Dynapac PL 500/20 S Скачать руководство пользователя страница 150 | Manualshive

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background image

D 110

D

PL5

00/

20S.

G

B 1

10-

1

16 -

04.

07

Error
code
and
warn-
ing
lamp

PID(P)
SID(S)
FMI

SPN(S)
FMI

Cause

Effect

382*
YEL-
LOW

S237
11

626
11

Fault detected in release circuit of
cold start auxiliary relay 2 on pin 31
of OEM wiring harness.

Intake air preheated cannot be com-
pletely energised / powered up by the
electronic control unit. Possibly white
smoke and/or starting problems.

385
YEL-
LOW

S232
3

620
3

Short circuit detected on pin 10 of
OEM wiring harness for +5 V power
supply to OEM wiring harness sen-
sor.

The sensors connected to this +5V DC
power supply (i.e. for remote speed ad-
justment) do not function.

386
YEL-
LOW

S232
3

620
3

Short circuit detected on pin 10 of
engine wiring harness for +5 V power
supply to engine position sensor.

Specified value for the sensors con-
nected to this +5V DC power supply.
Engine is restricted to zero charge fill
and loss of engine protection for oil
pressure, intake manifold pressure and
coolant temperature.

387
YEL-
LOW

P091
3

91
3

Short circuit on pin 29 of OEM wiring
harness for +5 V power supply to en-
gine speed adjustment unit.

Engine is running at idle speed when-
ever the idle speed switch indicates
„idle speed on“, 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 43 of the engine wiring har-
ness.

Possibly no impact on power, or engine
does not run.

415
RED

P100
1

100
1

The oil pressure signal indicates that
the oil pressure is below the lowest
limit value for engine protection pur-
poses.

Restriction of speed and possibly shut-
down of engine if the engine protection
shutoff function is enabled.

418
WIF

P097
0

097
0

The 'water in fuel' signal indicates
that water needs to be drained from
the fuel filter.

Too much water in the fuel can lead to
severe damage to the fuel supply sys-
tem.

422
YEL-
LOW

P111
2

111
2

Voltage detected simultaneously on
pins 27 and 37 of engine wiring har-
ness for high and low coolant level....
OR.... no voltage detected on any of
the pins (fault only active on coolant
level switch sensors).

No engine protection for coolant level.

429
YEL-
LOW

P097
4

097
4

Undervoltage detected on pin 40 of
the OEM wiring harness for the 'wa-
ter in fuel' signal.

No 'water in fuel' protection.

431
YEL-
LOW

P091
2

091
2

The idle speed signals on pins 25
and 26 of the OEM wiring harness in-
dicate that voltage must be detected
simultaneously on both pins (open
power circuit).

No impact on power, but loss of idle
speed.

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Содержание PL 500/20 S

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 10: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 32: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 40: ......

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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