Dynapac PL2000F Instruction Manual Download Page 1

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Instructions manual

Operating & Maintenance

High capacity planer

PL2000F (Engine stage IIIA / T3)

Diesel engine

CumminsQSX15-C600

PIN: 10000905EHC006777

Original instructions.

Reservation for changes

Printed in China

Summary of Contents for PL2000F

Page 1: ...ructions manual Operating Maintenance High capacity planer PL2000F Engine stage IIIA T3 Diesel engine CumminsQSX15 C600 PIN 10000905EHC006777 Original instructions Reservation for changes Printed in C...

Page 2: ......

Page 3: ...lights Indicators rotary beacons 12 Hazard warning lights on side panels 13 Reverse lights and folding warning signs 13 Traction unit supports 14 Steel retaining cables 15 Retaining hook of scraper fl...

Page 4: ...ts 26 Performance data 26 Loading system 27 Engine T3 27 Travel drive 27 Hydraulic system 28 Water system 28 Compressed air system 28 Electrical system 28 Tightening torques 29 Machine description 31...

Page 5: ...eft right 117 Battery s main switch 118 Batteries 118 Tilt display 119 Lock and Unlock the ground panel cover 120 Folding ladder 121 Guardrail 122 Transport position for ladder and guardrails 123 Hydr...

Page 6: ...area and protective flaps 139 Plumb fixture 140 Swivel mounted warning sign 141 Tool holder 141 Typical wear marks on tool holder 142 Typical wear marks on bits 143 Bits holder replacement 144 Bits r...

Page 7: ...paration 170 Parking the machine 174 Long term parking 175 Long term parking 175 Battery 175 Engine 175 Hoods tarpaulin 175 Fuel tank 175 Hydraulic reservoir 175 Watering system 176 Water pump 176 Mis...

Page 8: ...s regarding safety for maintenance 201 Liability exclusion in case of use of non original spare or wear parts as well as incorrect operating materials 202 Maintenance intervals 202 Engine drive unit 2...

Page 9: ...ood activation 230 Oil level check 230 Traction units 231 Planetary gear oil level check 231 Oil change 231 Chain tension 232 Bottom plate 233 Rubber pad 233 Steering system sliding parts steering arm...

Page 10: ...guides 246 Water system 247 Water tank 247 Feed pump 249 Water filter 250 Water pump Check oil level 251 Water pump Drain oil 251 Spray nozzles 252 Power supply 253 Batteries 253 Compressed air system...

Page 11: ...um bearing 259 Discharge conveyor 260 Tail roller pedestal bearing 260 Driver roller tension bearing 260 Springs joints and bolts 260 Primary conveyor 261 Drive roller tension bearing 261 Inspection 2...

Page 12: ...ic viability and environmental responsibility Technical modifications attachments and conversations The machine may only be operated with the extension parts optional equipment and accessories protect...

Page 13: ...planer as a traction mechanism or lifting device The intended usage also includes compliance with operating transport maintenance and repair conditions specified in the operating instructions The mach...

Page 14: ...ing Inspect the entire machine so that any leakages or other faults are detected Check the ground under the machine Leakages are more easily detected on the ground than on the machine itself THINK ENV...

Page 15: ...Introduction 4 4812313240 pdf 2017 12 1...

Page 16: ...Use the intended grips and rails Always use the three point grip both feet and one hand or one foot and both hands when mounting or dismounting from the machine Never jump down from the machine 6 Dri...

Page 17: ...the written approval of Dynapac 16 Avoid using the planer before the hydraulic fluid has reached its normal working temperature Braking distances can be longer than normal when the fluid is cold See...

Page 18: ...ctions from operating machines The operator may allow a person to remain in the danger area but should then observe caution and operate the machine only when the person is visible or has given clear i...

Page 19: ...e operating your vehicle in an inclined position gradient slope lateral inclination which is above the specified limit valve please consult the customer service department for your vehicle Where possi...

Page 20: ...n the conveyor The weight for the conveyor is specified on the unit rating plate The operator must make sure that nobody is in the working area while the machine is in use Risk of body and crush injur...

Page 21: ...anels The engine drives and steering system are shut down when the emergency stop button is pressed Any counter measures required Diverting lifting the discharge conveyor etc are then no longer availa...

Page 22: ...7 12 1 Horn On the left right console One the left right ergo box On the four ground control panels Before starting to operate the machine and moving the conveyor units the horn knob and or the horn b...

Page 23: ...can be connected can be found around the machine The headlights indicators and rotary beacons can be activated using the appropriate switches on the upper control panel The function of the headlights...

Page 24: ...he side panels are raised Reverse lights and folding warning signs The reverse lights illuminate the danger area behind the machine A warning sign can be folded out on the right hand side of the machi...

Page 25: ...to achieve a lower transport height the upper section of the separable support is used on the trailer during transport The full length of traction unit supports should be inserted during all maintena...

Page 26: ...5 4812313240 pdf 2017 12 1 Steel retaining ropes The steel ropes hold the discharge conveyor and should be regularly checked for damage If damage is found the steel ropes should be replaced immediatel...

Page 27: ...event the flap falling down Limit switch of scraper flap The switch is pressed when raising the scraper ensure the machine milling drum drive and the rear tower cannot be actuated Scraper flap safegua...

Page 28: ...rab bars and guardrails are also provided Climbing up and down the ladders during travel and travelling on the ladders themselves is prohibited Side shield A side shield is fitted to both sides of the...

Page 29: ...Safety General instructions 18 4812313240 pdf 2017 12 1...

Page 30: ...higher ambient temperatures however maximum 50 C 122 F the following recommendations apply The diesel engine can be run at this temperature using normal oil However the following fluids must be used...

Page 31: ...igh pressure water entering the vent hole in the filler cap This could cause malfunctions such as the blocking of filters Never aim the water jet directly at the fuel tank cap This is particularly imp...

Page 32: ...pment off Switch off the engine on the machine which is providing jump start power Jump leads must have 24V First connect the jump start battery s positive terminal 1 to the flat battery s positive te...

Page 33: ...Special instructions 22 4812313240 pdf 2017 12 1...

Page 34: ...ecified in directive 2002 44 EC The limit is 1 15 m s Measured hand arm vibrations also were below the action level of 2 5 m s specified in the same directive Limit is 5 m s Noise level The noise leve...

Page 35: ...Technical specifications 24 4812313240 pdf 2017 12 1 Dimensions...

Page 36: ...rive unit milling drum 2900 mm L Distance between suspension of rear drive unit milling drum 2100 mm M Length of drive unit suspension to end of drive unit 955 mm N Distance between suspension of fron...

Page 37: ...0 40 m min Milling width 2010 Milling depth 0 320 Max slope 10 degr Line spacing 15 Cutting diameter 1100 Cutting speed 4 8 6 0 Number of milling tools 162 mm mm mm mm items m s Weights Hydraulic Fold...

Page 38: ...QSX 15 C600 Version 6 cylinder diesel engine water cooled Power in accordance with DIN 6270 447 kW 607 PS 600 hp at 2100 rpm Capacity 15 L Fuel consumption full load Fuel consumption 2 3 load 120 L h...

Page 39: ...pment water system Hydraulic oil tank filling volume approx 270 L Water system Filling pump 6 12 m3 h High pressure cleaner 80 120 bar Water spray 5 10 bar Water tank filling volume approx 3400 L Wate...

Page 40: ...0 1 3 3150 1 9 3800 2 M4 3900 2 9 5450 4 1 6550 4 M5 6350 6 0 8950 8 5 10700 1 M6 9000 10 12600 14 15100 1 M8 16500 25 23200 35 27900 4 M10 26200 49 36900 69 44300 8 M12 38300 86 54000 120 64500 145 M...

Page 41: ...Technical specifications 30 4812313240 pdf 2017 12 1...

Page 42: ...Machine description 31 4812313240 pdf 2017 12 1 Descriptions of assemblies and functions 10 1 14 2 7 9 4 5 8 15 16 17 6 12 18 3 13 11...

Page 43: ...nels 5 Belt drive milling drum drive 6 Milling box be consistent 7 Track systems 8 Strut towers 9 Primary conveyor 10 Discharge conveyor 11 Water tank 12 Foldable ladder 13 Guardrails 14 Storage area...

Page 44: ...sides of the frame The cold planer can be fitted with a weather protecting sun roof can be folded in and all round panels as an option During transport the roof can be folded forwards hydraulically an...

Page 45: ...overed Ground control panels The operating panels housed here are located on both sides of the planer in front of and behind the milling drum box They contain duplicates of the main controls of the op...

Page 46: ...the milling drum housing the milling drum the moldboard the sliding shoe and the side boards All these elements are precisely tuned to one another and their designs adapted so that high performance mi...

Page 47: ...moldboard to the rear in all milling depths and therefore ensures optimum material pickup and a clean milling surface The side shields are fitted with replaceable zero wear hard metal plates to increa...

Page 48: ...spring accumulator brakes integrated in the gears of all four drive units The machine brakes when the control lever is swiveled back from the maximum position to neutral The accumulator or spring bra...

Page 49: ...he strut tower make a large lifting height possible so that the space required between the machine and ground is always provided during difficult manoeuvres such as loading Levelling equipment The lev...

Page 50: ...h a high pressure cleaner that consists of high pressure pump water lance and a tube reeling device Water refilling system optional Water filling port is mounted at the back of the milling machine It...

Page 51: ...speed of the lower conveyor automatically changes in proportion to the speed adjustment of the discharge conveyor All belt changes can be simply and rapidly performed The lower conveyor is positioned...

Page 52: ...circuit for height adjustment and steering these are switched between the load sensing adjustment pump and the hydraulic control blocks Electrical system 24 volt system with two cold start high power...

Page 53: ...essure system 5 Fine drum 2m 6 High pressure water 7 Water refilling pump 8 Basic leveling system 9 Additional slope sensor 10 Advance leveling system 11 Tools and wears 12 Rotated light 13 Option 12V...

Page 54: ...me Machine plate The machine plate 2 is fixed to the right hand inner front side of the machine The plate gives the name and address of the manufacturer type of machine PIN serial number operating wei...

Page 55: ...Machine description 44 4812313240 pdf 2017 12 1 Explanation of 17PIN serial number A Manufacturer B Family Model C Check letter D No coding E Production unit F Serial number...

Page 56: ...Machine description 45 4812313240 pdf 2017 12 1 Decals...

Page 57: ...Machine description 46 4812313240 pdf 2017 12 1...

Page 58: ...Machine description 47 4812313240 pdf 2017 12 1...

Page 59: ...ach decal 4700903832 Warning Belt rotation Keep your hands at a safe distance from the danger zone 4700903424 Warning Hot surfaces Keep your hands at a safe distance from the danger zone 4700903459 Wa...

Page 60: ...whole body attach support Maintain a safe distance from the crush zone D956052009 Warning Battery charging Maintain a safe distance D956052003 Warning Battery charging Prohibit to spray with water 48...

Page 61: ...4812248835 Warning Crush of whole body conveyor Maintain a safe distance from the crush zone 4812248836 Warning Crush of whole body conveyor Maintain a safe distance from the crush zone 4812248469 Wa...

Page 62: ...n Close the guard Maintain a safe distance from the crush zone 4812248494 Caution Do not climb Do not climb when the vehicle is moving 4812248466 Caution Do not step Do not step decal Maintain a safe...

Page 63: ...812313240 pdf 2017 12 1 Info labels Handbook compartment Battery voltage Master switch Diesel fuel Water Hydraulic fluid level Fixing point Lifting plate Lift point Hearing protection Milling depth Co...

Page 64: ...trols Control panel Two operating stations one on the left and the other on the right are provided on the platform It consists of a main panel with display and ergo box The left or the right operators...

Page 65: ...ions is displayed by means of LEDs The system also includes ignition lock rotary switch for work lighting and warning lamps EMERGENCY STOP impact switch 4 Display indicator Used in conjunction with th...

Page 66: ...Machine description 55 4812313240 pdf 2017 12 1 Switch panel Main console left right...

Page 67: ...indicated in the display To restart the engine all EMERGENCY STOP buttons must be in the upright position 3 Engine start stop engine Start engine by pressing the switch when the ignition lock is swit...

Page 68: ...Machine description 57 4812313240 pdf 2017 12 1...

Page 69: ...e indicating light is switched on 7 Driving light For switching on the driving lighting driving light rear lights control panel lighting and width lamp 8 Working light For switching on the working lig...

Page 70: ...Machine description 59 4812313240 pdf 2017 12 1...

Page 71: ...hts on Exit and enter other mode by pressing switch 13 or 14 The engine speed can be set in the display in ECO mode When in ECO mode engine speed value will be within the scope of 1700 2100 rpm This e...

Page 72: ...Machine description 61 4812313240 pdf 2017 12 1...

Page 73: ...16 Water refilling To activate the water refilling pump The LED will be lighted once this function is activated 17 Unfolding conveyor While the button is being pressed the conveyor continues being unf...

Page 74: ...Machine description 63 4812313240 pdf 2017 12 1...

Page 75: ...LED This button function is available only when the conveyor is stopped The reversing speed is 40 of the Max speed of conveyor 20 Reversing mode discharger conveyor At the touch of the button the dire...

Page 76: ...Machine description 65 4812313240 pdf 2017 12 1...

Page 77: ...se the engine speed by pressing this button when the machine is in transport mode or service mode keep pressing the engine speed will increase continuously adjust range is 1000 2100 rpm 25 Engine spee...

Page 78: ...Machine description 67 4812313240 pdf 2017 12 1...

Page 79: ...uto mode press the conveyor or water pump manual button LED flashes and auto function stops Press conveyor or water pump manual button again auto function is ON again 28 Set up button As an aid for st...

Page 80: ...Machine description 69 4812313240 pdf 2017 12 1 Control lever panel...

Page 81: ...der is controlled by the operator When the control lever is released in the neutral position it will be automatically shifted to auto mode again 3 Raising lowering front left side of vehicle While the...

Page 82: ...Machine description 71 4812313240 pdf 2017 12 1 LH RH Ergo control...

Page 83: ...ontrol lever forward the front drive units are swiveled to the straight forward position Pull it backward the rear drive units are swiveled to the straight forward position Turn it to the left the rea...

Page 84: ...ard the planer moves forward Pull it backward the planer moves backward If this function is engaged the milling drum is deactivated The top button is used for electrically locking unlocking the drive...

Page 85: ...and steering are disengaged whenever the EMERGENCY STOP button is pressed No movement e g of the lower conveyor is then possible Risk of accident Seven emergency stops are located on the left right c...

Page 86: ...And it stops when released The engaged function is confirmed by LED This button function is available only when the conveyor is stopped The reversing speed is 40 of the Max speed of conveyor 5 Water...

Page 87: ...hing on the water pump 10 Conveyor For actuating and stopping the both conveyors 11 Direction change By pressing up front trackers turn to left position Pressing down front trackers turn to right posi...

Page 88: ...ng are disengaged whenever the EMERGENCY STOP button is pressed No movement e g of the lower conveyor is then possible Risk of accident Seven emergency stops are located on the left right console ergo...

Page 89: ...s function is related to the leveling control system When the leveling system of planer is in auto mode operate the joystick it will be switched to manual mode in which the cylinder is controlled by t...

Page 90: ...e board While the button is being pressed the left side board is being raised 11 Direction change By pressing up front trackers turn to left position Pressing down front trackers turn to right positio...

Page 91: ...structure for setting and display options The following graphics can be used to clarify the setup of the screen structure and to simplify operation or the procedure to be following during various sett...

Page 92: ...Machine description 81 4812313240 pdf 2017 12 1...

Page 93: ...ferent menu screen the focus change in proper order that is the same as the rotation direction of encoder A The chosen item from Action menu I will be highlighted while the remaining is in dark color...

Page 94: ...range of 99 9cm 2 The actual milling depth of the right hand side in cm inch in British system resolution ratio of 0 1cm and measuring range of 99 9cm 3 The system alarm driving direction and high low...

Page 95: ...setting speed is displayed under the meter of actual travelling speed with the unit of m min feet in British system During the transport runs the display shows actual road speed in km h mile in Britis...

Page 96: ...2 1 11 Engine alarm display when an alarm appears the right symbol will light Engine fault alarm Engine warning alarm Engine regeneration Engine regeneration prohibition High post processing temperatu...

Page 97: ...green The range of engine speed in ECO mode is from 1700rpm to 2200rpm C Deactivate ECO Select through Button D on the display E Enforce engine regenerate For T4f engine ONLY Select through Button E...

Page 98: ...2 1 Oil pressure bar Working hours h The engine s value and parameters displayed in this screen are come from J939 K Alarm Symbol message refer to main screen Six alarm light signals are displayed in...

Page 99: ...executed This issue is required to be addressed as soon as possible to prevent further damage 3rd state Red interface The display shows STOP ENGINE which indicates that the malfunction of the guide en...

Page 100: ...the display 3 which controls selecting each action Press Button B to change the value from left to right The setting depth of left side is increased by 0 1 cm at each press of button D and it is decre...

Page 101: ...n on the display 1 which controls selecting each action Press button C to set the number of consoles rotate knob A see Knob A location from Welcome screen description to select single or double one pr...

Page 102: ...n the conveyor from top to bottom are in the following order forward speed percentage reverse speed percentage delay time percentage of control handle back to neutral position The parameter of water p...

Page 103: ...revious one and press button G to return to the main interface Page 403 The left side of this screen displays the dual circuit voltage of potentiometer of the strut tower lifting lever on the left con...

Page 104: ...ng The value is displayed as the following order Pressure of driving system Pressure of discharge conveyor Lower conveyor pressure Oil temperature of hydraulic system Press button G to return to the m...

Page 105: ...If necessary carry out a visual inspection for signs of leakage When hot the system is pressurized Risk of scalding Coolant temperature Switch off engine immediately Check coolant water level If nece...

Page 106: ...oasting mode Engine stop solenoid Check wiring on stop solenoid If necessary call Service Fuel temperature If necessary top up fuel tank or carry out visual inspection for signs of leakage Check fuel...

Page 107: ...age 703 The previously appeared and stored warning information shows in sequence automatically after entering this interface Press button B the next alarm appears automatically press button D to clear...

Page 108: ...ault message has its own error code number When contacting technical service specify the error code number and other information from the fault message Indication Error code Significance E101 Right ma...

Page 109: ...n 98 4812313240 pdf 2017 12 1 E104 Left front ground box E stop is activated E105 Right front ground box E stop is activated E106 Left rear ground box E stop is activated E107 Right rear ground box E...

Page 110: ...pdf 2017 12 1 E108 Low voltage E109 CAN connection error between main controller and the engine E110 CAN connection error between main controller and the consoles E111 CAN connection error between th...

Page 111: ...Machine description 100 4812313240 pdf 2017 12 1 E112 CAN connection error between A3 and A4 E113 CAN connection error between A3 and A8 E114 Leveling system error E115 Propelling control lever error...

Page 112: ...r steering control lever error E117 Four strut towers control lever error Right side E118 Left front strut tower control lever error Right side E119 Right front strut tower control lever error Right s...

Page 113: ...1 E121 Four strut towers control lever error Left side E122 Left front strut tower control lever error Left side E123 Right front strut tower control lever error Left side E124 Rear strut towers contr...

Page 114: ...n 103 4812313240 pdf 2017 12 1 E126 Front steering sensor error E127 Rear steering sensor error E128 Left front motor speed sensor error E129 Right front motor speed sensor error E130 Left rear motor...

Page 115: ...tion 104 4812313240 pdf 2017 12 1 E131 Right rear motor speed sensor error E132 Fuel level sensor error E133 Hydraulic oil temperature high E134 Hydraulic oil level low E135 High pressures hydraulic o...

Page 116: ...105 4812313240 pdf 2017 12 1 E136 Low pressures hydraulic oil filter block E137 Water level low E138 Discharge conveyor pressures high Option E139 Lower conveyor pressure high Option E140 Propelling s...

Page 117: ...Machine description 106 4812313240 pdf 2017 12 1 E141 Tilt too much E149 Calibration values error E150 A3 controller error E151 A4 controller error E152 A8 controller error...

Page 118: ...Machine description 107 4812313240 pdf 2017 12 1 E153 Milling drum clutch error E154 Milling drum belt tension error E155 Parking valve error E156 Propelling pump error E157 Left rear motor error...

Page 119: ...Machine description 108 4812313240 pdf 2017 12 1 E158 Left front motor erro E159 Right rear motor error E160 Right front motor error E161 Front steering valve error E162 Rear steering valve error...

Page 120: ...Machine description 109 4812313240 pdf 2017 12 1 E163 Rear strut tower valve error E164 Discharge conveyor error E165 Lower conveyor error...

Page 121: ...carry out a visual inspection for signs of leakage Hydraulic filter pressure filter Replacing filter elements Hydraulic filter return flow filter Replacing filter element Display set up and system inf...

Page 122: ...t travel drive D Traction unit rear left travel drive A Rear drive unit steering angle recording B Front drive unit steering angle recording A B A Raising rear traction units B Lowering rear traction...

Page 123: ...oad to scraper blade D Scraper blade floating position E Scraper blade stop valve A Travel drive right hand operating panel drive axle B Travel drive right hand operating panel steering axle C Travel...

Page 124: ...Meaning Symbol A Travel drive forwards B Travel drive reverse A Travel drive brake function A A Starter relay A A Engine stop relay A A High pressure cleaner A A Spraying system high pressure pump pro...

Page 125: ...Machine description 114 4812313240 pdf 2017 12 1 A Clutch for milling drum drive A A Belt tensioner A A Tilt sensor Tilt outside range or measurements or Senor defective A...

Page 126: ...ower1 5A Junction Box F13 A4 controller power2 30A Junction Box F14 A8 controller power1 5A Junction Box F15 A8 controller power2 30A Junction Box F16 Engine ECN key switch 5A Junction Box F17 After t...

Page 127: ...Box F43 12 VDC output 20A Junction Box F44 Null Junction Box F45 Levelling display 10A Junction Box F46 T3 Engine ECM power1 10A Junction Box F47 T3 Engine ECM power2 10A Junction Box K0 Starter relay...

Page 128: ...fore work is started Pull out lever 1 and 2 to adjust seat position After set the seat position lock the seat position by locking lever 2 Risk of accident If possible always select the operator s cont...

Page 129: ...because otherwise you will not be able to start the machine For the specifications governing all fuses refer to Chapter Maintenance Batteries Behind the maintenance flap two batteries of the 24 volt...

Page 130: ...to provide a visual estimate of the size of the machine s present tilt The indicator ball in the sight glass shows the machine tilt on the scale fitted below the sight glass A warning message is displ...

Page 131: ...or need unlock the cover first follow up below actions to do this operation 1 Insert the key rotate the key as direction 1 shows 2 pull down the cover as direction 2 shows 3 put the cover in the acces...

Page 132: ...rung or the slip free step push the ladder upwards the ladder will fold in as moving up To fold out pull the ladder down the ladder will fold out as moving down Danger of crushing Do not reach into t...

Page 133: ...section can be adjusted regarding the rear guardrail only the inner section can be adjusted The diagram shown here indicates the different situations in which the guardrail should be set up A Close gu...

Page 134: ...ion for ladder and guardrails To reduce the machine width for transport and as an additional safety measure when parking in public places Swivel the guardrails in front of the slip free step Fold up t...

Page 135: ...l out the lock pin 2 Check that the changeover valve 3 under the compensation tank behind the maintenance flap is in position A To lower the roof turn the key operated switch 4 to the left until the r...

Page 136: ...der the compensation tank behind the maintenance flap is in position B Turn key operated switch 2 to the left until the hood is opened to its maxi mum level To lock in this open position slide the slo...

Page 137: ...e valve 2 Turn adjustment button clockwise slower speed for raising roof Turn adjustment button anticlockwise faster speed for raising roof Manual pump hood and roof A manual pump can be used to lift...

Page 138: ...ressure 80 bar Water filter 3 used in the water spray system Water filter 4 used in the high pressure cleaner system Pressure gauge 5 for water spray system Pressure gauge 6 for high pressure cleaner...

Page 139: ...ally engages here The hose will automatically roll back up again if pulled and released again The high pressure jet is started by pressing the trigger 4 Only if the high pressure cleaner function is a...

Page 140: ...tart filling process by pressing switch 2 Switch off filling pump as soon as the level water required is reached in the water tank monitor using the LCD display on the operating panel An overflow can...

Page 141: ...ecessary use wrench Attach pressure pipe and tighten Signal to the operator of the external filling pump that the filling process can be started Switch the filling pump as soon as the level of water r...

Page 142: ...od To separately operate the strut towers Raise machine to the height required and support Remove retaining pin 1 and grip Turn changeover lever 2 anticlockwise until the second detent bore 3 is under...

Page 143: ...rol marks can be found on both side shields and depending on the grating depth indicate the extent to which the milling drum is engaged The control marks are used as assistance e g if milling is to be...

Page 144: ...rlock 4 Rotate the bolt downwards so that the handle lies on the inner side of the sliding interlock 4 Retaining hook of scraper flap The retaining hook for the scraper flap can be found on the right...

Page 145: ...de of the machine The limit switch serves as a safety measure and is actuated as soon as the scraper flap is opened Once the switch has been actuated as an additional safety measure the clutch and bel...

Page 146: ...efore prevent the machine from being lowered further Extend traction units to their maximum limit position Remove complete supports 1 from the retaining tabs 2 and swivel down If necessary dismantle l...

Page 147: ...alve The valve for changing over between discharge conveyor in operating position discharge conveyor in floating position function can be found on the left hand side of the machine in the front sectio...

Page 148: ...e area of the milling track in front of the front drive unit the area of the sliding shoe in front of the milling drum housing the area of the scraper flap behind the milling drum housing the area of...

Page 149: ...s that the components connected have a longer service life The air pressure required can be set on the pressure reducer 1 The pressure level set is indicated on the pressure gauge 2 Various compressed...

Page 150: ...device 1 can be folded for operations Open latch 2 and raise flap Press the two flap sections together so that both bracket sections are pressed into one another To close the flap proceed in reverse o...

Page 151: ...s at a specified distance from the machine The machine should then be controlled ensuring that the suspended plumb line 1 is above the mark To set the handle to the mark unfasten wing screw 2 move the...

Page 152: ...raise the warning sign so that the detent pin no longer reaches into the bore Swivel the sign through 90 and lower into the detent bore To transport the machine fold in the warning sign Danger of acc...

Page 153: ...or bit replace as soon as possible Strong wear of flank replace immediately To check and replace bits and bit boxes the following safety measures are to be met and enforced Apply traction unit support...

Page 154: ...must be replaced immediately The machine capacity can be fully exploited only with perfect milling tools Typical wear marks on bits New bit Worn bit replace as soon as possible Washed out bit replace...

Page 155: ...e middle of the welding seam the marked pins dowel pins and the contact areas must remain undamaged the old welding seams have to be removed completely Position and weld on the new holder system 1 The...

Page 156: ...e torque wrench with the plug tool must be set to 120Nm The screw has to be inserted dry and free of oil and grease Don t reuse it Drive in the changeable holder tightly into the cone of the basic hol...

Page 157: ...sures during dismantling and welding Remove the screw a Disassemble the changeable holder b With hammer blows on the side of the changeable holder alternatively from LH RH Clean the basic holder and c...

Page 158: ...r that can be driven using the compressed air system of the machine is available Mounting the bits Drive the new bit into the bit box with a copper brass or hard plastic hammer Do not use a steel hamm...

Page 159: ...imeters Use this bit to determine the specifications height to bit tip distance between bit tip and drum edge Smooth the break point Position attach align and weld the bit holder The process always oc...

Page 160: ...149 4812313240 pdf 2017 12 1 Levelling unit Matic type leveling system provides automatic control of the milling drum in the vertical plane The system is optional and its operation is described in th...

Page 161: ...the right hand corner above the display As long as the key is held down the contrast is increased starting from the previously set value When the maximum value is reached the process reverses and the...

Page 162: ...control loop with signs 4 The cross slope arrows only are displayed if the cross slope sensor has been selected as active sensor for one of the two control loops The cross slope direction indicated b...

Page 163: ...selected sensor Sensor selection for the control loops left and right 1 Press the sensor change key of the control loop left or right for the sensor to be changed 350 3 26 0 4 00 A list of all sensor...

Page 164: ...exit without making any changes After either key is pressed the software returns to the working window Left sensor select No sensor Cross slope Sonic ski string Select Sonic ski ground Proceed in ana...

Page 165: ...or 1 If the automatic light of the side selected for cross slope operation lights up switch this control loop to manual mode by pressing the corresponding A M key manual automatic light off 2 Enter th...

Page 166: ...light on by pressing the corresponding A M key The RAISE or LOWER valve light first indicates that an existing deviation is being controlled out The controller of the MLS508 then automatically holds t...

Page 167: ...levant to your day s work scratching 2 Position the grade sensor s above the reference Please consider the individual specifications of the various sensors when doing so If you are working with laser...

Page 168: ...T Wire Rope Sensor C 250 300 OFFSET Wire Rope Sensor C 0 0 OFFSET The current value measured by the grade sensor actual value is taken over as set point and both values are assigned the value 0 0 Ther...

Page 169: ...orks too unstable on one side in automatic mode the sensitivity of the corresponding control loop should be reduced If the system operates too slowly however the sensitivity of the corresponding contr...

Page 170: ...to the working window Please note If the same type of sensor is chosen for both the left and the right control loop of the MLS 508 e g the system operates with Sonic Ski sensors in ground sensing mode...

Page 171: ...Setting the measurement unit of the grade sensors 1 From the working window switch to the parameter Change grade units via the menu items Configuration menu User settings and Change units 2 Call up t...

Page 172: ...l use English French and German have already been installed ex works and can be selected immediately Please contact your dealer referring the implementation of other languages Setting the language 1 F...

Page 173: ...Machine description 162 4812313240 pdf 2017 12 1...

Page 174: ...al rulings Close shut off valve 1 Unscrew filter housing 2 and drain Open hoses on pumps 3 and run empty Observe safety measures gloves protective goggles etc Devices and aids To prevent delays and to...

Page 175: ...d equipment removed for safe keeping should be fitted again in accordance with the appropriate instructions Walk around the machine to check for damage and leaks to ensure that the machine can be safe...

Page 176: ...e whether further maintenance work should be conducted Check the safety and protection equipment Check the position of the lever for changing over the discharge conveyor If necessary move the lever in...

Page 177: ...on description from Machine description chapter Press the horn button before starting The machine cannot be started if the control lever and function keys are not in position 0 or if one of the emerge...

Page 178: ...orrect polarity Always connect the negative cable last and remove it first Insert ignition lock in position 0 Switch on ignition pos 1 Start screen 4 appears on display Position diodes of main operati...

Page 179: ...d and without any load The optimum operating values of a warm machine are engine 60 110 C coolant temperature 2 4 2 8 bar oil pressure at idle speed hydraulic system 45 85 C hydraulic oil temperature...

Page 180: ...witched to 0 if necessary press button to change over Always engage the warning lights rotary beacons and hazard flasher and unfold the warning sign when moving the machine Slide unlocking switch of r...

Page 181: ...een inserted to the milling depth of cm required exactly on the rear dimension mark Switch the A M button of the digital controller of the levelling system AUTO function lights up Set milling depth an...

Page 182: ...description Switch panel Main console left right RH LH ergo control Front Rear ground plate control The floating function of the scraper sliding shoe the auto function of discharge and primary convey...

Page 183: ...nction key 4 of the control lever panel control down so that the machine dips into a horizontal position and in its final position is tilted slightly more at the rear than at the front This milling po...

Page 184: ...conveyor menu Smoothly raise the machine by operating joystick 1 or button 2 4 of the main control panel Pressing button 7 8 9 of the rear side ground plate control until the distance required betwee...

Page 185: ...ng shoe and side boards Remove ignition key and master switch and take them with you do not leave them hidden in the machine Fit cover to operating panel and lock Close protective covers of the side c...

Page 186: ...y is otherwise maintenance free Engine See the manufacturer s instructions in the engine manual Hoods tarpaulin Lower the instrument cover over the instrument panel Cover the entire planer with a tarp...

Page 187: ...t by pumping clean water After this open the intake circuit to the air and leave the pump in operation until the internal circuit is completely empty Following this simple procedure at the end of ever...

Page 188: ...eparated traction unit supports When in this position the milling tool tips of the milling drum are approx 1 cm above the ground If a wooden support is fitted the milling drum can rest gently on this...

Page 189: ...ng transport on public roads The machine driver must have a valid driving license for this type of vehicle The operating panel must be on the side facing oncoming traffic and be secured in place The h...

Page 190: ...Miscellaneous 179 4812313240 pdf 2017 12 1 Fix points Fig Fix points...

Page 191: ...transporter using sufficiently sized shackles chains and secured so that it cannot tilt slide or fall off Attention when working be sure that the front lifting point is as state A The lifting weight o...

Page 192: ...al There must be sufficient possible attachment points on the trailer Approach ramps and trailers must be upright during loading to prevent the machine from sliding or tilting sideways Always keep app...

Page 193: ...den supporting if fitted Sliding shoe and scraper plate are raised slightly Weather protecting sun roofs ladders operating equipment should be folded in or removed The parking brake is engaged and the...

Page 194: ...rive motor of wheel track should be locked Lower the machine until the milling drum is just above the ground approx 5 cm or if wooden supports are used the drum should rest lightly against them Lower...

Page 195: ...d on the platform Lashings in the same direction are placed in different lashing mounts on the trailer The lashing hooks must not lose grip if the lashings become slack The lashings are protected agai...

Page 196: ...ocating surface is not on the towing machine but on the trailer the swivel hydraulics must always be shifted into the operating positon When transporting the machine on different forms of transport su...

Page 197: ...on a public highway it should be cordoned off in accordance with the relevant regulations and secured to prevent the machine from rolling away tilting or swiveling If the machine components protrude...

Page 198: ...s working position Milling drum is not activated Loading and discharge conveyors are not being operated Steps required for folding process 1 Firstly raise machine as far forward as possible over tract...

Page 199: ...hile the Button 17 is being pressed the conveyor continues being folded out until the button is released 4 Once the discharge conveyor is folded out completely release Button 17 to finish this process...

Page 200: ...e vehicle wherever it is parked up Move discharge conveyor into operating position Weather protecting sun roof may be deployed Safely store loose components and accessories such as removable spotlight...

Page 201: ...sure side This function enables a machine to be moved without the drive shaft rotating Start the engine and allow it to idle Unlock the control lever and place the Forward Reverse lever in the forward...

Page 202: ...sting screw 3 to the lowest position Press the pump handle 5 until the brake pressure was released completely About 3bar Rotate the towing valve 1 from horizontal position to vertical position After f...

Page 203: ...oint of the planer The planer must be towed slowly max 0 5 km h and only towed short distances max 300 m When towing retrieving a machine the towing device must be connected to both holes Towing retri...

Page 204: ...ires straps and lifting hooks must be dimensioned in accordance with the relevant safety regulations for lifting equipment They must be strong enough to hold the 3ton weight of conveyor Lifting convey...

Page 205: ...key 1 and master switch 2 and take them with you do not leave them hidden in the machine Fit cover 3 onto operating panel and lock Fold up the ladder on both sides of the machine and swivel the guard...

Page 206: ...esired position 9 Check that the milling drum clears the ground at least 10cm Raise the machine if necessary 10 Drive the planer Operate the forward reverse lever with care 11 Check the brakes Remembe...

Page 207: ...Operating instructions 196 4812313240 pdf 2017 12 1...

Page 208: ...n arrival before delivery to the customer delivery inspection must be conducted as per the check list in the warranty document Any transport damage must be immediately reported to the transport compan...

Page 209: ...Preventive maintenance 198 4812313240 pdf 2017 12 1...

Page 210: ...ners that are clean on both the inside and the outside to add oil or fuel Observe the filling amounts Using the incorrect oil lubricant leads to increased wear and machine breakdowns Fluid volumes PL2...

Page 211: ...Maintenance Lubricants and symbols 200 4812313240 pdf 2017 12 1...

Page 212: ...sign DO NOT START on the control panel so that it is clearly visible when working under the machine position all traction unit supports and wear a hardhat If required use chocks to prevent the drive...

Page 213: ...g materials For maintenance and repair work only the wear and spare parts allowed by the manufacturer are permitted to be used and are to be installed by experts Consult the manufacturer in case of do...

Page 214: ...el tank Check level Add fuel Clean tank and system Engine Check oil level Add oil Replace oil Replace oil filter Clean fuel pre filter Replace fuel filter Drain water for pre fuel filter Replace pre f...

Page 215: ...annually 2000 biannually when required 3 1 Engine drive unit Engine Check engine brackets Tighten engine brackets Check screw connections between pump distribution transmission and engine Tighten scr...

Page 216: ...c filter Check maintenance display Replace filter element Suction return hydraulic filter Check maintenance display Replace filter element Pump distribution transmission Check oil level Add oil Replac...

Page 217: ...l Check visible noglued nuts and screws tighten if necessary Traction unit Check chain tension Adjust chain tension Check condition of bottom plates Replace bottom plates Retaining device for track ro...

Page 218: ...ce belt Clutch DESCH TYPE Check friction lining wear Replace friction lining Drum transmission Check oil level Add oil Replace oil Check visible nonglued nuts and screws tighten if necessary Milling d...

Page 219: ...aper and bottom wear plate Replace wear plate Side plate Check side plate and bottom wear plate Replace wear plate Sliding shoe Check sliding shoe and wear plate Adjust Replace wear plate Limit switch...

Page 220: ...en required 3 5 Loading equipment Conveyor belt Check belt tension sag Adjust belt tension sag Check wear condition Replace conveyor belt Conveyor roller Check condition Replace rolls Funnel rubber of...

Page 221: ...lace both filter elements Drain water Spraying water pump Check oil level Replace oil Inspect mounting Inspect connection of pump to power source Inspect pipes and connections Check inflation pressure...

Page 222: ...ace 3 8 Pneumatic system Maintenance unit Check oil level Add oil Drain water 3 9 Levelling device Sensors controllers connecting cable Check condition Clean or replace 3 10 Brake system Brake system...

Page 223: ...0 100 250 500 1000 annually 2000 biannually when required 4 0 Lubrication points Drive unit Lubricate support legs grease nipple Check lubrication of sliding sur faces Lubricate steering cylinder grea...

Page 224: ...r standard fixed Lubricate pedestal bearing for tail roller grease nipple Lubricate tension bearing for drive roller grease nipple Discharge conveyor foldable Lubricate pedestal bearing for tail rolle...

Page 225: ...12313240 pdf 2017 12 1 Service point Task Operating hours 10 50 100 250 500 1000 annually 2000 biannually when required 5 0 Inspections General visual inspection Inspection by an expert Maintenance Ma...

Page 226: ...the sensor 1 check it during daily operation The tank neck is located below the operator s control station on both sides of the vehicle When filling the tank ensure that no fuel reaches into the soil...

Page 227: ...t seal cap 1 Dispose of the fuel drained off properly Diesel engine The oil level in the engine should be tested before each start with the dipstick Check the oil only when the machine is at a standst...

Page 228: ...nd dispose of property Leave engine to warm up slightly for oil change Unscrew seal cap 1 and open stop cock 2 in position 2B After draining close the stopcock in position 2A fit the seal cap 1 with a...

Page 229: ...oil filter keep an eye on the seals and the oil pressure display Follow Engine operating instructions Fuel filter The fuel filter can be found behind the maintenance flap of the operator s control pan...

Page 230: ...only clear fuel runs out Then slide the neck back again and close drain valve until hand tight Follow Engine operating instructions Air filter The air filter can be found in the rear section of the en...

Page 231: ...f properly Follow engine operating instructions Coolant filter The coolant filter can be found in the rear section of the engine compartment and is accessible once the engine hood has been opened The...

Page 232: ...ward after opening the lock In case of especially strong soiling it is good idea to first spray the cooler with a suitable dirt solvent and to then sprays the dirt off with a water jet Drive belt Visu...

Page 233: ...ions Engine brackets left right The connecting screws of the engine brackets on the left 1 and on the right 2 3 should be checked regularly to ensure that they are secure Switch off engine when checki...

Page 234: ...g If the screws have come loose these must immediately be individually dis mantled secured with screw cement and re inserted using the torque required Centa coupling If you have to replace the Centa c...

Page 235: ...d skin contact with hydraulic oil Use only recommended hydraulic oils Hydraulic oil drainage valve The drainage point for hydraulic oil is in the rear section of the machine underside In order to empt...

Page 236: ...ilter pot with a hexagonal key and unscrew it by hand After unscrewing the filter pot empty the separated dirt into a used oil container Remove the filter element and put it into a container for recyc...

Page 237: ...entire filter insert from the casing Pull the intermediate plate 1 and the dirt collection dish 2 from the used filter element Clean the dirt collection dish Insert the intermediate plate and the dirt...

Page 238: ...d The dipstick 1 can be found on the left on the transmission housing The oil level should be between the MAX and MIN marks Top up oil if necessary The oil filling screw 2 is located on the upper side...

Page 239: ...1 and open stopcock 2 in position 2C After draining close the stopcock in position 2A fit the seal cap 1 with a new seal and screw back on Add new oil via the unscrewed filling screw Continue to do s...

Page 240: ...heck the radiators of the cooler daily for soiling and leakage The oil cooler is located at the rear of the machine behind the cooler grill to the left of the water cooler The cooler grill can be swiv...

Page 241: ...ose 2 Never install aged hoses observe the permitted pressure Hydraulic unit for roof and hood activation Oil level check The hydraulic unit can be found in the engine compartment on the right There i...

Page 242: ...hould be in the 9 o clock position Do not change oil when the engine is cold but rather directly after the transmission has stopped This ensures that solid particles do not settle Wear protective clot...

Page 243: ...be 0 7mm depending on the use conditions between the chain and the framework of the drive measured in the drive middle After adjusting the chain tension drive the machine a few meters and check the s...

Page 244: ...ough of the bottom plate using a socket wrench and dismantle The bottom plates and fastening bolts should always be replaced together Install the new bottom plate in the same manner tighten the bolts...

Page 245: ...tire screw connection should be cemented back in and tightened to the specified tightening torque Worn or loosened pipe scraper 3 should be replaced or tightened immediately Replacing sliding shoes Re...

Page 246: ...o be removed from the grooves of the V belt The belts are always to be replaced in pairs The belt drive is located in the protective box on the left side of the machine Ensure that the drive engine ca...

Page 247: ...ch casing must be removed to carry out the inspection Remove the four locking screws 2 of an accessible inspection cover 1 Remove the inspection cover Through the open inspection opening check the dis...

Page 248: ...e cannot be started Turn the milling drum until the mark 1 on the drum is in the 9 o clock position Remove the Allen screw 2 and the screw protection 3 Remove the inspection screw The oil level should...

Page 249: ...gine cannot be started Turn the milling drum until the mark 3 on the drum is in the desired position Remove the Allen screw 4 and screw sleeve 5 on the drainage and inspection screw Remove the inspect...

Page 250: ...o each other on the milling drum Draining coolant Lower the machine on to the service supports Open and secure the drum flap Ensure that the drive engine cannot be started Turn the milling drum until...

Page 251: ...ure that hardly any removed material remains in the milled track and consequently guarantees problem free material removal The supporting wear bar 2 prevents the scrapers from digging themselves into...

Page 252: ...divided runners the relevant element is to be replaced Check the runners on both side boards regularly and replace if necessary Lower the machine on to the service supports Lift the side board and se...

Page 253: ...sition Ensure that the drive engine cannot be started Depending on the operating circumstances the adjustable runners can be installed at a distance of 0 10mm below the permanent runners When removing...

Page 254: ...drive must be deactivated The belt tensioner must be relaxed The milling drum coasts down slowly and must not be activated The machine cannot be driven Milling drum housing fastening bolts The milling...

Page 255: ...f the tightening equipment Increase the tension evenly on both sides using a fork wrench on the adjusting nuts 2 Tighten the lock nuts 1 again after the adjustment The tension setting of the loading b...

Page 256: ...s as well as the shackles of the discharge conveyor is to be tested daily Damaged steel cords and shackles must be replaced immediately Tearing steel cords represent a great danger for persons and mac...

Page 257: ...r rubber 1 lateral seal 2 lateral guide of primary conveyor 3 discharge funnel 4 primary funnel 5 lateral guide of discharge conveyor 6 All rubber parts are installed with screw connections and can be...

Page 258: ...Fully drain the tank by opening the drain valve 1 on the underside of the machine To drain out all the residue open the two outlet points 2 on the left and right of the machine underside Opening 3 ser...

Page 259: ...red a ladder is to be placed against the machine and secured accordingly Wet machine surfaces are slippery Risk of accident The water in the tank is service water not drinking water In case of frost c...

Page 260: ...screw 1 back in Fill the stipulated quantity of new oil via the opened filling cover Properly screw the filling screw 2 back in Wear protective clothing when working with hot oil Danger to health if...

Page 261: ...lter elements if necessary rinse out housing and insert new cleaned filter Clean the contact surface of the discharge and primary parts of the casing and check seal Screw both filter housing on by han...

Page 262: ...ill about 0 8kg Water pump Drain oil Release the pressure from accumulator 1 Unscrew the plug 2 and remove accumulator Unscrew the drain plug and drain oil from water pump Be careful to handle the oil...

Page 263: ...binet Pull the hose with the nozzle out of the holder Clean the nozzle with a wire brush If necessary remove or replace the nozzle to be cleaned Properly reinstall the nozzle and insert it into the gu...

Page 264: ...aintenance free The pole terminals must be free of oxide and be protected with special pole grease The gas formed in the battery is explosive Avoid naked flames and sparks When removing the batteries...

Page 265: ...he compressed air tank and connected maintenance unit can be found behind the storage room flap on the left hand side of the machine Unscrew the oil reservoir 1 by hand and replenish the stipulated oi...

Page 266: ...n interruption free and precise work flow Damaged parts such as cables and cords should be replaced immediately to avoid breakdowns of the levelling equipment and consequent unnecessary delays The equ...

Page 267: ...ive emergency stop buttons must be replaced immediately Emergency stop buttons are located on the discharge control panel on both upper control panels on all lower control panels See more details in M...

Page 268: ...grooves The sliding surfaces in the guide grooves must always be covered by a film of grease Steering cylinder A grease nipple is located on each bearing point of the steering cylinder Add 3 loads of...

Page 269: ...Add 3 loads of grease with a grease gun Clutch bearing Type DESCH The grease nipple for the clutch bearing is located behind the belt disc Turn the belt disc until one of the holes is in the upper mo...

Page 270: ...3 loads of grease with a grease gun Milling drum bearing Each time the drum is replaced the condition of the bearing must be checked and the bearing must be filled with fresh grease Lower side board...

Page 271: ...earing A grease nipple is located on the tension bearing on the right side of the discharge conveyor Add 3 loads of grease with a grease gun Springs joints and bolts Lubricate the springs joints and b...

Page 272: ...ted on the pedestal bearing on each side of the primary conveyor Add 4 loads of grease with a grease gun Drive roller tension bearing A grease nipple is located on the tension bearing on the right sid...

Page 273: ...ts or operating elements leaks in engine hydraulic system transmission etc all fastening points OK Eliminate problems immediately in order to avoid damage accidents and pollution Inspection by an expe...

Page 274: ...Maintenance 263 4812313240 pdf 2017 12 1...

Page 275: ...en withdraw from service scrapped The materials must be sorted correctly according to metal plastic electronic scrap various operating substances etc Any oil greasy parts hydraulic hoses lube pipes et...

Page 276: ...P091 4 091 4 Accelerator Pedal Position Sensor Circuit shorted low X 133 Red P029 3 974 3 Remote Accelerator Pedal Position Sensor Circuit shorted high X 134 Red P029 4 974 4 Remote Accelerator Pedal...

Page 277: ...4 175 4 Engine Oil Temperature Sensor Circuit shorted low X 214 Red P175 0 175 0 Engine Oil Temperature High Critical X 219 Maint P17 1 1380 17 Low Oil Level in the Centinel makeup oil tank X 221 Yell...

Page 278: ...Multiplexing Remote Throttle Data Error X 293 Yellow S154 3 1083 3 Auxiliary Temperature Sensor Input 1 Circuit shorted high X 294 Yellow S154 4 1083 4 Auxiliary Temperature Sensor Input 1 Circuit sh...

Page 279: ...oltage 1 Circuit shorted low X 378 Yellow S018 5 633 5 Fueling Actuator 1 Circuit open circuit X 379 Yellow S018 6 633 6 Fueling Actuator 1 Circuit grounded circuit X 386 Yellow S232 3 1079 3 Sensor S...

Page 280: ...on X 433 Yellow P102 2 102 2 Intake Manifold Pressure Sensor Circuit data incorrect X 434 Yellow S251 2 627 2 Power Lost without Ignition Off X 435 Yellow P100 2 100 2 Engine Oil Pressure Sensor Circu...

Page 281: ...high X 528 Yellow P093 2 093 2 OEM Alternate torque validation switch data incorrect X 529 Yellow S051 3 703 3 Auxiliary Input Output 3 Circuit shorted high X 546 Yellow P094 3 94 3 Fuel Delivery Pres...

Page 282: ...l Charging System Voltage Low Critical Level X 611 None S151 11 1383 31 Engine Hot Shutdown X 753 None S064 2 723 2 Engine Speed Position 2 Cam sync error X 755 Yellow P157 7 157 7 Injector Metering R...

Page 283: ...Dynapac China Compaction Paving Equipment Co Ltd No 38 Quanwang Road WuQing High Tech Industrial Park 301700 Tianjin China www dynapac com...

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Dynapac PL2000F, Instruction Manual

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