Bomag BM 2000/60 Cold Milling Machine Service Manual

Description

Complete Service & Repair Manual for Bomag BM 2000/60 Cold Milling Machine

The Bomag BM 2000/60 Cold Milling Machine Service Manual is the definitive workshop reference engineered specifically for heavy equipment technicians, field mechanics, and maintenance facilities tasked with maintaining, overhauling, and troubleshooting this high-production 2.0-meter cold planer. Applicable to machines bearing serial number S/N 821 836 16 and up, this comprehensive technical publication (catalogue number 008 915 97, published 04/2010) delivers factory-approved technical instructions covering mechanical assemblies, hydraulic closed-loop circuits, CAN-bus microcontrollers, operator consoles, and the complete 440 kW (598 HP) Deutz TCD 2015 V8 powertrain.

File Details

• Manual Type: Factory Service Manual / Workshop Repair Manual
• Equipment Brand: BOMAG (Fayat Group)
• Machine Model: BM 2000/60 Cold Milling Machine
• Serial Number Coverage: S/N 821 836 16 and above
• Catalogue Number: 008 915 97
• Publication Date: 04/2010 (April 2010 Edition)
• Document Language: English
• Page Count: 1090 pages
• File Format: PDF (Printable on all digital platforms)

Deutz TCD 2015 V8 Powertrain & Engine Management

At the mechanical core of the Bomag BM 2000/60 is the water-cooled, 8-cylinder V-type Deutz TCD 2015 four-stroke diesel engine delivering 440 kW (598 HP) at a rated speed of 1900 rpm. This service publication supplies complete mechanical and electronic servicing instructions for the powertrain. Technicians will find detailed procedures for checking and adjusting intake valve clearance (0.25 mm) and exhaust valve clearance (0.30 mm), performing fuel system maintenance on the MVS unit pump injection system, checking the turbocharger wastegate charge-pressure controller, and servicing the exhaust gas recirculation (EGR) circuit. Coverage includes routine servicing of fuel pre-filters, main fuel filter cartridges, water separators, dual-stage combustion air filters, crankcase breathers, and intercooler condensation drains. The manual integrates full diagnostic troubleshooting for the electronic engine management system (Deutz EMR3), detailing wiring pinouts, SERDIA diagnostic interface protocols (XMB connector), and exhaustive fault code tables with exact test steps for all engine sensors, including oil pressure, fuel temperature, charge-air pressure/temperature, coolant temperature, engine speed, and coolant level probes.

Advanced CAN-Bus Architecture, Microcontrollers & Diagnostics

Modern road milling machinery relies on real-time microprocessor communication. This manual features in-depth technical documentation covering the decentralized CAN-bus electronic control network on the Bomag BM 2000/60 Cold Milling Machine. Technicians are provided with complete circuit descriptions, terminal designations compliant with DIN 72552, connector assembly guidelines (including Deutsch DT/DTM series and X-COM spring clamping blocks), and signal characteristics for pulse-width modulated (PWM) proportional solenoids. It thoroughly documents each electronic hardware element:

IMAGES PREVIEW

• CR0505 Machine Controller (ID Node 30): Central unit handling 24 digital inputs, 8 analog outputs, 8 PWM outputs, dual CAN interfaces, and internal power-latching relays.
• CR2012 Input/Output Modules (ID Nodes 01–14): Distributed throughout operator consoles (106B1 left panel, 106B2 central console, 106B3 right panel) and the central electrics box (106.1B1) for gathering switch, joystick, potentiometer, and sensor inputs.
• CR2031 High-Current Solenoid Modules (ID Nodes 16–19): Located in the engine compartment with dedicated PWM drivers and current feedback monitoring for hydraulic proportional valves.
• CR1050 Multi-Function Display (114U1): Full diagnostic menu navigation, setup procedures, input/output status checking, fault code readouts, machine states pages, and software node ID configuration.
• Sensor Parameterization & Calibration: Complete operational instructions for programming ifm electronic pressure transmitters (SP1, rP1, hysteresis, and window functions on travel, conveyor, clutch, hold-down, and scraper circuits) and Pt1000 hydraulic temperature sensors. Step-by-step procedures detail rope sensor calibration for 3-point grade/slope height control and steering cylinder angle feedback.

Hydrostatic Travel, Steering & Grade Control Systems

The manual provides thorough coverage of the closed-loop hydrostatic travel drive that powers the four independent crawler track assemblies. Driven by a Bosch Rexroth A4VG 71 EP axial piston variable-displacement pump operating up to 450 bar high-pressure cutoff and four Rexroth A6VE 28 HZ1 bent-axis hydraulic motors paired with Bonfiglioli 705C3H10 planetary track gearboxes, the system delivers working speeds from 0 to 30 m/min and transport speeds up to 5 km/h. Service technicians are guided through pressure override settings (420 bar), charge pressure verification (27 bar at high idle), differential lock solenoid testing (206.6Y2), spring-applied multi-disc parking brake release (206.6Y3), and proportional travel pump displacement control. In addition, the steering section covers four distinct electronic steering modes (manual front, center steering, coordinated steering copy mode, and crabwalk) monitored via draw-wire rope sensors on the steering cylinders.

Milling Drum Drive, Mechanics & Working Hydraulics

The mechanical cutting system consists of a 2000 mm wide rotor with a 1070 mm cutting diameter, carrying 168 cutting tools at a 15 mm line spacing, spinning at 108.4 rpm. This manual covers complete service procedures for the heavy-duty power-band V-belt drive, tensioning cylinders, the 143/1SZ PHA hydraulically actuated dry multi-disc clutch (transfer torque 6490 Nm, switching torque 5190 Nm at 45 bar), and the F130/21/OM/OB/FL reduction gearbox (21:1 ratio). It provides step-by-step instructions for replacing cutting tools, ejectors, toolholder base blocks, scraper blades, and drum bearing seals. Detailed sections document the primary gathering belt (800 x 2400 mm) and high-capacity loading conveyor (800 x 7600 mm), including tensioning, guide roller lubrication, safety rope inspection, 180-degree hydraulic folding mechanisms, and conveyor drive hydraulics driven by an A10VG45EP variable pump and dual OMT 400 orbital motors. The hydraulic chapter details the Rexroth A10VO 45 DFR load-sensing pump (240 bar max working pressure, 210 bar steering pressure), the 18-section working hydraulic valve block, the temperature-controlled hydraulic fan drive, and the 3300-liter water sprinkling and pressure cleaning systems.

Chapters Covered

• Chapter 1 – General: Foreword, safety regulations, personal protective equipment, fuel and mineral oil handling, general repair practices, radial seal fitment, bearing installation, and comprehensive tightening torques for metric, UNC, and UNF fasteners (including anti-seizure paste specifications).
• Chapter 2 – Technical Data: General machine dimensions, CECE operating weights, milling drum cutting specifications, travel parameters, crawler track dimensions, filling capacities, and complete supplier technical data for hydraulic pumps, motors, and reduction gears.
• Chapter 3 – Maintenance: Maintenance fundamentals, running-in procedures for new/rebuilt assemblies, lubrication charts, fuel oil quality standards (DIN EN 590, ASTM D975), biodegradable hydraulic oils, and the full scheduled maintenance table (from 10 hours daily to 6000 operating hours).
• Chapter 4 – Electrics: How to read circuit diagrams, cross-references, DIN 72552 terminal numbering, Ohm’s law and electrical theory, PWM valve characteristics, metrology, diodes, relays, fuses, inductive proximity switches, Deutsch DT/DTM plug repair, Telemecanique switches, spring-clamp terminals, battery servicing, central electrics box 106.1B1, and operational testing of all machine sensors and solenoids.
• Chapter 5 – CAN-Bus, Parameter and Diagnose: CAN-bus architecture overview, ID node fuse allocations, CR1050 multi-function display setup, tuning parameters, Check Input/Output diagnostic menus, machine state inspection screens, steering calibration, levelling wire/slope sensor calibration, and conveyor/travel ramp adjustments.
• Chapter 6 – Engine Electrics: Deutz EMR3 electronic control unit pinouts, diagnostic testing via SERDIA, CAN communication, full EMR3 fault code diagnostic list with troubleshooting steps, engine sensor testing, alternator maintenance, and starter motor servicing.
• Chapter 7 – Engine: Deutz TCD 2015 V8 technical overview, lubrication circuit, cooling system, MVS injection pumps, EGR circuit, wastegate controller, valve clearance adjustment, routine fluid/filter servicing, troubleshooting charts, and engine-specific special service tools.
• Chapter 8 – Milling Drive, Mechanics: Milling rotor drive belt adjustment and replacement, reduction gearbox oil changes, bearing lubrication, cutting tool and quick-change base replacement, scraper flap kinematics, and dry clutch overhaul/friction lining wear measurement.
• Chapter 9 – Conveyor Belts, Mechanics: Gathering and loading conveyor belt replacement, tracking adjustment, safety cable inspection, suspension roller lubrication, and hydraulic folding/unfolding procedures.
• Chapter 10 – Travel Drive, Mechanics: Four-crawler track undercarriage maintenance, polyurethane track pad replacement, track shoe bolt torque verification, track tensioning, track drive planetary gear oil renewal, and steering linkage lubrication.
• Chapter 11 – Pump Transfer Case: Mechanical transfer gearbox configuration, daily fluid inspection, and oil drain/refill procedures.
• Chapter 12 – Hydraulics: Road milling machine hydraulics service training, hydrostatic closed-loop travel circuit diagnostics, conveyor drive hydraulics, 18-spool working hydraulic valve block, cooling fan hydraulic drive, and emergency auxiliary pump operation.
• Chapter 13 – Suppliers Documentation: In-depth factory service information from component manufacturers for Rexroth A10VO45 steering/working pump, A4VG71 travel pump, A10VG45 conveyor pump, A6VE28 travel motors, Bonfiglioli 705C travel gearboxes, Danfoss OMT400 conveyor motors, and water sprinkling pumps.
• Chapter 14 – Circuit Diagrams: Complete foldout schematics including hydraulic system schematic B2630030 and full machine electrical wiring diagram DE012004.

Together, these 14 detailed chapters provide an exhaustive, factory-certified knowledge base that enables professional service personnel to dismantle, inspect, rebuild, calibrate, and verify every mechanical, hydraulic, and electrical system on the machine to precise manufacturer tolerances.

Professional Capability, Factory Precision & Instant Delivery

Whether you are performing a complete overhaul of the Deutz TCD 2015 V8 engine, setting hydraulic pressures on the Rexroth A4VG travel pump, tracking down an intermittent communication fault on the CAN-bus network, or setting up the automatic 3-point levelling wire sensors, the Bomag BM 2000/60 Cold Milling Machine Service Manual equips you with the exact technical specifications, torque values, wiring schematics, and disassembly instructions required. Operating with official factory documentation eliminates guesswork, reduces costly machine downtime on road construction projects, and guarantees repairs meet strict BOMAG engineering guidelines. Available as an instant PDF download immediately upon checkout, this comprehensive manual contains no shipping delays, works across all desktop computers, laptops, tablets, and mobile smartphones, and can be printed entirely or page-by-page as needed in the workshop or field trailer.