Dynapac PL 500/20 S Operation & Maintenance Manual Download Page 23

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B 11

500/

20S.

B 1

-20 -

04.

4.4

Engine

4.5

Travel drive

4.6

Hydraulic system

Make/type

Cummins QSB 4.5-30-T-C110

Model

4-cylinder diesel engine (water-cooled)

Power (in accordance with DIN
6270)

82 kw / 110 hp / 112 hp (at 2100 1/min)

Capacity

4510 cm

Fuel consumption, full load
Fuel consumption, 2/3 load

23.6 l/h
15.8 l/h

Fuel tank filling volume

approx. 200 l

Drive

Hydrostatic drive, continuously variable across
two speed ranges.
Input via the front wheels and rear wheels

Steering

Hydraulic (power) steering system (Orbitrol)

Pressure generation

Hydraulic pumps (flange-mounted to the
engine)

Pressure distribution

Separate hydraulic circuits for:
Travel drive, chassis legs and steering system

Hydraulic oil reservoir - volume

approx. 100 l

Summary of Contents for PL 500/20 S

Page 1: ...503 02 0407 Operation Maintenance Keep for later use in document compartment Order no for this handbook 900 98 12 71 Valid from serial number 503 173 Cold planer PL 500 20 S...

Page 2: ...VALUE QUALITY THE ORIGINAL Your authorised Dynapac dealer SPARE PARTS...

Page 3: ...ption appropriate to the machine option is used 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...

Page 4: ...r regional specifications regarding technical regulations accident prevention and environmental protection In the interest of continued development the manufacturer reserves the right to make changes...

Page 5: ...m 11 4 7 Water system 12 4 8 Loading system 12 4 9 Electrical system 12 5 Identification points and type plates 13 5 1 Type plate and vehicle identification number 13 Type plate machine 14 5 2 Identif...

Page 6: ...t 45 Direction of travel indicator 46 Working lights rotary beacons 47 Water system 48 Steps up to water tank 49 Chocks 49 Non return valve Freewheel on milling drum 49 Vandalism protection 50 4 Level...

Page 7: ...lling device 89 8 1 Operating the Moba matic during milling 91 Initial situation for operation 91 8 2 Other tasks for adopting the initial position for milling 92 Milling with height sensors 92 Millin...

Page 8: ...g the fuel system 13 Air cleaner 14 Radiator 14 Radiator 15 Drive belt 16 3 2 Hydraulics 17 Hydraulic oil tank 17 Changing the hydraulic oil 18 Suction return hydraulic filter 19 Hydraulic hoses 19 3...

Page 9: ...el console 54 Hydraulic cylinder 55 5 Inspections 56 General visual checks 56 Checks by a specialist 56 6 Lubrication agents and fuel substances 57 6 1 Hydraulic oil 58 6 2 Filling volumes 59 7 Electr...

Page 10: ......

Page 11: ...te 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 manufacturer is not liable for...

Page 12: ...unauthorised parts and any attempt to take these out of serv ice either completely or partially render null and void the manufacturer s liability for any resultant damage The attachment or installatio...

Page 13: ...designed for tasks such as the partial removal of asphalt and concrete and for preparatory work in pipeline and cable laying operations The right hand chassis leg can be folded in to allow for precisi...

Page 14: ...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 indicator 8 Water tank 9 Water spraying system 10 Weather pro...

Page 15: ...pe control can be per formed comfortably from 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 machi...

Page 16: ...ng unit The cold planer attachment is designed as a rear loading unit and fea tures a one piece load transfer system Final loading of material occurs from the upper conveyor to the transport container...

Page 17: ...g 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 Danger of accidents Th...

Page 18: ...rol 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 precaution be rem...

Page 19: ...B 7 B PL500 20S GB 7 20 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: ...B 8 B PL500 20S GB 8 20 04 07 4 Technical data standard version 4 1 Dimensions PL500_measure_side_long wmf PL500_measure_top_long wmf...

Page 21: ...B 9 B PL500 20S GB 9 20 04 07 PL500_measure_side_short wmf PL500_measure_top_short wmf...

Page 22: ...ht 8 550 8 050 kg Operating weight 8 850 8 350 kg Ballast weight total max 9 100 8 600 kg Transport speed 0 6 km h Working speed 0 30 m min Milling width 500 mm Milling depth 0 200 mm Spacing 15 mm Cu...

Page 23: ...full load Fuel consumption 2 3 load 23 6 l h 15 8 l h Fuel tank filling volume approx 200 l Drive Hydrostatic drive continuously variable across two speed ranges Input via the front wheels and rear wh...

Page 24: ...system 4 9 Electrical system Spray nozzles 4 units Water tank filling volume approx 400 l Belt width upper conveyor 400 mm Belt speed approx 4 m s Loading capacity theoretical approx 80 m3 h On board...

Page 25: ...pe 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 ha...

Page 26: ...ar of construction 6 Serial number of machine model 7 Maximum permitted operating weight in kg 8 Maximum permitted axle load at front in kg CE 9 Maximum permitted axle load at rear in kg CE 10 Rated p...

Page 27: ...B 15 B PL500 20S GB 15 20 04 07 5 2 Identification points 8 10 2 2 9 3 7 6 4 2 12 1 2 5 25 11...

Page 28: ...B 16 B PL500 20S GB 16 20 04 07 14 13 16 16 3 17 20 19 2 2 18 13 21 22 23 24 14...

Page 29: ...adiator 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 0...

Page 30: ...der free field conditions Sound pressure level at the operator s position at the height of the head LAF dB A Noise level at the machine LWA dB A 6 2 Operating conditions during measurement The diesel...

Page 31: ...e EMC guideline 89 336 EEC 08 95 interference emission according to DIN EN 50081 1 03 93 40 dB V m for frequencies of 30 MHz 230 MHz at 3 m measuring distance 47 db V m for frequencies of 20 MHz 1 GHz...

Page 32: ......

Page 33: ...rised 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 Clo...

Page 34: ...should be fastened to these points during transport on the transport ve hicle The machine is to be fixed to the transporter using sufficiently sized shackles chains and secured so that it cannot tilt...

Page 35: ...n The 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 dist...

Page 36: ...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 must also be chocked to prevent it from rolling awa...

Page 37: ...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 transport...

Page 38: ...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 Retighten the lock nut for safety Now use th...

Page 39: ...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 not lea...

Page 40: ......

Page 41: ...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 to life and limb Always make sure during wo...

Page 42: ...D 2 D PL500 20S GB 2 116 04 07 2 Controls 2 1 Operating panel Panelkompl_ALL_V3 bmp Verriegel_Lenk cdr Panel4_V2_Iso bmp C B A D 1 3 2 1...

Page 43: ...wards or downwards using both hands Close safeguard again once desired position has been reached 2 Armrest The armrest can be swivelled up into the storage area provided to protect it from vandalism...

Page 44: ...D 4 D PL500 20S GB 4 116 04 07 Panel3_V2 bmp A 4 7 6 9 10 8 5...

Page 45: ...on switch Integrated flasher switch and switch for high beam and low beam lighting and horn button 7 Use turn signals flashers to change direction of travel on roads High beam headlights are switched...

Page 46: ...D 6 D PL500 20S GB 6 116 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: ...l EMERGENCY STOP 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...

Page 48: ...D 8 D PL500 20S GB 8 116 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: ...y or Used to adjust the discharge rate for mill material to prevailing conditions quantity of material involved de livery speed This adjustment can also be made while the milling op eration is running...

Page 50: ...D 10 D PL500 20S GB 10 116 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: ...eat 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 The direction of wheel rotation is reversed auto matically 30 Electrica...

Page 52: ...D 12 D PL500 20S GB 12 116 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: ...switch positions can be selected 0 upper conveyor transport function OFF AUTO Transport function is linked to the drive le ver The upper conveyor only starts when the mill ing operation begins The up...

Page 54: ...D 14 D PL500 20S GB 14 116 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: ...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 56: ...D 16 D PL500 20S GB 16 116 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 57: ...n the control lever for the travel drive is fully extended milling operation 1 Levelling unit ON levelling unit active responds independently of control lever Adjustments using the connected levelling...

Page 58: ...D 18 D PL500 20S GB 18 116 04 07 Panel1_500_1000_V2 bmp Panel_Leucht_500_1000_V2 bmp 53 52 51 50 49 48 47 46 45 44 C 54 43 42 41 40 60 55 56...

Page 59: ...eration 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 cool...

Page 60: ...D 20 D PL500 20S GB 20 116 04 07 Panel1_500_1000_V2 bmp Panel_Leucht_500_1000_V2 bmp 53 52 51 50 49 48 47 46 45 44 C 54 43 42 41 40 60 55 56...

Page 61: ...s once the ignition has been switched on for checking purposes Do not start the engine until this indicator lamp has gone out 46 Maintenance yel low Indicates too low a coolant water level in the engi...

Page 62: ...D 22 D PL500 20S GB 22 116 04 07 Panel1_500_1000_V2 bmp Panel_Leucht_500_1000_V2 bmp 53 52 51 50 49 48 47 46 45 44 C 54 43 42 41 40 60 55 56...

Page 63: ...aid Always lights up when the steering system is in straight ahead position as well as during steering movements with the differential lock activated 51 Error check Travel drive red If a fault occurs...

Page 64: ...D 24 D PL500 20S GB 24 116 04 07 Panel1_500_1000_V2 bmp Panel_Leucht_500_1000_V2 bmp 53 52 51 50 49 48 47 46 45 44 C 54 43 42 41 40 60 55 56...

Page 65: ...raising lowering moldboard is actuated raising lowering sliding shoe is actuated raising side boards is actuated control lever on upper conveyor is actuated Emergency Stop actuated 56 Tilt alarm Ligh...

Page 66: ...D 26 D PL500 20S GB 26 116 04 07 Panel4_1000 cdr D 73 74 70 75 77 78 76 71 72...

Page 67: ...els the upper conveyor to the right Swivel direction forwards raises the upper conveyor Swivel direction backwards lowers the upper con veyor The upper conveyor is moved continuously while the control...

Page 68: ...D 28 D PL500 20S GB 28 116 04 07 Panel4_1000 cdr D 73 74 70 75 77 78 76 71 72...

Page 69: ...s raised or lowered to the upper or lower limit position whenever the switch is being pressed in the relevant direction Danger resulting from raised loads Do not en ter the danger area Danger resultin...

Page 70: ...D 30 D PL500 20S GB 30 116 04 07 Panel4_1000 cdr D 73 74 70 75 77 78 76 71 72...

Page 71: ...its lower limit position Danger resulting from raised loads Do not en ter the danger area Danger resulting from escaping material 78 Raising the right side board While the button is being pressed the...

Page 72: ...D 32 D PL500 20S GB 32 116 04 07 Sockets and interfaces on the operating panel Panel_Interface_500_1000 bmp 91 92 93 94 95 90...

Page 73: ...vice and deleted 92 Interface for ASC diagnosis travel 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 leve...

Page 74: ...derside of ergonomics set 3 Slide ergonomics set 3 into desired position on handrail Tighten the locking screw 4 back down Distance between driver s seat 5 controls longitudinal adjustment of seat Pul...

Page 75: ...is displayed on the scale 2 For height adjuster of the backrest unfasten both handles 3 on the back rest slide the backrest upwards or downwards then tighten the handles again to secure backrest in th...

Page 76: ...ers 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 77: ...aise the roof whilst the battery is discharged a manual pump is available 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 78: ...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 as...

Page 79: ...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 indic...

Page 80: ...l in retracted position secure by placing pin in bore 2 If the chassis leg is retracted the direc tion of rotation of the wheel must be reversed The changeover valve in the hydraulic circuit is locate...

Page 81: ...of the vehicle Operating instructions see section 2 1 Carefully and uniformly lower machine onto milling drum and fully retract the left chassis leg Remove the pin 1 and swivel in the chassis leg Wit...

Page 82: ...ook 1 using le ver 2 Extend the moldboard until the retain ing tab on the flap 3 locates in the re taining hook 1 Swivel retaining hook 1 into retaining position using lever 2 To lower the moldboard f...

Page 83: ...setting screw 29 If an inclined angle is not desirable the relevant chassis leg can be extended to compensate for this restoring the ma chine to a level position Pressure gauge Relief pressure for mol...

Page 84: ...for pressure setting is located on the valve block underneath the seat console The current pressure setting can be read off from the pressure gauge 2 Setting load Use handwheel 1 to set the desired pr...

Page 85: ...wo throttle valves are located un derneath the roof console Upper throttle valve 1 left hand chassis leg Lower throttle valve 2 right hand chassis leg Adjust deployment speed Rotate adjusting knob clo...

Page 86: ...k etc There are two different direction indica tors on the chassis frame Indicator 1 runs exactly over the out er edge of the milling drum The depth of the indicator can be ad justed using the length...

Page 87: ...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 ta...

Page 88: ...ne can be drained completely with the help of a pump Completely drain the tank Pump residual water out of pressure line by pressing switch 3 Switch pump back off again switch 3 in zero setting This wa...

Page 89: ...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 accidentally Non return valve Freewheel on...

Page 90: ...ngine flap is a cover secured with a screw to provide protection against vandalism to the op erating panel When work finishes this cover should be fitted over the operating panel and secured retaining...

Page 91: ...nsor 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 two cab...

Page 92: ...D 52 D PL500 20S GB 52 116 04 07 5 Operating the MOBA matic Nivellcompl cdr A C B...

Page 93: ...p control system for the levelling unit on the left side of the machine B MOBA actual value indi cator Actual value indicator for height sensing and lateral slope on left right sides of machine C MOBA...

Page 94: ...D 54 D PL500 20S GB 54 116 04 07 6 Operating the MOBA matic Moba1can jpg M10 A C M2 M3 M6 M7 M9 M8 M4 M5 M1 M11...

Page 95: ...al 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 va...

Page 96: ...D 56 D PL500 20S GB 56 116 04 07 Moba1can jpg M10 A C M2 M3 M6 M7 M9 M8 M4 M5 M1 M11...

Page 97: ...hine re sponds in automatic or manual mode change to ac tual value Machine does not respond in semi automatic mode only for preselections i e nominal value specifica tions M8 Automatic semi automatic...

Page 98: ...y 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 A LOWER B Controlled controller outp...

Page 99: ...should be remind ed 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 100: ...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 Small...

Page 101: ...6 2 Actual value indicator O The optional actual value indicator provides a means of comparing the nominal val ue as displayed by the MOBA matic and the prevailing actual value FP LQFK Moba2 cdr M20 M...

Page 102: ...e 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 c...

Page 103: ...ese two sockets The cable sensor for the side board on the left side of the machine B is also arranged at this location on the under side of the machine frame If required the tension cable on the sens...

Page 104: ...roceed 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 f...

Page 105: ...these 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...

Page 106: ...tion 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 purpos...

Page 107: ...uch of the button and either changes its milling depth or lateral slope 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 108: ...00 20S GB 68 116 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 M...

Page 109: ...s 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 adop...

Page 110: ...ia 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 aut...

Page 111: ...ly 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 rotat...

Page 112: ...t 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 th...

Page 113: ...efine 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 sight...

Page 114: ...e 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 re...

Page 115: ...rs 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 the...

Page 116: ...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 sa...

Page 117: ...iately af ter actuation The button engages and must be pulled out so that the engine can be started again Horn on the operating panel Briefly press the horn button Horn signal must sound Lights Operat...

Page 118: ...mponents and function settings Note the condition fastening and wear of individual elements completeness and wear of milling tools as well as checking for specified settings seal integrity and lu bric...

Page 119: ...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 devices and protective d...

Page 120: ...ts 0 position or if the emergency stop button is pressed and the milling drum transmission or height adjuster must also be engaged If the engine does not start straightaway continue starting for a max...

Page 121: ...bles Observe the polarity Always connect the negative cable last and disconnect it first Insert ignition key 5 in ignition lock in setting P Switch on ignition Pos 1 Turn ignition key in Pos 2 to star...

Page 122: ...should be engaged The optimum operating values of a warm machine are Coolant temperature of engine 70 C Hydraulic oil temperature 60 70 C Take due note of visual signal from the hydraulic system If i...

Page 123: ...toise 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 controll...

Page 124: ...D 84 D PL500 20S GB 84 116 04 07 8 Milling instructions Driving position Chassis legs lowered planer raised Milling position Chassis legs raised planer lowered PL600_Back1 cdr PL600_Back2 cdr...

Page 125: ...d Surface milling 1 With deployed right hand chassis leg The right hand chassis leg engages in the mill and cleaned first lane Depth setting right zero left desired milling depth 2 With retracted righ...

Page 126: ...n For milling 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 127: ...116 04 07 Milling at the curb with chassis leg retracted Advantages Maximum milling depth is reached direct milling against kerb possible Disadvantages Less precise milling results Less exact milling...

Page 128: ...sition and is disengaged automati cally as soon as the machine is stopped Item Switch Position 28 Traction drive fast slow Working gear tortoise mode 27 Preselector for travel drive Approx average pow...

Page 129: ...D 89 D PL500 20S GB 89 116 04 07 Milling without automatic levelling device 71 70 73 74 Panel2_500_1000 bmp Panel4_V2 cdr Skald wmf A 25 20...

Page 130: ...ro 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 the...

Page 131: ...value and or actual value calibration has been conducted the machine is in its operating position all other settings required for milling have been conducted on the machine The A M button is switched...

Page 132: ...sensors Use switch 73 74 on control panel to lower planer above rear chassis legs until baseplates of side boards touch the ground in the rear section When starting to mill with offset i e lower machi...

Page 133: ...pth 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 p...

Page 134: ...D PL500 20S GB 94 116 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 135: ...e 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 start...

Page 136: ...D 96 D PL500 20S GB 96 116 04 07 Milling with height sensors together with the transverse slope sensor 71 73 74 Panel2_500_1000 bmp Panel4_V2 bmp Moba1a cdr Moba29 jpg 37 38 M2 M8 M7 M6...

Page 137: ...illing depth 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 adj...

Page 138: ...aising and lowering speed 36 to rapid adjustment beforehand Allow milling drum transmission 31 water pump 33 and upper conveyor 24 to run on briefly then switch to 0 Move switch 28 to transportation s...

Page 139: ...nsure 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 with...

Page 140: ...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 0...

Page 141: ...small planers Remedying longitudinal and transverse bumps in the road surface Remedying cracks Remedying potholes frost damage Plan1 tif after before Planing Selective milling Plan2 tif after before...

Page 142: ...age to edges and bumps Producing adjoining edges Producing slots joints and cable trenches Plan4 tif after before Wedge shaped milling Plan5 tif after before Wedge shaped milling Plan6 tif Selective m...

Page 143: ...blishing surface grip Plan7 tif after before Selective milling with special purpose joint milling tools Plan8 tif after before Planing off road surface markings using fine spaced milling drums or mark...

Page 144: ...sing the retrieval switch for error 54 The flash code is issued by the second warning lamp If an error is displayed in warn ing lamp 44 it is issued by warning lamp 45 and vice versa Output of numeric...

Page 145: ...ion the warning light which indicat ed the error lights up again This continues until the corresponding error or malfunc tion has been rectified If several errors occur at the same time the various fl...

Page 146: ...om removal of speed adjust ment on the OEM wiring harness Engine fails to respond to removed speed adjustment 134 YEL LOW P029 4 029 4 Undervoltage detected on pin 9 re sulting from removal of speed a...

Page 147: ...es until engine speed has dropped back below the upper rpm limit 235 Mainte nance P111 1 111 1 The coolant level signal on pin 37 of the engine wiring harness indicates that the coolant level is low R...

Page 148: ...ss of ability to control OEM pressure 319 Mainte nance P251 2 251 2 Power supply to real time clock was interrupted and its setting is no long er accurate The time stamp in the ECM shutdown data will...

Page 149: ...e speed selection Whenever data transmission between the electronic control unit and the regu lator on fuel pump VP44 is interrupted the engine regardless of speed ad justment only runs at a speed sli...

Page 150: ...n and runs up to a preset speed at which point the idle speed switch signals idle speed off 391 YEL LOW S017 11 632 11 Fault detected in release control cir cuit of the VP44 power supply relay on pin...

Page 151: ...tronic control unit properly battery voltage is maintained for 30 seconds after key OFF Possibly no perceptible impacts on power OR engine cuts out OR prob lems when starting Error information travel...

Page 152: ...YEL LOW P113 2 113 2 Error detected on pin 24 of engine wiring harness for selector switch in put of speed governor reducer HSG Alternatively reduction of speed gover nor setting cannot be selected No...

Page 153: ...trol unit has de tected that the engine performed a safety cut out or that the ignition was switched off while above a defined load limit No impact 768 YEL LOW S009 11 923 11 Fault detected on pin 21...

Page 154: ...PL500 20S GB 114 116 04 07 10 2 Error messages for anti slip control Inform the after sales service for your cold planer of the error numbers displayed They will discuss with you what course of action...

Page 155: ...15 D PL500 20S GB 115 116 04 07 10 3 Travel drive error message Inform the after sales service for your cold planer of the error numbers displayed They will discuss with you what course of action to t...

Page 156: ...D 116 D PL500 20S GB 116 116 04 07 10 4 MOBA Matic error messages...

Page 157: ...in the danger area Protect machine 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 sw...

Page 158: ...rry out milling operations with out the upper conveyor this should be removed from the machine This operation in volves following a few simple steps Upper conveyor and milling drum must be disengaged...

Page 159: ...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 bracket...

Page 160: ...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 PL500_conv3...

Page 161: ...d 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 the fr...

Page 162: ...sed For maintenance and repair work only 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...

Page 163: ...e Check oil level Top up the 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 164: ...r voir Check oil level Top up the oil Change oil Suction return hydraulic filter Change filter cartridge Hydraulic hoses Perform a visual inspection Replace hoses 3 3 Drive wheels Planetary gear drive...

Page 165: ...Replace sliding shoes Replace support plates Belt drive Check the belts Replace belt Clutch Check the friction lining Replace belt Angle drive Check oil level Top up the oil Change oil Milling drum ge...

Page 166: ...eck tension deflection Adjust tension deflection Check for signs of damage Replace conveyor belt Conveyor belt roll ers Check condition Replace rollers Steel securing rope Check condition Replace secu...

Page 167: ...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 ba...

Page 168: ...ase the clutch bearing grease nipple Lubricate Grease the clutch bearing grease nipple Upper conveyor reversing roller Lubricate clamping mount for drive drum grease nipple Upper conveyor drive Grease...

Page 169: ...d spaces Danger to health Have a fire extinguisher ready 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 f...

Page 170: ...mpartment This flap is opened using a square sec tion wrench Too high an oil level destroys the seals in the engine not enough oil leads to overheating and destruction of the en gine The filler apertu...

Page 171: ...pstick behind 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 Operating...

Page 172: ...he water sensor Send used filter for proper disposal Ensure seal integrity is good after changing the filter Follow advice in the Operating instructions for the engine Water drain point in fuel filter...

Page 173: ...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 174: ...ssed air Follow advice in the Operating instructions for the engine Radiator Check the coolant level daily before starting work Replace the coolant at least once a year The expansion tank with the fil...

Page 175: ...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 d...

Page 176: ...F 16 F PL500 20S GB 16 74 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 177: ...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 178: ...e drainage point then remove the screw plug When returning the screw make sure to use a new seal Top up new oil through the filler aperture in the hydraulic oil tank behind the right hand maintenance...

Page 179: ...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 180: ...e 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 181: ...particles 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 collec...

Page 182: ...nd Unscrew stop plate 2 Disconnect the cable 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...

Page 183: ...F 23 F PL500 20S GB 23 74 04 07 Box1_Pl500_V2 wmf Box5_PL500 wmf 8 2 3 4 5 A B C D E 7 9 1 6...

Page 184: ...sleeves bit boxes 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 bit does not cause wear to the b...

Page 185: ...F 25 F PL500 20S GB 25 74 04 07 SYSTEM C10 C10HD The two part C10 C10HD quick change system comprises Bit 1 Block 2 Bit_C10_parts jpg 1 2...

Page 186: ...ed bits wearing sleeves and blocks The machine capacity can only be fully utilised if milling tools are in perfect condition Wearing features on round shafted bits New bits Worn bits replace as soon a...

Page 187: ...wearing sleeves Ensure that the engine cannot be started When using the pneumatic extractor ensure compliance with the relevant safety reg ulations Wearing features of bit boxes New bit box Serious we...

Page 188: ...th 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 injury from flying metal splinters After assem...

Page 189: ...iver 1 into bore on re verse side of bit box then drive out worn and damaged wearing sleeves by striking with a hammer Fit the drawing tool 2 to the bit box guide the pin 2a through the bore in the sl...

Page 190: ...wearing sleeves into the bit boxes using the sleeve driver Only use the sleeve driver or a drawing tool when dismantling or assembling these wearing sleeves When installing new bits and wearing sleeve...

Page 191: ...ions 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 s...

Page 192: ...be replaced in pairs The belt drive comprising 6 individual belts can be accessed from the left side of the milling section and from the main tenance flap on the control panel Ensure that the drive e...

Page 193: ...ion Remove the four locking screws 2 of an accessible inspection cover 1 Remove the inspection cover Apply pressure to axial oil feed of clutch through an external source en suring that the piston is...

Page 194: ...ri zontal position Unscrew and remove the filler and lev el checking screw 1 The oil level should reach the lower edge of the hole for the locking screw Top up with oil through the opened bore until a...

Page 195: ...ng when draining hot oil Health hazard caused by contact with the skin Park machine in horizontal position Remove the inspection screw 2 Remove the oil drainage screw 1 and collect draining oil After...

Page 196: ...n Unscrew and remove the filler and lev el checking screw 1 The oil level should reach the lower edge of the hole for the locking screw Top up with oil through the opened bore until a small amount of...

Page 197: ...t with the skin Park machine in horizontal position Remove the inspection screw 2 Remove the oil drainage screw 1 and collect draining oil After all the oil has drained properly screw the drainage scr...

Page 198: ...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 Unscrew sto...

Page 199: ...ashion 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 pr...

Page 200: ...nts 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 side...

Page 201: ...04 07 Milling box screw connections The connecting screws 1 between mill ing box and machine frame must be checked retightened using a suitable torque wrench Tightening torque 1060 Nm Iso500_Complback...

Page 202: ...se or vice versa for an ticlockwise 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 appl...

Page 203: ...check of belt and conveyor 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 204: ...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 These rubber comp...

Page 205: ...possible once it is empty Spray out the tank as thoroughly as pos sible with a water jet lance which can be inserted into the tank through the filler aperture If the machine is not operating continuo...

Page 206: ...completely drain the water tank Remove hose connection from tank by untightening the hose clamp Also remove the two horizontal tank screws 1 located at the back on the underside of the machine frame...

Page 207: ...rench 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 lower housing sections and ch...

Page 208: ...r inspection and cleaning purposes these nozzles can be pulled out of their retaining brackets Pull nozzles 1 out of bracket Clean nozzles with a wire brush If necessary dismantle nozzle for clean ing...

Page 209: ...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 The...

Page 210: ...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 Danger of accidents Limit switch on upper conveyor The safety cu...

Page 211: ...d 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 Load...

Page 212: ...a grease nipple on the swivel joint on the chassis leg Fill 5 strokes of grease using the grease press Steering There are two grease nipples beside the steering system underneath the ma chine Fill 5...

Page 213: ...oint on the belt tightener of the milling drum transmission Fill 3 strokes of grease using the grease press Lubricate The grease nipple for the clutch bearing is located behind the belt disc Fill 5 st...

Page 214: ...ase press Upper conveyor drive There is a grease nipple on clamp mounting to the right hand side of the upper conveyor Fill 3 strokes of grease using the grease press Upper conveyor swivel console The...

Page 215: ...F 55 F PL500 20S GB 55 74 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 216: ...on engine hydraulic system or gearbox etc All fastening points OK Remedy defects immediately to prevent damage danger of accidents and environ mental contamination Checks by a specialist The cold pla...

Page 217: ...2 Mobiplex 47 Aral Aralub MPU SHELL EP 2 Retinax A Engine oil Refer to Operating instructions for the engine Shell Rimula 10 W 40 is the factory filled grade Hydraulic oil Refer to Section 7 1 Shell...

Page 218: ...en changing from mineral oil pressurised fluids to biodegradable pressure fluids please contact our factory advisory service Only use containers which are clean on inside and outside for filling oil o...

Page 219: ...Water tank approx 400 litres up to max fill level Planetary gear on drive wheels approx 0 5 litres on each up to max fill level Angle drive approx 4 0 litres to max of filling level display Milling dr...

Page 220: ...tric fuses 7 1 Main fuses 1 behind the right hand flap of the engine compartment 1 F1 1 Main fuse F1 4 Main alternator fuse F1 2 Hydr weather protecting sun roof O F1 3 Hydr weather protecting sun roo...

Page 221: ...F 61 F PL500 20S GB 61 74 04 07 7 2 Fuses and relays in the control panel 2 Fuses 3 Relays Panel_interface_500_1000 bmp InsidePult_16S_V2 bmp 4 2 3...

Page 222: ...10 11 3 3 24V connector 10 12 3 4 Left hand low beam headlights 10 13 3 5 Right hand low beam headlights 10 14 3 6 Left hand high beam headlights 10 15 3 7 Right hand high beam headlights 10 16 3 8 L...

Page 223: ...tem 6 K6 ASC 7 K7 High beam headlights 8 K8 Brake light 9 K12 Raise scraper 10 K13 Raise scraper 11 K16 Changeover cylinder on chassis leg 12 K17 Changeover cylinder on chassis leg 13 K19 Slope on bel...

Page 224: ...50 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 64...

Page 225: ...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 replacing the air filter general visual inspection...

Page 226: ...F 66 F PL500 20S GB 66 74 04 07 9 1 Assembly engine engine systems Result name signature Comments about scope of work Occasion MH Date...

Page 227: ...F 67 F PL500 20S GB 67 74 04 07 9 2 Hydraulic system Result name signature Comments about scope of work Occasion MH Date...

Page 228: ...F 68 F PL500 20S GB 68 74 04 07 9 3 Drive wheels steering system brakes Result name signature Comments about scope of work Occasion MH Date...

Page 229: ...F 69 F PL500 20S GB 69 74 04 07 9 4 Milling section Result name signature Comments about scope of work Occasion MH Date...

Page 230: ...F 70 F PL500 20S GB 70 74 04 07 9 5 Water system Result name signature Comments about scope of work Occasion MH Date...

Page 231: ...F 71 F PL500 20S GB 71 74 04 07 9 6 Electrical system Result name signature Comments about scope of work Occasion MH Date...

Page 232: ...F 72 F PL500 20S GB 72 74 04 07 9 7 Other equipment Result name signature Comments about scope of work Occasion MH Date...

Page 233: ...that INFORMATION The easiest way to solve a minor problem out in the field is to contact Your Dynapac dealer for troubleshooting and advise Make us a visit to inform Yourself about the whole range of...

Page 234: ...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 500/20 S, Operation & Maintenance Manual

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