Dynapac PL 1000 RS Operation & Maintenance Manual Download

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502

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02-0407

OPERATION

MAINTENANCE

Keep this manual for future reference

Order number for this manual:

900 98 12 29

Gültig ab Seriennummer:xxx.xxx

Cold Planer

PL 1000 RS

Summary of Contents for PL 1000 RS

Page 1: ...502 02 0407 OPERATION MAINTENANCE Keep this manual for future reference Order number for this manual 900 98 12 29 G ltig ab Seriennummer xxx xxx Cold Planer PL 1000 RS...

Page 2: ...VALUE QUALITY THE ORIGINAL Your Authorizied Dynapac Dealer SPARE PARTS...

Page 3: ...yed The machine may only be operated by trained staff These Operating Instructions must be read and applied by every person engaged in the operation upkeep maintenance repair servicing or transport of...

Page 4: ...existing national or regional specifications regarding technical regulations accident prevention and environmental protection In the interest of further technical development the manufacturer reserves...

Page 5: ...4 7 Water system 11 4 8 Loading system 11 4 9 Electrical system 11 5 Identification points and type plates 12 5 1 Type plate and vehicle identification number 12 Type plate machine 13 5 2 Identificat...

Page 6: ...hocks 45 Vandalism protection 46 4 Levelling unit 47 4 1 MOBA matic type 47 5 Operating the MOBA matic 48 6 Operating the MOBA matic 50 6 1 Liquid crystal display M1 54 Activation message 54 Sensor me...

Page 7: ...height sensors 87 Milling with height sensors together with the transverse slope sensor 91 Ending the milling procedure 93 Parking the machine 94 Parking the machine for long periods of time 95 9 Sco...

Page 8: ...Hydraulics 17 Hydraulic oil tank 17 Changing the hydraulic oil 18 Suction return hydraulic filter 19 Hydraulic hoses 19 Pump pedestal 20 3 3 Drive wheels chassis legs 21 Planetary gears 21 3 4 Millin...

Page 9: ...ydraulic cylinder 56 5 Inspections 57 General visual inspection 57 Inspection by a specialist 57 6 Lubrication agents and fuel substances 58 6 1 Hydraulic oil 59 6 2 Filling volumes 60 7 Electrical fu...

Page 10: ......

Page 11: ...ting transport mainte nance and repair conditions specified in the Operating Instructions The machine is not designed for any type of usage not described in the intended us age section The manufacture...

Page 12: ...with other unauthorised parts and any attempt to take these out of service either completely or partially render null and void the manufacturer s li ability for any resultant damage The attachment or...

Page 13: ...ngle section rear loading conveyor This cold planer has been developed for tasks such as the cost effective removal of asphalt and concrete for medium to large milling operations The right hand chassi...

Page 14: ...em Designation 1 Frame 2 Operator s control station 3 Driver s seat 4 Drive wheel 5 Chassis leg 6 Swivel mounted chassis leg 7 Milling depth display 8 Water tank 9 Water spraying system 10 Weather pro...

Page 15: ...the operator s control station Access to all major switching and connection points as well as to all maintenance lo cations can be locked Engine The machine is equipped with a powerful 6 cylinder Cum...

Page 16: ...eed ranges The hydraulic travel drives are connected to the wheel hubs by means of planetary gears This ensures optimum feed and high gradeability A multi disc brake on the rear wheels acts as brake W...

Page 17: ...steering sys tem are shut down when the emergen cy stop button is pressed Any countermeasures which may be re quired manoeuvring deploying the chassis legs are then no longer pos sible The EMERGENCY S...

Page 18: ...on the control panel The function of the headlights and warn ing lamps should be checked on a daily basis before starting work The headlights are easy to remove and should therefore as a safety precau...

Page 19: ...7 B_PL1000RS_GB fm 7 18 04 07 Limit switch on upper conveyor A limit switch on the frame of the upper conveyor prevents unfavourable load levels arising from excessive raising ac tion Limit_PL600 wmf...

Page 20: ...PL1000RS_GB fm 8 18 04 07 4 Technical data standard version 4 1 Dimensions 2250 1850 840 630 1400 73 37 R360 25 25 PL1000_measure_side cdr PL1000_measure_top cdr 8550 4350 4100 1060 2360 860 2600 3460...

Page 21: ...a Operating weight 12 400 kg Transport weight 11 400 kg Ballast weight total max 13 200 kg Transportation speed 0 6 km h Operating speed 0 30 m min Milling width 1000 mm Milling depth 0 250 mm Spacing...

Page 22: ...n full load Fuel consumption 2 3 load 23 2 l h 15 5 l h Fuel tank filling volume approx 340 l Input Hydrostatic drive continuously variable across two speed ranges Input via the front wheels and rear...

Page 23: ...ystem 4 9 Electrical system Spray nozzles 6 units Water tank filling volume approx 1200 l Belt width upper conveyor 400 mm Belt speed approx 4 m s Loading capacity theoretical approx 80 m3 h On board...

Page 24: ...ype plate and vehicle identification number Item Designation Position 1 Type plate Vehicle frame recess for swivel mounted chassis leg 2 Vehicle Identification Number VIN Vehicle frame at rear right h...

Page 25: ...ntification number 11 Item Designation 4 Planer type 5 Year of construction 6 Serial number of machine model 7 Maximum permitted operational weight 8 Maximum permitted axle load at front in kg CE 9 Ma...

Page 26: ...B 14 B_PL1000RS_GB fm 14 18 04 07 5 2 Identification points 8 10 2 2 9 3 7 6 11 4 2 12 1 2 5 25...

Page 27: ...B 15 B_PL1000RS_GB fm 15 18 04 07 14 14 13 16 16 3 17 20 19 2 2 18 13 21 22 23 24...

Page 28: ...radiator 8 956 05 20 02 9 956 05 20 09 Beside the batteries 10 956 05 30 02 11 990 00 02 15 On filler neck for diesel fuel 12 956 05 30 39 13 956 04 49 00 14 956 05 20 10 15 956 05 20 11 16 956 05 20...

Page 29: ...ISO 4872 under free field conditions Sound pressure level at driver s seat head height LAF dB A Sound pressure level on the machine LWA dB A 6 2 Operating conditions during the measurements The diesel...

Page 30: ...the protection require ments of the EMC Guideline 89 336 EEC 08 95 Emitted radiation in accordance with DIN EN 50081 1 03 93 40 dB V m for frequencies of 30 MHz 230 MHz at 3 m measuring distance 47 d...

Page 31: ...thorised for transport of this type and that the maximum transport load is not exceeded Store all components which are not permanently connected to the machine in the boxes and storage areas provided...

Page 32: ...uld be fastened to these points during transport on the transport ve hicle The machine must be secured on the vehicle with appropriately sized lifting tackle chain pulleys and protected against tippin...

Page 33: ...machine should be cleaned before being loaded The machine should be parked and secured as follows Position the machine on the transporter ensuring that the transport height width and loaded distribut...

Page 34: ...easures cor doning off required for this should be implemented If a machine needs to be parked in an area of heavy traffic it must be cordoned off in accordance with specifications and the machine mus...

Page 35: ...vehicle using lifting gear Secure vehicle wherever it is parked up Store loose parts and accesso ries e g lamp fittings in a safe place Attach lifting gear to the four at tachment points 1 2 During t...

Page 36: ...ted in order to tow away the machine First of all unfasten the lock nut 1 on the hand pump and tighten the thread ing dowel 2 as far as possible into the pump Re tighten the lock nut for safety Now us...

Page 37: ...r the machine evenly until the milling drum is almost in contact with the ground Access to the milling drum should be cordoned off Remove ignition key 1 and master switch 2 and take them with you do n...

Page 38: ......

Page 39: ...mit the machine to be started safely Sound the horn as a warning before starting the machine Do not stand in the danger area of the vehicle unless absolutely necessary Danger of death While the equipm...

Page 40: ...D 2 D_PL1000RS_GB fm 2 112 04 07 2 Controls 2 1 Control panel Panelkompl_500_1000 bmp Verriegel_Lenk cdr C B A D 1 2...

Page 41: ...Safeguard steering unit The entire steering unit can be set up to suit the needs of the driver Open both safeguards and turn steering unit to left or right using steering wheel then swivel upwards or...

Page 42: ...D 4 D_PL1000RS_GB fm 4 112 04 07 P 0 I I I 8 Panel3_600 cdr A 7 5 3 4 6...

Page 43: ...ot be started until indicator lamps 38 39 40 41 42 go out Key can only be removed from ignition lock in positions P and 0 5 Multi function switch Integrated flasher switch and switch for high beam and...

Page 44: ...D 6 D_PL1000RS_GB fm 6 112 04 07 Panel2_500_1000 bmp B 23 24 22 21 20 25 27 26 36 37 38 28 29 30 34 32 33 35 31...

Page 45: ...OP but tons must be raised The traction unit brakes are applied whenever an emergency stop button is pressed 21 Hazard flasher Switch on for safety on roads 22 Warning lights Two switch positions can...

Page 46: ...D 8 D_PL1000RS_GB fm 8 112 04 07 Panel2_500_1000 bmp B 23 24 22 21 20 25 27 26 36 37 38 28 29 30 34 32 33 35 31...

Page 47: ...nditions quantity of material involved de livery speed This adjustment can also be made while the milling op eration is running Ensure that no cut material accidentally gets slung from the upper conve...

Page 48: ...D 10 D_PL1000RS_GB fm 10 112 04 07 Panel2_500_1000 bmp B 23 24 22 21 20 25 27 26 36 37 38 28 29 30 34 32 33 35 31...

Page 49: ...ds to be retracted completely and the driv er s seat needs to be slid inwards as far as pos sible Travel is only approved when the chassis leg is swivelled all the way in or out 30 Electric differenti...

Page 50: ...D 12 D_PL1000RS_GB fm 12 112 04 07 Panel2_500_1000 bmp B 23 24 22 21 20 25 27 26 36 37 38 28 29 30 34 32 33 35 31...

Page 51: ...is engaged 32 Mode Upper conveyor Three switch positions can be selected 0 upper conveyor transport function OFF AUTO transport function is linked to the control le ver The upper conveyor only starts...

Page 52: ...D 14 D_PL1000RS_GB fm 14 112 04 07 Panel2_500_1000 bmp B 23 24 22 21 20 25 27 26 36 37 38 28 29 30 34 32 33 35 31...

Page 53: ...is however possible for the scraper to dig into the substrate This can be avoided through use of the blocking or relief function 35 Selector switch Sliding shoe Two switch positions can be selected 0...

Page 54: ...D 16 D_PL1000RS_GB fm 16 112 04 07 Panel2_500_1000 bmp B 23 24 22 21 20 25 27 26 36 37 38 28 29 30 34 32 33 35 31...

Page 55: ...when the control lever for the travel drive is fully extended milling mode 1 Levelling unit ON levelling unit active responds independently of control lever Adjustments using the connected levelling...

Page 56: ...D 18 D_PL1000RS_GB fm 18 112 04 07 Panel1_500_1000 bmp Panel_Leucht wmf 63 53 52 51 50 49 48 47 46 45 44 62 C 54 43 42 41 40 64 60 55 61 56...

Page 57: ...ration at excessively low or high cool ant temperature can damage the engine Check coolant temperature gauge frequently Switch off engine if temperature does not match the specified values Check coola...

Page 58: ...D 20 D_PL1000RS_GB fm 20 112 04 07 Panel1_500_1000 bmp Panel_Leucht wmf 63 53 52 51 50 49 48 47 46 45 44 62 C 54 43 42 41 40 64 60 55 61 56...

Page 59: ...Lights up for a few seconds to check that the ig nition is engaged Do not start the engine until this indicator lamp has gone out 46 Maintenance yel low Indicates that coolant water level in engine i...

Page 60: ...D 22 D_PL1000RS_GB fm 22 112 04 07 Panel1_500_1000 bmp Panel_Leucht wmf 63 53 52 51 50 49 48 47 46 45 44 62 C 54 43 42 41 40 64 60 55 61 56...

Page 61: ...avel drive yel low Always lights up when the steering system is in straight ahead position as well as during steering movements with the differential lock activated If a fault occurs in the travel dri...

Page 62: ...D 24 D_PL1000RS_GB fm 24 112 04 07 Panel1_500_1000 bmp Panel_Leucht wmf 63 53 52 51 50 49 48 47 46 45 44 62 C 54 43 42 41 40 64 60 55 61 56...

Page 63: ...ined angle of 5 5 Whenever the tilt alarm is enabled the levelling function is switched into semi automatic mode 60 Lighting To light operating panel when parking lights are switched on 61 Water scale...

Page 64: ...D 26 D_PL1000RS_GB fm 26 112 04 07 Panel4_1000 cdr D 73 74 70 75 77 78 76 71 72...

Page 65: ...swivels the upper conveyor to the right Swivel direction forwards lowers the upper con veyor Swivel direction backwards raises the upper con veyor The upper conveyor is moved continuously while the co...

Page 66: ...D 28 D_PL1000RS_GB fm 28 112 04 07 Panel4_1000 cdr D 73 74 70 75 77 78 76 71 72...

Page 67: ...the danger area 76 Raising lower ing the sliding shoe The sliding shoe is raised or lowered to the upper or lower limit position whenever the switch is being pressed in the relevant direction Danger...

Page 68: ...D 30 D_PL1000RS_GB fm 30 112 04 07 Sockets and interfaces on the operating panel Panel_Interface_500_1000 bmp 91 92 93 94 95 90...

Page 69: ...l drive At these interfaces action can be taken when faults occur in the anti slip control system and in the drive control system 93 Socket on levelling unit left Socket for connecting up manual set c...

Page 70: ...of back rest support until the approximate weight of the driver is displayed on the scale 2 To set the correct distance from the operating panel pull lever 3 for wards then slide seat forwards or bac...

Page 71: ...gers near the articulated joints during the roof folding operation To raise the roof reverse the order of this procedure Side roof A side roof can be pulled out from the right hand side of the weather...

Page 72: ...the roof has to be raised when the bat tery is flat there is a hand pump on the hydraulic unit First of all unfasten the lock nut 2 on the hand pump and tighten the thread ing dowel 3 as far as possi...

Page 73: ...not be able to start the machine For the specifications governing all fus es refer to Chapter Maintenance Always switch off the master switch after finishing work otherwise battery might dis charge a...

Page 74: ...d chassis leg has a display unit on both sides for these positions Chassis leg deployed Chassis leg retracted To set the indicator to a desired value the retainer 2 needs to be unfas tened and the ind...

Page 75: ...in bore 3 If the chassis leg is retracted the direc tion of rotation of the wheel must be re versed The changeover valve in the hydraulic circuit is located in the wheel bracket on the swivel mounted...

Page 76: ...pper position by means of a re taining hook Extend the moldboard until the retain ing tab on the flap 1 locates in the re taining hook 2 To lower the moldboard first raise the flap slightly until the...

Page 77: ...the control panel If the air bubble is located inside the marked area 1 in the centre of the tube the machine is standing on level ground If the air bubble leaves the marked ar ea one side of the mach...

Page 78: ...g equipment the setting values need to be adapted after adjust ment Load relief of moldboard For certain defined working situations the load relief on the moldboard can be adjust ed The handwheel 3 us...

Page 79: ...chalk etc Two different direction indicators are lo cated on the machine frame Pointer 1 runs accurately over the outside edge of the milling drum The depth of the indicator can be ad justed using th...

Page 80: ...desired position and secure using wing nut 2 The function of the headlights and warn ing lamps should be checked on a daily basis before starting work The headlights are easy to remove so should be t...

Page 81: ...ain the water tank move valve lever 2 into through flow direction The water in the tank is then drained out of an outlet underneath the machine This water is definitely not drinking quality If there i...

Page 82: ...ntighten the knurled screw 2 to the desired setting Check the water pump oil pressure on the pressure gauge 3 then tighten down the lock nut 1 to its correct set ting If the adjusting screw 2 is unscr...

Page 83: ...m 45 112 04 07 Chocks The machine s accessories pack in cludes a chock If the machine is parked on uneven ground a chock should be placed under the rear wheels to prevent it from rolling away accident...

Page 84: ...secured with a screw to provide protec tion against vandalism to the operating panel When work finishes this cover should be fitted over the operating panel and secured retaining clamps and locks on...

Page 85: ...ce sensor 4 Digi Rotary sensor distance sensor 5 Laser receiver distance sensor 6 Digi Slope sensor slope sensor If the optional levelling unit is fitted to this machine two digital controllers and tw...

Page 86: ...D 48 D_PL1000RS_GB fm 48 112 04 07 5 Operating the MOBA matic Nivellcompl cdr A C B...

Page 87: ...op control system for the levelling unit on the left side of the machine B MOBA actual val ue indicator Actual value indicator for height sensing and lateral slope on left right sides of machine C MOB...

Page 88: ...D 50 D_PL1000RS_GB fm 50 112 04 07 6 Operating the MOBA matic Moba1can jpg M10 A C M2 M3 M6 M7 M9 M8 M4 M5 M1 M11...

Page 89: ...ual mode The display indicates the nominal value selected Lamp on Machine operating in automatic mode automatic mode has been activated on the main operating panel The display indicates the nomi nal v...

Page 90: ...D 52 D_PL1000RS_GB fm 52 112 04 07 Moba1can jpg M10 A C M2 M3 M6 M7 M9 M8 M4 M5 M1 M11...

Page 91: ...hine re sponds in automatic or manual mode change to ac tual value Machine does not respond in semi automatic mode only for pre selections i e nominal value specifica tions M8 Automatic semi automatic...

Page 92: ...and all function lamps are activated for approx 2 seconds Should symbols not appear on the display please contact After Sales Service Symbol Meaning ARROWS RAISE 12 LOWER 13 Controlled controller outp...

Page 93: ...should be reminded that the sensor has been replaced and that settings for the sensor should therefore be checked Changeover between height sensor and lateral slope Press the A M button and the input...

Page 94: ...e RAISE control out put constantly lit Arrow flashing Arrow flashing Average control variance RAISE control out put runs through cycle with large pulse width Arrow flashing Bar lit arrow flashing Smal...

Page 95: ...7 6 2 Actual value indicator O The optional actual value indicator provides a means of comparing the nominal value as displayed by the MOBA matic and the prevailing actual value FP LQFK Moba2 cdr M20...

Page 96: ...ce versa The lateral slope can only be displayed in one of the two indicators M23 Receptacle For connecting with the associated connection cable on one of the operating panel s receptacles and or for...

Page 97: ...ese two sockets The cable tension sensor for the side board on the left side of the machine 2 is also arranged at this location on the underside of the machine frame If required the tension cable on t...

Page 98: ...Proceed as follows during the connection process Unscrew protective cap from connector Fit connector in position determined by plastic ridge on socket and groove in side of connector Tighten cap ring...

Page 99: ...devices can also be connected to the machine locations illustrated here The sockets for the two distance sensors and the lateral slope controller are located underneath the machine frame between the...

Page 100: ...ection cable is not damaged Keep threads on plugged connections and cable connections free of dirt and grease to prevent bad contacts Only appropriate cleaning agents should be used for cleaning purpo...

Page 101: ...ouch of the button and either changes its milling depth or lateral slop depending on the sensor connected up The newly set nominal value does not need to be con firmed using the SET button in these op...

Page 102: ...00RS_GB fm 64 112 04 07 UP DOWN keys simultaneous press ing During the milling process with the height sensors in automatic mode The nominal value is immediately set to 0 useful when milling recesses...

Page 103: ...is must be done before changing over into automatic mode so that this value is adopted as the nominal value When the height sensors are being used if the actual value or a preselect ed value is to ado...

Page 104: ...via the digital controller Automatic mode for milling operations can only be set from the operating panel of the operator s control station During the milling process changes to all operating modes au...

Page 105: ...tly and provides a clear line of sight to the rotating mill ing drum and the ground Other tasks Lower back of machine using the ap propriate function key on the control panel without allowing the rota...

Page 106: ...ut keys of the left and right controllers approx 1 5 sec until SET and then the value 0 0 ap pear on the display The actual and nominal values are now set to zero If the Digi Sonic sensor is used as t...

Page 107: ...define the lateral slope of the ground The side boards are lowered The milling drum is activated the diesel engine runs at idle speed The moldboard is raised slightly and provides a clear line of sigh...

Page 108: ...he display then the display changes again to the actual value The input key remains depressed and the actual value is corrected to the val ue required example 2 3 using the UP DOWN buttons Only then r...

Page 109: ...ars on the display then the display changes again to the actual value The input key remains depressed and the actual value is corrected to the val ue measured in the milling lane ex ample 1 2 using th...

Page 110: ...spare bits and other spare parts required as well as items of clothing for personal safety protective clothing reflective jackets gloves ear protection should be available Before starting work Read s...

Page 111: ...How Emergency stop button on main control panel Check with engine running Engine must shut down immediately af ter actuation The button engages and must be pulled out so that the engine can be starte...

Page 112: ...ted and the ma chine can be operated Daily machine maintenance Check the operating hours counter to determine whether further maintenance work should be conducted Check the safety and protection equip...

Page 113: ...0 position or if the emergency stop button is pressed and the milling drum drive or height ad juster must also be engaged If the engine does not start straightaway continue starting for a maximum of...

Page 114: ...ble cables Check correct polarity Always connect the negative cable last and remove it first Insert ignition key 4 in ignition lock in setting P Switch on ignition Pos 1 Turn ignition key in Pos 2 to...

Page 115: ...d be engaged The optimum operating values of a warm machine are Coolant temperature of engine 60 C Hydraulic oil temperature 40 C Take due note of visual signal from the hydraulic system If the indica...

Page 116: ...tortoise symbol Check that all other functions are switched to 0 and if necessary select this set ting Always operate hazard lights when moving the machine rotary beacons and hazard flashers Set cont...

Page 117: ...D 79 D_PL1000RS_GB fm 79 112 04 07 8 Milling instructions Driving position Chassis legs lowered milling drum raised Milling position Chassis legs raised planer lowered PL600_Back1 cdr PL600_Back2 cdr...

Page 118: ...n any way Surface milling 1 With deployed right hand chassis leg The right hand chassis leg engages in the milled and cleaned first lane Depth setting right zero left desired milling depth 2 With fold...

Page 119: ...n For planing operations lower the ma chine evenly down to the desired milling depth Depth setting left desired milling depth right desired milling depth height of offset or in such a way that the pla...

Page 120: ...12 04 07 Milling at the curb with chassis leg swivelled in Advantages Maximum milling depth is reached direct planing against kerb possible Disadvantages Less precise planing results Less exact planin...

Page 121: ...position and is disengaged automatically as soon as the machine is stopped Item Switch Position 28 Transport working gear Working gear tortoise mode 27 Preselector for travel drive Approx average powe...

Page 122: ...D 84 D_PL1000RS_GB fm 84 112 04 07 Planing without automatic levelling device Panel2_500_1000 bmp Panel4_1000 cdr Skala5 wmf A 70 71 73 74 25 20...

Page 123: ...o zero Press the switches 74 73 again to lower the machine carefully down to the de sired milling depth paying careful attention to the milling depth indicators Set desired milling speed by adjusting...

Page 124: ...value and or actual value calibration has been conducted the machine is in its operating position all other settings required for planing have been conducted on the machine The A M button is switched...

Page 125: ...er using switch 1 on operating panel to control the rear chassis legs evenly until baseplates on the side boards make contact with the ground at the back of the machine When starting to mill with offs...

Page 126: ...th preselected with the drive lever deflected slightly Set desired milling speed by adjusting the setting of the drive lever The machine starts to move when the drive lever moves out of its central po...

Page 127: ..._PL1000RS_GB fm 89 112 04 07 When starting to mill without offset i e lower machine gradually from zero to the milling depth required Panel2_500_1000 bmp Panel4_1000 cdr Moba1a cdr Moba29 jpg 37 38 M2...

Page 128: ...e the DOWN buttons M7 to slowly set the nominal value and therefore continuously lower to the milling depth required Set desired milling speed by adjusting the setting of the drive lever The machine s...

Page 129: ...D 91 D_PL1000RS_GB fm 91 112 04 07 Milling with height sensors together with the transverse slope sensor Panel2_500_1000 bmp Panel4_1000 cdr Moba1a cdr Moba29 jpg 37 38 M2 M8 M7 73 74 M6 71...

Page 130: ...th note direction of slope Use switches 37 and 38 on the main control panel to shift the levelling unit to automatic The machine now lowers to the values set Set desired milling speed by adjusting the...

Page 131: ...r raising and lowering speed 36 to rapid adjustment beforehand Allow milling drum drive 31 water pump 33 and upper conveyor 32 to run on briefly then switch to 0 Move switch 38 to transportation speed...

Page 132: ...ensure that unau thorised persons and children cannot do any damage to the machine The machine should be parked on level ground Lower the machine evenly until the milling drum is almost in contact wit...

Page 133: ...protect the operating panels by fitting the supplied locking cover and se curing its lock Storage temperature must not exceed 70 C or be less than 12 C If the machine is stored at temperatures below...

Page 134: ...small planers Remedying longitudinal and transverse bumps in the road surface Remedying cracks Remedying potholes frost damage Plan1 tif after before Planing Selective cutting Plan2 tif after before...

Page 135: ...age to edges and bumps Producing adjoining edges Producing slots joints and cable trenches Plan4 tif after before Wedge shaped cutting Plan5 tif after before Wedge shaped cutting Plan6 tif Selective c...

Page 136: ...lishing surface grip Plan7 tif after before Selective cutting with special purpose joint cutting tools Plan8 tif after before Planing off road surface markings using fine spaced milling drums or marki...

Page 137: ...ry key 3 This flash code is issued in each case by a second warning lamp If a malfunction af fects warning lamp 44 the flash code is then issued by warning lamp 45 and vice versa Output of the numeric...

Page 138: ...first indicated the presence of the error lights back up again This continues until the malfunction or defect has been remedied In cases where several defects occur simultaneously the various differe...

Page 139: ...when the idle validation switch indicates off idle 133 YELLOW P029 3 029 3 High voltage detected at remote throttle position signal pin 9 of the OEM harness Engine will not respond to remote throttle...

Page 140: ...led 191 P050 11 876 11 A C Clutch drive signal indicates a short to ground when com manded on Can not turn on A C 234 RED P190 0 190 0 Engine speed signal indicates engine speed has exceeded the overs...

Page 141: ...e the VP44 pump speed as a backup Possible white smoke and power loss 297 YELLOW P223 3 1084 3 High voltage detected at OEM pressure signal pin 48 of the OEM harness Default value used for OEM pres su...

Page 142: ...hieve the timing value being commanded by the engine ECM Significant engine power loss 369 YELLOW P190 2 1078 2 VP44 fuel pump controller does not detect engine position pulse at pin 7 of the engine h...

Page 143: ...r sensors con nected to this 5 VDC supply Engine will derate to no boost fueling and loss of engine protec tion for oil pressure intake manifold temperature and coolant tempera ture 387 YELLOW P091 3...

Page 144: ...d and load indicate boost pressure should be low Possible overfueling during acceler ation Increase in black smoke 434 YELLOW S251 2 627 2 Supply voltage to the ECM fell below 6 0 VDC for a fraction o...

Page 145: ...valve has been detected by the VP44 fuel pump controller Engine may shut down 524 YELLOW P113 2 113 2 Error detected on the High Speed Governor Droop selec tion switch input pin 24 of the engine harn...

Page 146: ...own or has been keyed off while above a specified load limit No effect 768 YELLOW S009 11 923 11 Error detected in the Output De vice Driver Transmission Shift Modulation Signal signal pin 21 on the O...

Page 147: ...112 04 07 10 2 Error messages for anti slip control Advise our After Sales Service staff of the malfunction number being displayed for your road planer and we will be only too pleased to discuss what...

Page 148: ...0 112 04 07 10 3 Error message from travel drive Advise our After Sales Service staff of the malfunction number being displayed for your road planer and we will be only too pleased to discuss what act...

Page 149: ...D 111 D_PL1000RS_GB fm 111 112 04 07 10 4 MOBA Matic error messages...

Page 150: ......

Page 151: ...ine to prevent it from being started accidentally Move drive lever into centre position and turn preselector controller to zero remove ignition key and battery s main switch Secure raised machine comp...

Page 152: ...carry out planing operations without the upper conveyor this should be removed from the machine This operation involves following a few simple steps Upper conveyor and milling drum must be disengaged...

Page 153: ...supported on the ground Set up cylinder bracket 3 so that it is located directly underneath the cylinder Using the chassis legs lower the machine until the hydraulic cylinder is located in its bracke...

Page 154: ...4 4 04 07 Remove the locking pins 6 from both sides Lower the moldboard slightly until the retaining pins 7 are located above the re taining brackets 8 Drive machine off its upper conveyor PL600_conv...

Page 155: ...ine feed to Zero using the preselector Remove ignition key and main battery isolator Attach DO NOT START panel to control panel in clearly visible location When working below the machine always secure...

Page 156: ...y use wearing parts and spare parts approved by the manufacturer and fit them properly In cases of doubt consult the manufacturer Only use substances recommended in these Operating Instructions as lub...

Page 157: ...ystem Check oil level Top up oil Change oil Change oil filter Change fuel filter Fuel filter drain water separa tor Bleed fuel system Check air cleaner Empty dust collection tank Clean replace air fil...

Page 158: ...eck oil level Top up oil Change oil Suction return hydraulic filter Change filter cartridge Hydraulic hoses Perform a visual inspection Replace hoses Pump pedestal Change oil 3 3 Drive wheels Planetar...

Page 159: ...d Replace sliding shoes Replace support plates Belt drive Check belt Replace belt Clutch Check friction lining Replace belt Angular gear Check oil level Top up oil Change oil Milling drum gear box Che...

Page 160: ...Check tension deflection Adjust tension deflection Check for signs of damage Replace conveyor belt Loading belt rollers Check condition Replace rollers Steel securing rope Check condition Replace secu...

Page 161: ...filter Replace filter Drain off water Spray nozzles Check function Drain off water 3 7 Electrical power supply Batteries Check fill level of battery acid Top up with distilled water Apply grease to b...

Page 162: ...teering system Grease the steering unit grease nipple Belt tensioner Grease the clutch bearing grease nipple Clutch bearing Lubricate clutch bearing grease nipple Upper conveyor Lubricate clamping mou...

Page 163: ...Health hazard Keep fire extinguishers close at hand If there is any need for cleaning work which requires the fuel tank to be emp tied drain off all remaining fuel from the tank The drain screw for t...

Page 164: ...is opened using a square sec tion wrench Excessive oil in the engine damages the gaskets not enough oil leads to over heating and destruction of the engine The filler aperture 2 for engine oil is lo...

Page 165: ...nd the left hand flap of the engine compartment Before checking the oil level with the dipstick wait for a moment to allow the filled oil to reach the oil pan Follow advice in the instrucciones de uso...

Page 166: ...n to the water sensor Send used filter for proper disposal Ensure seal integrity is good after changing the filter Follow advice in the instrucciones de uso del motor Draining water from the fuel filt...

Page 167: ...d pump 2 are located near the fuel filter Unfasten bleed screw 1 slightly Operate lever 2 on the mechanical hand pump several times until fuel starts to emerge from the open bleed screw bore Tighten t...

Page 168: ...uso del motor Radiator Check the coolant level daily before starting work Replace the coolant at least once a year The expansion tank with the filler aper ture is located directly on the radiator and...

Page 169: ...ribs on the radiator for dirt and leaks on a daily basis The radiator is located in the front sec tion of the engine compartment With severe contamination it is advisa ble to spray the radiator with...

Page 170: ...F 16 F_PL1000RS_GB fm 16 76 04 07 Drive belt Check the drive belt daily for visual signs of damage For maintenance of the drive belt refer to Engine Operating Instructions Riemen2_Pl600 tif Belt tif...

Page 171: ...op erating hours and at least once a year The filler neck for the hydraulic oil is lo cated behind the rear flap of the engine compartment To top up the hydraulic oil open the screw cap 2 and fill new...

Page 172: ...then remove the screw plug After draining the fuel fit a new seal to the screw plug and tighten back into place Top up new oil through the filler aperture in the hydraulic oil tank behind the left han...

Page 173: ...ilter housing cover 4 properly Wear protective clothing when draining hot oil Health hazard caused by contact with the skin Never clean and reuse the filter Always fit a new filter Send used filter fo...

Page 174: ...aining oil To bleed the system unscrew and re move the filler plug 2 Once the oil has drained off complete ly fasten the drain plug 1 back into place Top up oil through the opened filler screw with th...

Page 175: ...le fill ing with oil the screw plug used for oil level checks 1 must be in its 9 o clock position The oil level should reach the lower edge of the bore for the screw plug Top up oil through the opened...

Page 176: ...icles of solid matter do not have time to settle and form sediment Wear protective clothing when draining hot oil Health hazard caused by contact with the skin Unscrew the oil drain screw 2 collect dr...

Page 177: ...late 2 Disconnect the cable tension sensor 3 if fitted Remove the cables 4 used for raising and lowering the side board Eye bolts can be employed instead of cables for restraining and raising the side...

Page 178: ...F 24 F_PL1000RS_GB fm 24 76 04 07 Nivellswitch1000 cdr Moba1a cdr Moba29 jpg Moba21 jpg 8 2 3 4 5 A B C D E 7 9 1 6...

Page 179: ...bit blocks SYSTEM KPF201 The three part KPF 201 quick change system comprises Bit 1 Wearing sleeve 2 Block 3 The wearing sleeve 2 is there to ensure that a worn planing tool does not cause wear to the...

Page 180: ...M KPF301 The three part KPF 301 quick change system comprises Bit 1 Wearing sleeve 2 Block 3 The wearing sleeve 2 is there to ensure that a worn planing tool does not cause wear to the block Bit_KPF30...

Page 181: ...wearing sleeves and blocks The machine capacity can only be fully utilised if planing milling tools are in perfect condition Wearing features on round shafted bits New bits Worn bits replace as soon...

Page 182: ...eeves Ensure that the engine cannot be started When using the pneumatic extractor ensure compliance with the relevant safety reg ulations Wearing features of bit blocks New bit block Serious wear to l...

Page 183: ...nock new bits into the bit box with a hammer with copper brass or rigid plastic head Do not use a steel headed hammer to drive bits into their holders because this could destroy their bit tips Risk of...

Page 184: ...iver 1 to the bore on the back of the bit block then drive out worn and damaged wearing sleeves by striking with a hammer Fit the drawing tool 2 to the bit block guide the pin 2a through the bore in t...

Page 185: ...The sleeve extractor 2 can be used to press the loosened wearing sleeve out of its bore For broken wearing sleeves Fit the drawing tool 3 to the bit box guide the pin 3a through the bore in the sleeve...

Page 186: ...sleeves always ensure that all bores and locating surfaces are free of dirt System KPF301 Apply a coat of non stick compound in scope of supply or a light grade of oil to the contact surfaces 1 2 of...

Page 187: ...itions e g old steel rails lying concealed in the milling surface Worn bit boxes are then relatively easy to replace Remove the worn bit box from the mill ing drum and ensure that the locating face is...

Page 188: ...rs The belt drive comprises 6 individual belts It is located on the left hand side of the milling section and can be accessed via the maintenance flap on the control panel Ensure that the engine canno...

Page 189: ...utch housing Remove the four screw plugs 2 from an accessible inspection cover 1 Remove the inspection cover Check the gap between piston and cylinder with a measuring gauge in serted through the insp...

Page 190: ...e must be standing on level ground Unscrew and remove the filler and in spection screw 1 The oil level should reach the lower edge of the bore for the screw plug Top up oil through the open bore until...

Page 191: ...clothing when draining hot oil Health hazard caused by contact with the skin Park machine on level ground Unscrew and remove the inspection screw 2 Unscrew the oil drain screw 1 collect draining oil...

Page 192: ...on level ground Unscrew and remove the filler and in spection screw 1 The oil level should reach the lower edge of the bore for the screw plug Top up oil through the open bore until a little oil star...

Page 193: ...contact with the skin Park machine on level ground Unscrew and remove the inspection screw 2 Unscrew the oil drain screw 1 collect draining oil Once the oil has drained off completely fasten the drai...

Page 194: ...the shoes have to be replaced Check the sliding shoes on both side boards at regular intervals and replace if required Remove side board 1 A Lower side board until it makes con tact with the ground Un...

Page 195: ...fashion If the material on the support plates be comes too thin these must be replaced Check the support plates on both side boards at regular intervals and replace if required Remove side board see...

Page 196: ...ponents installed down the full length of the moldboard are fitted with hardened metal tips which gradually wear down over time Raise the machine completely retract the moldboard and fully raise the s...

Page 197: ...drum housing screw connections The connecting screws 1 attaching milling drum housing to vehicle chassis need to be checked with a torque wrench and if necessary retightened Tightening torque 1060 Nm...

Page 198: ...ise or vice versa for anti clockwise rotation Avoid excessive angle setting on the reversing drum because this can cause the belt fabric to stretch excessively If the reversing roller is unable to app...

Page 199: ...check of belt and loading belt rollers for signs of damage or wear Remove encrusted material from the drums on a regular basis Inspect bolt connections on a regular basis During all work on the upper...

Page 200: ...ve cannot be started Rubber funnel gasket at transfer point and rubber seals guides Various rubber components are located on the upper conveyor which should pro vide problem free material removal Thes...

Page 201: ...rted into the tank through the filler aperture If the machine is not operating continuously this water should be changed once a year Completely drain the tank by opening up the drain valve 3 behind th...

Page 202: ...lete ly empty the water tank Remove hose connection from tank 2 by untightening the hose clamp Also remove the two horizontal tank screws 5 from behind the battery flap these connect the tank to the m...

Page 203: ...filter housing 2 using the wrench in the on board toolkit and un screw by hand Remove filter cartridge 3 also rinse out housing and install a new cleaned filter Clean the locating faces of upper and l...

Page 204: ...nozzles can be pulled out of their retaining brackets Pull hose and nozzles 1 out of brack et Clean nozzles with a wire brush If necessary dismantle nozzle for clean ing purposes or replace Reinstall...

Page 205: ...p to the top mark If re quired top up the battery but only use distilled water to do so The battery terminal clips must be free of corrosion oxide and protected with a special grade of terminal grease...

Page 206: ...engine drives and steering system are shut down when the emergency stop but ton is pressed Any action which may then be required e g steering is no longer pos sible at this time Risk of accident Limi...

Page 207: ...ed position apply grease to the sliding surfaces of the square tube with a brush Adjust clearance Clearance on the chassis leg guides is adjusted on either side by three individual slid ing plates Loa...

Page 208: ...a grease nipple on the swivel joint on the chassis leg Fill 5 strokes of grease using the grease press Steering system There are two grease nipples beside the steering system underneath the ma chine...

Page 209: ...grease press Clutch bearing The grease nipple for the clutch bearing is located behind the belt disc Add 5 loads of grease with a grease gun Clamp mounting on the drive drum There is a grease nipple o...

Page 210: ...F 56 F_PL1000RS_GB fm 56 76 04 07 Hydraulic cylinder There are grease nipples on each bear ing point on most hydraulic cylinders Fill 3 strokes of grease using the grease press Zylschmier wmf...

Page 211: ...ns of leakage on engine hydraulic system or gearbox etc All fastening points OK Remedy defects immediately to prevent damage danger of accidents and environ mental contamination Inspection by a specia...

Page 212: ...Mobiplex 47 Aral Aralub MPU SHELL EP 2 Retinax A Engine oil Refer to Engine Operating Instructions Shell Rimula 10 W 40 is the factory filled grade Engine Oil Pump pedestal Shell Rimula 10 W 40 is th...

Page 213: ...hen changing from mineral oil pressurised fluids to bio degradable pressure fluids please contact our factory advisory service Only use containers which are clean on inside and outside for filling oil...

Page 214: ...tank approx 1200 litres up to max fill level Planetary gear on drive wheels approx 0 5 litres on each up to max fill level Pump pedestal 0 3 litres Angular gear approx 4 0 litres up to max fill level...

Page 215: ...1 behind the right hand flap of the engine compartment 1 F1 1 Main fuse F1 2 Main alternator fuse F1 3 Ignition F1 4 Heating system 100 a 100 a 30 a 100 a 2 O F1 5 Hydr weather protecting sun roof F1...

Page 216: ...l Fuse holder 2 No F2 1 F2 8 A 1 Alternator 10 2 Fittings 10 3 Susmic travel drive 10 4 ASC 10 5 Levelling unit 10 6 Front rear scraper side board cutting drive 10 7 Conveyor belt tilt alarm 10 8 Rota...

Page 217: ...beam headlights 10 5 Right hand low beam headlights 10 6 Left hand high beam headlights 10 7 Right hand high beam headlights 10 8 Left hand parking lights 5 No F4 1 F4 8 A 1 Right hand parking lights...

Page 218: ...F 64 F_PL1000RS_GB fm 64 76 04 07 7 3 Fuses in the operating panel No F5 1 F5 2 A 1 Advance fuse protection power supply 40 2 Lights 20 Panelkompl_500_1000 bmp Deskfuse eps...

Page 219: ...250 1 3 3150 1 9 3800 2 3 M4 3900 2 9 5450 4 1 6550 4 9 M5 6350 6 0 8950 8 5 10700 10 M6 9000 10 12600 14 15100 17 M8 16500 25 23200 35 27900 41 M10 26200 49 36900 69 44300 83 M12 38300 86 54000 120 6...

Page 220: ...H Occasion Comments about scope of work Result name signature 2001 06 10 980 1000 hour service Replacing fuel oil and water filters changing the oil re placing the air filter general visual inspection...

Page 221: ...F 67 F_PL1000RS_GB fm 67 76 04 07 9 1 Assembly engine engine systems Result name signature Comments about scope of work Occasion MH Date...

Page 222: ...F 68 F_PL1000RS_GB fm 68 76 04 07 9 2 Hydraulic system Result name signature Comments about scope of work Occasion MH Date...

Page 223: ...F 69 F_PL1000RS_GB fm 69 76 04 07 9 3 Drive wheels steering system brakes Result name signature Comments about scope of work Occasion MH Date...

Page 224: ...F 70 F_PL1000RS_GB fm 70 76 04 07 9 4 Milling section Result name signature Comments about scope of work Occasion MH Date...

Page 225: ...F 71 F_PL1000RS_GB fm 71 76 04 07 9 5 Water system Result name signature Comments about scope of work Occasion MH Date...

Page 226: ...F 72 F_PL1000RS_GB fm 72 76 04 07 9 6 Electrical system Result name signature Comments about scope of work Occasion MH Date...

Page 227: ...F 73 F_PL1000RS_GB fm 73 76 04 07 9 7 Other equipment Result name signature Comments about scope of work Occasion MH Date...

Page 228: ......

Page 229: ...eed of that INFORMATION The easiest way to solve a minor problem out in the field is to contact your Dynapac dealer for trouble shooting and advise Make us a visit to inform yourself about the whole r...

Page 230: ...Don t hesitate to contact your local dealer for service spare parts documentation accessories and information about the complete Dynapac paving and planing range...

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Dynapac PL 1000 RS, Operation & Maintenance Manual

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Summary of Contents for PL 1000 RS

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