol elements, the working principle of the machine Always sound the warning horn before starting the
and the working area. machine
Use your personal protective outfit (hard hat, safe- Check the function of the emergency stop buttons.
ty boots, if necessary also goggles and ear de- The engine must stop. The machine must not be
fenders). operated with damaged, missing or non-functional
safety installations.
Make sure that the machine is equipped with the
appropriate illumination according to the require- For starting set all control levers to 'neutral posi-
ments of the application. tion'.
Check the condition and correct fit of safety ropes, Do not use any starting aids like start pilot or ether.
bolts, spring plugs and other safety elements. After starting check all gauges and control lights.
Do not take any loose objects with you or fasten Do not leave the machine with the engine running.
them to the machine.
Starting with jump wires
Before mounting the machine check whether:
Connect positive with positive and negative with
l persons or obstructions are beside or under negative (ground cable) always connect the
the machine ground strap last and disconnect it first! A wrong
l the machine is free of oily and combustible connection will cause severe damage in the elec-
material tric system.
l all grips, steps and platforms are free of obsta- Do not start the engine by shorting the electric ter-
cles, grease, oils, fuel, dirt, snow and ice minals on the starter motor, because the machine
may start to drive immediately.
l engine compartment door and all safety cov-
ers are closed and locked. Starting in closed rooms
Use steps and grips to mount the machine. Exhaust gases are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
Do not use control levers or hoses as hand grips
in closed rooms!
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 BOMAG BM 2000/60
Safety regulations
Driving the machine, milling operation Always keep a sufficient distance to excavation
walls and embankments and do not use working
Persons in the danger area methods that could impair the stability of the ma-
Before taking up work, also after breaks, you chine.
should always convince yourself that the danger Check the load bearing capacity before driving
zone is free of persons or obstructions, especially over bridges, cellar roof, vaults or similar.
when driving in reverse.
Leave the machine in case of thunderstorms. Dan-
Give warning signals, if necessary. Stop work im- ger of lightning.
mediately if persons remain in the danger zone,
despite the warning. Milling operation
Driving
Danger
!
In events of emergency and in case of danger ac-
tuate one of the emergency stop buttons immedi- Health hazard!
ately. Do not use the emergency stop switch as When milling road covering layers harmful
service brake. dusts may be released.
Restart the machine only after the danger that In order to avoid any damage to health the ma-
caused the actuation of the emergency stop switch chine operator and other persons, who have to
has been eliminated. work in the immediate vicinity of the milling
When displacing/transporting the machine: machine, should wear breathing masks (half
mask with exhalation valve or respirator) to re-
l Level the machine in transverse direction and
duce the dust particles, when a development
raise it completely
of dust is noticed.
l Align the loading belt straight ahead
Contaminated parts of the body should be
l Do not activate any work equipment thoroughly washed before breaks and at the
Always keep the machine horizontal when driving end of work. After work the dust covered work-
into or out of the milling track. ing clothes should be replaced by normal
Always keep a sufficient distance when passing clothes. Working clothes and respiratory
through subways, under bridges, tunnels, electric equipment should not be stored together with
power lines etc. normal clothes. Dust covered working clothes
must be cleaned at regular intervals.
If the machine has contacted high-voltage power
lines: Special caution is required when lowering the mill-
ing drum into the ground and during the subse-
l do not leave the operators stand quent work process:
l warn others from coming close to or touching l During careless starting of a new milling track
the machine the machine can suddenly make a sudden and
l if possible drive the machine out of the danger uncontrolled backwards move.
zone l There may be foreign objects (pipes, metal
parts or similar) in the milling range, which can
l have the power switched off
cause dangerous operating conditions.
Operate the machine only from the operators l Worn cutting tools can also cause dangerous
stand. operating conditions, worn cutting tools should
Do not climb onto or off the machine while the ma- therefore be replaced in due time.
chine is driving. Keep a safety distance of at least 2 metres when
Change the travel direction only at standstill. checking the milling depth.
Do not use the machine to transport persons. Make sure that no persons are in the danger area
In case of unusual noises and development of when operating the drum flap or the milling drum
smoke perform trouble shooting and have the fault drive.
corrected.
BM 2000/60 BOMAG 17
Safety regulations
Always chose the belt speed so that no milling ma- Parking the machine
terial is thrown out in an uncontrolled manner.
Empty the conveyor belt from all milled material.
Never reach into the running conveyor system for
Do not park the machine in front of stairs or lad-
the purpose of cleaning.
ders, water hydrants etc., if this would obstruct
Never swing the loading conveyor belt over per- their use.
sons or the truck cabin
Park the machine on horizontal, level, firm ground.
Inclination 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.
18 BOMAG BM 2000/60
Safety regulations
Support the engine hood for all maintenance and l the outer layer is brittle (formation of cracks in
repair work in the engine compartment. the hose material)
Maintenance work must only be performed by l the hose shows deformations in pressurized
qualified and authorized persons. and depressurized condition, which do not
For overhead maintenance and assembly work comply with the genuine shape of the hydrau-
use the access steps and working platforms pro- lic hose
vided or other secure means. Do not use machine l the hose shows deformations in bends, e.g.
parts as access steps. squeezing, buckling, layer separation, forma-
Keep unauthorized persons away from the ma- tion of blisters
chine. l parts of the hose are leaking.
Do not perform maintenance work while the ma- l hoses are not correctly installed.
chine is driving or the engine is running.
l the hydraulic hose has separated from the fit-
Park the machine on horizontal, level, firm ground.
ting
Pull the key out of the ignition switch.
l the fitting shows corrosion that impairs both
Secure the articulated joint with the articulation function and strength.
lock.
l hoses are mixed up by mistake.
Work on hydraulic lines l fittings are damaged or deformed, whereby
Relieve hydraulic pressures before working on hy- the function and strength of the hose/hose
draulic lines. Hydraulic oil escaping under pres- connection is impaired.
sure can penetrate the skin and cause severe Only genuine BOMAG replacement hydraulic hos-
injury. When being injured by hydraulic oil consult es ensure that the correct hose type (pressure
a medical doctor immediately, as otherwise this range) is used at the right location.
may cause severe infections.
Do not step in front of or behind the drums/wheels Working on the engine
when performing adjustment work in the hydraulic Shut the engine down before opening the engine
system. hood.
Do not change the setting of pressure relief valves. Do not work on the fuel system while the engine is
Drain the hydraulic oil at operating temperature running - danger to life due to high pressures!
danger of scalding! l Wait another minute after the engine has
Catch running out hydraulic oil and dispose of en- stopped.
vironmentally. l Keep out of the danger zone during the initial
Always catch and dispose of hydraulic oils sepa- test rung.
rately. l In case of leaks return to the workshop imme-
Do not start the engine after draining the hydraulic diately.
oil. l Make sure that the engine cannot be started
Once all work is completed (with the system still unintentionally during service and repair work.
depressurized!) check all connections and fittings
Drain the engine oil at operating temperature
for leaks.
danger of scalding!
Changing hydraulic hoses Wipe off spilled oil, catch running out oil and dis-
Hydraulic hoses must be visually inspected at reg- pose of environmentally.
ular intervals. Store used filters and other oil contaminated ma-
Hydraulic hoses must be immediately replaced if: terials in a separate, specially marked container
and dispose of environmentally.
l the outer layer is damaged down to the inlay
(e.g. chafing, cuts, cracks) Do not leave any tools or other objects, that could
cause damage, in the engine compartment.
BM 2000/60 BOMAG 19
Safety regulations
The settings for idle speed and highest speed Working on wheels and tires
must not be changed, since this would affect the Explosion-like bursting of tires or parts of tires and
exhaust gas values and cause damage to engine rims can cause most severe or even deadly inju-
and power train. ries.
Turbo chargers work with high speeds and high Assembly of tires must only be performed with ap-
temperatures. Keep hands, tools and materials propriate experience and tools. If necessary have
away from the intake and outlet openings of the tires assembled in a qualified workshop.
nturbo charger and do not touch any hot surfaces.
Always ensure the correct tire pressure and do not
Check and change coolant only when the engine exceed the specified maximum pressure.
is cold.
Check tires and wheels every day for specified
Catch coolant and dispose of environmentally. pressure, cuts, bulges, damaged rims, missing
Working on electric parts of the machine wheel studs or nuts. Do not drive with damaged
tires or wheels.
Before starting to work on electric parts of the ma-
chine disconnect the battery and cover it with insu- Ant-sticking emulsions for tires must only consist
lating material. of water and anti-sticking agent, in a concentration
in accordance with the specifications of the manu-
Do not use fuses with higher ampere ratings and facturer of the anti-sticking agent. Observe appli-
do not repair fuses with a piece of wire. Fire haz- cable environmental regulations.
ard!
Disconnect the battery before starting welding Cleaning work
work on the machine. Do not perform cleaning work while the engine is
running.
Working on the battery
Do not use gasoline or other easily inflammable
When working on the battery do not smoke, do not substances for cleaning.
use open fire!
When cleaning with steam cleaning equipment do
Do not let acid come in contact with hands or not subject electrical parts and insulation material
clothes! When injured by acid flush off with clear to the direct jet of water, or cover it beforehand.
water and seek medical advice.
l Do not guide the water jet into the exhaust and
Metal objects (e.g. tools, rings, watch straps) must into the air filter.
not come in contact with the battery poles dan-
ger of short circuit and burning! After maintenance work
When recharging serviceable batteries remove all After all maintenance work is completed reinstall
plugs, to avoid the accumulation of explosive gas- all guards and safety installations.
es.
Observe the applicable instructions when starting Repair
with an auxiliary battery.
Mark a defective machine by attaching a warning
Dispose of old batteries according to regulations. tag to the steering wheel.
Switch off the charging current before removing Repair work must only be performed by qualified
the charging clamps. and authorized persons. Use our repair instruc-
Ensure sufficient ventilation, especially if the bat- tions for this work.
tery is to be charged in a closed room. Exhaust gases are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
Working on the fuel system
in closed rooms!
Do not inhale any fuel fumes.
Do not work on the fuel system while the engine is
Avoid open fire, do not smoke, do not spill any fuel. running - danger to life!
Catch running out fuel, do not let it seep into the The system is under high pressure! Keep away
ground and dispose off environmentally. from leakages in the high pressure system, be-
cause fuel squirting out may cause severe injury.
20 BOMAG BM 2000/60
Safety regulations
After shutting down the engine wait for another Work on hydraulic lines
minute, until the pressure has dropped to a per- Relieve hydraulic pressures before working on hy-
missible level. In case of leakages you should con- draulic lines. Hydraulic oil escaping under pres-
tact the Service Department of the engine sure can penetrate the skin and cause severe
manufacturer and refrain from starting the engine. injury. When being injured by hydraulic oil consult
Test a medical doctor immediately, as otherwise this
may cause severe infections.
The safety of compaction equipment must be
checked by a specialist as required in dependence Do not step in front of or behind the tracks when
on the application and the operating conditions, performing adjustment work in the hydraulic sys-
however at least once every year. tem.
Do not change the setting of pressure relief valves.
Maintenance work Drain the hydraulic oil at operating temperature
Comply with the maintenance work described in danger of scalding!
the operating and maintenance instructions, in- Catch running out hydraulic oil and dispose of en-
cluding the information concerning the replace- vironmentally.
ment of parts. Always catch and dispose of hydraulic oils sepa-
Maintenance work must only be performed by rately.
qualified and authorized persons. Do not start the engine after draining the hydraulic
For overhead maintenance and assembly work oil.
use the access steps and working platforms pro- Once all work is completed (with the system still
vided or other secure means. Do not use machine depressurized!) check all connections and fittings
and control parts as access steps and handles. for leaks.
Keep unauthorized persons away from the ma-
chine. Changing hydraulic hoses
Do not perform maintenance work while the ma- Hydraulic hoses must be visually inspected at reg-
chine is driving or the engine is running. ular intervals.
Park the machine on horizontal, level, firm ground. Hydraulic hoses must be immediately replaced if:
Pull off the ignition key and attach a warning label. l the outer layer is damaged down to the inlay
(e.g. chafing, cuts, cracks)
Wear safety gloves when working on the hot en-
gine. l the outer layer is brittle (formation of cracks in
the hose material)
When removing the radiator cap hot coolant may
leak out, danger of scalding! l the hose shows deformations in pressurized
and depressurized condition, which do not
Anti-freeze agents can be toxic. Dispose of
comply with the genuine shape of the hydrau-
drained off coolant environmentally.
lic hose
Do not start the engine without engine oil or cool-
ant. l the hose shows deformations in bends, e.g.
squeezing, buckling, layer separation, forma-
Dispose of old oil, oil filter and filter elements envi- tion of blisters
ronmentally.
l parts of the hose are leaking.
Avoid sparks and open flames in the vicinity of bat-
teries. l hoses are not correctly installed.
Do not disconnect the batteries while the engine is l the hydraulic hose has separated from the fit-
running. ting
Do not reach with your hands into the running con- l the fitting shows corrosion that impairs both
veyor system. function and strength.
BM 2000/60 BOMAG 21
Safety regulations
l hoses are mixed up by mistake. Metal objects (e.g. tools, rings, watch straps) must
not come in contact with the battery poles dan-
l fittings are damaged or deformed, whereby
ger of short circuit and burning!
the function and strength of the hose/hose
connection is impaired. When recharging serviceable batteries remove all
plugs, to avoid the accumulation of explosive gas-
Only genuine BOMAG replacement hydraulic hos-
es.
es ensure that the correct hose type (pressure
range) is used at the right location. Observe the applicable instructions when starting
with an auxiliary battery.
Working on the engine
Dispose of old batteries according to regulations.
Shut the engine down before opening the engine
Switch off the charging current before removing
hood.
the charging clamps.
Do not work on the fuel system while the engine is
Ensure sufficient ventilation, especially if the bat-
running - danger to life due to high pressures!
tery is to be charged in a closed room.
l Wait another minute after the engine has
stopped. Working on the fuel system
l Keep out of the danger zone during the initial Do not inhale any fuel fumes.
test rung. Avoid open fire, do not smoke, do not spill any fuel.
l In case of leaks return to the workshop imme- Catch running out fuel, do not let it seep into the
diately. ground and dispose off environmentally.
l Make sure that the engine cannot be started Cleaning work
unintentionally during service and repair work.
Do not perform cleaning work while the engine is
Drain the engine oil at operating temperature running.
danger of scalding!
Do not use gasoline or other easily inflammable
Wipe off spilled oil, catch running out oil and dis- substances for cleaning.
pose of environmentally.
When cleaning with steam cleaning equipment do
Store used filters and other oil contaminated ma- not subject electrical parts and insulation material
terials in a separate, specially marked container to the direct jet of water, or cover it beforehand.
and dispose of environmentally.
l Do not guide the water jet into the exhaust and
Do not leave any tools or other objects, that could into the air filter.
cause damage, in the engine compartment.
Safety information for high pressure cleaning
Working on electric parts of the machine equipment
Before starting to work on electric parts of the ma- Check hoses and fittings for leaks before use.
chine disconnect the battery and cover it with insu-
Do not use damaged high pressure hoses.
lating material.
Use only hoses and connecting elements that
Do not use fuses with higher ampere ratings and
have been approved by the manufacturer.
do not repair fuses with a piece of wire. Fire haz-
ard! Use only properly serviced and safe working
equipment.
Disconnect the battery before starting welding
work on the machine. Do not draw in solvent containing fluids like petrol,
paint thinner, diesel or similar. The spray mist is
Working on the battery highly inflammable, explosive and health threaten-
When working on the battery do not smoke, do not ing.
use open fire! Always wear appropriate safety clothing.
Do not let acid come in contact with hands or Do not guide the water jet towards persons, ani-
clothes! When injured by acid flush off with clear mals, the high pressure cleaning unit or electrical
water and seek medical advice. components.
22 BOMAG BM 2000/60
Safety regulations
Jet wash vehicle tires and valves only with a mini- Information and safety stickers/decals
mum distance of 30 cm. Damaged vehicle tires on the machine
and valves can be extremely dangerous.
Keep stickers/decals complete (see spare parts
Do not clamp the gun lever during operation. catalogue) and fully legible and observe their
Asbestos containing and health impairing sub- meaning.
stances must not be jet washed. Replace damaged or illegible stickers/decals im-
Use only permitted cleansing agents. mediately.
Do not run the unit unattended.
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
26 BOMAG BM 2000/60
3 Indicators and Controls
BM 2000/60 BOMAG 27
Indicators and Controls
Fig. 23
28 BOMAG BM 2000/60
Indicators and Controls
1 Push button for warning horn 18 Rotary switch for grade shoes
2 Control lever, loader conveyor belt 19 Steering lever
3 Control lever, rear steering 20 Travel lever
4 Control lever, rear steering mode 21 Emergency stop push button
5 Control lever, height adjustment front left 22 General fault warning light and diagnostics
6 Control lever for height adjustment, front right button
7 Rotary button, total height adjustment 23 Multi-function display
8 Control lever, rear height adjustment 24 Rotary momentary contact switch for protec-
tive roof
9 Rotary switch for travel ranges
25 Rotary button, engine hood
10 Rotary switch for engine anti-stall control
26 Rotary switch for lighting
11 Rotary switch, differential lock
27 Rotary switch for flashing beacon
12 Rotary switch for conveyor belts
28 Ignition switch, engine
13 Rotary switch for water spray system
29 Rotary momentary contact switch for engine
14 Rotary switch for milling drum
speed
15 Rotary switch for gathering belt foot
30 Rotary switch to fold the loading belt
16 Rotary button for scraper
31 Potentiometer for conveyor belt speed
17 Rotary switch work on/off
32 Rotary switch for grade shoes
BM 2000/60 BOMAG 29
Indicators and Controls
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
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
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
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
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
! 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
40 BOMAG BM 2000/60
Indicators and Controls
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.
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
Fig. 62
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
* Optional equipment
BM 2000/60 BOMAG 45
Indicators and Controls
Fig. 63
46 BOMAG BM 2000/60
Indicators and Controls
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
Fig. 64
48 BOMAG BM 2000/60
Indicators and Controls
! 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
Fig. 65
50 BOMAG BM 2000/60
Indicators and Controls
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
Fig. 66
52 BOMAG BM 2000/60
Indicators and Controls
BM 2000/60 BOMAG 53
Indicators and Controls
54 BOMAG BM 2000/60
Indicators and Controls
BM 2000/60 BOMAG 55
Indicators and Controls
* Optional equipment
Fig. 67
56 BOMAG BM 2000/60
Indicators and Controls
Fig. 68
BM 2000/60 BOMAG 57
Indicators and Controls
58 BOMAG BM 2000/60
4 Operation
BM 2000/60 BOMAG 59
Operation
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
Fig. 69
Fig. 70
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
!
62 BOMAG BM 2000/60
Operation
4.4 Starting with jump wires 4.5 Shutting down the engine
! Caution ! Caution
When using external starting aid two external Do not shut the engine down all of a sudden
batteries (24 V system) are required, one for from full speed, but let it idle for a while for
each on-board battery. temperature equalization.
A wrong connection will cause severe damage
in the electric system.
Fig. 75
! Caution
If no powerful consumer is switched on volt-
Fig. 76
age peaks may occur when separating the con-
necting cables between the batteries, which l Turn the ignition switch (Fig. 76) to position "0"
could damage electrical components. and pull the ignition key out.
l After starting disconnect the negative poles
(ground cable) first and the positive poles af- ! Caution
ter. Secure the machine against unauthorized use,
l Switch off the consumer. 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
Fig. 79
64 BOMAG BM 2000/60
Operation
Fig. 82
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.
Fig. 83
Fig. 81
BM 2000/60 BOMAG 65
Operation
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
Switch off
l Shift the travel lever to "Neutral"
l Adjust the engine speed to "Idle speed"
Fig. 84
66 BOMAG BM 2000/60
Operation
i Note
The scraper can also be operated from the control
panel on the operator's stand.
Fig. 87
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
BM 2000/60 BOMAG 67
Operation
! Danger
Danger of injury!
Before switching on the conveyor belt make
sure that there are no persons in the loading
area.
! Caution
If the machine is to be moved in transport
Fig. 90 speed you should always lower the loading
conveyor belt and align it in middle position.
l Turn switch (Fig. 90) clockwise.
Only switch the conveyor belt on or off if there
The scraper shield moves up as long as the
is no material on the belt.
switch is operated.
The control lamp goes out.
The left and right warning lamps are flashing.
i Note
The conveyor belts can only be switched on when
the loading conveyor belt is fully extended.
Fig. 91
68 BOMAG BM 2000/60
Operation
Fig. 92 Fig. 94
l To switch off turn the momentary contact l Turn the selector switch (Fig. 94) to position
switch (Fig. 92) anti-clockwise, until the control "0" and hold it for approx. 3 seconds.
lamp goes out. The conveyor runs in reverse with low speed, until
the switch is released.
Setting the speed
Lifting / lowering the loading conveyor
belt
Fig. 93
BM 2000/60 BOMAG 69
Operation
Fig. 98
Fig. 97
70 BOMAG BM 2000/60
Operation
! 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
4.12 Preparing for work
! 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
l Press button a (Fig. 100) and shift the travel le- Health hazard!
ver to the desired travel direction. When milling road covering layers harmful
dusts may be released.
i Note In order to avoid any damage to health the ma-
The further the travel lever is shifted forward or chine operator and other persons, who have to
back, the faster the machine will drive. work in the immediate vicinity of the milling
machine, should wear breathing masks (half
When the travel lever is released, it will return to
mask with exhalation valve or respirator) to re-
middle position, however, the machine will drive
duce the dust particles, when a development
on with the selected speed.
of dust is noticed.
To reduce the travel speed shift the travel lever to
Contaminated parts of the body should be
the opposite direction.
thoroughly washed before breaks and at the
To stop the machine operate the travel lever to the end of work. After work the dust covered work-
opposite direction against the stop. The machine ing clothes should be replaced by normal
will decelerate down to standstill and the parking clothes. Working clothes and respiratory
brake will be applied. 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.
72 BOMAG BM 2000/60
Operation
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
!
Fig. 104
! 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
Fig. 105
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
Fig. 106
! Danger
Danger of injury!
74 BOMAG BM 2000/60
Operation
Fig. 111
Fig. 110
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
Danger
!
Danger of accident!
Fig. 113
If the rotor is lowered too quickly into hard
l Open the water pump drain cock (Fig. 113).
ground, the crawler tracks may loose ground
l Adjust the water quantity as necessary. contact. The machine will thereby move back-
wards.
Switching on the flashing beacon Switch the milling drum off immediately or op-
erate the emergency stop switch.
Caution
!
Fig. 114
76 BOMAG BM 2000/60
Operation
Fig. 116
!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.
Fig. 117
BM 2000/60 BOMAG 77
Operation
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
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
78 BOMAG BM 2000/60
Operation
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
! 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
! Caution
i Note
Shut down the machine before replacing the
The above operations can also be performed us- sensors of one side from wire sensor to slope
ing the switch "Stopping work" (see section 4.18). 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.
80 BOMAG BM 2000/60
Operation
Fig. 126
l Lower the machine evenly at front and rear, l Use button 23 to select "DEPTH" mode for the
until the cutting tools touch the road surface. left hand side.
l Press button (21/22) to adjust the desired cut-
ting depth.
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. 127
Fig. 129
BM 2000/60 BOMAG 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
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
Operation
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-
Fig. 132 trasound measurements the three closest to the
original adjustment are used to form a mean value.
l With the ignition switched off press buttons 11, Inaccuracies or obstructions can thus be directly
21 and 22 (Fig. 132) at the same time. excluded from the calculation of the mean value.
l Switch the ignition back on with the buttons When scanning the rope the sensor always uses
pressed (second person required). the oscillation with the shortest distance to the
rope for the purpose of measurement.
A page with five symbols (A, B, C, D and X) is dis-
played. The side with the sensor installed is height regulat-
l Release the buttons and select the desired ed by the ultrasonic sensor. The opposite side can
setting "A" or "B" under the symbol. 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
BM 2000/60 BOMAG 83
Operation
l On "Manual" mode press button 2 (Fig. 133), l To switch over press both buttons 3 and 4 (Fig.
until the display shows "0". 135) together.
l Press button (1) A/M, until the control lamp If the symbol (b) lights up, the rope scanning mode
AUTO (a) lights up. is activated.
l If the milling depth is to be changed press but-
tons (3) or (4).
Fig. 134
84 BOMAG BM 2000/60
Operation
Fig. 136
Fig. 137
BM 2000/60 BOMAG 85
Operation
Fig. 141
Fig. 140
86 BOMAG BM 2000/60
Operation
i Note
The protection roof can be folded down with the
help of an auxiliary hydraulic pump for transport.
Fig. 145
Fig. 143
Fig. 146
!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
! 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
Operation
Fig. 150
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 BOMAG 89
Operation
Fig. 153
Fig. 151
Fig. 154
Fig. 152
90 BOMAG BM 2000/60
Operation
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
Fig. 159
Fig. 161
92 BOMAG BM 2000/60
Operation
! 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.
BM 2000/60 BOMAG 93
Operation
l Swing the lock for conveyor belt 1 (Fig. 164) l If necessary open the bypass valve f (Fig. 166)
out of the bracket and fasten it to the eye in the for the loader conveyor cylinders.
cross strut. Secure the bolt (2) with the cotter By opening the bypass valve the loader conveyor
pin (3). 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
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
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
Settings
Setting brightness, contrast
Fig. 171
Fig. 172
96 BOMAG BM 2000/60
Operation
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.
BM 2000/60 BOMAG 97
Operation
98 BOMAG BM 2000/60
5 Maintenance
BM 2000/60 BOMAG 99
Maintenance
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.
ticular in connection with low ambient tempera- Do not mix different coolants and additives of
tures. any other kind.
The following fuel specifications are permitted:
l DIN/EN 590 Environment
Cooling system protection agents must be dis-
l BS 2869: A1 and A2
posed of environmentally.
l ASTM D 975-88: 1-D and 2-D.
l Nato Codes: F-54, F-75; Hydraulic oil
Winter fuel 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
! Danger only high-quality hydraulic oil, type HVLP accord-
Fire hazard! ing to DIN 51524, part 3, or hydraulic oils type HV
according to ISO 6743/3. The viscosity index (VI)
Diesel fuels must never be mixed with gaso- should be at least 150 (observe information of
line. manufacturer).
For winter operation use only winter diesel fuel, to
avoid clogging because of paraffin separation. At
! 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.
! Caution
These two lubricants are not suitable for mix-
ing!
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).
Engine Engine oil SAE 10 W-40 ACEA: E4-99/E6-04 or approx. 47 litres incl. oil fil-
ter
Fuel
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 3 25 g every 250 operating
Clutch, milling drive BOMAG part-no.: 00996009 hours
! 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.
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
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
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
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.
Fig. 176
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
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
Fig. 180
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.
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.
! Caution
Do not run the water pump without water.
Fig. 183
Fig. 182
l Swing the scraper plate completely open, until l Fold out the seat (Fig. 186).
the safety hooks (Fig. 184) click into place.
The warning lamps on both sides are flashing. Preparations with electro-hydraulic
drive*
l Raise the machine completely.
Fig. 185
* Optional equipment
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
Fig. 189
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.
! 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
Fig. 201
If the tool holder is in such a condition (Fig. 201) it
must be replaced immediately.
Fig. 199
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.
Fig. 203
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
Fig. 207
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.
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.
Fig. 208
Fig. 211
Fig. 213
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.
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.
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
Fig. 221
Fig. 222
Steering
Fig. 225
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.
Fig. 227
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.
Fig. 228
i Note
Start to blow out from the exhaust side.
l Blow the cooler (Fig. 228) out with com-
pressed air.
Fig. 229
Fig. 230
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.
Fig. 233
! Danger
Danger of injury!
Work on the generator V-belt must only be per-
formed with the engine shut down.
! 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 l Check with thumb pressure whether the V-belt
minutes, so that all oil can flow back into the oil can be depressed more than 5 to 10 mm be-
sump. tween the V-belt pulleys, retighten if neces-
sary.
l Check the oil level again, if necessary fill up to
the Max.-mark.
Fig. 238
Fig. 237
Fig. 241
Fig. 239 l Loosen the counter nut 1 (Fig. 241) and tight-
en the stop screw (2).
l Check the entire circumference of the V-belts
(Fig. 239) for damage and cracks. Replace l Take the old V-belt off.
damaged or cracked V-belts. 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
! Danger
Danger of accident!
Perform this work only with the engine shut
down!
! Caution
A wrong track tension causes higher wear.
Fig. 243
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
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
Caution
!
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).
Fig. 246
! Caution
Always replace the track drive wheel when re-
placing the crawler track.
Fig. 250
Gathering belt
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
Fig. 252
Caution
!
! 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.
l Remove all valve covers (Fig. 253). Adjustment schematic (Fig. 254)
Caution
!
Fig. 256
! 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 Fig. 259
cartridge (Fig. 257) using an appropriate filter
wrench. l Apply a thin coat of oil to the rubber seal of the
water separator 1 (Fig. 259).
l Clean the sealing face on the filter carrier from
any dirt. 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.
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
Catch running out fuel, do not let it seep into
the ground.
l Open the left hand engine compartment doors.
Fig. 260
Fig. 262
Fig. 263
Fig. 265
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
!
Environment
Catch running out oil and dispose of environ-
mentally.
i Note
Generally replace the hydraulic oil filter element
after the test run.
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
Fig. 268
! 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
Fig. 271
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
Fig. 273
! 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.
Fig. 274
Environment
l Fill in new oil (Fig. 274).
Catch the oil and dispose of environmentally.
For quality and quantity of oil refer to the table
l Park the machine so that milling drum is in hor-
of fuels, lubricants and filling capacities.
izontal position.
Fig. 275
Fig. 276
l Check the oil level on the dipstick (Fig. 275), if
necessary correct the filling level. 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.
! Caution
Drain oil only at operating temperature.
Environment
Catch old oil and dispose of environmentally.
l Park the machine horizontally.
Fig. 278
Fig. 277
! Caution
Drain oil only at operating temperature.
Environment
Catch old oil and dispose of environmentally.
l Park the machine horizontally.
Fig. 280
Fig. 279
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.
!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
Fig. 283
Environment
Catch running out coolant and dispose of envi-
ronmentally.
Fig. 284
Fig. 285
i Note
This work must only be performed by authorized
service personnel.
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.
i Note
This work must only be performed by authorized
service personnel.
! 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
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.
! 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.
Caution
!
Fig. 290
Caution
!
Fig. 292
Fig. 293
! 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
Fig. 295
Fig. 297
Fig. 298
l Open the drain taps (Fig. 298) and drain off all
water.
l Close the shut-off valves again
Environment
After the frost period drain off the anti-freeze
mixture and dispose of environmentally.
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.
! Danger
Danger of injury!
Keep away from rotating parts of the engine.
6.2 Engine
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.
Battery discharged or not connected Tighten the pole clamps, check the cable
connections
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.
Excessive play in the throttle cable Adjust the throttle cable, change it if nec-
essary
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
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
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
Poor engine Engine oil level too high Drain the engine oil down to the upper dip-
power stick mark
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