Service Training

BM 1X00 / 35

Version 1.04

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1 Contents
1 Contents ........................................................................................ 2

2 Version history ............................................................................... 5

2.1 Document ................................................................................................................................ 5

2.2 Reference Documents ............................................................................................................. 5

2.3 Software Display ...................................................................................................................... 6

2.4 Software machine control 883 135 45 .................................................................................. 10

2.5 Software machine control C. 883 331 46 .............................................................................. 10

2.6 Software machine control V2.X 883 331 01 .......................................................................... 11

3 Machine display ........................................................................... 12

3.1 Navigation display menu ....................................................................................................... 12

3.1.1 Measuring value screens ............................................................................................... 12

3.1.2 Service access ................................................................................................................ 13

3.1.3 Teach and Learn procedures ......................................................................................... 14

3.1.4 Configurations ............................................................................................................... 15

3.1.5 Actuator test .................................................................................................................. 17

3.2 Fault log – display and delete ................................................................................................ 18

3.2.1 Display of active faults................................................................................................... 19

3.2.2 Display of the stored passive errors .............................................................................. 19

3.2.3 Display of engine faults ................................................................................................. 20

3.2.4 Deleting the fault log ..................................................................................................... 21

3.2.5 Showing the fault log (SWervice - Access) .................................................................... 21

3.3 Warnings................................................................................................................................ 22

3.3.1 Warnings (status bar) .................................................................................................... 22

3.3.2 Warnings (work screen)................................................................................................. 24

3.3.3 Warning if serious fault occurs ...................................................................................... 25

3.4 Display update ....................................................................................................................... 26

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 3.5 Start the display without machine identification .................................................................. 27

4 Procedures for machine commissioning ...................................... 28

4.1 Closing the parking brake ...................................................................................................... 28

4.2 Resetting levelling ................................................................................................................. 29

4.2.1 Starting the procedure via the machine display ........................................................... 29

4.2.2 Manual settings via the levelling display ....................................................................... 30

4.3 Resetting the slewing wheel end position values ................................................................. 31

4.4 Code input ............................................................................................................................. 32

5 Teach and Learn procedures ........................................................ 33

5.1 Lifting column adjustment learning function ........................................................................ 33

5.2 Setting the zero position of the steering rear right............................................................... 35

5.3 Steering learning function ..................................................................................................... 36

5.4 Setting the zero position of the front steering...................................................................... 37

6 Configurations ............................................................................. 38
6.1 Deactivating automatic levelling with side plate .................................................................. 38

6.2 Activating split scraper .......................................................................................................... 38

6.3 Activating the AdBlue filling pump ........................................................................................ 39

6.4 Activating dust extraction ..................................................................................................... 41

6.5 Assigning travel lever Info button 1 ...................................................................................... 43

6.6 Assigning to travel lever Info 2 button .................................................................................. 43

6.7 Activating the side plate camera ........................................................................................... 44

6.7.1 Calibration of the side plate camera ............................................................................. 45

6.8 Setting the machine type ...................................................................................................... 49

6.9 Y419 Activating flow divider free-wheeling .......................................................................... 49

6.10 Activating the milling drum when reversing ......................................................................... 50

6.11 Activating the flow divider automatics ................................................................................. 50

6.12 Travel lever ramp setting....................................................................................................... 50

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7 How to proceed when replacing components? ........................... 51
7.1 Replacement of an ESX control ............................................................................................. 51

7.2 Replacement of engine components .................................................................................... 51

7.3 Which components can be replaced without a subsequent adjustment procedure?.......... 52

8 CAN bus structure ........................................................................ 52

9 Commissioning of the level control.............................................. 53

9.1 The configuration menu ........................................................................................................ 53

9.1.1 Calibrating MIN pulse .................................................................................................... 53

9.1.2 Calibrating MAX pulse ................................................................................................... 56

9.1.3 Information lines for switch on message ...................................................................... 59

9.2 Summary of automatic hydraulics calibration: ..................................................................... 60

9.3 The following values should be set: ...................................................................................... 60

10 Inspection and troubleshooting levelling control ........................ 61

10.1 Special functions.................................................................................................................... 61

10.2 System diagnostics ................................................................................................................ 61

10.3 Quick sensor inspection: ....................................................................................................... 63

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2 Version history

2.1 Document

Version Date Description of changes Editor

00:01 09/04/2015 First version Summer

01:00 28/07/2015 Adaptation with display V1.07 Summer

01:01 08/01/2016 Adaptation with display V1.08 and ECU SW 2.0 Summer

01:02 14/07/2016 Adaptation with display V1.09 Summer

01:03 01/12/2016 Adaptation with display V1.10 and ECU V2.30 Summer
2.6 Software Update information supplemented,
6.12 Configuration extended, 3.2 Display of error log
changed.
01:04 24/04/2017 Adaptation with display V1.11 and ECU V2.40 Summer

2.2 Reference Documents

No. Title Memory location

1 AA-E-016 Commissioning MTU-engines Tier 4 BOMAG Intranet (quality management ->

final with SCR-system in assembly Head Office (BB) -> Work instructions (AA)
department

2 AA-E-019 Commissioning MTU-engines Tier 3 BOMAG Intranet (quality management ->

in assembly department Head Office (BB) -> Work instructions (AA)

3 AA-E-017 Programming / Update Display BOMAG Intranet (quality management ->

eVision²7.0 Head Office (BB) -> Work instructions (AA)

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2.3 Software Display

Version Date Description of changes Editor

01:00 10/04/2014 First version Summer

01:01 25/07/2014 NEW: Updating of fault code Summer

NEW: Updating of measuring values
Change: Optimization of initialization
NEW: Reading out the machine type code
Change: Firmware V1.6.0.0
NEW: Display of emergency stop switches
Change: Colour of numerical display for conveyor belt
and water adjustment
NEW: Measuring values for offset timer of differential
pressure switches
NEW: Display of conditions during teach and learn
processes
NEW: Configuration of AdBlue filling pump
NEW: Display of fault list FMI - text and FMI - index
01:02 11/08/2014 Bugfix: Learn - procedure steering sides interchanged Summer
NEW: Learn - procedure lift columns display of all
learned currents after the end
01:03 26/08/2014 Bugfix: Conversion bar - psi Summer
NEW: Updating of fault code
Change: Deactivation of the light button in standby
mode
Change: Updating of fault list when called up
01:04 03/09/2014 Change: Milling depth correction Summer
Change: Colour of numerical display for conveyor belt
and water adjustment
NEW: Status light for the condition active / inactive
conveyor belt / water adjustment
01:05 29/10/2014 NEW: BTDPI – 1 Display reading - Serial number Summer
NEW: BTDPI – 2 Si unit time
Bugfix: BTDPI – 4 Display initialization text string
Correction of text string in English
Bugfix: BTDPI – 5 Switch off initialization
When switching off during the initialization phase the
display is not deactivated.
Bugfix: BTDPI – 6 Fault list refresh
Optimization of the fault list updating without ignition
change
Bugfix: BTDPI – 7 Actuator test: Reset of the default
settings
After an ignition change the adapted values in the
service menu “Actuator Test” are not reset.
NEW: BTDPI – 11 Textbox element
Limitation of the string length, so that the printing
cannot exceed end of the line.

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 Bugfix: BTDPI – 12 Indication of filling levels
Optimization of the averaging for the filling level display.
Bugfix: BTDPI – 13 Display of water flow rate
Plausibility check of interval limits.
Bugfix: BTDPI – 14 Filling level displays: Actual value
display > 0 if tank is empty
Bugfix: BTDPI – 15 AdBlue warning message
Change of icon colour.
Bugfix: BTDPI – 16 Standby function display
2 seconds offset time implemented.
Bugfix: BTDPI – 17 Display initialization text input
2 seconds offset time implemented.
01:06 08/12/2014 Change: BTDPI – 19 Deactivation of Ethernet portal Summer
Only the service log-in releases the ethernet portal.
Bugfix: BTDPI – 20 Activation of the dust extraction
The latest adjusted value of the dust extraction is saved.
Change: BTDPI – 21 Learn / Teach "0" rear right: Edit
information text
Optimization of the information text.
NEW: BTDPI – 22 Configuration: “Short conveyor belt”
New configuration
Bugfix: BTDPI – 25 Update package: Damaged illustration
files
NEW: Evaluation of version flag for control beta version
01:07 10/08/2015 NEW: BTDPI – 8 Emergency operation levelling Summer
NEW: BTDPI – 29 Display of software version MRS IO
Module
NEW: BTPDI – 31 Lift column height front:
Representation height 50%
NEW: BTDPI – 32 Application extension: New slewing
wheel, conveyor belt speed adjustment
Change: BTDPI – 37 Measuring side engine
Display of measuring values dependent on TIER 3A / TIER
4final
Change: BTDPI – 38 Measuring side slewing arm
NEW: BTDPI – 39 Configuration: “Dust extraction”
New configuration.
Change: BTDPI – 40 Updating of fault list for slewing
wheel C1
NEW: BTDPI – 43 Display of software version release
NEW: BTDPI – 46 Configuration: Push button assignment
travel lever
New configuration.
Change: BTDPI – 47 Display of lamp messages: Extension
of display time
NEW: BTDPI – 48 Display of operating mode milling /
transport
NEW: BTDPI – 49 Display of machine type
Change: BTDPI – 52 Measuring side steering
Change: BTDPI – 53 Measuring side conveyor belt
Change: BTDPI – 54 Measuring side slewing arm
Change: BTDPI – 56 Texts for fault solutions and fault
causes
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 Change: BTDPI – 57 Filling level display: Filling levels are
displayed, even if the medium tank is empty
Change: BTDPI – 58 Measuring side height adjustment
Change: BTDPI – 59 Measuring side engine
NEW: BTDPI – 60 Camera image of side plate
NEW: BTDPI – 62 Configuration: Activation of the
cylinder travel measuring systems
NEW: BTDPI – 63 Warning: Cylinder for pivot point
dislocation not in end position
NEW: BTDPI – 65 Warning that high pressure cleaner is
active
NEW: BTDPI – 66 Warning that water pump is active
01:08 21/03/2016 NEW: BTDPI-26 Language setting French Summer
NEW: BTDPI-67 Fault list for engine faults
NEW: BTDPI-69 Teach procedure: Zeroizing of front
steering
NEW: BTDPI-71 Service function: Code input
NEW: BTDPI-73 Display of teach values for steering
zeroizing
NEW: BTDPI-77 Routine: Resetting of slewing arm end
position
NEW: BTDPI-78 Measuring side slewing arm - extension
Bugfix: BTDPI-79 Language setting French is not saved
Change: BTDPI-80 Saving the water quantity setting
01:09 14/07/2016 NEW: BTDPI-28 Test routine: USB Stick / USB cable Summer
NEW: BTDPI-61 Updating of symbols
NEW: BTDPI-81 Diagnose: Status display if the offboard
diagnose is active
NEW: BTDPI-90 Diagnose: Measuring value Y419: Bypass
valve for flow divider
NEW: BTDPI-94 New machine type for contgrol concept
conversion
NEW: BTDPI-95 BMK texts for hydraulics - differential
pressure switches
NEW: BTDPI-96 Diagnose: Configuration of flow divider
bypass valve
NEW: BTDPI-97 Diagnose: Measuring value / status K022
NEW: BTDPI-98 Diagnose: Information text under the list
NEW: BTDPI-99 Diagnose: Lamp message for water
pump dry running protection
NEW: BTDPI-100 Diagnose: Lamp message for high
pressure cleaner dry running protection
NEW: BTDPI-101 Diagnose: Lamp message for engine
stop K22 has been switched
NEW: BTDPI-102 Diagnose: Supplementation of display
for further fault information data
Change: BTDPI-68 Warning general
Change: BTDPI-86 Display of imperial unitsImperial units
Change: BTDPI-87 Deactivation of fault counter
Change: BTDPI-88 Deactivation of automatic brightness
control
Change: BTDPI-92 Warnings: Differential pressure switch

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 Change: BTDPI-93 Diagnose: Supplementation of lack of
oil warning
Change: BTDPI-103 Diagnose: Set time stamp for ignition
start
Bugfix: BTDPI-82 Teach routine: Zero position, steering
angle, front
Bugfix: BTDPI-91 BMK S159 is unknown
01:10 21/11/2016 Bugfix Summer
[BTDPI-112] - Adblue filling pump: Reset display
command after automatic stop
[BTDPI-116] - Measurement Engine: Engine oil pressure
[BTDPI-118] - Measurement Column: value for B0199,
B0200 exchange

Changes
[BTDPI-110] - Diagnostic: Set timestamp by ignition start
[BTDPI-111] - Diagnostic error list: Display engine hours
and minutes
New Feature
[BTDPI-114] - Warning lamp: CAN Error
[BTDPI-115] - Configuration: Travel backwards with
active milling drum
01:11 24/04/2017 [BTDPI-83] - Diagnostic: Standard measurement page
[BTDPI-104] - Diagnostic milling: leveling sensor side
plates
[BTDPI-126] - Teach / Learn: Add factor for speed pivot
drive
[BTDPI-129] - Start / Init Screen: Cancel the routine and
display the SW - Version
[BTDPI-131] - SW - Version: Request the display SW -
compatibility
[BTDPI-133] - Configuration: Flow divider automatic
[BTDPI-128] - Measurement Engine: Display Request RPM
[BTDPI-119] - Configuration: Remove "Short conveyor"
[BTDPI-120] - Configuration: Joystick / Travelramp
[BTDPI-122] - 2.3.5.4 Zero steering front:
Menu back to 2.3.5
[BTDPI-123] - 2.3.4.2 Zero steering rear: information text
[BTDPI-124] - BMK Pressure travel pump (B0112,B0308)
additional textinformation
[BTDPI-127] - Start / Init Screen: Machinetyp not available
[BTDPI-135] - 2.3.2 Configurations / minimize the font size
[BTDPI-136] - 2.3.2 Configurations / Deactivate leveling
with side plate cylinder
[BTDPI-137] - 2.2.1 Measurements / Update the icon for
propel
[BTDPI-138] - 2.2.1 Measurements / Update the icon for
steering
[BTDPI-139] - Errorlist passive / Deactivate list for user
level 1
[BTDPI-140] - Diagnostic: Update the Icon design

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2.4 Software machine control 883 135 45
Version Date Description of changes Editor

V1.10 28/11/2014 NEW: BTPI – 1 Fault message MTU control unit after Mi. Gerhardy
Flashing/ quick ignition change
NEW: BTPI – 2 Slewing arm chain assists steering in
unfolded condition
NEW: BTPI – 5 Restrict travel path of lift column
NEW: BTPI – 6 Improve MRS-module fault description
NEW: BTPI – 7 Automatic shut-down function for
water/belt/rotor
NEW: BTPI – 8 Change of rear scraper basic function
Bugfix: BTPI – 9 Fault monitoring 12- and 3-stage
switch
V1.11 08/12/2014 Bugfix: BTPI – 10 rear steering inverted Mi. Gerhardy
V1.20 11/03/2016 NEW: Status light when the high pressure cleaner is Mi. Gerhardy
activated
Changes: Rotation angle sensor for conveyor belt
evaluation set to 210°
Changes: Evaluation of water level filling sensor
improved
Changes: DM1 (engine fault) improved
Bugfix: J1939 protocol, motors – communication
Bugfix: MOBA evaluation side plate sensors

2.5 Software machine control C. 883 331 46

Version Date Description of changes Editor

V1.00 03/08/2015 First version Mi. Gerhardy

V1.40 19/02/2016 Changes: Travel ramp brake operation steeper Mi. Gerhardy
Changes: Steering limitation of rear chain to the right
Changes: Fault monitoring for K97 (emergency
operation of pump) debounced
Changes: Improved fault monitoring of stage switches
Bugfix: Monitoring of brake pressure switches too
sensitive

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2.6 Software machine control V2.X 883 331 01
Version Date Description of changes Editor

V2.30 01/12/2016 New: Mi. Gerhardy

- New configuration: Milling drum on when
reversing
- New configuration: Bypass valve for flow
divider
- Conveyor belt stops while reversing
Changes
- Height correction slewing arm retracted /
extended
- Response of warning horn optimized
- Limitation of slewing arm steering angle
- No engine shut-down in case of triggering of
differential pressure switch or air filter
monitoring
Bugfix
- Watchdog settings corrected
V2.40 07/04/2017 New:
- New configuration: Automatic flow divider
(electric conversion required)
- New configuration: Slewing speed setting

CHANGES:
- Engine characteristic changed for reversing with
rotor switched on

Software – Update to V2.X

! Info
After the software update from V1.X to V2.X the machine type of the
machine needs to be reset, see chapter 6.8 Setting the machine type.

The V2.X Update may be made for machines equipped with S308 [conveyor
belt speed potentiometer]. The slewing arm type is of no relevance.

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3 Machine display
3.1 Navigation display menu

3.1.1 Measuring value screens

Select “Menu”

Select “Diagnose”

Select “Measuring values”

[A] and [B] open the modulized measuring value

pages. [C] scrolls to the next pre-selection.

A B
C

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3.1.2 Service access
Select “Menu”

Select “Service”

Select “Service access”

Use the arrow keys [A] and [B] for input and
navigation between the individual inputs.

A B

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3.1.3 Teach and Learn procedures
The Teach and Learn procedures are only
available after the service access has been
released.

Select “Menu”

Select “Service”

Select “Teach”

Use the arrow keys in areas [A] and [B] to select

the procedures.

The OK button starts the selected procedure.

A B This procedure is initiated via a dialogue
window.

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3.1.4 Configurations
Only part of the configurations are enabled at
user level. The full extent is only available after
Service - Access has been released.

Select “Menu”

Select “Service”

Select “Configuration”

Selection of the configurations for the user level.

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Selection of the configurations for the service
level.

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3.1.5 Actuator test
The Teach and Learn procedures are only
available after the service access has been
released.

Select “Menu”.

Select “Service”.

Select “Actuator test”.

Use the arrow keys [A] and [B] for input and
navigation between the individual inputs.

A B

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3.2 Fault log – display and delete
Select “Menu”.

Select “Diagnose”.

Here you see the list of active faults.

The display shows the faulty operating

equipment. The fault code and corresponding
brief text are shown in addition in the footer.

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3.2.1 Display of active faults
In the list you can select the individual faults.

The display shows the faulty operating

equipment. The fault code and corresponding
brief text are shown in addition in the footer.

When confirming with “OK”, the listed fault will

be shown with additional information.

With “OK” or “ESC” you can close the window

gain.

3.2.2 Display of the stored passive errors

Release the service access with “9 9 9 9”.

Navigation to the service access; see

3.1.2 Service access.

The marked key loads the table with the passive

faults.

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 The display shows the faulty operating
equipment. The fault code and corresponding
brief text are shown in addition in the footer.

When confirming with “OK”, the listed fault will

be shown with additional information.

With “OK” or “ESC” you can close the window

gain.

3.2.3 Display of engine faults

Select “Engine faults”.

The engine faults are listed as follows:

[Control unit] SPN: XXX – FMI : XXX

The footer shows the associated DTC - code.

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3.2.4 Deleting the fault log
Release the service access with “9 9 9 9”.

Navigation to the service access; see

3.1.2 Service access.

The Service Access activates the selection

“Delete / Update” key.

Pressing this key updates the fault log “Faults

active” and deletes the fault log “Faults passive”.

3.2.5 Showing the fault log (SWervice - Access)

Release the service access with “9 9 9 9”.

Navigation to the service access; see

3.1.2 Service access.

The Service Access activates the selection

"Delete / Update” key.

Pressing this key updates the fault log

“Faults active” and deletes the fault log
“Faults passive”.

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 The fault display is supplemented with the
entries OC and HLO.

OC [Occurrence Count] = Fault counter

HLO [Hours of last occur] = Engine hours /

engine minutes since the last occurrence

Every time a fault occurs, the fault counter goes

up one digit. The fault is thereby set as active
fault. The fault remains active until the next
ignition change.

3.3 Warnings

3.3.1 Warnings (status bar)

Symbol Description

Engine fault lamp

Parking brake

Warning hydraulic oil filter

Warning engine oil press

Warning engine oil filling level

Warning coolant filling level

Warning coolant temperature

General warning minor

Engine control light

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AdBlue warning

Power reduction

Charge control light

Warning water separator

Warning hydraulic oil temperature

Warning air filter

Warning dry-running protection or water pump malfunction

Warning dry-running protection or high pressure cleaner malfunction

Warning off-board diagnostics tester is active. On-board diagnostics functions are

deactivated

Information: Slewing wheel in straight ahead position

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3.3.2 Warnings (work screen)
General warning. CAN bus fault

B021 Hydraulic oil filter

B022 Hydraulic oil filter

B121 Hydraulic oil filter

B122 Hydraulic oil filter

S113 Emergency stop switch

S112 Emergency stop switch

S125 Emergency stop switch

Water pump for tank filling

High pressure cleaner

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 Wheel not locked

Vision improvement cylinder not in end position

Side plate top position

Scraper top position

Tool change switch actuated

3.3.3 Warning if serious fault occurs

If an active fault is reported that automatically leads to the engine stopping, this is indicated by the
general warning light with corresponding text.

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3.4 Display update
Release the service access with “9 9 9 9”.

Navigation to the service access; see

3.1.2 Service access.

Then select “Menu”

Select “Service”

Select “Update”

The “Test” function is pre-selected. Insert the

USB-stick with the update and press “OK” to
confirm.

If the status changes to OK (green), the “update”

function can be selected. Press “OK” again to
confirm. The display starts again and starts with
the update.

Further information concerning the Update can

be found in the document [3].

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3.5 Start the display without machine identification

Once the display does no longer receive and

machine identification from the machine control,
the application can no longer be started.

This could happen if the CAN bus is incorrectly

wired or disturbed, or if a wrong software
version is installed in the machine control or in
the display.

The machine identification can be skipped by

pressing the key combination 0 and 4.

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4 Procedures for machine commissioning
4.1 Closing the parking brake
The parking brake can be manually activated on the display. The following steps are required to do so:

Release the service access with “9 9 9 9”.

Navigation to the service access; see

3.1.2 Service access.

Call up the measuring value page “Travel

system”.

Navigation to the measuring value pages; see

3.1.1 Measuring value screens.

Select the “Measuring page travel system”.

Press “OK” to confirm. Press the key “Close

Break” to activate the parking brake.

Pressing the “ESC X” button deactivates the

parking brake.

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4.2 Resetting levelling
The “Reset levelling” function is used to automatically transfer important parameters to the levelling
control. This makes adjustment work easier during commissioning of the system, after replacement
of the levelling control, and allows restoration of the default parameters if the levelling had been
deadjusted and stops working properly as a result.

Changes are included in the version history.

Resetting levelling via the display automatically configures the following parameters:

1. Data record set to Mill 1000, memory location 4

2. Proportional band setting

3. Hydraulic speed

In order to be able to use these features, the machine must at least have the software level:

• ECU A34 [883 135 45] SW: V1.03

• ECU A66 [883 135 45] SW: V1.03
• ECU A34 [883 331 46] SW: V1.00
• ECU A66 [883 331 46] SW: V1.00
• Display SW: V1.05

A minimum and maximum pulse for hydraulics can then be calibrated via the levelling display.

4.2.1 Starting the procedure via the machine display

Release the service access with “9 9 9 9”.

Navigation to the service access; see

3.1.2 Service access.

Call up the measuring value page “Milling”.

Navigation to the measuring value pages; see

3.1.1 Measuring value screens.

Select the “Measuring page milling”.

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 Press “OK” to confirm. Press the button “Reset
Levelling”.

After a short moment, the levelling display will

be restarted.

4.2.2 Manual settings via the levelling display

The following parameters must still be set by hand:

1. Activating the cross-slope coupling

a. Configuration menu
b. User settings
c. Hydraulic calibration
d. Cross-slope coupling active.
e. Activate = Yes

Fig. 1 Cross-slope coupling

2. Adjust the control window of the cross slope sensor

a. Configuration menu
b. User settings
c. Adjust the control window
d. Cross Slope
e. Value -> 12 %

12 %

Fig. 2 Cross-slope control window

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4.3 Resetting the slewing wheel end position values
This point must solely be applied to machines with slewing arm variant “C”. During machine
commissioning, the end position values of “rotation angle sensor B258” are saved during the first
slewing process.

These saved values have to be reset after components of the slewing drive have been serviced.
This is performed as follows.

Release the service access with “9 9 9 9”.

Navigation to the service access; see

3.1.2 Service access.

Call up the measuring value page “Milling”.

Navigation to the measuring value pages; see

3.1.1 Measuring value screens.

Select the “Measuring page slewing wheel”.

Press “OK” to confirm. Press the button “Reset”.

Then the slewing process must be carried out

manually for once.

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4.4 Code input
For special functions a code input is available.

Release the service access with “9 9 9 9”.

Navigation to the service access;

see 3.1.2 Service access.

After successful Service Login. If further

numerical fields appear.

Use the arrow keys right and left to change from

field to field.

If one of the first four fields is selected start the

code input for control A034. If one of the last
four fields is selected start the code input for
control A066.

Press “OK” to send the entered code for either

A034 or A066.

Supported input codes:

Input code A034 A066

--- --- ---

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5 Teach and Learn procedures
Release the service access with “9 9 9 9”.

Navigation to the service access; see

3.1.2 Service access.

Call up the menu page “Teach”.

Navigation to the page; see 3.1.3 Teach and

Learn procedures.

Successful execution of the routines is indicated

by a green light to the left of the button.

5.1 Lifting column adjustment learning function

During the measurement the machine will move when the surge current is
! Danger
reached!

Do not leave the machine while the measurement is in progress!

Please take notice of the emergency stop button in the dashboard to be able
to quickly shut down the machine, if this should be required.

During the measurement watch your environment and interrupt the

measurement if people come too close to the machine!

Select the “Lift column” and press “OK” to

confirm.

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Follow the instructions in the dialog box and
press “PK” to confirm.

Once all conditions are met, the routine is

automatically started.

The routine can be interrupted by pressing

“ESC X”, “Menu” or “Home”.

The routine is ended if the status “OK” or

“ERROR” is displayed.

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5.2 Setting the zero position of the steering rear right
Select “Steering rear 0” and press “OK” to
confirm.

Follow the instructions in the dialog box and

press “PK” to confirm.

Once all conditions are met, manual adjustment

will be released.

There are no automated machine movements

with this routine.

The user himself decides about the steering zero

position.

Once the settings via the control lever S259 are

finished, the position can be saved by pressing
“OK”.

The procedure can be aborted by pressing

“ESC X”, “Menu” or “Home”.

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5.3 Steering learning function
During the measurement the machine will move when the surge current is
! Danger
reached!

Do not leave the machine while the measurement is in progress!

Please take notice of the emergency stop button in the dashboard to be able
to quickly shut down the machine, if this should be required.

During the measurement watch your environment and interrupt the

measurement if people come too close to the machine!

Select “Steering front” and press “OK” to

confirm.

Follow the instructions in the dialog box and

press “PK” to confirm.

Once all conditions are met, the routine is

automatically started.

The routine can be interrupted by pressing

“ESC X”, “Menu" or “Home”.

The routine is ended if the status “OK” or

“ERROR” is displayed.

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5.4 Setting the zero position of the front steering
Select “Steering front” and press “OK” to
confirm.

Follow the instructions in the dialog box and

press “PK” to confirm.

There are no automated machine movements

with this routine.

The user himself decides about the steering zero

position.

Once the settings via the steering unit are

finished, the position can be saved by pressing
“OK”.

The procedure can be aborted by pressing

“ESC X”, “Menu” or “Home”.

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6 Configurations
Release the service access with “9 9 9 9”.

Navigation to the service access; see

3.1.2 Service access.

Call up the menu page “Configuration”.

Navigation to the page; see 3.1.4 Configurations.

Without releasing the Service Access, the

configurations are only available to a limited
extent.

6.1 Deactivating automatic levelling with side plate

This configuration deactivates the automatic levelling, so that the side plates are operated via the
travel lever.

6.2 Activating split scraper

This configuration releases the adjustment of the split scraper. The adjustment of the scraper
pressure on the main working side is thereby supplemented.

Activation of this configuration requires the following optional equipment:

- FO68 – scraper, split 600

- FO76 – scraper, split 900
- FO75 – scraper, split 1000

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 Configuration is deactivated.

Configuration is activated. The main scraper

board is pre-selected.

6.3 Activating the AdBlue filling pump

This configuration releases the operation of the AdBlue filling pump. It can be operated in the menu.
Operation may be directly linked with the operation of the dust extraction system, which can also be
configured.

Activation of this configuration requires the optional equipment FOXX – AdBlue filling pump.

AdBlue filling pump is deactivated.

Dust extraction system is deactivated.

AdBlue filling pump is activated.

Dust extraction system is deactivated.

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AdBlue filling pump is deactivated.

Dust extraction system is activated.

AdBlue filling pump is activated.

Dust extraction system is activated.

Operation of the AdBlue filling pump with

deactivated dust extraction system.

Operation of the AdBlue filling pump with

activated dust extraction system.

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6.4 Activating dust extraction
Activation of this configuration requires the optional equipment FO54 – dust extraction.

AdBlue filling pump is deactivated.

Dust extraction system is deactivated.

AdBlue filling pump is activated.

Dust extraction system is deactivated.

AdBlue filling pump is deactivated.

Dust extraction system is activated.

AdBlue filling pump is activated.

Dust extraction system is activated.

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Operation of the dust extraction system with
deactivated AdBlue filling pump.

Operation of the dust extraction system with

activated AdBlue filling pump.

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6.5 Assigning travel lever Info button 1
The configuration can be activated or
deactivated via “OK” and “ESC”.

The button assignment can be selected with the

“arrow right” and “arrow left” keys.

Button assignment Info 1

“Config 001” Not used

“Config 002” Not used

“Config 003” Not used

“Config 004” Not used

“Config 005” Not used

6.6 Assigning to travel lever Info 2 button

The configuration can be activated or
deactivated via “OK” and “ESC”.

The button assignment can be selected with the

“arrow right” and “arrow left” keys.

Button assignment Info 2

“Config 001” Not used

“Config 002” Not used

“Config 003” Not used

“Config 004” Not used

“Config 005” Not used

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6.7 Activating the side plate camera
This configuration enables the side plate camera with additional marks on the image. Activation of
this configuration requires the following additional setting:

Select “Camera”

The arrow keys can be used to change the

camera channel. The “OK” button starts the full
camera view.

If the configuration is active, green bars will

appear in the image.

These bars must once be moved to a defined

position.

If this has not yet been done, the display shows

the message “System not calibrated”.

The system was calibrated.

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6.7.1 Calibration of the side plate camera
The 4 represented markings must be set to a defined reference position. This is done by the testing
personnel.

How do you displace / position a marking in the display?

Release the service access with “9 9 9 9”.

Navigation to the service access; see

3.1.2 Service access.

Select “Camera”

The arrow keys can be used to change the

camera channel. The “OK” button starts the full
camera view.

Press the “OK” button to select the first mark

“5 cm”.

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 The “5 cm” mark has thus been selected. Use
the “Arrow” keys to change to the next mark.

Pressing “OK” again selects this mark for

moving.

Use the “Arrow” keys to move the mark.

The “5 cm” mark is moved to the right.

Pressing the “OK” button quits and saves the

setting.

You can now change to the next mark.

The “5 cm” mark is moved to the right.

Pressing the “OK” button quits and saves the

setting.

You can now change to the next mark.

How to position?

This adjustment requires two persons. Person 1 operates the display and moves the machine across
the mark. Person 2 checks the machine position relative to the mark and navigates person 1.

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Draw a mark under a right angle to the machine
and move the machine across this mark.

Move the machine 5 cm across the mark.

Person 2 navigates person 1, until the mark is in
line with the side plate mark.

Person 1 now adjusts the 5 cm mark in the

display, until it is in line with the mark on the
carriageway.

Move the machine across the 10 cm mark.

Person 2 navigates person 1, until the mark is in
line with the side plate mark.

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Person 1 now adjusts the 10 cm mark in the
display, until it is in line with the mark on the
carriageway.

Move the machine across the 20 cm mark.

Person 2 navigates person 1, until the mark is in
line with the side plate mark.

Person 1 now adjusts the 20 cm mark in the

display, until it is in line with the mark on the
carriageway.

Move the machine across the 30 cm mark.

Person 2 navigates person 1, until the mark is in
line with the side plate mark.

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 Person 1 now adjusts the 30 cm mark in the
display, until it is in line with the mark on the
carriageway.

6.8 Setting the machine type

With the update to software version ECU SW 2.0
the machine type must be configured once
during commissioning.

For this purpose change to the entries BM1X00

TIER 4 to BM1X00 TIER 3 – C1. The milling width
does not have to be set.

Once activated, the display automatically

restarts.

6.9 Y419 Activating flow divider free-wheeling

If the solenoid valve Y419 for free-wheeling of
the flow divider is installed, it must first be
activated by using the corresponding
configuration.

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6.10 Activating the milling drum when reversing
Required SW versions of the components:
A34 [work control]: V2.30
A66 [Travel control]: V2.30
A81 [Display]: V1.10
A48 [Engine control unit]:
Parameter set
05767861_02 or 05767801_03
(see reference document [1])

Activation also requires the updating of the

parameter set for A48. From production date
2016/12 these machines are delivered with this
parameter set.

If this parameter set has not yet been updated,

a corresponding note will appear in the display.
Updating is accomplished with Xentry, see
reference document [1].

6.11 Activating the flow divider automatics

Required SW versions of the components:
A34 [work control]: V2.40
A66 [Travel control]: V2.40
A81 [Display]: V1.11
The flow divider is switched off during reversing.

6.12 Travel lever ramp setting

Required SW versions of the components:
A34 [work control]: V2.40
A66 [Travel control]: V2.40
A81 [Display]: V1.11
A pre-configured setting can be selected with the
“arrow right” and “arrow left” keys.

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7 How to proceed when replacing components?
Each machine is adjusted individually during initial commissioning. This adjustment or teaching
process is necessary to make sure that all functions work to satisfaction on all machines. Background
of these adjustment procedures are the tolerances of the components used, e.g. hydraulic pump for
travel system, proportional valves for steering, steering angle sensors and control. These tolerances
apply for both mechanical as well as electrical functions and are unavoidable for manufacturing
reasons.

To enable simple and quick adjustment procedures we have decided to do without expensive tools.
All that is needed is this manual and a bit of time. By following the described procedure it is possible
to take a machine back into operation after the replacement of one of the components specified
above and to re-establish the usual functional quality, with almost any previous knowledge. Even an
incorrectly or incompletely conducted teaching procedure can be repeated without problems as
often as necessary.

7.1 Replacement of an ESX control

Since the controls store all machine learning values, each learning procedure must be performed
with the new control after a replacement. Furthermore, the configuration has to be checked and
reset after a control replacement.

Now the following steps must be carried out:

- Automatic detection of surge currents in height adjustment (see chapt. 5.1 Lifting column
adjustment learning function).

- Neutral position of the rear right slewing wheel (see 5.2 ).

- Automatic detection of surge currents in steering (see chapt. 5.3 Steering learning function).

- Adjustment of the machine configuration (see 6 Configurations).

7.2 Replacement of engine components

After replacing parts on the engine block, especially when replacing control components, a
subsequent function test is highly recommended.

Note: A final function test of the complete machine is highly recommended.

The associated work steps are described in separate job instructions.

Machines with a Tier 4 final engine:

AA-E-016 Commissioning MTU-engines Tier 4 final with SCR-system in assembly department

(see no. 1 in 2.2 Reference Documents)

Machines with a Tier 3 engine:

AA-E-019 Commissioning MTU-engines Tier 3 in assembly department (see no. 2 in 2.2 Reference
Documents)

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7.3 Which components can be replaced without a subsequent adjustment
procedure?

- Display (A81)
- CAN IO module (A145)
- Travel lever
- All switches on the dashboards

Note: A final function test of the complete machine is highly recommended.

8 CAN bus structure

Travel lever

IO Module
A145 Display

ECU 1 A66

ECU 2 A34 ECU

levelling

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9 Commissioning of the level control

9.1 The configuration menu

Important parameters for the behaviour of the control in general and for the operation of
the individual sensor types in particular are compiled in the configuration menu of the MLS 508.
Here you will also find the calibration procedures for all sensors used in the system and the
hydraulics in the machine.

In the work window click on the function key F4 “Config.”

for 4 seconds to enter the Configuration menu.

9.1.1 Calibrating MIN pulse

Here the operator has the possibility to adjust the Min-pulse, i.e. the minimum control pulse
required for the hydraulic cylinder to move the shortest possible distance. This setting can be made
automatically by the system (only the two control circuits left and right), but also manually by the
user (all control circuits). Moreover, the automatic Min-pulse calibration strictly demands the
installation and connection of a Cross-Slope sensor.
During Min-pulse calibration finest cylinder movements are performed, which
must then be detected and interpreted by the operator during manual calibration,
or by the connected Cross-Slope sensor during automatic calibration.

During automatic calibration you should therefore avoid vibrations of any kind
(entering and exiting, load changes by acceleration, etc.) to ensure trouble-free
measuring and to avoid falsified results.

The Min-pulse calibration - no matter whether automatic or manual - must always

be carried out at nominal or working speed of the engine, because on most
machines different engine speeds result in different hydraulic pressures and thus
in different cylinder movements.

How to have the Min-pulses of the two control circuits on left and right hand side automatically
calibrated by the system:

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1) From the work screen change to the parameter Automatic Calibration via the menu options
Configuration menu, Hydraulic Calibration and Calibrate Min-Pulse.

2) Call up the parameter Automatic Calibration and follow the instructions in the display.

2a) Press function key F2 to start the test routine

The hydraulic system is automatically moved.

The test routine can be stopped at any time by

simply pressing the function key F2 once again!

Lifting and lowering of channel 1 and subsequently

channel 2 are triggered one after the other.

The arrow of the currently tested direction of movement

flashes in the display.

Unit for control valves = ms

Unit for proportional valves = %

The display does not show any units.

The Min-pulse values for lifting and lowering of the two

control circuits left and right determined by the system
are displayed.

3) Finish calibrating the Min-pulse and return to the work screen or continue by calibrating the Max-
pulse.

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How to calibrate the Min-pulses of the MLS 508 control circuit manually:

1) From the work screen change to the parameter Manual Calibration via the menu options
Configuration menu, Hydraulic Calibration and Calibrate Min-Pulse.

2) Call up the parameter Manual Calibration and follow the instructions in the display.

2a) Choose the channel for which you want to calibrate

the Min-pulses.

2b) Press function key F2 to start the test routine.

The hydraulic system is automatically moved.

Pressing the function key

F2 again stops the test routine at any time!

The system controls the hydraulic cylinder of the selected

channel alternately with one lifting pulse and one
lowering pulse.

Purpose of this setting is to find the smallest cylinder

movement and to synchronize this movement for lifting
and lowering.

2c) Use the UP/DOWN keys for the left or right control
circuit to increase or reduce the triggering signal for the
lifting or lowering signal of the selected channel, until the
corresponding cylinder performs minimum movements.

The two Min-pulses must be adjusted in such a way, that

the travel of the hydraulic cylinder triggered by the lifting
or lowering signal is identical to both directions; i.e. that
the cylinder performs shortest possible movement on the
spot during testing. The values found this way define the
Min-pulses for lifting and lowering in the selected
channel.

2d) Press function key F2 again to quit the test routine.

The arrow of the currently tested direction of movement

flashes in the display.

Unit for control valves = ms

Unit for proportional valves = %

The display does not show any units.

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3) By pressing the function key F3 the Min-pulse calibration of the selected channel is completed.
Execute the Min-pulse calibration for all other channels used in the same way. Finish calibrating the
Min-pulse and return to the work screen or continue by calibrating the Max-pulse.

9.1.2 Calibrating MAX pulse

CAUTION! Danger of injury caused by long cylinder movements!

Long cylinder movements are automatically executed during the calibration

of the hydraulic system.
Rotary and/or linear moving components and assemblies of the machine can
cause severe injuries and material damage.
Therefore:
• Keep persons out of the working range of the milling machine or the
milling drum.
• Remove any objects from the working range of the milling machine or
the milling drum.
• Do not reach into moving machine parts during operation

The maximum cylinder speed of each machine is determined by the physical conditions. In most
cases a tool will move much faster in "lowering" direction, because the weight of the tool will
additionally pull on the hydraulic cylinder.
This menu option gives the operator the possibility to synchronize the travel of the cylinder when
fully triggered for "Lifting" and "Lowering", by simply adjusting the submitted Max-pulse. This setting
can be made automatically by the system (only the two control circuits left and right), but also
manually by the user (all control circuits).

During Max-pulse calibration finest cylinder movements are performed, which must
then be detected and interpreted by the operator during manual calibration, or by the
connected Cross-Slope sensor during automatic calibration.

During automatic calibration you should therefore avoid vibrations of any kind
(entering and exiting, load changes by acceleration, etc.) to ensure trouble-free
measuring and to avoid falsified results.

The Max-pulse calibration - no matter whether automatic or manual - must always be

carried out at nominal or working speed of the engine, because on most machines
different engine speeds result in different hydraulic pressures and thus in different
cylinder movements.

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How to have the Max-pulses of the two control circuits on left and right hand side automatically
calibrated by the system:
1) From the work screen change to the parameter Automatic Calibration via the menu options
Configuration menu, Hydraulic Calibration and Calibrate Max-Pulse.

2) Call up the parameter Automatic Calibration and follow the instructions in the display.

2a) Press function key F2 to start the test routine.

The hydraulic system is automatically moved.

The test routine can be stopped at any time by

simply pressing the function key F2 once again!

Lifting and lowering of channel 1 and

subsequently channel 2 are triggered one after the
other.

The pulses occur with a relatively big temporal

distance.

Unit for control valves = ms

Unit for proportional valves = %

The display does not show any units.

The Max-pulse values for lifting and lowering of

the two control circuits left and right determined
by the system are displayed.

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 How to calibrate the Max-pulses of the MLS 508 control circuit manually:
1) From the work screen change to the parameter Manual Calibration via the menu options
Configuration menu, Hydraulic Calibration and Calibrate Max-Pulse.
2) Call up the parameter Manual Calibration and follow the instructions in the display.

2a) Choose the channel for which you want to calibrate

the Max-pulses.

2b) Press function key F2 to start the test routine

The hydraulic system is automatically moved.

The test routine can be stopped at any time by

simply pressing the function key F2 once again!

The system controls the hydraulic cylinder of the selected

channel alternately with one lifting pulse and one lowering
pulse.

In most cases the milling drum will drift off to one direction
after a few pulses. Purpose of this setting is the
synchronization of lifting and lowering movement.

2c) Use the UP/DOWN keys of the left or right control

circuits to increase or reduce the triggering signal for lifting
or lowering in the selected channel in steps, until the travel
of the hydraulic cylinder triggered by the pulses is identical
to both directions; i.e. the cylinder jumps to and fro when
being tested.

The values found this way define the Max-pulses for lifting
and lowering in the selected channel.

2d) Press function key F2 again to quit the test routine.

Unit for control valves = ms

Unit for proportional valves = %

The display does not show any units.

3) By pressing the function key F3 the Max-pulse calibration of the selected channel is completed.
Execute the Max-pulse calibration for all other channels used in the same way. Then quit the
calibration of the Max-pulses and return to the work screen.

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9.1.3 Information lines for switch on message

When the system is switched on, 3 information lines appear in addition to the system designation
and the logo of the manufacturer.
In the current menu option these information lines can be freely edited by the user (e.g. with
company name, model designation of the machine, name of driver, etc.).

Each line may contain max. 20 digits.

How to edit the information line for the switch-on message:

1) From the work screen change to the parameter Info lines for switch-on message via the menu
options Configuration Menu and Special Functions.
2) Call up the parameter Info lines for the switch-on message. and determine the contents of the
3 information lines that should be displayed as switch-on message.

= Change between the lines with the available

characters.
= Change between the available characters of a
line.

Enter = Accepts the character which is currently

highlighted and transfers it into the information line or
executes the commands “Clear” or “Save”.

Clear = Deletes the last character in the information line

that is currently edited.

Save = Saves a completely entered information line and

opens the window for entering the next.

3) Save the latest setting and return to the work screen.

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9.2 Summary of automatic hydraulics calibration:

Info: in software version V1.03 the travel speed range selector switch must be set to milling speed
and the milling rotor must be active. Otherwise the lifting post valves will not be addressed.
Attention!!! The machine must be approx. in the middle of its lifting post and should not contact
the ground.
For safety reasons the driver must remain seated on the machine!!!
New: from software version V1.05 activation of the milling rotor can be bypassed via input code
(seeFehler! Verweisquelle konnte nicht gefunden werden.).
The complete process takes about 10 minutes.

1. Press the button “Config” (3 seconds)

2. Choose the menu for hydraulics calibration and confirm
3. Choose the menu option “Min-pulse calibration” and confirm
4. Select “Automatic calibration”
5. Press key F2 (key “Finished”)
6. Press the “Run-Stop” button (the program starts)
7. Press the “Save” button to acknowledge
8. Press the “Exit” key
9. Select the menu option “Max-pulse calibration” and confirm
10. Select “Automatic calibration”
11. Press key F2 (key “Finished”)
12. Press the “Run-Stop” button (the program starts)
13. Press the “Save” button to acknowledge

14. Return to the configuration menu

15. Change to the menu option "“Special functions” and confirm
16. Use the arrow keys to enter the corresponding text and press “SAVE” to acknowledge

Line 1: BOMAG GmbH “Save”

Line 2: Hellerwald “Save”
Line 3: D-56154 Boppard “Save”

17. Press Exit to leave the menu, restart the machine and check the text!!!

9.3 The following values should be set:

Rope sensor deadband = 1 mm

Inclination deadband = 0,10 %
Control window for all distance sensors = 120 mm (as desired by the driver)
Distance sensors measuring units = mm
Slope sensor measuring unit =%
Sensor sensitivity rope sensor = 75 - 85
Sensor sensitivity slope sensor = 95 (85 – 95 as desired by the driver)

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10 Inspection and troubleshooting levelling control

10.1 Special functions

The menu “Special functions” primarily contains adjusting possibilities and parameters concerning
the configuration of the system or its functions /system diagnostics, menu language, energy
management, etc.) and the basic physics of the machine as well as its basic settings (dimensioning of
tools, allocation of control circuits, etc.).

10.2 System diagnostics

The system diagnose should draw the attention of the user to irregularities in the system and help
the service engineer to localize and rectify malfunctions.
It is automatically called up by the program if a component fails during operation or is removed from
the CANbus (cable breakage, cable disconnected, etc.).
However, the system diagnose can also be run manually at any time.
How to call up the system diagnose:

1) From the work screen change to the parameter System diagnose via the menu options
Configuration Menu and Special Functions.

2) Call up the parameter System diagnose.

The sensor monitoring screen appears . Normally the screen will display a valid measuring value
behind the sensors plugged in to the CAN-bus. In case of a fault the measuring value of a sensor will
be replaced by four horizontal dashes. In this case replace the connecting cable of the faulty
component with a fully functional one. If the fault has been rectified, the connecting cable is defect;
otherwise examine or replace the corresponding system component.

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2a) Press CONTINUE to receive more information about the system.

This window shows how often the associated component has logged in to the system
act. = since the supply voltage has been switched on the last time
absolute = since the commissioning of the system. If one of the sensors or actuators needs to be re-
initialized by the system several times, because e.g. the connecting cable has intermittent contact or
the voltage supply is interrupted from time to time, the number of new logins of these components
deviates considerably from the other ones (the example to the left allows the conclusion, that the
Cross-Slope sensor or its connecting cable is defective).
Holding the right hand Automatic/Manual button depressed for a longer period of time, deletes the
fault log.

2b) Press CONTINUE to receive more information about the system.

Current status 26.10.12: 1.102 10.05.11

1.300 12/11/2009

This window lists the version and date of creation of the application software* currently installed in
control panel and control unit as well as the available languages.
* Application software = specific user software

2c) Press CONTINUE to receive more information about the system.

Current status 26.10.12: 1.101 03/05/2011

1.101 02/05/2011

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This window lists the version and date of creation of the firmware** currently installed in control
panel and control unit. The communication version for control panel and control unit must therefore
be identical.
** Firmware = program to control peripheral equipment; similar to the operating system

2d) Press CONTINUE to receive more information about the system.

This window lists the IDs (identifications) of the sensors connected in the system.

2e) Press CONTINUE to receive more information about the system.

This window is normally empty. Here you find plain text descriptions of system faults that have
occurred. In the example shown at the left a rope sensor would have logged in to the system with an
impermissible address (e.g. due to a defective cable).

System diagnose page 9:

shows the Cross-Slope calibration protocol.

Here you can see by how many percent the sensor has been re-calibrated. Should the protocol show
implausible values, the calibration must be checked and may have to be repeated. If a calibration is
necessary, the calibration value is normally within the 0.xy% range.

10.3 Quick sensor inspection:

1. Move the right hand side plate (the value in the display should change)
2. Move the left hand side plate (the value in the display should change)
3. Move the lift posts, the inclination display (Slope) should change

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