Page 1 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...
Page 3: Table Of Contents
Contents Contents Instruction .............................
Page 4 Contents ..........................19 Temperatures ........................20 High pressure cleaning ............................ 20 Fire fighting ..........................20 Battery handling ........................21 Jumping starting (24V) ........................23 Technical specifications ......................23 Vibrations – Operator station ............................23 Noise level ............................24 Dimensions ............................. 26 Weights ..........................
Page 5 Contents ..........................
Page 6 ......................148 Replacing the holder box ............................ 149 Leveling unit ........................... 149 Matric type ..................150 Operating the Dynapac Leveling System ........................150 Setting the contrast ................151 Symbols and displays in the working window .......................... 152 Sensor selection ..................154 Operating with the Cross-Slope sensor ...........................
Page 7 Contents ............................
Page 8 Contents ..............191 Short distance towing when the engine is inoperative ..........................192 Towing the planer ......................... 193 Lifting the conveyor ......................194 Securing before parking up ...................... 195 Operating instructions – Summary ........................197 Preventive maintenance ....................199 Maintenance – Lubricants and symbols ...................
Page 9 Contents ..........................
Page 10 Contents ......................241 Runners on the side boards ........................242 Sliding shoe runners ........................243 Drum flap limit switch ....................243 Milling drum housing fastening bolts .......................... 244 Loading equipment ............................. 244 Belt tension ............................ 245 Drum holder ............................245 Steel cords ............
Page 11 Contents ..........................
Page 12: Instruction
Introduction The machine Dynapac PL2000F is a high performance cold milling machine for removing asphalt and concrete in a controlled manner. The track driven machine has a high capacities discharge conveyor. The milling drum is ...
Page 13: Intended Use
Introduction Intended use PL2000F is mainly intended to be used for roadworks:  to partially or completely remove asphalt, asphalt based and/or cement layers  to remove distortions in the forms of track ...
Page 14: General
Introduction General This manual contains instructions for machine safety, operation, transport and maintenance. The machine must be correctly maintained for top performance level. The machine should be kept clean so that any ...
Page 15 Introduction ...
Page 16: Safety - General Instructions
Safety - General instructions Safety - General instructions (Also read the safety manual) Read the entire manual before starting the machine and before carrying out any maintenance. Do not remove the manual from ...
Page 17 15. Do not make any changes or modifications to the planer, this could put safety at risk. Changes may only be made following the written approval of Dynapac. 16. Avoid using the planer before the hydraulic fluid has reached its normal working temperature.
Page 18: Safety - When Operating
Safety - General instructions Safety - when operating Prevent persons from entering or remaining in the danger area, i.e. a distance of at least 7m (23 ft) in all directions 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...
Page 19: Slopes (Tip Over Risk)
Safety - General instructions Slopes (Tip over risk) Bear in mind that loose ground, and conveyor movements changes the center of gravity and can cause the machine to tip over on slopes ...
Page 20: Safety Devices
Safety - General instructions Safety devices machine only safely operated if the control and safety devices are functioning perfectly and if the protective equipment is fitted correctly. ...
Page 21: Emergency Stop Button
Safety - General instructions Emergency stop button On the left/right console One the left/right ergo box On the four ground control panels The engine, drives and steering system are shut down when the emergency stop ...
Page 22: Horn
Safety - General instructions 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 ...
Page 23: Headlights, Indicators Rotary Beacons
Safety - General instructions Headlights, indicators rotary beacons Lights for illuminating different operating areas and for indicating danger areas and/or dangerous situations are located at various machine positions. Several contacts, to which headlights can be connected, can be found around the machine.
Page 24: Hazard Warning Lights On Side Panels
Safety - General instructions Hazard warning lights on side panels One hazard warning light can be found above the side panel on both the left and right-hand sides of machine. The hazard warning lights are operated as soon as the side panels are raised.
Page 25: Traction Unit Supports
Safety - General instructions Traction unit supports One separable traction unit support can be found on every traction unit as a safety measure. The complete traction unit support is ...
Page 26: Steel Retaining Cables
Safety - General instructions 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 immediately. Fig.
Page 27: Retaining Hook Of Scraper Flap
Safety - General instructions Retaining hook of scraper flap When open the scraper flap, the retaining hook must be inserted to prevent the flap falling down. ...
Page 28: Exit Ladders, Grab Bars And Guardrails
Safety - General instructions Exit ladders, grab bars and guardrails The ladders on both sides of the machines are fitted with slip-free covers. Grab bars and guardrails are also provided. Climbing up and down the ladders during travel and travelling on the ladders themselves is prohibited.
Page 29 Safety - General instructions 4812313240.pdf 2017-12-1 ...
Page 30: Special Instructions
Special instructions Special instructions Standard lubricants and other recommended oils and fluids Before leaving the factory, the systems and components are filled with the oils and fluids specified in the lubricant specification. These are suitable for ambient temperatures in the ...
Page 31: High Pressure Cleaning
Special instructions High pressure cleaning Do not spray directly onto electrical components. Do not use high pressure cleaning for dashboard/display. The Electrical Drive Control and the computer box may not be washed with high pressure ...
Page 32: Jumping Starting (24V)
Special instructions Jump starting (24V) Do not connect the negative cable to the negative terminal on the dead battery. A spark can ignite the oxy-hydrogen gas formed around the battery. ...
Page 33 Special instructions ...
Page 34: Technical Specifications
EU Directive 2000/14/EC on machines equipped for the EU market; nominal speed of diesel engine and milling and transport devices in operation. Guaranteed sound power level, L 447kW 112 dB(A) PL2000F Sound pressure level at the operator's ear (platform), L 94 dB(A) PL2000F ...
Page 35: Dimensions
Technical specifications Dimensions ...
Page 36 Technical specifications PL2000F Standard Designation A Machine length with max. paving height 14110 B Machine length with discharge conveyor at transport height 15310 C Max. paving height 5670 D Transport height of discharge conveyor E Machine length without discharge conveyor...
Page 37: Weights
Technical specifications Weights (Hydraulic Foldable discharge conveyor) Operating weight CE* 33.3 Transport weight Operating weight (with full tank) Discharge conveyor Max axle load, front Max axle load, rear *CE weight: water and fuel tank half filled, driver and tools on board Performance data Transportation speed 0 - 5...
Page 38: Loading System
Technical specifications Loading system Belt width, primary conveyor Belt width, discharge conveyor Belt speed, primary conveyor Belt speed, discharge conveyor m3/h Loading capacity (theoretical) Engine (T3) Make/type Cummins QSX 15-C600 Version 6-cylinder diesel engine (water-cooled) Power (in accordance with DIN 447 kW / 607 PS / 600 hp (at 2100 rpm) 6270) Capacity...
Page 39: Hydraulic System
Technical specifications Hydraulic system Hydro pumps via transfer box Pressure creation (directly flange-mounted on engine) Separate hydraulic circuits, e.g. for: loading and discharge conveyor, Pressure distribution cylinder functions clutch, belt tensioner fan, filling equipment, water system Hydraulic oil tank - filling volume approx.
Page 40: Tightening Torques
Technical specifications Tightening torque Tightening torque in Nm (lbf.ft) for oiled or dry bolts tightened with a torque wrench. Maximum torque for shaft screws with metric ISO coarse-pitch thread 8.8 10.9 ...
Page 41 Technical specifications 4812313240.pdf 2017-12-1 ...
Page 42: Machine Description
Machine description Descriptions of assemblies and functions 4812313240.pdf 2017-12-1 ...
Page 43 Machine description Item Designation Frame Weather protecting roof Control panel Ground control panels Belt drive (milling drum drive) Milling box (be consistent) Track systems Strut towers Primary conveyor Discharge conveyor Water tank Foldable ladder Guardrails Storage area Radiator grille Connection for external water filling (filling under pressure)
Page 44 Machine description Frame assembly: Robust, distortion-resistant steel welded design with useful brackets for supporting the assemblies, units, attachments and tanks. All parts can be easily accessed for maintenance and repair work. ...
Page 45 One digital controller for the milling depth and one for the slope position are attached next to the rear operating panels on the left and right sides. Dynapac CAN-BUS data communication system: The tried and tested state-of-the-art ...
Page 46 Machine description and errors are noted and can be corrected immediately. Engine: The machine is fitted with a powerful 6-cylinder Cummins turbo diesel engine which effortlessly covers the power requirements of the ...
Page 47 Machine description gear are configured specially for the milling drum drives and finely tuned to the engine rating of the machine. Material is removed by the process of upwilling – if the machine is moving from left ...
Page 48 Machine description When overloaded, machine feed automatically reduced using limit load control. Steering system The machine has fully-tracked steering. When used in conjunction with a pre-selection button, the control lever allows the machine to be driven in four ...
Page 49 Machine description The height of the strut tower is adjusted using an integrated hydraulic cylinder which is activated by proportional valves. The milling depth and slope are set by means of the ...
Page 50 Machine description Water system: Water spray system is need to cool the bits and minimize dust during milling operation. Spray bars consists of nozzles that can be easily replaced. ...
Page 51 Machine description The speed of the conveyors can be adjusted using the control levers. It can be run in both directions. The discharge conveyor can swing up, down, left & right. ...
Page 52 Machine description - a large return suction filter, fitted in the hydraulic oil tank, for the drive circuits of the traction unit, loading belt, fan and water system as well as for the ...
Page 53 Machine description Optional equipment: Fold roof Dust suction system Option weight Air pressure system Fine drum 2m High pressure water ...
Page 54: Machine Description
Machine description Machine description Identification The machine PIN (1) is punched on the front right side of the frame. Machine plate The machine plate (2) is fixed to the right hand inner front side of the machine.
Page 55: Explanation Of 17Pin Serial Number
Machine description Explanation of 17PIN serial number A= Manufacturer B= Family/Model C= Check letter D= No coding E= Production unit F= Serial number ...
Page 56: Decals
Machine description Decals ...
Page 57 Machine description 4812313240.pdf 2017-12-1 ...
Page 58 Machine description ...
Page 59: Safety Decals
Machine description Safety decals Always make sure that all safety decals are completely legible, and remove dirt or order new decals if they have become illegible. Use the part number specified on each decal. ...
Page 60 Machine description 4812248460 Warning – Risk of crushing of whole body-attach support Maintain a safe distance from the crush zone. D956052009 Warning – “Battery charging” Maintain a safe distance. D956052003 Warning –...
Page 61 Machine description 4812248833 Warning – Electrical hazard decal Danger of electric shock. Maintain a safety distance. 4812248835 Warning – Crush of whole body conveyor Maintain a safe distance from the crush zone. ...
Page 62 Machine description 4812248474 Warning – Crush of whole body Maintain a safe distance from the crush zone. 4812248495 Caution – Close the guard Maintain a safe distance from the crush zone. ...
Page 63: Info Decals
Machine description Info labels Handbook compartment Battery voltage Master switch Diesel fuel Water Hydraulic fluid level Fixing point Lifting plate Lift point ...
Page 64: Instruments/Controls
Machine description Instruments/Controls 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 Machine description Pos. Designation Brief description Controls the following functions of the discharge Control lever discharge conveyor „Swivel“, „Raise“, „Lower“. It also conveyor provides infinitely variable control for the conveyor speed. Is used after system is unlocked for the purposes of driving, steering and braking.
Page 66: Switch Panel
Machine description Switch panel Main console – left & right 4812313240.pdf 2017-12-1 ...
Page 67 Machine description Pos. Designation Symbol Brief description Insert the key and turn it to the right, the vehicle is Ignition lock supplied with power. When resetting, the vehicle is powered off and the engine stop working. Press in emergencies (people in danger, risk of collision etc.)! - The engine, drive units and steering are...
Page 68 Machine description 4812313240.pdf 2017-12-1 ...
Page 69 Machine description Pos. Designation Symbol Short description Moving to the At the touch of the button, the platform moves to left-platform the left, and the indicating light is switched on. Moving to the At the touch of the button, the platform moves to right-platform the right, and the indicating light is switched on.
Page 70 Machine description 4812313240.pdf 2017-12-1 ...
Page 71 Machine description Pos. Designation Symbol Brief description The switch is located on the left and right console respectively. When pressed, the LED lights up, and the corresponding console enters Console into controlling mode, all switches in it are selector available, while the others are unavailable.
Page 72 Machine description 4812313240.pdf 2017-12-1 ...
Page 73 Machine description Pos. Designation Symbol Brief description Water pump For switching on the water pump. switch LED indicates activation. To activate the water refilling pump. The LED will Water refilling be lighted once this function is activated. While the button is being pressed, the conveyor Unfolding continues being unfolded..
Page 74 Machine description 4812313240.pdf 2017-12-1 ...
Page 75 Machine description Pos. Designation Symbol Brief description At the touch of the button, the direction of the lower conveyor is switched over to the reversing Reversing mode, And it stops when released. The engaged mode lower function is confirmed by LED.
Page 76 Machine description 4812313240.pdf 2017-12-1 ...
Page 77 Machine description Pos. Designation Symbol Brief description Position Indicate the present position of the front and diodes rear drive units. Increase the engine speed by pressing this Engine speed button when the machine is in transport mode adjustment or service mode, keep pressing, the engine speed will increase continuously;...
Page 78 Machine description 4812313240.pdf 2017-12-1 ...
Page 79 Machine description Pos. Designation Symbol Brief description At the touch of the button, the milling drum starts working, and stops when it is released. The Milling drum activated function is confirmed by LED. The milling drum drive can only be engaged at idle speed At the touch of the button, the system enters into automatic control mode.
Page 80: Control Lever Panel
Machine description Control lever panel 4812313240.pdf 2017-12-1 ...
Page 81 Machine description Pos. Designation Symbol Brief description While the control lever is being pulled upward/downward, all four strut tower Raising/lowering cylinders are extended/retracted and the the vehicle vehicle is raised/lowered continuously until they reach their upper/lower limit position.
Page 82: Rh/Lh - Ergo Control
Machine description LH / RH – Ergo control 4812313240.pdf 2017-12-1 ...
Page 83 Machine description Pos. Designation Symbol Brief description Press in emergencies (people in danger, risk of collision etc. )! - The engine, drive units and steering are disengaged whenever the EMERGENCY STOP button is pressed. No movement, e.g.
Page 84 Machine description Pos. Designation Symbol Brief description The driving and steering direction are controlled by the dual-axis control lever. - Turn the control lever to the left, the vehicle is swiveled to the left (the selection of steering mode is required, and it defaults to front drive units steering.
Page 85: Ground Plate Panel
Machine description Ground plate panel Front left & Front right Pos. Designation Symbol Brief description Press in emergencies (people in danger, risk of collision etc.)! - The engine, drive units and steering are disengaged whenever the EMERGENCY STOP button is pressed.
Page 86 Machine description Pos. Designation Symbol Brief description At the touch of the button, the direction of the discharge conveyor is switched over to the reversing mode, And it stops when released. Reversing The engaged function is confirmed by LED. mode-discharge This button function is available only when the conveyor...
Page 87 Machine description Pos. Designation Symbol Brief description Water pump For switching on the water pump. Conveyor For actuating and stopping the both conveyors. By pressing up, front trackers turn to left position; Direction Pressing down, front trackers turn to right change...
Page 88: Rear Left & Rear Right
Machine description Rear left & Rear right Pos. Designation Symbol Brief description Press in emergencies (people in danger, risk of collision etc.)! - The engine, drive units and steering are disengaged whenever the EMERGENCY STOP...
Page 89 Machine description Pos. Designation Symbol Brief description While the joystick is being pulled upward/downward, the front left strut tower is extended/retracted and the body of vehicle is raised/lowered continuously until it reaches its upper/lower limit position. Raising/lowering This function is related to the leveling control front left side of...
Page 90 Machine description Pos. Designation Symbol Brief description Raising left While the button is being pressed, the left side side board board is being raised. By pressing up, front trackers turn to left position; Direction Pressing down, front trackers turn to right change position.
Page 91: Screen Structure For Setting And Display Options
Machine description Screen 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 setting and ...
Page 92 Machine description 2017-12-1 4812313240.pdf ...
Page 93 Machine description Operation, displays and setting options in the menu Welcome Screen The system gets electricity once the key switch is turned on. Welcome screen appears in the display, and then the main screen is showed 3 seconds later , meanwhile, all LEDs on the control table are lighted for 3 seconds, the state of vehicle is indicated normally.
Page 94 Machine description Main screen - information and warning messages Following the welcome screen, the system enters into the main screen automatically in three seconds later. The following main parameters are indicated in the main screen: ...
Page 95 Machine description BOX: Display status: Alarm display OR Normal display BOX: Drive Forward mode OR Neutral position OR Reverse mode 4. The actual torque load of engine is shown in percentage. 4.
Page 96 Machine description 11. Engine alarm display, when an alarm appears the right symbol will light. Engine fault alarm Engine warning alarm Engine regeneration Engine regeneration prohibition ...
Page 97 Machine description Engine screen (Page 101) This screen is used to set the engine speed in ECO mode and indicates whether the machine is in ECO mode or not. ...
Page 98 Machine description 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 this screen, with the same state as home page. ...
Page 99 Machine description Engine warning screen (Page 102) This screen is used for displaying the engine SPN fault code. This screen has 3 different states: state: Green interface – The display shows “ENGINE OK”, which indicates no fault code. ...
Page 100 Machine description Leveling, setting leveling value The setting value and actual measured value of leveling system are displayed in this screen. The actual travelling speed of planer displayed at the upper position of the screen. ...
Page 101 Machine description Adjustment screen (Page 301) The number of console (the machine is standard-equipped with two consoles, and only choosing the right side one is available); adjustment discharge conveyor (mechanical folding or hydraulic folding); unit of display data (metric or British system) and parameters of conveyor, water pump and ...
Page 102 Machine description (Page 302) Press button D to set parameters of working device in page 301. It is required to select parameters needed to be changed first. The red frame indicates the focus point, press ...
Page 103 Machine description Press button B to enter into the next electrical screen in page 401, and press button G to return to the main screen. (Page 402) The left side of this screen displays the dual-circuit voltage of potentiometer of the strut tower lifting lever on the left control box.
Page 104 Machine description This screen displays the speed of four hydraulic motors of the driving system in rmp. Press button C to switch back to the previous electrical page and press button G to return to the main interface. Hydraulic screen (Page 501) The signal value of each pressure sensor of the hydraulic system is displayed in...
Page 105 Machine description Key to component and status symbols Warning Symbol Action Allow engine to heat up at slightly Oil temperature raised idle speed. Switch off engine immediately! Check engine oil level. If necessary, Oil pressure carry out a visual inspection for signs of leakage.
Page 106 Machine description Designation Symbol Action Reduce engine speed (possible coasting mode) Engine speed Check wiring on stop solenoid. If necessary, call Service. Engine stop solenoid If necessary, top up fuel tank or carry out visual inspection for signs of Fuel temperature leakage.
Page 107 Machine description Press button B under page 701 to enter into the current fault warning screen (page 702). The current system alarm is showed in sequence automatically after entering this interface. Press button B , the next alarm is displayed automatically, press button G ...
Page 108: Description Of Error Codes (Of Page 703), Dialog Boxes
Machine description Description of error codes (of page 703), dialog boxes Every fault message has its own error code number. When contacting technical service, specify the error code number and other information from the fault message. ...
Page 109 Machine description 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-stop is activated. 4812313240.pdf ...
Page 110 Machine description E108 Low voltage. E109 connection error between main controller and the engine. E110 connection error between main controller and the consoles. E111 connection error between the main controller and the display. 2017-12-1 4812313240.pdf ...
Page 111 Machine description E112 connection error between A3 and A4. E113 connection error between A3 and A8. E114 Leveling system error E115 Propelling control lever error 4812313240.pdf 2017-12-1 ...
Page 112 Machine description E116 Rear 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 side E120 Rear strut towers control lever error- Right side...
Page 113 Machine description 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 control lever error- Left side E125 Slop sensor error...
Page 114 Machine description 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 speed sensor error 2017-12-1 4812313240.pdf ...
Page 115 Machine description E131 Right rear motor speed sensor error E132 Fuel level sensor error E133 Hydraulic temperature high E134 Hydraulic oil level low E135 High pressures hydraulic oil filter block 4812313240.pdf 2017-12-1 ...
Page 116 Machine description 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 system pressure high 2017-12-1 4812313240.pdf ...
Page 117 Machine description E141 Tilt too much E149 Calibration values error E150 A3 controller error E151 A4 controller error E152 A8 controller error 4812313240.pdf 2017-12-1 ...
Page 118 Machine description E153 Milling drum clutch error E154 Milling drum belt tension error E155 Parking valve error E156 Propelling pump error E157 Left rear motor error 2017-12-1 4812313240.pdf ...
Page 119 Machine description 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 4812313240.pdf 2017-12-1 ...
Page 120 Machine description E163 Rear strut tower valve error E164 Discharge conveyor error E165 Lower conveyor error 2017-12-1 4812313240.pdf ...
Page 121 Machine description Key to component and status symbols Designation Symbol Action Allow the hydraulic oil to cool down. Hydraulic oil temperature Check the hydraulic oil level. Check radiator for signs of contamination. ...
Page 122 Machine description Key to function and component symbols Meaning Display mode A: Front traction units, right steering movement Front traction units, left steering movement C: Rear traction units, right steering movement Rear traction units, left steering movement A: Traction unit / rear right travel drive B: Traction unit / front left travel drive...
Page 123 Machine description Meaning Display A: Forwards drive for discharge conveyor B: Reverse drive for discharge conveyor C: Forwards drive for lower conveyor D: Reverse drive for lower conveyor A: Raising left side board B: Lowering right side board A: Raising sliding shoe B: Lowering sliding shoe C: Applying load to sliding shoes...
Page 124 Machine description Meaning Symbol A: Travel drive, forwards B: Travel drive, reverse A: Travel drive brake function A: Starter relay A: Engine-stop-relay A: High-pressure cleaner A: Spraying system high-pressure pump proportioning valve A: Fuel pump A: Spray valve 2017-12-1 4812313240.pdf...
Page 125 Machine description A: Clutch for milling drum drive A: Belt tensioner A: Tilt sensor - Tilt outside range or measurements or - Senor defective ...
Page 126: Electrical System
Machine description Electrical system Fuses, machine The figure shows the different positions of the fuses. The table below gives the amperage and function of the fuses. All fuses are flat pin fuses. Fuses boxes Intake Air Heater Fuse=150A Fuse box Charging Fuse=100A...
Page 127: Relay, Machine
Machine description A8 controller enable=1A Junction Box Pressure sensors=10A Junction Box Null Junction Box Conveyor position switches=10A Junction Box Fan motor speed sensor=3A Junction Box Lightings=40A Junction Box Traffic lights=20A Junction Box Rotation beacon=10A Junction Box Horns=20A Junction Box Back lights=20A...
Page 128: Driver's Seat On Left/Right
Machine description Driver’s seat on left/ right A driver’s seat can be found on both the left and right. The seat should be set to the driver’s requirements before work is started. Pull out lever (1) and (2), to adjust seat position.
Page 129: Battery's Main Switch
Machine description Battery’s main switch The battery’s main switch can be found under the right-hand grid plate. It separates the power supply from the battery for main fuse. To deactivate the master switch, turn to the right and remove.
Page 130: Tilt Display
Machine description Tilt display A tilt display (1) can be found in the center of the front panel in the operator’s control station. The tilt display is used to provide a visual estimate of the size of the machine’s present tilt.
Page 131: Lock And Unlock The Ground Panel Cover
Machine description Lock and Unlock the ground panel cover When using the ground panel to control machine, the operator need unlock the cover first, follow up below actions to do this operation: 1, Insert the key, rotate the key as direction 1 ...
Page 132: Folding Ladder
Machine description Folding ladder A robust ladder with slip-free steps can be found on both the left and right. The ladder can be folded up on both sides of the machine. ...
Page 133: Guardrail
Machine description Guardrail There is one guardrail on both the left and right between the ladders and operator’s control stations. The guardrails must be set up as required and ...
Page 134: Transport Position For Ladder And Guardrails
Machine description Transport position 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 the ladder on both sides of the machine.
Page 135: Hydraulic Folding Roof Operation
Machine description 1 Hydraulic folding roof operation The hydraulically folded roof (1) is locked to the rear suspension of the left and right-hand side of the machine by a lock pin (2). The key-operated switch (4) for actuating the folding roof and hood hydraulics can be found to the left of the belt drive’s protective box.
Page 136: Hydraulic Hood Operations
Machine description Hydraulic hood operations The machine’s engine hood (1) can be opened and closed hydraulically and provides good access to the various monitoring and maintenance points. The key-operated switch (2) for actuating the folding roof and hood hydraulics can be found to the left of the belt drive’s protective box.
Page 137: Throttle Valves For Deployment Speed Of Hood And Roof
Machine description Throttle valves for deployment speed of hood and roof The hydraulic unit for hood and roof operation can be found behind the maintenance flap of the operator’s control station. The unit has two throttle valves for setting the speed for raising and lowering the roof.
Page 138: Water System
Machine description Water system 7 3 The water system on the machine comprises the following elements: Diaphragm water pump (1): used in the water spraying system to produce pressure, 8 1 High pressure pump (2): used in the high pressure cleaner system to produce pressure, 80 bar ...
Page 139: High Pressure Cleaner
Machine description High pressure cleaner The hose reel (1) of the high pressure cleaner can be found on the top of accessory box at the rear of the machine. The spray pistol (2) is locked in its detent ...
Page 140: Filling Pump For Water Tank
Machine description Filling pump for water tank The filling pump for the water tank is located at the front left of the machine. To fill the water tank: Unscrew seal cap (1) (if necessary use wrench) Attach suction line and tighten Start filling process by pressing switch (2).
Page 141: Water Filling (Pressure Fill) Connection For Water Tank
Machine description Water filling (pressure fill) connection for water tank The connection for the water tank’s pressure fill can be found on the left rear underside of the machine. To fill the water tank: Open lock cock.
Page 142: Changeover For Separate Circuits Of Rear Strut Towers
Machine description Changeover for separate circuits of rear strut towers For some maintenance and repair work, the rear strut towers will have to be individually operated. The joint hydraulic circuit will have to be separated in such instances.
Page 143: Milling Depth Display
Machine description Milling depth display One milling depth display, indicating cm and/or inches, is located on both sides of the milling housing. This provides additional visual assistance in addition to the leveling equipment. ...
Page 144: Interlock On Scraper Flap
Machine description Interlock on scraper flap One interlock for the scraper flap can be found on either side of the back of the drum box. The interlock must be released before the scraper flap can be opened. When interlocked, the bolt (1) is in the detent bore (2).
Page 145: Limit Switch Of Scraper Flap
Machine description Limit switch of scraper flap The limit switch can be found behind the milling drum housing on the frame of the left-hand side of the machine. The limit switch serves as a safety measure and is actuated as soon as the scraper flap is opened.
Page 146: Traction Unit Supports
Machine description Traction unit supports One separable traction unit support can be found as a safety measure on every traction unit. The complete traction unit support is used for retaining purposes during maintenance and repair work. In order to achieve a lower transport height, the upper section of the separable support is used on the trailer during transport.
Page 147: Scraper Flap Function Changeover" Valve
Machine description “Scraper flap function changeover” valve The valve for the raise and lower scraper flap / swivel scraper flap function changeover (1) can be found above the frame on the right-hand side of the machine behind the milling drum box.
Page 148: Monitoring Camera
Machine description Monitoring camera Six video cameras are fitted to the machine to observe the 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 fl ap b e h i n d the milling drum housing, the area of the rear track during reverse, the area of the top of...
Page 149: Compressed Air System (O)
Machine description Compressed air system (O) The compressed air tank and connected maintenance unit can be found behind the storage room flap on the left-hand side of the machine. There maintenance unit...
Page 150: Storage Area And Protective Flaps
Machine description Storage area and protective flaps The section of storage area and protective flap which covers the operating side panels and the levelling 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 ...
Page 151: Plumb Fixture
Machine description Plumb fixture The part of the lockable storage area and protective flap which covers the operating side panels and leveling device (1) can be turned down for operations. The plumb line fixture can be used to work along one particular longitudinal mark which is at a specified distance from the machine.
Page 152: Swivel-Mounted Warning Sign
Machine description Swivel-mounted warning sign The swivel-mounted warning sign is located on the rear of the machine, on the right. The sign should be swiveled out if this side of the machine is on the offside, closest to passing traffic or if the machine is driven on public highways.
Page 153: Typical Wear Marks On Tool Holder
Machine description Typical wear marks on tool holder New bit box Strong wear of contact surfaces of bit - replace as soon as possible ...
Page 154: Typical Wear Marks On Bits
Machine description The condition of the milling bits and bit boxes is to be checked several times a day. Worn or damaged bits and boxes must be replaced immediately The machine capacity can be fully exploited only with perfect milling tools. ...
Page 155: Bits Holder Replacement
Machine description Bits holder replacement Remove the used holder system. Cut off along the 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.
Page 156 Machine description Remove the old screw and replace it by the new coated screw (2). Locking torque is 200 Nm. The torque wrench with the plug tool must be set to 120Nm. The screw has to be inserted dry and free of oil and grease.
Page 157 Machine description 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 check it for damage. Inner cone free of dirt and grease Make surfaces free...
Page 158: Bits Replacement
Machine description Bits replacement Dismantling the bits ‐ Position the bit extractor in the hole at the rear of the bit box, and drive out worn and damaged bit by hitting with a hammer. Optionally, a pneumatically operated hammer that can be driven using the compressed air system of ...
Page 159: Replacing The Holder Box
Machine description Replacing the holder box The bit holders, which are arranged on the milling drum In a spiral shape, are welded so solidly and reliably with the drum that they are torn off extremely rarely and in extreme situations (for example, forgotten steel rails in the milling surface).
Page 160: Leveling Unit
Machine description 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 the following chapter. 4812313240.pdf 2017-12-1 ...
Page 161: Operating The Dynapac Leveling System
Operating the Dynapac Levelling System Setting the contrast The contrast of the graphic display can be adjusted at the control panel to achieve easy viewing, also in poor lighting conditions. To do so press the contrast key in the right hand corner above the display.
Page 162: Symbols And Displays In The Working Window
Machine description Symbols and displays in the working window Left control loop Right control loop Active sensors Sonic‐ski Ground Sonic‐ski Ground 35 3.26 Measuring unit, actual values Signed target value 0 4.00 Slope direction(Slope actual value) CONFIG OFFSET 350 Assignment of the function keys 0 ...
Page 163: Sensor Selection
Machine description Sensor selection If several sensors are connected to the MLS 508 CAN-bus network at the same time, desired sensor selected using sensor selection menu. Please note that the sensor has to be connected to and mounted on the side of the machine corresponding to the respective control loop.
Page 164 Machine description 4) Press the function key F3 (Enter) to save the selection or press the function key F4 (Exit) to exit without making any changes. After either key is pressed, the software returns to the working window. Left sensor select ...
Page 165: Operating With The Cross-Slope Sensor
Machine description Operating with the Cross-Slope sensor The Cross-Slope sensor has been selected for one of the two sides with the help of the sensor change key (also see “6.6 Sensor selection”). The other side is controlled manually or by means of a grade sensor.
Page 166 Machine description 3) Now switch the controller to automatic mode (automatic = automatic 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 the milling drum at the set slope, even if it is moved in height (manually or by the other side’s control...
Page 167: Zero Adjustment
Machine description Zero adjustment Before describing operations with the various grade sensors, the term “zero adjustment” has to be defined. every application after mounting remounting grade sensor, the current value measured by the sensor has to be adjusted to zero. In doing so, the current mounting level of the grade sensor above the reference is saved in the system and a clear reference value is provided for all future set points at the same time.
Page 168 Machine description Wire Rop e Sens or Wire Rop e Sens or Wire Rop e Sens or OFFSET OFFSET 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.
Page 169: Sensitivity Setting
Machine description Sensitivity settings The most varied influences (e.g. the machine size and motorization, the size of the hydraulics, the subsoil condition or the sensing reference or, simply, just the selection of a different type of sensor) may require adjusting the sensitivity settings of the MLS 508 control system in manual and automatic mode.
Page 170 Machine description Setting the sensor sensitivity: 1) From the working window switch to the menu item Configuration menu and then to the parameter Sensitivity. 2) Call up the parameter Sensitivity and set the desired values for the active sensors.
Page 171: Changing The Measurement Units
Machine description Changing the measurement units In this menu item, the country-specific physical measurement unit and the resolution of the displayed sensor values for grade and slope can be preset. 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.
Page 172: System Languages
Machine description System languages To enable the operator to also take full advantage of the graphic navigation menu with comprehensible texts and symbols in other languages the system language can be set for universal use. English, French German have...
Page 173 Machine description 4812313240.pdf 2017-12-1 ...
Page 174: Operation
Operation Operation Before starting Preparing for operation To protect the water system from corrosion and frost, it is filled with around 5-7litres of antifreeze in the factory. Before first starting up the machine, this must be drained off, collected and disposed of in an environmentally sound...
Page 175: Before Starting Work
Operation Before starting work Read safety instructions. Check personal protective equipment. The parts and 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 safely started.
Page 176: Starting The Machine
Operation Starting the machine The following should be done before the diesel engine can be started and the machine can be operated. ‐ Daily machine maintenance Check the operating hours counter to determine whether further maintenance work should be conducted.
Page 177 Operation ‐ Insert ignition key lock in position”0”. ‐ Switch ignition on (pos.1). Start screen appears on the display, position indicator of main operating panel light up. ‐ The start screen (4) is displayed while, the on-board computer is booting up.
Page 178: External Starting (Starting Aid)
Operation External starting (starting aid) If the batteries are flat and the starter is not running, the engine can be started using an external source of power. The following are suitable as sources of power. Another vehicle with a 24V system; Additional 24V battery;...
Page 179: Allowing Engine To "Warm Up
Operation Allowing engine to “warm up” To keep excessive wear and increased load of individual assemblies to a minimum, the engine should always, but especially at low outside temperatures (<10°C), warm up for approx. 5 minutes at idle speed and without any load.
Page 180: Driving The Machine
Operation Driving the machine Smoothly raise the machine by pressing button (1) or buttons (2), (4) until the distance required between the machine and ground has been reached. Never fully raise the machine for driving purposes! Risk of tipping! Slightly raise sliding shoe by pressing button (32).
Page 181: Milling (Preparation)
Operation Milling (preparation) - Drive the machine to the milling section and lower manually as far as possible (side boards are lowered, milling drum does not quite touch the ground) ‐ Correct start position with the help of the reference points on sideboards for various milling depth (4,10,20,30 cm) Example: Milling starts...
Page 182 Operation Activate the AUTO function from the main operation panel. more instructions from chapter “Machine 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 conveyor, water spray equipment can also be activated or deactivated from the lower control...
Page 183 Operation Once all the preparations for milling are complete, the machine is ready for milling, the automatic levelling device is activated from the main control panel and the machine is lowered to the depth required while at a standstill. Release control lever (3) by pressing slide switch and gently slide forwards out of central point (within dead band range).
Page 184 Operation Stop the machine and raise at the end of the milling track: Depending on the milling depth, the end of the cut will be at the height of the reference point marked on the side boards: -To remove the milled material from the conveyor belts, let the lower and discharge conveyors run on as is necessary.
Page 185: Parking The Machine
Operation Parking the machine Before parking the machine, read the operating hours counter check whether maintenance work is to be conducted. When parking the machine on publicly accessible land, secure it to ensure that unauthorized persons and children cannot do any damage to the machine.
Page 186: Long-Term Parking
Long-term parking Long-term parking The following instructions should be followed when long term parking (more than one month). Before using the planer again attend to the items marked with a “below”. ...
Page 187: Watering System
Long-term parking Watering system *Empty the water tank and all hoses of water. Empty the filter housing and the water pump. Undo all sprinkler nozzles. See maintenance sections for “Watering system - ...
Page 188: Miscellaneous
Miscellaneous Transport Safety regulations for transport There is a risk of accident if the machine is prepared incorrectly transportation conducted incorrectly. Prepare machine ensuring that components are secured and cannot come loose.
Page 189 Miscellaneous Use the cover to secure the main control panel, close the side operating units. When loading via ramps, there is a risk that the machine will slip, tilt or overturn. ...
Page 190: Fix Points
Miscellaneous Fix points Fig. Fix points 2017-12-1 4812313240.pdf ...
Page 191 Miscellaneous There are two fix points (1) on each side of the machine frame, at the front and back. The machine should be fastened to these points during transport on the transport vehicle. ...
Page 192: Transport On Trailers
Miscellaneous Transport on trailers When transporting the machine on trailers, the load dimensions and weights should be taken into account when selecting and using appropriate tractor vehicles and transporters in accordance with ...
Page 193 Miscellaneous Activities and preventive measures: - In order to achieve a lower transport height, the machine is evenly lowered down to the upper section of the separated traction unit supports. ...
Page 194 Miscellaneous Secure PL2000F for transporting. (The instructions also apply to machine without conveyor.) Direct of travel Fig.1 1-14 = single lashings, i.e. one lashing with two parts, one head on the machine, another head on the platform.
Page 195 Miscellaneous Lashings - The lashings 1-14 comprise a lashing strap or chain with a permitted load (LC/MSL) of at least in table 1. -The lashings are re-tightened as required, the lashing preload should follow the lashing supplier instruction.
Page 196 Miscellaneous If the support for the discharge conveyor or the locating surface for the folded in discharge conveyor is placed on the frame of the towing machine, the swivel hydraulic of the discharge conveyor must be changed over to the floating position once parts have been placed on this frame.
Page 197 Miscellaneous Normal on-road travel The machine is not intended for normal on-road travel and is not equipped for such circumstances. It should be used within enclosed building sites. ...
Page 198: Hydraulically Foldable Discharge Conveyor
Miscellaneous Hydraulically foldable discharge conveyor Folding in the discharge conveyor machine’s transport length significantly reduced in a few simple steps by using hydraulic foldable discharge conveyor. fold discharge conveyor, various...
Page 199: Folding Out Discharge Conveyor
Miscellaneous Folding out the discharge conveyor To fold out, proceed as for the folding in process but in reverse. The following should be noted: 1. Firstly raise machine as far forward as possible over traction unit legs then lower as far as possible to the rear.
Page 200: Load By Crane
Miscellaneous Load by crane In the event of break down, should it no longer be possible for the machine to be towed or if it cannot be loaded in any other way, there is also the possibility of raising it by crane.
Page 201: Towing/Retriving
Miscellaneous Towing/Retrieving The planer can be moved up to 300 meters using the instructions below. Short distance towing with the engine running Activate the parking brake, and temporarily stop the engine. Chock the wheels to prevent the planer from moving.
Page 202: Short Distance Towing When The Engine Is Inoperative
Miscellaneous Short distance towing when the engine is inoperative Chock the wheels to prevent the planer from moving when the brakes are hydraulically disengaged. Open the two foot boards on the platform and found the propel system by-pass ball valve (1) which handle should be in line with pipeline to put the system in working mode.
Page 203: Towing The Planer
Miscellaneous Towing the planer When towing/retrieving, the planer must be tied by the towing vehicle. A towing bar must be used on the fix point of the planer. ...
Page 204: Lifting The Conveyor
Miscellaneous Lifting the conveyor Refer to the fig1, there are lifting holes on the conveyor head, middle section and support legs. Lifting equipment such as chains, steel wires, straps lifting hooks must dimensioned in accordance with the relevant safety regulations for lifting equipment.
Page 205: Securing Before Parking Up
Miscellaneous Secure before parking up When parking on publicly accessible areas, the machine should be secured to ensure that unauthorized persons and children cannot cause any damage to it. The machine should be parked on level ground; the discharge conveyor lowered and, if possible, swiveled into a safe area.
Page 206: Operating Instructions - Summary
Operating instructions Operating instructions – Summary 1. Follow the SAFETY INSTRUCTIONS specified in the Safety Manual. 2. Make sure that all instructions in the MAINTENANCE are followed. 3. Turn the master switch to the ON position. ...
Page 207 Operating instructions 4812313240.pdf 2017-12-1 ...
Page 208: Preventive Maintenance
Preventive maintenance Preventive maintenance Complete maintenance is necessary for the machine to function satisfactorily and at the lowest possible cost. The maintenance section includes the periodic maintenance that must be carried out on the ...
Page 209 Preventive maintenance 4812313240.pdf 2017-12-1 ...
Page 210: Maintenance - Lubricants And Symbols
Using the incorrect oil/lubricant leads to increased wear and machine breakdowns Fluid volumes PL2000F Fuel tank 1100L Engine oil Hydraulic fluid tank 370L Water tank 3400L Pump distribution transmission Planetary gear, milling drum...
Page 211 Maintenance – Lubricants and symbols ...
Page 212: Maintenance
Maintenance schedule Maintenance Notes regarding safety for maintenance During all maintenance work, the regulations regarding health, work and fire protection are to be heeded. The necessary protective equipment is to be worn continuously. If not described otherwise, maintenance work must only be carried out with the engine stopped (heed the notes regarding checking and replacing milling bits and milling bit holders!).
Page 213: Materials
Maintenance schedule Avoid electrical soldering work on the machine; this can lead to damage of the electronic and hydraulic modules! However, if exceptional electrical soldering work on the machine should become necessary, the following is to be heeded before beginning work: the ignition is turned off the power circuit is interrupted the electrical devices are disconnected from the power supply...
Page 214 Maintenance schedule Operating hours Service point Task (3.1) Engine drive unit Check level Fuel tank Add fuel Clean tank and system 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-fuel filter Check air filter Engine...
Page 215 Maintenance schedule Operating hours Service point Task (3.1) Engine drive unit Check engine brackets Tighten engine brackets Check screw connections between pump distribution Engine transmission and engine Tighten screw connections between pump distribution transmission and engine Maintenance Maintenance during run-in period 4812313240.pdf ...
Page 216 Maintenance schedule Operating hours Service point Task (3.2) Hydraulic system Check oil level Hydraulic oil tank Add oil Replace oil Check maintenance display High-pressure hydraulic filter Replace filter element Check maintenance display Suction/return hydraulic filter Replace filter element Check oil level Add oil Pump distribution...
Page 217 Maintenance schedule Operating hours Service point Task (3.3) Traction units, chassis legs and steering system Check oil level Add oil Planetary gear Replace oil Check visible, noglued nuts and screws; tighten if necessary Check chain tension Adjust chain tension Traction unit Check condition of bottom plates...
Page 218 Maintenance schedule Operating hours Service point Task (3.4) Milling section Check condition Milling bit, bit boxes Replace bits / bit boxes Check condition Belt drive Replace belt Check friction lining wear Clutch "DESCH" TYPE Replace friction lining Check oil level Add oil Replace oil Drum transmission...
Page 219 Maintenance schedule Operating hours Service point Task (3.4) Milling section Check scraper and bottom wear plate Scraper and supporting skids Replace wear plate Check side plate and bottom Side plate wear plate Replace wear plate Check sliding shoe and wear Sliding shoe plate Adjust/Replace wear plate...
Page 220 Maintenance schedule Operating hours Service point Task (3.5) Loading equipment Check belt tension/sag Adjust belt tension/sag Conveyor belt Check wear condition Replace conveyor belt Check condition Conveyor roller Replace rolls Check wear condition Funnel rubber of transfer points and Replace funnel rubber / sealing rubber sealing rubber...
Page 221 Maintenance schedule Operating hours Service point Task (3.6) Water system Check level Add water Water tank Clean tank Replace oil Filling pump Drain water Check water filter Water filter Replace both filter elements Drain water Check oil level Replace oil Inspect mounting Spraying water...
Page 222 Maintenance schedule Operating hours Service point Task (3.7) Power supply Batteries Replace (3.8) Pneumatic system Check oil level Maintenance unit Add oil Drain water (3.9) Levelling device Sensors, Check condition controllers, Clean or replace connecting cable (3.10) Brake system Check brake function Brake system Check brake pressure...
Page 223 Maintenance schedule Operating hours Service point Task (4.0) Lubrication points Lubricate support legs (grease nipple))/ Check lubrication of sliding sur- faces Drive unit Lubricate steering cylinder (grease nipple) Lubricate floating pin (grease nipple) Lubricate belt tensioner (grease nipple) Milling section Lubricate hydraulic cylinder of rear scraper (grease...
Page 224 Maintenance schedule Operating hours Service point Task (4.0) Lubrication points Lubricate pedestal bearing for Discharge tail roller (grease nipple) conveyor, Lubricate tension bearing for standard (fixed) drive roller (grease nipple) Lubricate pedestal bearing for tail roller (grease nipple) Discharge Lubricate tension bearing for conveyor (foldable)
Page 225 Maintenance schedule Operating hours Service point Task (5.0) Inspections General visual inspection Inspection by an expert Maintenance Maintenance during run-in period 4812313240.pdf 2017-12-1 ...
Page 226: Engine Drive Unit
Maintenance Engine drive unit Fuel tank The fuel tank should be filled before every work session so that the fuel system is not "run dry", which would require time- consuming aeration. The fuel level can be found in the display through the sensor (1), check it during daily operation.
Page 227: Cleaning Tank And System
Maintenance Cleaning tank and system For maintenance and repair work, it may be necessary for the fuel to be drained off. The drainage point for this diesel tank is in the rear section of the machine underside. ‐...
Page 228: Engine Oil Drainage Point
Maintenance Engine oil drainage point The drainage point for the engine and gear oil is in the rear section of the machine underside. The stopcock (2) has three switch positions: -Closed (2A) -Drain for engine oil (2B) -Drain for pump distribution transmission (2C) Danger of scalding due to hot oil.
Page 229: Oil Filter
Maintenance Oil filter The oil filter can be found in the rear section of the engine compartment and is accessible once the engine hood has been opened. Loosen the filter and clean the contact surface. Slightly lubricate the seal of the new filter and fill the filter with oil before installing it.
Page 230: Fuel Filter Water Separator
Maintenance Fuel filter water separator Drain the water separator every day or when engine electronics error messages appear. Collect fuel-water mixture in a suitable container and dispose of properly. There is a drain valve (1) on the underside of the filter cartridge.
Page 231: Cooler
Maintenance Cooler Check the coolant level daily before starting work. Replace the coolant at least once per year. The filler neck of the coolant compensation tank can be found behind the maintenance flap of the operator’s control panel.
Page 232: Cooler
Maintenance Cooler Check the radiators of the cooler daily for soiling and leakage. The water cooler is located at the rear of the machine, behind the cooler grill. The cooler grill can be swiveled upward after opening the lock.
Page 233: Valve Clearance
Maintenance Valve clearance To check and adjust the valve clearance: see Engine operating instructions. Fig. Valve 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.
Page 234: Connecting Screws, Pump Distribution Transmission/Engine
MUST note that these parts are fitted without the use of oil and grease! When replacing the Centa coupling, please contact the Dynapac service team. They will discuss the process with you. ...
Page 235: Hydraulic System
Maintenance Hydraulic system Hydraulic oil tank Use a dipstick (1) to check the oil level every day. Dust and dirt should be regularly removed from the oil tank vent. Change the hydraulic oil every 1000 operating hours, but at least every year. The hydraulic tank can be found in the left section of the engine compartment and is accessible once the engine hood has been opened.
Page 236: High-Pressure Hydraulic Filter
Maintenance High-pressure hydraulic filter Replace filter cartridges once the maintenance indicator (1) is red. The filters should be checked 10 operating hours after repairs on the hydraulic system and replaced if necessary! Always replace the filter elements in pairs! ...
Page 237: Return Hydraulic Filter
Maintenance Return hydraulic filter Replace the filter element according to the soiling display, but at least once a year! The return hydraulic filter can be found on the hydraulic oil tank in the left section of the engine compartment and is accessible once the engine hood has been opened.
Page 238: Pump Distribution Transmission
Maintenance Pump distribution transmission Oil level check The pump distribution transmission can be found in the left section of the engine compartment and is accessible once the engine hood has been opened. The dipstick (1) can be found on the left on the transmission housing.
Page 239: Oil Cooler
Maintenance Oil cooler The drainage point for the gear and engine oil is in the rear section of the machine underside. The stopcock (2) has three switch positions: Closed (2A) Drain for engine oil(2B) Drain for pump distribution transmission(2C) Collect used oil in a suitable container and dispose of properly.
Page 240: Bleeder
Maintenance Bleeder The bleeder can be found on the housing of the pump distribution transmission. The functioning of the bleeder must be ensured. If soiling has occurred, the ventilator should be cleaned. Fig. Bleeder ...
Page 241: Hydraulic Hoses
Maintenance Hydraulic hoses All hydraulic hoses on the machine should also be replaced by the interval specified! Old hoses become porous and can burst! Risk of accident! A number punched into the connection provides information about the date of manufacture (1) and the highest permitted pressure for this hose (2).
Page 242: Traction Units
Maintenance Traction units Planetary gear – oil level check To check the oil level and while adding oil, the locking screw for the oil level check (1) must be in the 9 o’clock position. The oil level should reach the lower edge of the hole for the locking screw.
Page 243: Chain Tension
Maintenance Chain tension The chain tension of the drives is to be tested daily and adapted to the given use and roadway conditions. The chain sag should be 0-7mm (depending on the use conditions) between the chain and the framework of the drive, measured in the drive middle.
Page 244: Bottom Plate
Maintenance Bottom plate The condition of the bottom plates of the drives is to be tested daily. Damaged and worn bottom plates should be replaced immediately. Each bottom plate is connected with the contact surface of the chain link by four fastening screws. - Hold the square nut with a fork wrench fork wrench, loosen the fastening bolts in the trough of ...
Page 245: Steering System Sliding Parts, Steering Arms, Stop Ring And Scraper
Maintenance Steering system sliding parts, steering arms, stop ring and scraper Check steering arms (1), two-section stop ring (2) and scraper (3) for correct function, clearance, perfect attachment and excess wear. If these components are attached or function insufficiently, subsequent excess wear will allow dirt to penetrate and will result in possible...
Page 246: Retaining Device For Track Rod And Steering Cylinder Bolts
Maintenance Retaining device for track rod and steering cylinder bolts Check that retaining bolts of retaining plates on track rods and on cylinder bolts are secured correctly. If necessary, retighten screws. Fig. Retaining device for track ...
Page 247: Clutch "Desch" Type
Maintenance Clutch ”DESCH” Type Worn friction lining should replaced immediately. The clutch is located behind the belt disc in the protective box on the left side of the machine. Ensure that the drive engine cannot be started! The inspection cover (1) of the clutch casing must be removed to carry out the inspection.
Page 248: Milling Drum Gear Box
Maintenance Milling drum gear box Oil level check To check the oil level and while adding oil, the lock screw for the oil check (1) must be in the 9 o’clock position. Lower the machine on to the service supports.
Page 249: Oil Change
Maintenance Oil change To drain oil, the drainage screw (2) should be in the 6 o’clock position and 2 the filling screw (1) should be in the 9 o’clock position. Do not change oil when the engine is cold, but rather directly after the transmission has stopped.
Page 250: Milling Drum
Maintenance Milling drum The coolant must be replenished when necessary, depending on operating conditions. Freezing water in the milling drum can destroy the component; use the stipulated coolant. There are two drainage and filling/in section screws (1) positioned opposite to each other on ...
Page 251: Checking Fluid Level/Adding Fluid
Maintenance Checking fluid level / adding fluid 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 the inspection and filling screw lies at an angle of approx.
Page 252: Runners On The Side Boards
Maintenance Runners on the side boards The runners of the side boards continuously slide over the asphalt during milling operation and are thus subjected to an elevated degree of wear. If the material of the runner becomes too thin, it must be replaced.
Page 253: Sliding Shoe Runners
Maintenance Sliding shoe runners The runners of the sliding shoe continuously slide over the asphalt that has not yet been removed during milling operation and are thus subjected to an elevated degree of wear. The runners exert downward pressure and prevent bigger parts from being ripped out.
Page 254: Drum Flap Limit Switch
Maintenance Drum flap limit switch The limit switch is located on the rear part of the milling drum box on the left side of the machine. Open the drum flap using the corresponding operating elements until the limit switch is activated.
Page 255: Loading Equipment
Maintenance Loading equipment Belt tension The belt tension of the loading belt and the discharge conveyor is to be checked daily. If the belt sags too far, the tension must be increased. In the first weeks of operation, the belt will stretch excessively (permanent and elastic stretching).
Page 256: Drum Holder
Maintenance Drum holder As a result of high loading levels, clearance in the seat of the holder (2) for the shaft end of the roller (1) may increase over time. Fig. 1. Roller ...
Page 257: Funnel Rubber Of Transfer Point And Sealing Rubbers/Guides
Maintenance Funnel rubber of transfer point and sealing rubbers / guides On the primary and discharge conveyors, different rubber parts provided guarantee problem-free material removal. These rubber parts should be visually checked for damage weekly: - scraper rubber (1) - lateral seal (2) ...
Page 258: Water System
Maintenance Water system Water tank The filling level of the water tank should be tested before each start. If necessary, the tank must be refilled. Check the water level of the water tank several times a day using water level indicators located on the sides of the tank.
Page 259 Maintenance During cleaning work in the interior of the tank, a second person must always oversee the person in the tank! If the tank must be entered, a ladder is to be placed against the machine and secured ...
Page 260: Feed Pump
Maintenance Feed pump Drain water When the temperature is below freezing, the water in the pump must be drained since freezing water can destroy the pump. Replace oil The feed pump is located on the left forefront of the machine.
Page 261: Water Filter
Maintenance Water filter Check the filter element at the end of work every day and according to the soiling display! The machine accessories include a second set of water filters which makes daily replacement possible without delay. One water filter is under the frame, in front of the milling drum housing on the right side of the machine, the other one is located nearby the conveyor suspension...
Page 262: Water Pump - Check Oil Level
Maintenance Water pump – Check oil level Check oil level, oil level should between Min. and Max. If oil level lower than Min., please fill specified oil. If oil level over Max., please drain some oil out until the level keep between Min.
Page 263: Spray Nozzles
Maintenance Spray nozzles The spray nozzles are located on the milling drum cabinet and are secured against twisting by guides. To check and clean them, the nozzles can be removed from the guides through the gaps in ...
Page 264: Power Supply
Maintenance Power supply Batteries ‐ Behind the maintenance flap, two batteries of the 24 volt system can be found on both the left and right behind the driver’s seat. ‐ ‐ The batteries are maintenance–free. ‐...
Page 265: Compressed Air System
Maintenance Compressed air system Maintenance unit and compressed air system maintenance unit that separates water from the air and enriches the air- flow with a fine oil mist, thus providing for a longer lifetime of the parts, is located on the compressed air tank.
Page 266: Leveling System
Maintenance Levelling system Sensors, displays, connection cables The sensors, displays and connection cables of the levelling equipment should be checked daily in order to guarantee an interruption-free and precise work flow. Damaged parts, such as cables ...
Page 267: Emergency Stop Button
Maintenance Emergency stop button For your own safety, the safety of other persons and the safety of the machine, the function of all the emergency stop buttons located on the machine should be tested daily. ...
Page 268: Lubrication Points
Maintenance Lubrication points Traction unit Chassis legs A grease nipple is located on each chassis leg. Add grease with a grease gun until grease flows out of the front and rear guide grooves. sliding surfaces in the guide grooves must always be covered by a film of...
Page 269: Milling Section
Maintenance Milling section Belt tensioner A grease nipple is located on the bearing point on belt tensioner milling drum transmission. Add 3 loads of grease with a grease gun. Fig. Lubrication point ...
Page 270: Scraper Hydraulic Cylinder
Maintenance Scraper hydraulic cylinder A grease nipple is located on each bearing point (top and bottom) of the hydraulic cylinder on the drum flap. Add 3 loads of grease with a grease gun. Fig. Lubrication point ...
Page 271: Discharge Conveyor
Maintenance Discharge conveyor Tail roller pedestal bearing A grease nipple is located on the pedestal bearing on each side of the discharge conveyor. Add 3 loads of grease with a grease gun. Fig. Lubrication point ...
Page 272: Primary Conveyor
Maintenance Primary conveyor Tail roller pedestal bearing A grease nipple is located on the pedestal bearing on each side of the primary conveyor. Add 4 loads of grease with a grease gun. Fig. Lubrication point ...
Page 273: Inspection
Maintenance Inspection General visual inspection The daily routine includes walking around the machine with the following inspections: - damage to parts or operating elements? - leaks in engine, hydraulic system, transmission, ...
Page 274 Maintenance 4812313240.pdf 2017-12-1 ...
Page 275: Disposal
Disposal Disposal Correctly sorted disposal must be carried out after replacing wear and spare parts and after the machine has been withdraw from service (scrapped). materials must sorted correctly according to metal, plastic, electronic scrap, various operating substances etc. Any oil greasy parts (hydraulic hoses, lube pipes etc.) must be treated separated.
Page 276: Appendix
Appendix Appendix 1: Engine Fault Code SID(S) FAULT CODE PID(P) DESCRIPTION (LAMP) 111 (Red) S254 Engine Control Module – Critical internal failure 115 (Red) P190 Engine Speed/Position Sensor Circuit - lost both of two signals from the magnetic pickup sensor 121 (Yellow) P190 Engine Speed/Position Sensor Circuit - lost...
Page 277 Appendix SID(S) FAULT CODE PID(P) DESCRIPTION (LAMP) 151 (Red) P110 Engine Coolant Temperature High – Critical 153 (Yellow) P105 Intake Manifold Temperature Sensor #1 Circuit - shorted high 154 (Yellow) P105 Intake Manifold Temperature Sensor #1 Circuit - shorted low 155 (Red) P105 Intake Manifold Temperature #1 High -...
Page 278 Appendix SID(S) FAULT CODE PID(P) DESCRIPTION (LAMP) 245 (Yellow) S033 Fan Clutch Circuit - shorted low 254 (Red) S017 Fuel Shutoff Valve Circuit - shorted low 255 (Yellow) S017 Fuel Shutoff Valve Circuit - shorted high 259 (Red) S017 Fuel Shutoff Valve - stuck open 284 (Yellow) S221 1043...
Page 279 Appendix SID(S) FAULT CODE PID(P) DESCRIPTION (LAMP) 314 (Yellow) S006 Injector Solenoid Valve Cylinder #6 Circuit - grounded circuit 315 (Yellow) S002 Injector Solenoid Valve Cylinder #2 Circuit – grounded circuit P251 Real Time Clock - Power Interrupt Maint. 341 (Yellow) S253 Engine Control Module –...
Page 280 Appendix SID(S) FAULT CODE PID(P) DESCRIPTION (LAMP) 415 (Red) P100 Engine Oil Pressure Low – Critical P097 Water in Fuel Indicator High – Maintenance WIF / Maint. 422 (Yellow) P111 Engine Coolant Level Sensor Circuit - data incorrect 426 (None) S231 SAE J1939 datalink - cannot transmit 428 (Yellow)
Page 281 Appendix SID(S) FAULT CODE PID(P) DESCRIPTION (LAMP) 482 (Yellow) P094 Fuel Pressure Low - Warning 483 (Yellow) P129 1349 Injector Metering Rail #2 Pressure Sensor Circuit - shorted high 484 (Yellow) P129 1349 Injector Metering Rail #2 Pressure Sensor Circuit - shorted low 485 (Yellow) P129 1349...
Page 282 Appendix SID(S) FAULT CODE PID(P) DESCRIPTION (LAMP) 596 (Yellow) P167 Electrical Charging System Voltage High - warning level 597 (Yellow) P167 Electrical Charging System Voltage Low - Warning Level 598 (Red) P167 Electrical Charging System Voltage Low - Critical Level 611 (None) S151 1383...
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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