This is the factory service manual for the Bomag BM 500/15 and BM 600/15 compact cold milling machines, and it is the real workshop book, not an operator pamphlet. You get full repair chapters for the milling drive (clutch, V-belt unit, gearbox), milling drum and tool holders, drum housing, conveyor belt, travel drive and levelling, plus complete hydraulics with pump descriptions and the travel/milling/steering circuits. The diagnostic side is genuinely useful: dedicated Error code lists (p.155-188), Query codes (p.189-200) and Input codes (p.201-210) you work through the machine display, plus ESX control replacement steps. Engine coverage runs deep on the 4-cylinder Deutz diesel: lubrication, coolant and fuel circuits, EMR3 electrics with pin assignments, and wiring plus hydraulic diagrams at the back.
What's Inside This Bomag BM 500, BM 15, BM 600 Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 1-28 | Bm 500/15, Bm 600/15, Compact Milling Machine, Safety Regulations, Important Notes, Transport Work with Cranes and Lifting Tackle, Electric Shock! |
| Technical Data | 29-34 | Dimensions, Weights, Milling Depth and Width, Travel Speeds, Engine Data, Filling Capacities |
| Maintenance | 35-44 | General Notes on Maintenance, Fuels and Lubricants, Engine Oil, Fuels, Quality, The Following Fuel Specifications Are Permitted:, En 590 |
| Electrics | 45-148 | Battery Service, Danger of Cauterisation ! Danger of Explosion!, Starting with Jump Wires, Main Battery Switch, No. 1 = Main Battery Switch, Position "I", Main Fuse |
| Codes - General Information | 149-154 | Codes -- General Information, Query Codes - General Information, Error Codes - General Information, Input Codes - General Information |
| Error Codes | 155-188 | Error Code Lists |
| Query Codes | 189-200 | Query Code Lists |
| Input Codes | 201-210 | Input Codes -- Display Function and Operation, Display Function and Operation, Input Codes -- Restoring Factory Settings, Input Codes -- Showing Logged Errors, Input Codes -- Deleting the Error Log |
| Replacement of Components | 211-212 | How to Proceed When Replacing Components?, Replacing the Control (ESX) |
| Engine | 213-258 | Checking the Engine Oil Level, Diesel Engine, Engine Description TCD 2012, Lubrication Oil Circuit TCD 2012 / 2013, Coolant Circuit TCD 2012 / 2013, Fuel System TCD 2012 / 2013, Exhaust Gas Recirculation TCD 2012 / 2013 |
| Engine Electrics | 259-364 | EMR3 System Components, Engine Control Unit, Pin Assignment of Engine Control EDC16 / EMR3, Rotary Speed Sensor for Camshaft, Speed Sensor, B114, Rotary Speed Sensor for Crankshaft, B130 |
| Milling Drive | 365-400 | Description, Milling Drive -- Overview, Repair, Overview Clutch Repair, Repair Overview V-Belt Unit, Gearbox Repair Overview, Remove the Clutch |
| Milling Drum | 401-418 | Description, Milling Drum - Overview, Repair, Replacing the Milling Drum, Repair Overview Milling Drum, Replacing Tool Holders, Wear Safety Goggles! |
| Milling Drum Housing | 419-442 | Repair, Repair Overview Hold-Down, Repair Overview Right Hand Side Plate, Repair Overview Left Hand Side Plate, Repair Overview Scraper, Split, Remove the Hold-Down |
| Conveyor Belt | 443-478 | Description, Conveyor Belt -- Overview, Frame, Care and Maintenance Work, Long - Repair, Repair Overview Conveyor Belt, Check, Tighten the Conveyor Belts |
| Travel Drive | 479-526 | Description, Travel System, Travel System -- Overview, Support Wheel Left, Support Wheel Right, Levelling, Care and Maintenance Work |
| Hydraulics - General | 527-560 | Hydraulics - Component Overview, Hydraulic Circuit, Open Circuit, Arrangement of Hydraulic Pumps, Variable Displacement Pumps, A10VG28/45/56 Ep, Description of Travel Pump, EP Control with Proportional Solenoid |
| Hydraulics - Travel, Milling, Functions | 561-582 | Hydraulics - Travel Circuit, Travel System, Description of Driving, Folding the Right Hand Wheel, Description of Crawler System, Levelling, Steering Circuit |
| Tests and Adjustments | 583-606 | Checking and Adjusting the Levelling, Special Tools, Checking/Adjusting the Roof Adjustment, Measuring the Clutch Operating Pressure, Checking/Adjusting the Brake Releasing Pressure, Checking the Brake Releasing Pressure, Checking and Adjusting the Steering Pressure |
| Suppliers Documentation | 607-852 | Travel Pump, Travel Motor, Steering Valve, Conveyor Belt Motor |
| Circuit Diagrams | 853-1178 | Hydraulic Diagram 161, Wiring Diagram 72, Wiring Diagram 77, Wiring Diagram 84, Wiring Diagram 98, Wiring Diagram 108 |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine | 4-cylinder Deutz diesel, 92 kW at 2100 rpm | p. 31 |
| Milling width | 500 mm | p. 30 |
| Milling depth | 0-210 mm | p. 30 |
| Milling cutters | 58 pieces, 15 mm line distance | p. 30 |
| Milling drum speed | 115/130/145 rpm | p. 30 |
| Operating weight (CECE), with conveyor belt | 7600 kg | p. 30 |
| Max. operating weight | 8400 kg | p. 30 |
| Working speed | 0-30 m/min | p. 30 |
| Travel speed | 0-6 km/h | p. 30 |
| Fuel capacity | approx. 230 litres | p. 31 |
| Water capacity (sprinkler) | approx. 600 litres | p. 31 |
| Hydraulic oil capacity | approx. 100 litres, HV 46 (ISO) | p. 31 |
Bomag BM 500, BM 15, BM 600 Common Problems This Manual Covers
Engine cuts out during milling or will not start, with no obvious mechanical cause
Pull the stored faults first using the Input codes procedure for showing logged errors, match them against the Error code lists on pages 155-188, then trace the flagged circuit with the wiring diagrams instead of blind parts swapping on switches and solenoids.
Manual Section: Error Codes (p.155-188) / Input Codes (p.201-210) p. 155Travel drive will not engage or the brake will not release
The Tests and Adjustments chapter gives the procedure for checking and adjusting the brake releasing pressure with proper gauge points, and the hydraulics travel circuit description explains the valve logic so you can tell a pressure problem from a coil or wiring fault.
Manual Section: Tests and Adjustments - Checking the brake releasing pressure p. 583Conveyor belt slipping, running off track or spilling millings
The Conveyor belt chapters (p.449-478) cover both the long and short belt with a full repair overview, the frame, and the specific procedure for checking and tightening the belts, plus the routine care and maintenance work that keeps the 400 mm belt tracking straight.
Manual Section: Conveyor Belt - long/short repair (p.449-478) p. 449Milling drive slips under load from a worn clutch or loose V-belts
Follow the Milling drive repair section on pages 375-382: clutch removal, clutch repair overview and V-belt unit overview with the factory torques (clamping element 250 Nm, position 25 at 412 Nm), then verify with the clutch operating pressure measurement in Tests and Adjustments.
Manual Section: Milling Drive - repair (p.375-382) p. 375Frequently Asked Questions
My machine cuts out mid-pass or randomly refuses to start, and nobody can find the fault. Will this manual actually help?
This is the exact book for that job. Intermittent cutouts on these machines almost always trace to the interlock and sensor chain, and the manual gives you three tools: the Error code lists (p.155-188) to identify what the control logged, the Input codes chapter (p.201-210) to pull the stored error log through the display, and the wiring diagrams (72, 77, 84, 98, 108) to chase the circuit wire by wire. That beats swapping switches on guesswork. p. 155
Can I read and clear fault codes without a dealer laptop?
Yes. The BM 500/15 and BM 600/15 work through the onboard display, and the manual walks you through it: Query codes for reading live values, Input codes for showing logged errors, deleting the error log, and restoring factory settings. There is also a general chapter explaining how the whole code system works before you start punching buttons. p. 149
Does it cover changing the milling drum and the cutter tool holders?
Fully. The Milling drum chapter (p.401-418) covers replacing the complete drum, replacing worn tool holders, and the repair overview for the drum itself. For reference, the drum carries 58 cutters at 15 mm line spacing and runs at 115/130/145 rpm. The separate drum housing chapter handles the hold-down, side plates and scrapers, which wear out just as often as the picks do. p. 401
The milling drive is slipping. Are the clutch and V-belt repairs in here with real torque figures?
Yes. The Milling drive repair section (p.375-382) has the clutch removal procedure, the clutch repair overview, the V-belt unit repair overview and the gearbox overview, with actual tightening values: 250 Nm on the clamping element and 412 Nm at position 25. There is also a clutch operating pressure check in the Tests and Adjustments chapter so you can confirm the fix. p. 375
What engine is in these machines and how deep does the engine coverage go?
A 4-cylinder Deutz diesel from the TCD family, rated 92 kW at 2100 rpm. The Engine chapter covers the lubrication oil circuit, coolant circuit, fuel system and exhaust gas recirculation. The Engine Electrics chapter is the valuable part for troubleshooting: EMR3 system components, engine control unit pin assignments, and the camshaft and crankshaft speed sensors (B114, B130) that cause plenty of no-start calls. p. 213
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