Description
Workshop coverage for the BM 2000/60-2 cold planer
The BOMAG BM 2000/60-2 Cold Planer Service Manual 00891769 2019 is written for BOMAG customer service and professionally trained personnel who repair this cold planer in the workshop. It supports deinstallation, dismantling, assembly, installation, and component repair where tools and spare-parts supply make that work practical. The title page identifies the machine as a cold planer, prints document number 008 917 69 with the 03/2019 date, and lists serial ranges S/N 861 884 12 1001> and S/N 821 836 26 1001>. Intended use in the safety chapter is milling of asphalt or concrete road surfaces inside cordoned-off construction sites.
File Details
- Manual type: Service Manual
- Brand / model: BOMAG BM 2000/60-2 cold planer
- Language: English
- Page count: 794
- File format: PDF
- Document number: 008 917 69
- Date: 03/2019
- Serial ranges on cover: S/N 861 884 12 1001> / S/N 821 836 26 1001>
Machine identity and published data
Technical data in this copy of the BOMAG BM 2000/60-2 Cold Planer Service Manual 00891769 2019 places the planer on a chain-type track drive and gives a milling width of 2000 mm (79 in), milling depth of 0–320 mm (0–12.6 in), milling line distance of 15 mm (0.6 in), cutting diameter of 1070 mm (42 in), 168 cutting tools, and drum rated speed of 108 min-1. Published weights are a maximum operating weight of 32500 kg (71650 lbs), operating weight (CECE) of 30300 kg (66800 lbs), and basic weight of 28100 kg (61950 lbs). Travel speed is 0–5 km/h (0–3 mph), working speed 0–40 m/min (0–131 ft/min), and maximum gradeability depending on soil is 18° / 32%.
The drive chapter specifies a fluid-cooled Deutz TCD 2015 V08 eight-cylinder engine rated 440 kW (600 hp) ISO 3046 at 1900 min-1. Later engine text describes a water-cooled V8 with cylinder banks at 90°, four-valve heads, turbocharger and intercooler, solenoid-valve electronic injection (MVS), internal exhaust-gas recirculation, and emission compliance stated as EPA/COM/Tier/stage III. Electrical system voltage is 24 V. Filling capacities listed include 1200 l (317 gal US) diesel, 3500 l (925 gal US) water, 45 l engine oil, 100 l coolant, and 230 l hydraulic oil HVLP 46.
Chapters Covered
- 1 General — Introduction; Concerning your safety; Signage; Maintenance and repair; Notes on repair; Preliminary remarks and safety notes; Preparations/concluding work
- 2 Technical data — Terms and basis of calculation; Fuels and lubricants (engine oil, fuel, coolant, hydraulic oil, gear oils, greases); List of fuels and lubricants
- 3 Overview of machine — Component overview electrics; Component overview hydraulics; Machine assemblies (engine, conveyor system, steering, radiator module, milling unit, milling drum, water system)
- 4 Electric systems — Basic principles (Deutsch DT/DTM connectors, clip-on technology, magnetic coil plug, Telemecanique switch); Operating consoles; Central electrics; Installation locations; Description of electrical components; Generator and generator repair; Electric starter and starter repair; Wiring looms; CAN BUS overview; Display (control elements, indicators, information/warnings/error messages); Service settings (hydraulics screen, engine screen, fault messages, advanced functions, configuration parameters, Check Input Output, machine states, CAN BUS settings); Fuse assignment; Starting the engine with jump leads; List of equipment; Inspection and maintenance work
- 5 Hydraulic system — Open and closed circuits; Swash plate principle for motor and pump; Hydraulic component and pump positions; Hoses; Description of hydraulic components (cylinders, travel motor, travel pump, working pump, fan motor A2FM32, conveyor belt pump, 4/3 way valve, pressure limiting valve, flow divider, main valve block, fan block, valve block for auxiliary control); Tests and adjustments including travel-pump check and adjustment; Inspection and maintenance work
- 6 Machine assemblies — Diesel engine; Conveyor system; Track chain drive and steering; Radiator module; Milling unit; Milling drum; Water system
- 7 Troubleshooting — Diesel engine (jump starting, engine malfunctions, Deutz DTC fault code list EMR3); Hydraulics (component table, axial piston motors and pumps, insufficient hydraulic power)
- 8 Special tools — Special tools, Deutz engine (TCD 2015)
- 9 Index
- Appendix A Circuit diagram
- Appendix B Hydraulic diagram
Taken together, those chapters give a technician a single path from safety and fluids through electrical and hydraulic architecture into the physical assemblies that cut, convey, steer, and cool the machine, then into fault-code and hydraulic-power diagnosis and the engine special-tool list. Circuit and hydraulic diagrams sit in the appendix rather than as standalone shop books.
Electrical service content
Chapter 4 of the BOMAG BM 2000/60-2 Cold Planer Service Manual 00891769 2019 starts with connector practice: Deutsch DT and DTM series, clip-on technology, magnetic coil plugs, and Telemecanique switches. It then maps operating consoles, central electrics, and installation locations before describing individual components. Generator and starter sections include repair sequences, not only identification. Wiring-loom and CAN BUS overviews sit ahead of the display chapter, which covers control elements, indicators, and information, warning, and error messages.
Service settings walk through starting the display, calling the hydraulics and engine screens, reading fault messages, opening advanced functions, working with configuration parameters, running Check Input Output, reviewing machine states, and adjusting CAN BUS settings. Fuse assignment covers safety notes, central electrics, and main fuses. Jump-lead starting is documented with polarity rules. A long equipment list tags operating devices by function, and electrical inspection work is scheduled at 250 and 1000 operating hours.
Hydraulic service content
The hydraulic chapter explains open versus closed circuits and the swash-plate principle on both motor and pump before locating components and pumps on the machine. Hose information is followed by component descriptions for hydraulic cylinders, the Bosch Rexroth A4VG travel pump and A6VE travel motor, the A10VO working pump, fan motor A2FM32, conveyor belt pump, 4/3 way valve, pressure limiting valve, flow divider, main valve block, fan block, and the auxiliary-control valve block. Published pump and motor figures include travel-pump high-pressure limitation of 380 bar and low-pressure limitation of 25 bar, conveyor-belt pump high-pressure limitation of 260 bar, and working-pump high-pressure limitation of 315 bar. Tests and adjustments include special tools plus checking and adjusting the travel pump. Hydraulic maintenance tables cover 10-hour and 1000-hour work.
Engine, milling drum, tracks, and water
Machine-assembly chapters treat the Deutz TCD 2015 diesel as a serviceable unit, then move to the conveyor (loading belt 800 × 2400 mm, discharge belt 800 × 7600 mm), track-chain drive and steering with repair and inspection, the radiator module, the milling unit (milling box, door, side plates, hold-down, scrapers), the milling drum with repair and inspection, and the water spraying system. Track-chain dimensions are given as 1700 × 300 × 640 mm. Travel gear data names a Bonfiglioli 705 C 3 H unit with reduction ratio 1:80, nominal torque 6000 Nm, brake torque 180–220 Nm, and minimum brake release pressure 15 bar.
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “BOMAG BM 2000/60-2 Cold Planer Service Manual 00891769 2019” are as follows:
Table of contentsp. 3
+1 Generalp. 7
1.1 Introductionp. 8
+1.2 Concerning your safetyp. 10
+1.3 Maintenance and repairp. 33
+1.3.1 Notes on repairp. 33
+1.3.1.1 General repair instructionsp. 33
1.3.1.1.1 Repair notes for electricsp. 33
1.3.1.1.2 Repair notes for hydraulicsp. 35
1.3.1.1.3 Repair notes for gaskets and mating surfacesp. 36
1.3.1.1.4 Repair notes for ball and roller bearingsp. 38
1.3.1.1.5 Feather keys and keywaysp. 38
1.3.1.1.6 Repair notes for cotter pinsp. 39
1.3.1.1.7 Repair notes for screws and nutsp. 39
1.3.1.1.8 Strength classes, metric screws and nutsp. 39
1.3.1.1.9 Identification of UNF-threadsp. 41
1.3.1.2 Tightening torquesp. 41
1.3.2 Preliminary remarks and safety notesp. 47
1.3.3 Preparations/concluding workp. 48
+2 Technical datap. 49
2.1 Terms and basis of calculationp. 54
+2.2 Fuels and lubricantsp. 56
+2.2.1 Engine oilp. 56
2.2.1.1 Oil qualityp. 56
2.2.1.2 Oil viscosityp. 57
2.2.1.3 Oil change intervalsp. 57
+2.2.2 Fuelp. 57
2.2.2.1 Fuel qualityp. 57
2.2.2.2 Winter fuelp. 58
2.2.2.3 Storagep. 58
+2.2.3 Coolantp. 58
2.2.3.1 Generalp. 58
2.2.3.2 Water qualityp. 59
2.2.3.3 Cooling system protection agentp. 59
+2.2.4 Hydraulic oilp. 61
2.2.4.1 Mineral oil based hydraulic oilp. 61
2.2.4.2 Bio-degradable hydraulic oilp. 61
2.2.5 Gear oil ISO VG 220p. 61
2.2.6 Gear oil SAE 75W-90p. 62
2.2.7 Lubrication greasep. 62
2.2.8 High-temperature lubrication greasep. 62
2.3 List of fuels and lubricantsp. 63
+3 Overview of machinep. 65
3.1 Component overview – Electricsp. 67
3.2 Component overview – hydraulicsp. 68
+3.3 Component overview – machine assembliesp. 69
3.3.1 Enginep. 69
3.3.2 Conveyor systemp. 70
3.3.3 Steeringp. 71
3.3.4 Radiator modulep. 72
3.3.5 Milling unitp. 73
3.3.6 Milling drump. 74
3.3.7 Water systemp. 75
+4 Electric systemsp. 77
+4.1 Basic principlesp. 79
4.1.1 Deutsch connectors, DT and DTM seriesp. 79
4.1.2 Clip-on technologyp. 83
4.1.3 Magnetic coil plugp. 86
4.1.4 Telemecanique switchp. 88
4.2 Operating consolesp. 91
4.3 Central electricsp. 100
4.4 Installation locations of electrical componentsp. 103
+4.5 Description of electrical componentsp. 110
4.5.1 Generatorp. 147
4.5.2 Generator repairp. 152
4.5.3 Electric starterp. 155
4.5.4 Repair of starterp. 161
4.6 Wiring loomsp. 166
4.7 CAN BUS overviewp. 176
+4.8 Displayp. 178
4.8.1 Control elementsp. 178
4.8.2 Display indicatorsp. 179
4.8.3 Information, warnings and error messagesp. 182
+4.9 Service settingsp. 184
4.9.1 Starting up the displayp. 184
4.9.2 Calling up the hydraulics screenp. 185
4.9.3 Calling up the engine screenp. 186
4.9.4 Fault messagesp. 187
4.9.5 Access to advanced functionsp. 188
+4.9.6 Configuration parametersp. 190
4.9.6.1 Access to advanced functionsp. 190
4.9.6.2 Special configurationsp. 192
4.9.6.3 Advanced settings – fan drivep. 194
4.9.6.4 Advanced settings – milling drump. 198
+4.9.6.5 Advanced settings – steeringp. 200
4.9.6.5.1 Calibrating the steering leverp. 200
4.9.6.5.2 Calibrating the steering cylinderp. 202
4.9.6.5.3 Calibrating the potentiometer for steering rear axlep. 205
4.9.6.5.4 Calibrating steering straight aheadp. 208
4.9.6.5.5 Calibrating the front steering stopp. 212
4.9.6.5.6 Calibrating synchronisation front and rearp. 215
4.9.6.5.7 Currents of handling drive solenoid valvep. 217
+4.9.6.6 Advanced settings – conveyor beltp. 219
4.9.6.6.1 Teaching the potentiometer for conveyor belt speedp. 219
4.9.6.6.2 Defining the conveyor belt pump currentsp. 221
+4.9.6.7 Advanced settings – travel systemp. 223
4.9.6.7.1 Calibrating the travel leverp. 223
4.9.6.7.2 Setting Softgearp. 225
4.9.6.7.3 Reading out the Engine Load Managerp. 227
4.9.6.7.4 Defining start rampsp. 229
4.9.6.7.5 Defining the travel pump currentsp. 234
4.9.6.7.6 Defining the travel motor currentsp. 236
+4.9.6.8 Advanced settings – breakp. 238
4.9.6.8.1 Displaying and changing the time for a work breakp. 238
4.9.6.8.2 Displaying and changing the time for resumption of workp. 240
+4.9.6.9 Advanced settings – levellingp. 243
4.9.6.9.1 Levelling using wire rope sensorsp. 243
4.9.6.9.2 Levelling using a cross-slope sensorp. 245
4.9.6.9.3 Lifting column traversing speedp. 248
4.9.6.9.4 Calibration of wire rope and cross-slope sensorsp. 251
4.9.6.9.5 Currents of lifting column solenoid valvep. 253
+4.9.6.10 Advanced settings – scraperp. 257
4.9.6.10.1 Defining scraper pressuresp. 257
+4.9.7 Check Input Outputp. 261
4.9.7.1 CR2012 – inputs and outputs of ID nodesp. 269
4.9.7.2 CR2031 – inputs and outputs of ID nodesp. 281
4.9.7.3 CR0505 – inputs and outputsp. 283
4.9.8 Machine statesp. 284
4.9.9 CAN BUS settingsp. 289
+4.10 Fuse assignmentp. 294
4.10.1 Notes on safetyp. 294
4.10.2 Central electricsp. 294
4.10.3 Main fusesp. 297
4.11 Starting the engine with jump leadsp. 298
4.12 List of equipmentp. 299
+4.13 Inspection and maintenance workp. 311
4.13.1 Maintenance Tablep. 311
+4.13.2 Every 250 operating hoursp. 311
4.13.2.1 Checking, replacing the generator V-beltp. 311
+4.13.3 Every 1000 operating hoursp. 313
4.13.3.1 Battery maintenancep. 313
+5 Hydraulic systemp. 315
+5.1 Basic principlesp. 317
5.1.1 Open and closed hydraulic circuitp. 317
5.1.2 Swash plate principle, motorp. 319
5.1.3 Swash plate principle, pumpp. 320
5.2 Hydraulic components positionp. 322
5.3 Position of hydraulic pumpsp. 327
5.4 Hosesp. 328
+5.5 Description of hydraulic componentsp. 349
+5.5.1 Hydraulic cylinderp. 349
5.5.1.1 Repairing hydraulic cylindersp. 349
+5.5.2 Travel motorp. 353
5.5.2.1 Operating principlep. 353
5.5.3 Travel pumpp. 356
+5.5.4 Working pumpp. 363
5.5.4.1 Axial piston pumps, A10VO/VSO 18 to 100 DF1p. 363
5.5.5 Fan motor A2FM32p. 369
5.5.6 Conveyor belt pumpp. 371
5.5.7 4/3 way valvep. 378
5.5.8 Pressure limiting valvep. 379
5.5.9 Flow dividerp. 380
5.5.10 Main valve blockp. 382
5.5.11 Fan blockp. 384
5.5.12 Valve block for auxiliary controlp. 386
+5.6 Tests and adjustmentsp. 389
5.6.1 Special tools, tests and adjustmentsp. 389
5.6.2 Checking & adjusting the travel pumpp. 391
+5.7 Inspection and maintenance workp. 397
5.7.1 Maintenance Tablep. 397
+5.7.2 Every 10 operating hoursp. 397
5.7.2.1 Checking the hydraulic oil levelp. 397
+5.7.3 Every 1000 operating hoursp. 398
5.7.3.1 Changing the hydraulic oilp. 398
5.7.3.2 Changing the hydraulic oil filterp. 400
+6 Machine assembliesp. 403
+6.1 Diesel enginep. 405
+6.1.1 Diesel enginep. 405
+6.1.1.1 Descriptionp. 405
6.1.1.1.1 Description of enginep. 406
6.1.1.1.2 Lubrication oil circuitp. 408
6.1.1.1.3 Coolant circuit TCD 2015p. 409
6.1.1.1.4 Fuel circuitp. 410
6.1.1.1.5 Injection systemp. 413
6.1.1.1.6 Exhaust gas recirculation TCD 2015p. 416
6.1.1.1.7 Wastegate charge pressure controllerp. 417
+6.1.1.1.8 Engine electricsp. 418
+6.1.1.2 Repairp. 426
6.1.1.2.1 Checking the thermostat in disassembled statep. 426
+6.1.1.3 Inspection and maintenance workp. 428
6.1.1.3.1 Maintenance Tablep. 428
+6.1.1.3.2 Every 10 operating hoursp. 429
Checking the engine oil levelp. 429
Checking and cleaning the water separatorp. 429
+Checking the fuel level; topping up fuelp. 430
Checking the fuel levelp. 430
Refuellingp. 430
+6.1.1.3.3 Every 50 operating hoursp. 431
Checking the coolant levelp. 431
+6.1.1.3.4 Every 250 operating hoursp. 432
Clean the cooling fins on engine and hydraulic oil coolerp. 432
Change engine oil and oil filter cartridgep. 433
Checking, replacing the generator V-beltp. 434
+6.1.1.3.5 Every 1000 operating hoursp. 436
Checking, adjusting the valve clearancep. 436
+Replacing the fuel filter, bleeding the fuel systemp. 438
Preliminary remarksp. 438
Replacing the fuel filterp. 438
Bleeding the fuel systemp. 439
Check fastening of engine / turbocharger / combustion air hosesp. 440
Checking the crankcase pressurep. 440
Drain the sludge from the fuel tankp. 441
Check the preheating systemp. 441
+6.1.1.3.6 Every 2000 operating hoursp. 441
Changing the coolantp. 441
+6.1.1.3.7 Every 6000 operating hoursp. 443
Replacing the crankcase ventilation valvep. 443
Replace the injection valvesp. 443
Replace the coolant pumpp. 443
Replacing glow plugsp. 443
+6.1.1.3.8 As requiredp. 443
Service the combustion air filterp. 443
Engine conservationp. 446
+6.2 Conveyor systemp. 447
6.2.1 Descriptionp. 447
+6.2.2 Inspection and maintenance workp. 452
6.2.2.1 Maintenance Tablep. 452
+6.2.2.2 Every 10 operating hoursp. 452
6.2.2.2.1 Check, tighten the conveyor beltsp. 452
6.2.2.2.2 Checking the safety ropesp. 454
6.2.2.2.3 Lubricating the machinep. 454
+6.2.2.3 Every 50 operating hoursp. 456
6.2.2.3.1 Lubricating the machinep. 456
+6.2.2.4 Every 250 operating hoursp. 456
6.2.2.4.1 Lubricating the machinep. 456
+6.3 Track chain drive and steeringp. 457
6.3.1 Descriptionp. 457
+6.3.2 Repairp. 462
6.3.2.1 Repairp. 462
+6.3.2.2 Operating the levelling systemp. 464
6.3.2.2.1 Preliminary remarks and safety notesp. 464
+6.3.2.2.2 Control unit for levelling systemp. 466
Buttons and displaysp. 466
Displayp. 468
Navigating through the menusp. 469
+6.3.2.2.3 Preparations for levellingp. 469
Setting the screen contrastp. 469
Sensor selection for control circuits left and rightp. 470
Zero balancingp. 471
+6.3.2.2.4 Working with levelling systemp. 473
Setting the nominal valuep. 473
Adjusting actual value equals nominal valuep. 474
Lifting up and cutting inp. 476
6.3.2.2.5 Adapting the control speedp. 477
+6.3.2.2.6 Adjusting the control windowp. 477
Adjusting the control window equally for all distance sensorsp. 478
Adjusting the rope sensor control windowp. 478
Adjusting the cross-slope sensor control windowp. 479
+6.3.2.2.7 Changing measurement unitsp. 479
Changing rope sensor measurement unitsp. 479
Changing cross-slope sensor measurement unitsp. 479
6.3.2.2.8 Changing the deadbandp. 480
6.3.2.2.9 Changing the work modep. 481
+6.3.3 Inspection and maintenance workp. 482
6.3.3.1 Maintenance Tablep. 482
+6.3.3.2 Every 10 operating hoursp. 482
6.3.3.2.1 Checking the track platesp. 482
+6.3.3.3 Every 50 operating hoursp. 482
6.3.3.3.1 Retightening the track shoe fastening screwsp. 482
6.3.3.3.2 Lubricating the machinep. 483
+6.3.3.4 Every 1000 operating hoursp. 485
6.3.3.4.1 Changing the oil in the travel gearp. 485
+6.4 Radiator modulep. 486
6.4.1 Descriptionp. 486
+6.4.2 Inspection and maintenance workp. 488
6.4.2.1 Maintenance Tablep. 488
+6.4.2.2 Every 50 operating hoursp. 488
6.4.2.2.1 Checking the coolant levelp. 488
+6.4.2.3 Every 250 operating hoursp. 489
6.4.2.3.1 Clean the cooling fins on engine and hydraulic oil coolerp. 489
+6.4.2.4 Every 2000 operating hoursp. 490
6.4.2.4.1 Changing the coolantp. 490
+6.5 Milling unitp. 492
6.5.1 Descriptionp. 492
+6.6 Milling drump. 502
6.6.1 Descriptionp. 502
6.6.2 Repairp. 513
+6.6.3 Inspection and maintenance workp. 514
6.6.3.1 Maintenance Tablep. 514
+6.6.3.2 Every 10 operating hoursp. 514
6.6.3.2.1 Checking/replacing cutting tools, scraperp. 514
+6.6.3.3 Every 250 operating hoursp. 519
6.6.3.3.1 Checking, replacing the milling drum V-beltp. 519
+6.6.3.4 Every 1000 operating hoursp. 520
6.6.3.4.1 Changing the oil in the milling gearp. 520
6.6.3.4.2 Oil change in milling drum bearingp. 521
+6.7 Water systemp. 523
+6.7.1 Descriptionp. 523
6.7.1.1 Overview of water spraying systemp. 523
6.7.1.2 Operating the water spray systemp. 524
6.7.1.3 Water spraying systemp. 527
+6.7.1.4 Inspection and maintenance workp. 528
6.7.1.4.1 Maintenance Tablep. 528
+6.7.1.4.2 Every 10 operating hoursp. 528
Check water level, spray nozzlesp. 528
+6.7.1.4.3 As requiredp. 529
Clean water tank and water filterp. 529
Water spray system, maintenance in case of frostp. 530
+7 Troubleshootingp. 533
+7.1 Trouble shooting, diesel enginep. 535
7.1.1 Starting the engine with jump leadsp. 535
7.1.2 Engine malfunctionsp. 535
7.1.3 Deutz DTC fault code list, EMR3p. 538
+7.2 Trouble shooting, hydraulicsp. 605
7.2.1 Troubleshooting table for hydraulic componentsp. 605
7.2.2 Troubleshooting axial piston motorsp. 613
7.2.3 Troubleshooting axial piston pumpsp. 615
7.2.4 Insufficient hydraulic powerp. 617
+8 Special toolsp. 621
8.1 Special tools, Deutz engine (TCD 2015)p. 622
9 Indexp. 643
+Appendixp. 655
A Circuit diagramp. 657
B Hydraulic diagramp. 791
Fuels and lubricants specify Deutz DQC III-10 or DQC IV-10 engine oils, diesel to EN 590 / ASTM D975 Grade 1-D and 2-D / JIS K 2204 with sulphur limits, coolant mixing ratios from 35% to 50% protection agent, hydraulic oil HV 46 (HVLP per DIN 51524 part 3), optional ester-based biodegradable oil, gear oil ISO VG 220 for milling gear and drum support bearings, SAE 75W-90 for travel gear and transfer case, and the two grease specifications used on lubrication points and the milling-drum-drive clutch.
Diagnosis and special tools
Troubleshooting separates engine and hydraulic work. Engine coverage includes jump starting, malfunction tables, and the Deutz DTC fault code list for EMR3. Hydraulic troubleshooting includes a component table, axial-piston motor and pump fault paths, and a section on insufficient hydraulic power. Chapter 8 lists special tools for the Deutz TCD 2015, including base plates and crankshaft-seal assembly tools named in that chapter.
What this manual lets you do
With the BOMAG BM 2000/60-2 Cold Planer Service Manual 00891769 2019 on the bench, a trained technician can locate electrical modules and hydraulic blocks, work display service menus and configuration parameters, follow fuse maps, service the generator and starter, check and adjust the travel pump, repair track-chain drive and steering, service the milling unit and drum, maintain the conveyor and water system, and use EMR3 fault codes plus hydraulic-power checks when the machine will not produce expected travel or work power. Correct pressures, fluid grades, serial applicability, and torque or adjustment values from this book keep those jobs aligned with the published procedure instead of guesswork.
After payment you receive instant PDF delivery. There is no shipping wait. Open the file on a workshop PC, tablet, or phone and print the pages you need at the machine.
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