Page 1 OPERATION & MAINTENANCE Cold Planer PL 1000 RS Keep this manual for future reference Order number for this manual: 900 98 12 29 02-0407 Gültig ab Seriennummer:xxx.xxx ......
Page 2 VALUE QUALITY THE ORIGINAL SPARE PARTS Your Authorizied Dynapac Dealer :...
Page 3 Preface If the machines are to be operated safely, the information provided in these Operating Instructions will be required. The information is shown in a brief and clear form. The Chapters are ordered by letter. Each Chapter starts with Page 1. The pages are iden- tified using a Chapter letter and Page number.
Page 4 These Operating Instructions must always be stored in a convenient location on the machine. They are valid in conjunction with the Dynapac safety manual, the informa- tion on intended usage and the supplementary operator’s instructions required on the basis of existing national or regional specifications regarding technical regulations, accident prevention and environmental protection.
Page 5: Table Of Contents
Table of contents Intended usage ................ 1 Vehicle description ..............1 Description of usage .................. 1 Descriptions of assemblies and functions ..........2 Vehicle ....................... 3 Assembly ....................3 Safety devices .................... 5 Emergency-stop button ................5 Horn ....................... 5 Headlights, flashers, rotary beacons .............
Page 6 Operation ................. 1 Safety regulations ..................1 Controls ...................... 2 Control panel ....................2 Other controls ..................32 Controls at operator’s control station ............32 Driver’s seat ..................32 Weather protecting sun roof ..............33 Side roof ....................33 Weather-protecting sun roof, hydraulic (O) .......... 34 Battery’s main switch ................
Page 7 Operation ....................72 Preparing for operation ................72 Devices and aids ................. 72 Before starting work ................72 Checklist for machine operator ............73 Starting the machine ................74 Auxiliary starting (electrical starting aid) ..........76 ......................76 Allowing engine to „warm up“ .............. 77 Driving the machine ................
Page 8 Maintenance ................1 Safety regulations for maintenance ............1 Liability is rendered null and void if non-genuine spares or wearing parts or incorrect fuel substances are used..........2 Maintenance intervals ................2 Power unit - engine ..................9 Fuel tank ....................9 Diesel engine ..................
Page 9 Loading unit ..................... 44 Belt tension ..................44 Steel cables ..................46 Rubber funnel gasket at transfer point and rubber seals / guides ..46 Water system ................... 47 Water tank ................... 47 Remove water tank ................48 Water filter ................... 49 Spray nozzles ..................
Page 11: A Intended Usage
A Intended usage The Dynapac „Guideline for the intended and correct usage of cold planers“ falls with- in the scope of supply of this machine. It forms part of these Operating Instructions and must be observed. National regulations apply without restriction.
Page 12 Technical modifications, attachments and conversions: The cold planer may only be operated with the extension parts, optional equipment and accessories, pro- tection and safety devices authorised by the manufacturer as well as the setting val- ues specified by the manufacturer. Autonomous changes to assemblies, their removal or replacement with other unauthorised parts and any attempt to take these out of service either completely or partially render null and void the manufacturer’s li- ability for any resultant damage.
Page 13: B Vehicle Description
B Vehicle description Description of usage The DYNAPAC cold planer PL 1000 RS is a compact, very versatile four-wheel cold planer which is equipped with all-wheel drive, electronic anti-slip control and a single- section rear loading conveyor. This cold planer has been developed for tasks such as the cost-effective removal of asphalt and concrete for medium to large milling operations.
Page 14: Descriptions Of Assemblies And Functions
Descriptions of assemblies and functions PL600_compl.wmf Item Designation Frame Operator’s control station Driver’s seat Drive wheel Chassis leg Swivel-mounted chassis leg Milling depth display Water tank Water spraying system & Weather protecting sun roof ( Upper conveyor...
Page 15: Vehicle
Vehicle Assembly Frame and 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. Operator’s control station: The operator’s control station, conveniently located at the rear of the machine affording good all-round visibility, can be reached via a ladder and is equipped with a driver’s seat on the right-hand side.
Page 16 Milling depth adjustment: Milling depth adjustment is performed hydraulically, and separately for each rear wheel. To the left and right sides of the operator’s control station are two clearly legible mill- ing depth indicators. Traction system, steering system, travel drive, brake: Suspension of the two front wheel using a parallelogram-shaped rocker arm ensures an optimum contact surface at all times.
Page 17: Safety Devices
Safety devices Safe operation is only possible if the operating and safety equipment works perfectly, and that guards are properly fitted. The function of these devices must be checked regularly (refer to Chapter D, Section „Checklists for the machine operator“). Emergency-stop button - On the control panel The engine, drives and steering sys-...
Page 18: Headlights, Flashers, Rotary Beacons
Headlights, flashers, rotary beacons Lights for illuminating different operating areas and for indicating danger areas and/or dangerous situations are located at various machine positions. The machine has two contacts which can be fitted to the headlights or to the rotary beacons. The headlights or rotary beacons are en- gaged using their respective switches on the control panel.
Page 19: Limit Switch On Upper Conveyor
Limit switch on upper conveyor A limit switch on the frame of the upper conveyor prevents unfavourable load levels arising from excessive raising ac- tion. Limit_PL600.wmf...
Page 20: Technical Data, Standard Version
Technical data, standard version Dimensions 2360 1060 8550 PL1000_measure_side.cdr, PL1000_measure_top.cdr...
Page 21: Weights
Weights Operating weight 12.400 Transport weight 11.400 Ballast weight, total max. 13.200 Performance data Transportation speed 0 - 6 km/h Operating speed 0 - 30 m/min Milling width 1000 Milling depth 0 - 250 Spacing Cutting diameter Number of milling tools items...
Page 22: Engine
Engine Make/type Cummins QSB 5.9-30-TAA Version 6-cylinder diesel engine (water-cooled) Power (in accordance with DIN 129 kw / 173 hp / 175 PS (at 2100 rpm) 6270) Capacity 3260 cm Fuel consumption, full load 23.2 l/h Fuel consumption, 2/3 load 15.5 l/h Fuel tank filling volume approx.
Page 23: Water System
Water system Spray 6 units nozzles Water tank - filling volume approx. 1200 Loading system Belt width, upper conveyor Belt speed approx. 4 Loading capacity (theoretical) approx. 80 Electrical system On-board voltage 24 V Batteries 2 x 12 V, 170 Ah/ 640A Generator 24 V / 100 A B 11...
Page 24: Identification Points And Type Plates
Identification points and type plates Type plate and vehicle identification number Side600_compl.wmf/Iso600_complback.wmf Item Designation Position Vehicle frame, recess for swivel- Type plate mounted chassis leg. Vehicle Identification Number Vehicle frame at rear, right-hand side (VIN) of engine compartment flap. B 12...
Page 25: Type Plate, Machine
Type plate, machine Fertiger3.tif Item Designation Planer type Year of construction Serial number of machine model Maximum permitted operational weight Maximum permitted axle load at front in kg (CE) Maximum permitted axle load at rear in kg (CE) Nominal power in kW Product identification number (PIN) The vehicle identification no.
Page 26: Identification Points
Identification points B 14...
Page 27 B 15...
Page 28 Item Spare parts no. Comments 956.05.20.07 990.00.02.05 956.05.20.03 956.05.30.03 990.00.02.17 956.04.53.00 956.05.20.08 Left and right on radiator 956.05.20.02 956.05.20.09 Beside the batteries 956.05.30.02 990.00.02.15 On filler neck for diesel fuel 956.05.30.39 956.04.49.00 956.05.20.10 956.05.20.11 956.05.20.05 956.05.20.04 956.04.31.00 956.05.10.04 990.00.02.21 990.05.20.18 On both sides of the conveyor covering 956.05.20.19 956.05.20.20...
Page 29: European Standards
European standards Permanent sound-pressure level Ear protectors must be worn when operating this machine. The acoustic emission val- ue may fluctuate greatly on the driver’s ear as a result of the different materials used and may exceed 85 dB(A). Hearing damage may occur if ear protection is not worn. The measurements of noise emissions of the cold planer have been taken in accord- ance with the draft of ENV 500-6, dated March 1997 and ISO 4872 under free-field conditions.
Page 30: Vibration Acting On The Entire Body
Vibration acting on the entire body When the machine is used for its intended purpose, the weighted effective values of acceleration at the driver’s seat of a = 0.5 m/s as defined in the draft of prEN 1032- 1995 are not exceeded. Vibration acting on the hand-arm When the machines used for its intended purpose, the weighted effective values of acceleration at the driver’s seat of a...
Page 31: C Transport
C Transport Safety regulations for transport There is a risk of accident if the machine is prepared incorrectly and transportation is conducted incorrectly Prepare the machine ensuring that all components are secured and cannot come loose. Dismantle all protruding and removable components and/or fit them so that they do not represent a hazard! Lower the machine until the bit tips on the milling drum are approx.
Page 32: Fix Points
Fix points Side1000_compl.cdr 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 ve- hicle. The machine must be secured on the vehicle with appropriately sized lifting tackle (chain pulleys) and protected against tipping, slipping and dropping.
Page 33: Transport On Trailers
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 the road traffic and registration authorities. Approach ramps and tracks of the trailer should be coated with a slip-free material. There must be sufficient possible attachment points on the trailer.
Page 34: Normal On-Road Travel
Normal on-road travel The machine can be registered for use on public roads by fitting a few optional items of extra equipment. However, these are only intended for use within enclosed con- struction sites. If the loading or discharge section of the machine is outside the enclosed construction site, or if the machine needs to be driven from one section of a site to another, a sec- ond person must accompany the machine for that journey.
Page 35: Loading By Crane
Loading by crane In the event of breakdown, 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. Use lifting tackle with sufficient load bearing capacity.
Page 36: Towing Procedure
Towing procedure Comply with all specifications and introduce all requisite safety measures required for the towing of construction equipment. The tractor vehicle must be such that it can still hold the machine when travelling downhill. Only use authorised towbars! Do not disengage travel drive and release brake until the machine has been properly secured to prevent accidental rolling away, or is already properly connected to the towing vehicle.
Page 37: Secure Before Parking Up
Secure before parking up When parking on publicly accessible ar- eas, the machine should be secured to ensure that unauthorised persons and children cannot cause any damage to it. The machine should be parked on level ground. - Lower the machine evenly until the milling drum is almost in contact with the ground.
Page 39: D Operation
D Operation Safety regulations Injury or death can result whenever the engine, travel drive, milling drum, conveyor or lifting units are engaged. When operating the machine, therefore maintain strict compliance with the sections of these operating instructions and the safety specifications dealing with personal conduct.
Page 40: Controls
Controls Control panel Panelkompl_500_1000.bmp/Verriegel_Lenk.cdr...
Page 41 Item Designation Short description The entire steering unit can be set up to suit the needs of the driver. Open both safeguards and turn steering unit to left or Safeguard right using steering wheel, then swivel upwards or steering unit downwards.
Page 42 Panel3_600.cdr...
Page 43 Item Designation Short description Steering action is transmitted hydraulically to the front wheel or wheels. Steering wheel To allow for safe handling, the steering wheel is equipped with a bracket handle. Key positions: P: Active lighting + hazard flasher can be engaged 0: Ignition OFF 1: Ignition ON 2: Starter function...
Page 44 28 29 30 Panel2_500_1000.bmp...
Page 45 Item Designation Short description Press in emergencies (people in danger, risk of colli- sion, etc.) The engine, drive units and steering are disen- gaged whenever the EMERGENCY STOP button EMERGENCY is pressed. STOP button To restart the engine, all EMERGENCY STOP but- tons must be raised.
Page 46 28 29 30 Panel2_500_1000.bmp...
Page 47 Item Designation Short description Pressure control for moldboard relief Pressure control- ler -relief pres- To set the pressure at which the moldboard slides over sure the milling lane. Moldboard The pressure setting determines the extent to which the milling lane is cleared of milling debris. Used to adjust the discharge rate for cut material to prevailing conditions (quantity of material involved, de- Speed governor...
Page 48 28 29 30 Panel2_500_1000.bmp D 10...
Page 49 Item Designation Short description Two switch positions can be selected: Hare: Transportation speed Tortoise: Operating speed When changing from working speed to transpor- tation speed, the milling drum transmission is Travel drive automatically disengaged. fast / slow This operating mode can only be changed over once the machine is stationary and the drive le- ver is in centre position! To swivel the right-hand chassis leg in and out, e.g.
Page 50 28 29 30 Panel2_500_1000.bmp D 12...
Page 51 Item Designation Short description This switches the milling drum drive on or off. Top shift position: Milling drum drive engaged, Bottom shift position: Milling drum drive engaged. Before the milling drum drive is engaged, check to ensure that the machine is not lowered to such a point that the milling drum makes contact with the substrate.
Page 52 28 29 30 Panel2_500_1000.bmp D 14...
Page 53 Item Designation Short description Two switch positions can be selected: 0: Moldboard blocked - remains in desired position. : Moldboard in floating position Selector switch During milling operations, the scraper should al- Scraper ways be in float position. Under certain working (moldboard) ( ) conditions, it is however possible for the scraper to dig into the substrate.
Page 54 28 29 30 Panel2_500_1000.bmp D 16...
Page 55 Item Designation Short description Two switch positions can be selected: Top shift position: Fast raising and lowering Raising and low- speeds (e.g. for inching operation) ering speed Bottom shift position: Normal raising and lowering speed (e.g. for initial surface scraping and milling) Three switch positions can be selected: 0: Levelling OFF AUTO: Levelling engages automatically when the...
Page 56 Panel1_500_1000.bmp/Panel_Leucht.wmf D 18...
Page 57 Item Designation Short description Always keep an eye on the fuel gauge. Fuel gauge Never run the diesel tank dry! Otherwise, the en- tire fuel system would need bleeding. The coolant temperature should be between 60°C and 100°C. Continuous operation at excessively low or high cool- ant temperature can damage the engine.
Page 58 Panel1_500_1000.bmp/Panel_Leucht.wmf D 20...
Page 59 Item Designation Short description Lights up whenever a serious fault occurs in the en- gine. The engine is switched off automatically as a safety precaution. Error message Lights up for a few seconds to check that the ig- with engine stop nition is engaged.
Page 60 Panel1_500_1000.bmp/Panel_Leucht.wmf D 22...
Page 61 Item Designation Short description Lights up if there is excessive water in the fuel system separator. To prevent damage to the engine, drain off sep- arated water immediately, in accordance with the Maintenance Instructions. Warning lamp „water in fuel“ (yellow) Lights up for a few seconds to check that the ig- nition is engaged.
Page 62 Panel1_500_1000.bmp/Panel_Leucht.wmf D 24...
Page 63 Item Designation Short description Indicates that one of the following operating modes prohibits the machine from being started: milling drum engaged drive lever not in centre position Start inhibit raising/lowering scraper is actuated raising/lowering sliding shoe is actuated raising side boards is actuated control lever on upper conveyor is actuated Lights up whenever the machine exceeds a lateral inclined angle of >...
Page 64 Panel4_1000.cdr D 26...
Page 65 Item Designation Short description Engagement of travel drive and infinitely variable ad- justment of driving speed - forwards and reverse. Centre position: Engine can be started; engine running Drive lever at idle speed; no travel drive; machine braked (advance) Maximum speed can be set using the preselector con- troller.
Page 66 Panel4_1000.cdr D 28...
Page 67 Item Designation Short description The hydraulic cylinder of the right-hand chassis leg is retracted and/or extended by pressing the switch. Operated upwards: Raise vehicle Operated downwards: Lower the vehicle Machine raising/ In order to raise or lower the machine evenly, the lowering, right- switch can be operated simultaneously with hand side...
Page 68 Sockets and interfaces on the operating panel Panel_Interface_500_1000.bmp D 30...
Page 69 Item Designation Short description 24 volt socket for external consumers, e.g. addi- Socket tional working lights or diagnosis equipment. This is where the engine manufacturer’s diagno- Interface sis unit is connected. Error messages can be on diagnosis unit called up on, and deleted from, the diagnosis unit.
Page 70: Other Controls
Other controls Controls at operator’s control station Driver’s seat A driver’s seat on the operator’s control station should be adjusted to suit the needs of the driver/operator before start- ing work. - To adjust the seat for the weight of the driver, turn handle (1) on top of back- rest support until the approximate weight of the driver is displayed on the...
Page 71: Weather Protecting Sun Roof
Weather protecting sun roof The weather protecting sun roof can be folded down to a lower setting for trans- port purposes. - Remove folding cotter pins (1) and re- taining pins (2) from left and right guide tubes. - Move the roof into its lower position by pulling the bracket (3) on the articulat- ed roof joint.
Page 72: Weather-Protecting Sun Roof, Hydraulic (O)
Weather-protecting sun roof, hydraulic (O) The roof can be raised and lowered with- out the engine having to be started. - To lower the roof, turn key-operated switch (1) to the left until the roof has lowered to its minimum level. - To raise the roof again, turn key-oper- ated switch (1) to the right until the roof has risen to its maximum level.
Page 73: Battery's Main Switch
Battery’s main switch The battery’s main switch (1) is located under the right-hand flap on the engine compartment. It disconnects the electri- cal circuit from its earth/ground. The main fuses (2) are located beside the master switch. - To deactivate the master switch, turn to the left and remove.
Page 74: Milling Depth Display
Milling depth display There is an adjustable milling depth dis- play (1) to the left and right of the chassis legs. The right-hand 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 indicator (3) should be...
Page 75: Swivel-Mounted Chassis Leg
Swivel-mounted chassis leg For certain operating requirements, e.g. to ensure accurate edge grading, the right-hand chassis leg can be folded in hydraulically until it lies flush against the outer edge of the vehicle. - Evenly and carefully lower the ma- chine onto the milling drum and raise the left-hand chassis leg until it is no longer in contact with the ground.
Page 76: Retaining Hook, Moldboard
Retaining hook, moldboard For safety reasons, during maintenance work on the milling drum or on the milling drum housing, the moldboard is secured in its upper position by means of a re- taining hook. - Extend the moldboard until the retain- ing tab on the flap (1) locates in the re- taining hook (2).
Page 77: Water Scales / Inclination Indicator
Water scales / inclination indicator A fluid inclination indicator for lateral in- clination of the machine is located on top of the machine, immediately above the control panel. - If the air bubble is located inside the marked area (1) in the centre of the tube, the machine is standing on level ground.
Page 78: Throttle Valve, Levelling Unit
Throttle valve, levelling unit The retraction speed of the hydraulic cyl- inders on both chassis legs can be ad- justed by their respective throttle valves. These two throttle valves are located be- hind the left-hand flap on the engine compartment. - Left-hand throttle valve (1): Left-hand chassis leg - Right-hand throttle valve (2): Right-...
Page 79: Direction Of Travel Indicator
Direction of travel indicator To enable the planer to operate in a straight line, direction marks should be in place, or be added (edge of road sur- face, kerb, line of chalk, etc.). Two different direction indicators are lo- cated on the machine frame. - Pointer (1) runs accurately over the outside edge of the milling drum.
Page 80: Working Lights / Rotary Beacons
Working lights / rotary beacons At several points around the vehicle frame, plug-in contacts (1) are located for warning lamps and working lights. - Fit headlights in 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.
Page 81: Non-Return Valves For Water Spraying / Drain Valve On Water Tank
Non-return valves for water spraying / drain valve on water tank The non-return and drain valves for the water system are located behind the right-hand side flap. - To cut off water supply to the spray nozzles on the milling drum sprinkler, move valve lever (1) into locking posi- tion.
Page 82: Setting Valve For Water Pressure (Water Spraying)
Setting valve for water pressure (wa- ter spraying) There is a choke valve and a pressure gauge behind the lateral flap for adjust- ing and checking the water pressure in the sprinkling system. To set the water pressure and water vol- ume: - Unfasten lock nut (1) and tighten or untighten the knurled screw (2) to the...
Page 83: Chocks
Chocks The machine’s accessories pack in- cludes a chock. If the machine is parked on uneven ground, a chock should be placed under the rear wheels to prevent it from rolling away accidentally. Keil_PL600.wmf D 45...
Page 84: Vandalism Protection
Vandalism protection On the inside of the maintenance flap on the machine’s control panel is a cover secured with a screw to provide protec- tion against vandalism to the operating panel. When work finishes, this cover should be fitted over the operating panel and secured (retaining clamps and locks on left and right sides) To remove the cover, these two retain-...
Page 85: Levelling Unit
Levelling unit MOBA-matic type The MOBA-matic is a control and feedback control system for construction machinery and has been especially designed for use in milling operations. As optional equipment with this levelling unit is the Moba-matic with a very varied range of sensor combinations.
Page 86: Operating The Moba-Matic
Operating the MOBA-matic Nivellcompl.cdr D 48...
Page 87 Item Designation Short description MOBA-matic, left Open-loop and closed loop control system for the side levelling unit on the left side of the machine. MOBA actual val- Actual value indicator for height sensing and lateral ue indicator ( ) slope on left + right sides of machine. MOBA-matic, right Open-loop and closed loop control system for the side...
Page 88 Operating the MOBA-matic Moba1can.jpg D 50...
Page 89 Item Designation Short description Liquid crystal dis- Display can be easily read, even when the light is play poor, thanks to the integrated lighting. Three operating modes are available: Lamp off: Stand by position - direct adjustment of milling depth and lateral slope possible in manual mode.
Page 90 Moba1can.jpg D 52...
Page 91 Item Designation Short description No function To increase the nominal value. The machine re- sponds in automatic or manual mode (change to ac- tual value). UP button Machine does not respond in semi-automatic mode (only for pre-selections, i.e. nominal value specifica- tions.) To decrease the nominal value.
Page 92: Liquid Crystal Display (M1)
Liquid crystal display (M1) Moba35.jpg The display symbols have the following meanings: Symbol Meaning ARROWS Controlled RAISE (12) / controller output LOWER (13) Value without Positive prefix (14) display value Value with nega- Negative tive prefix (15) display value Bar dropping Slope to the right to the right (16) Bar dropping...
Page 93: Sensor Message
Sensor message After the activation message, the digital controller briefly twice indicates the sen- sor connected using an alternating dis- play image. While this image displayed, the two direction lamps also flash. The control then automatically changes into operating mode. If the sensor has been changed, the con- troller continues to issue the alternating sensor message until this message is...
Page 94: Led Display
LED display The LED‘s are only used to provide the operator with a better display of the status of each of the activated valve outputs. Its display is simply an enlarged and detailed depiction of the function of the arrow symbols on the LC display. The LED display is particularly useful when the operator is at a great distance from the controller and if the sun is strong.
Page 95: Actual Value Indicator (O)
Actual value indicator (O) LQ K Moba2.cdr The optional actual value indicator provides a means of comparing the nominal value, as displayed by the MOBA-matic, and the prevailing actual value. D 57...
Page 96 Item Designation Short description Actual value display for left-hand side of machine. Liquid crystal dis- Display is easy to read, even in poor light, thanks to play, left side integrated lighting. M21 No function When this key is pressed, the display changes from Lateral slope / the actual height value on this side of the machine to height display...
Page 97: Connection
Connection: The two digital controllers and the actual value indicator, with a retaining knob on its reverse side, are slid into their brack- ets from above and are clearly visible from the right side of the control panel on the machine frame. Moba1can.cdr/Halt.jpg/Halt2.jpg disconnected, plug...
Page 98 Proceed as follows during the connection process: - Unscrew protective cap from connector - Fit connector in position determined by plastic ridge on socket, and groove in side of connector. - Tighten cap ring firmly down to secure the connector. D 60...
Page 99: Connection Of Moba-Matic, Actual Value Indicator And Sensors
Connection of MOBA-matic, actual value indicator and sensors As optional equipment with other sensors, 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 the access steps and the milling drum hous- ing.
Page 100 Do not undertake connections when the machine is operating or the machine ele- ments are being driven! Always check that the connector / connection cable is not damaged! Keep threads on plugged connections and cable connections free of dirt and grease to prevent bad contacts.
Page 101: Button Usage And Possible Button Combinations On The Digital Controller During Milling
Button usage and possible button combinations on the digital controller during milling AM button This button is used to change between the operating modes: - manual - „AUTO“ function lamp off. - semi-automatic - „AUTO“ function lamp flashing. automatic mode - „AUTO“ function lamp on.
Page 102 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) Moba31.jpg D 64...
Page 103 SET button - When using the Digi-Slope sensor, the SET button must always be used to confirm an actual slope value set in manual mode or preselected or exist- ing in semi-automatic mode. This must be done before changing over into automatic mode so that this value is adopted as the nominal value.
Page 104: Basic Settings
Basic settings Always conduct all basic settings in manual mode! (Function lamp off) Moba23.jpg The levelling equipment cannot activate automatic mode via the digital controller. Automatic mode for milling operations can only be set from the operating panel of the operator’s control station. During the milling process, changes to all operating modes (automatic, semi- automatic, manual) can only be conduct-...
Page 105: Calibration To Zero
Calibration to zero Initial situation for calibration to zero - Sensors and controllers are fitted, all connection cables are connected. - The machine is standing on a smooth, level surface without lateral slope, uniformly lowered so that the milling drum is just slightly above the ground. - The side boards are lowered - The milling drum is activated, the diesel engine runs at idle speed.
Page 106: Calibration To Zero For Cable Tension And Digi-Sonic Sensors When Sensing The Ground Via The Side Boards
Calibration to zero for cable tension and Digi-Sonic sensors when sensing the ground via the side boards. - Hold down the input keys of the left and right controllers (approx. 1.5 sec) until „SET“ and then the value 0.0 ap- pear on the display.
Page 107: Actual Value Calibration
Actual value calibration Digi-Slope sensor (lateral slope sensor) During this process, the actual value display of both digital controllers is compared with the actual slope angle of the machine / milling drum Initial situation for actual value calibration - Sensors and controllers are fitted, all connection cables are connected. - The machine is standing on a smooth, level surface without lateral slope, uniformly lowered so that the milling drum is just slightly above the ground.
Page 108 - Changing the controller over to lateral slope is indicated in the display win- dow by a lateral slope symbol and the actual value of the planer / milling drum’s lateral slope is shown as a %. If the value displayed for lateral slop dif- fers from the value previously measured on the ground, the calibration must be undertaken as follows:...
Page 109: Height Sensors (To Correct The Actual Value To The Value Displayed)
Height sensors (to correct the actual value to the value displayed) - In automatic mode, press and hold down the input key. „SET“ appears 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 UP/ DOWN...
Page 110: Operation
Operation Preparing for operation Devices and aids To prevent delays and to ensure a problem-free flow of work, before starting work, operators should check whether all the devices and aids required for smooth opera- tions are available. A sufficient quantity of lubrication agents and fuel substances, tools, 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.
Page 111: Checklist For Machine Operator
Checklist for machine operator Once the maintenance and checking work listed in the maintenance manual has been conducted at the specified intervals, the inspections and control work listed in the fol- lowing list should also be noted and conducted. This work is used to assess the machine status and to assure perfect operations as well as personal safety.
Page 112: Starting The Machine
Starting the machine The following should be done before the diesel engine can be started and the ma- chine can be operated: - Daily machine maintenance. Check the operating hours counter to determine whether further maintenance work should be conducted. - Check the safety and protection equipment.
Page 113 - Insert ignition key (4) in ignition lock in setting „P“. When starting, ensure that the light is not switched on in order to save the battery. - Switch on ignition (Pos. 1). - Turn ignition key in Pos. 2 to start the diesel engine.
Page 114: Auxiliary Starting (Electrical Starting Aid)
Auxiliary starting (electrical starting aid) If the batteries are flat and the starter is not turning, the engine can be started using an external source of power. The following are suitable as sources of power: - another vehicle with a 24 V system; - additional 24 V battery;...
Page 115: Allowing Engine To „Warm Up
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. The milling drum should be engaged.
Page 116: Driving The Machine
Driving the machine Panel2_500_1000.bmp/Panel4_1000.bmp - Raise machine uniformly by pressing both switches (73) + (74) together until the desired ground clearance has been reached. Where applicable, press the switch for raising and lowering speed (36) to rapid adjustment beforehand. - Ensure that machine is as horizontally positioned as possible (pay close attention to the inclination - or „slope“...
Page 117: Milling Instructions
Milling instructions „Driving“ position - Chassis legs lowered - milling drum raised PL600_Back1.cdr „Milling“ position - Chassis legs raised - planer lowered PL600_Back2.cdr D 79...
Page 118: Zero Setting
Zero setting - Run milling drum at low rotational speed. - Lower the planer until the bit tips scratch the road surface across the entire breadth of the milling drum. - Set milling depth scales to zero. The zero setting has to be undertaken both when the chassis leg is swivelled out and in! Always undertake the zero setting on level ground which is not...
Page 119: Milling At The Edge Of The Lane Or At Steps
Milling at the edge of the lane or at steps Pay close attention to load-bearing ca- pacity of right-hand track. Raise planer sufficiently! The milling drum must have more ground clearance than the height of the offset. Always keep planer level when engag- ing it in the milling position! For planing operations, lower the ma- chine evenly down to the desired milling...
Page 120: Milling At The Curb (With Chassis Leg Swivelled In)
Milling at the curb (with chassis leg swivelled in) Advantages: - Maximum milling depth is reached - direct planing against kerb possible Disadvantages: - Less precise planing results - Less exact planing surface PL600_Back7.cdr D 82...
Page 121 Milling (preparation): Panel2_500_1000.wmf/Panel4_1000.bmp - Drive the machine to the planing location and lower manually as far as possible (milling drum does not make contact with ground at this stage). Engage the following functions on the main operating panel: Item Switch Position Transport/working gear Working gear (tortoise mode)
Page 122: Planing Without Automatic Levelling Device
Planing without automatic levelling device Panel2_500_1000.bmp/Panel4_1000.cdr Skala5.wmf D 84...
Page 123 Once all preparatory work for planing has been completed, the planer is ready for op- eration and a truck is parked below the upper conveyor to receive cutting debris, the stationary machine is lowered to the required depth. - Carefully lower the stationary machine by pressing the switches (74 + 73) until the milling drum makes gentle contact with the working surface.
Page 124: Operating The Moba-Matic During Milling
Operating the Moba-matic during milling Initial situation for operation - Sensors and controllers are fitted, all connection cables are connected. - The zero value and/or actual value calibration has been conducted, the machine is in its operating position, all other settings required for planing have been conducted on the machine - The A/M button is switched to semi- automatic mode (AUTO function lamp...
Page 125: Other Tasks For Adopting The Initial Position For Milling
Other tasks for adopting the initial position for milling: Milling with height sensors Lower planer using switch (1) on operating panel to control the rear chassis legs evenly until baseplates on the side boards make contact with the ground at the back of the machine.
Page 126 - Enable the automatic function on the levelling equipment using pushbutton (2) (function lamp AUTO (3) lights up). - Raise the engine speed and engage the milling drum drive. - Use switches (4) and (5) of the main control panel to switch the levelling unit into „AUTO“...
Page 127 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 D 89...
Page 128 - When in semi-automatic mode, set nominal value 0 on the two digital controllers using the DOWN buttons (M7), activate the levelling unit using buttons (M8) on the digital controllers (AUTO function lamp (M2) lights up), use switches (37) and (38) on the main control panel to shift to „ON“...
Page 129: Milling With Height Sensors Together With The Transverse Slope Sensor
Milling with height sensors together with the transverse slope sensor Panel2_500_1000.bmp/Panel4_1000.cdr/Moba1a.cdr/Moba29.jpg D 91...
Page 130 - Lower the machine to its zero cutting depth setting using switches (73), (74). - Move the A/M buttons (M8) of both controllers to automatic mode (the AUTO func- tion lamp (M2) lights up). - Set the desired nominal values for each of the digital controllers using the UP/ DOWN pushbuttons (M6), (M7) (milling depth (here -8cm), lateral slope (here 2.6% tilting downwards and to right side).
Page 131: Ending The Milling Procedure
Ending the milling procedure Panel2_500_1000.wmf/Panel4_1000.bmp Stop the machine and raise at the end of the milling lane: - The drive lever (70) is located in centre position. - If the automatic levelling device is used for planing, first shut down the levelling unit using switches (37) and (38).
Page 132: Parking The Machine
Parking the machine Before parking the machine, take a reading from the operating hours counter and check if any maintenance work is required at that point. When parking the machine on publicly accessible land, secure it to ensure that unau- thorised persons and children cannot do any damage to the machine.
Page 133: Parking The Machine For Long Periods Of Time
Parking the machine for long periods of time When storing the machine for the season, it should be parked so that it is protected from strong sunlight, wind, dampness and frost. If the machine cannot be parked in enclosed buildings, it should be parked in a cov- ered area or the entire machine should be covered with an appropriate canopy.
Page 134: Scope For Using The Small Planers
Scope for using the small planers Remedying longitudinal and transverse bumps in the road surface before after Planing Selective cutting Plan1.tif Remedying cracks before after Selective cutting Plan2.tif Remedying potholes, frost damage before after Partial cutting Plan3.tif D 96...
Page 135: Remedying Damage To Edges And Bumps
Remedying damage to edges and bumps before after Wedge-shaped cutting Plan4.tif Producing adjoining edges after before Wedge-shaped cutting Plan5.tif Producing slots, joints and cable trenches Selective cutting with special-purpose joint cutting tools Plan6.tif D 97...
Page 136: Removing Embedded Markings
Removing embedded markings before after Selective cutting with special-purpose joint cutting tools Plan7.tif Removing road markings before after Planing off road surface markings using fine spaced milling drums or marking removal rollers Plan8.tif Re-establishing surface grip before after Roughing up surface with fine spaced milling drums Plan9.tif D 98...
Page 137: Malfunctions
Malfunctions 10.1 Error code query for engine If a defect on the engine is detected by one of the warning lamps (44) or (43), a code to which a defined malfunction has been assigned can be displayed on screen by pressing the query key (3).
Page 138 Example: PAUSE PAUSE Flash sequence: 3-pause-5-pause-2. Error code: 352 If the output switch continues to be held in its upper position, the code is reissued. Once the malfunction query switch returns to its 0 position, the warning lamp which first indicated the presence of the error lights back up again. This continues until the malfunction or defect has been remedied.
Page 139: Error Codes
Error codes Error PID(P) code and SID(S) Cause Effect warning lamp 111* S254 Possible no effect or engine may ECM internal hardware error. YELLOW run rough or not start. No engine speed or position sig- 115* P190 Engine power derate. nal detected at pin 17 of the en- YELLOW Possible white smoke.
Page 140 Error PID(P) code and SID(S) Cause Effect warning lamp Coolant temperature signal indi- Power derate and possible engine P110 cates coolant temperature has shutdown if engine protection shut- YELLOW exceeded the minimum engine down feature is enabled. protection limit. Coolant temperature signal indi- Speed derate and possible engine P110 cates coolant temperature has...
Page 141 Error PID(P) code and SID(S) Cause Effect warning lamp Error detected in the fan clutch Electronic control module (ECM) S033 relay enable circuit at pin 31 of can not control the engine cooling NONE the engine harness. fan. Fan will remain on or off. VP44 Fuel Pump Control Mod- 261* P174...
Page 142 Error PID(P) code and SID(S) Cause Effect warning lamp Low or no voltage detected at S251 Engine will lose power and may the VP44 fuel pump control YELLOW shut down. valve. No fuel control valve movement S251 detected by the VP44 fuel pump Engine power loss.
Page 143 Error PID(P) code and SID(S) Cause Effect warning lamp 376* S233 1077 No calibration in the VP44 fuel Fueling to injectors disabled and pump controller. engine will shut down. VP44 fuel pump controller is not Equipment batteries may be S233 1077 powering down when key switch drained low during long shutdown...
Page 144 Error PID(P) code and SID(S) Cause Effect warning lamp Low voltage detected at water- P097 in-fuel signal pin 40 of the OEM No water-in-fuel protection. YELLOW harness. Idle validation signals on pins 25 and 26 of the OEM harness indi- P091 No effect on performance, but loss cate voltage detected simultane-...
Page 145 Error PID(P) code and SID(S) Cause Effect warning lamp Low voltage detected at OEM Sensors connected to this +5 VDC S232 harness sensor +5 VDC supply supply (i.e., remote throttle position YELLOW pin 10 of the OEM harness. sensor) will not function. Intake manifold air temperature signal indicates intake manifold Power derate and possible engine...
Page 146 Error PID(P) code and SID(S) Cause Effect warning lamp ECM detected the engine has S151 1020 initiated a protection shutdown 611* No effect. or has been keyed-off while above a specified load limit. Error detected in the Output De- S009 vice Driver (Transmission Shift Can not control the Transmission.
Page 147: Error Messages For Anti-Slip Control
10.2 Error messages for anti-slip control Advise our After-Sales Service staff of the malfunction number being displayed for your road planer and we will be only too pleased to discuss what action you should then take. D 109...
Page 148: Error Message From Travel Drive
10.3 Error message from travel drive Advise our After-Sales Service staff of the malfunction number being displayed for your road planer and we will be only too pleased to discuss what action you should then take. D 110...
Page 149: Moba-Matic Error Messages
10.4 MOBA-Matic error messages D 111...
Page 151: E Set-Up And Modification
E Set-up and modification Special safety instructions Injury or death can result whenever the engine, travel drive, release unit, conveyor or lifting units are engaged. When operating the machine, therefore maintain strict compliance with the sections of these operating instructions and the safety specifications dealing with personal conduct.
Page 152: Planing Without Upper Conveyor / Preparation For Transport
Planing without upper conveyor / Preparation for transport Dismantling the upper conveyor To reduce the transport length of the machine and to carry out planing operations without the upper conveyor, this should be removed from the machine. This operation involves following a few simple steps. Upper conveyor and milling drum must be disengaged before commencing this dis- assembly work! Operations required:...
Page 153 PL600_conv2_neu.cdr - Lower upper conveyor until the front and rear parking legs (1) + (2) can be extended to the desired length: - Remove parking legs and secure to required length with dowels and cotter pins. - Continue lowering machine until at least the two rear parking legs (1) are supported on the ground.
Page 154 PL600_conv3_neu.cdr - 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.
Page 155: F Maintenance
F Maintenance Safety regulations for maintenance Always comply with Health & Safety and Fire Prevention regulations when carrying out maintenance work. Always wear appropriate protective clothing and equipment. If not otherwise stated, always switch of the engine before carrying out maintenance work.
Page 156: Liability Is Rendered Null And Void If Non-Genuine Spares Or Wearing Parts Or Incorrect Fuel Substances Are Used
Avoid electric welding work on the machine because this can lead to damage to elec- tronic and hydraulic assemblies! In exceptional circumstances, if electric welding work is required on the machine, al- ways take due note of the following before starting work: - ignition must be switched off - interrupt the electrical circuit - fit earth/ground terminal of welding unit as close as possible to welding location.
Page 157 Operating hours Maintenance lo- Activity cation (3.1) Engine (power unit) Check fill level Top up fuel Clean tank and system Check oil level Top up oil Change oil Change oil filter Change fuel filter Fuel filter (drain water separa- tor) Bleed fuel system Fuel tank Check air cleaner...
Page 158 Operating hours Maintenance lo- Activity cation (3.2) Hydraulics Check oil level Hydraulic oil tank Top up oil Change oil Suction /return Change filter cartridge hydraulic filter Perform a visual inspection Hydraulic hoses Replace hoses Pump-pedestal Change oil (3.3) Drive wheels Check oil level Top up oil Planetary gear...
Page 159 Operating hours Maintenance lo- Activity cation (3.4) Milling section Milling drum Dismantle milling drum Check condition Bits, wearing sleeves Replace bits, wearing sleeves, bit blocks bit blocks Replace sliding shoes Side board Replace support plates Check belt Belt drive Replace belt Check friction lining Clutch Replace belt...
Page 160 Operating hours Maintenance lo- Activity cation (3.5) Loading unit Check tension / deflection Adjust tension / deflection Conveyor belt Check for signs of damage Replace conveyor belt Check condition Loading belt rollers Replace rollers Check condition Steel securing rope Replace securing rope Check for signs of damage Hopper rubber on transfer points and...
Page 161 Operating hours Maintenance lo- Activity cation (3.6) Water system Check fill level Top up top up water level Water tank Change water Clean tank Dismantle tank Check water filter Water filter Replace filter Drain off water Check function Spray nozzles Drain off water (3.7) Electrical power supply Check fill level of battery acid...
Page 162 Operating hours Maintenance lo- Activity cation (4.0) Lubricating points Chassis leg, right Grease the joint side (grease nipple) Grease the steering unit Steering system (grease nipple) Grease the clutch bearing Belt tensioner (grease nipple) Lubricate Clutch bearing clutch bearing (grease nipple) Lubricate clamping mount for Upper conveyor drive drum (grease nipple)
Page 163: Power Unit - Engine
Power unit - engine Fuel tank The fuel tank should be filled before eve- ry job to ensure that it does not run dry: if this did happen, time-consuming and costly bleeding of the fuel system would be required. Check fuel level at regular intervals us- ing the display on the operating panel.
Page 164: Diesel Engine
Diesel engine The engine oil level should always be checked before starting work using the dipstick (1). Always check the oil with the machine stationary. The dipstick is located behind the left- hand flap on the engine compartment. This flap is opened using a square-sec- tion wrench.
Page 165: Oil Changes
Oil changes An oil drain cock is located on the right- hand side of the machine on the frame. Risk of scalding from hot oil! Collect used oil in a suitable container and send for disposal. Before changing the oil, run the engine up to operating temperature.
Page 166: Fuel Filter
Fuel filter Replace the fuel filter every 500 operat- ing hours. The fuel filter is located behind the left- hand flap on the engine compart- ment.This flap is opened using a square- section wrench. Unfasten the electrical plugged connec- tion (1) on the water sensor, unfasten the filter using a filter key and clean the supporting surfaces.
Page 167: Bleed Fuel System
Bleed fuel system If it proves necessary to bleed the fuel system, e.g. after changing the filter, use the bleed screw and hand pump provid- The bleed screw (1) and hand 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...
Page 168: Air Cleaner
Air cleaner The air cleaner is located behind the right-hand flap of the engine compart- ment. This flap is opened using a square-section wrench. Drain the dust collector (1) every 50 hours. To gain access to the filter cartridge, the connections (2) on the housing and the sealing cover must be removed from the filter housing.
Page 169 Radiator Check the cooling 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 dirt solvent, then to spray it down with a water jet.
Page 170: Drive Belt
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 F 16...
Page 171: Hydraulics
Hydraulics Hydraulic oil tank Check the oil level daily on the indicator (1) located on the left-hand side of the machine. Change the hydraulic oil every 1000 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.
Page 172: Changing The Hydraulic Oil
Changing the hydraulic oil The oil drain screw (3) for hydraulic oil is located under the machine in the left- hand direction of travel. To drain the hydraulic oil, first place a suitable receptacle under the drainage point, then remove the screw plug. After draining the fuel, fit a new seal to the screw plug and tighten back into place.
Page 173: Suction-Return Hydraulic Filter
Suction-return hydraulic filter The return line to the hydraulic filter is lo- cated on the hydraulic oil tank behind the left-hand maintenance flap on the en- gine compartment. This maintenance flap is opened using a square-section wrench. - Unfasten the filter housing cover (4) by removing the square-section bolts.
Page 174: Pump-Pedestal
Pump-pedestal Oil change: - Unscrew the oil drain screw (1), collect draining oil. - To bleed the system, unscrew and re- move the filler plug (2). - Once the oil has drained off complete- ly, fasten the drain plug (1) back into place.
Page 175: Drive Wheels, Chassis Legs
Drive wheels, chassis legs Planetary gears Oil level check Check oil level every 50 operating hours. When checking the oil level and while fill- ing with oil, the screw plug used for oil level checks (1) must be in its 9 o’clock position.
Page 176 Changing oil in planetary gear unit First oil change after 250 hours of run- ning-in period, thereafter every 1000 hours, but at least once a year. To drain the oil, turn the drain screw (2) into its 6 o’clock position, ensuring that the filler screw (1) is in its 9 o’clock posi- tion.
Page 177: Milling Section
Milling section Milling drum The milling drum is bolted to the angle gearbox on the milling drum drive. It is not mounted in bearings on its right-hand side. Dismantling milling drum The milling drum is easy to dismantle for repair work, or for replacement of the tool, e.g.
Page 178 Nivellswitch1000.cdr/Moba1a.cdr/Moba29.jpg/Moba21.jpg F 24...
Page 179: Bits, Wearing Sleeves, Bit Blocks
Bits, wearing sleeves, bit blocks SYSTEM KPF201 ( ) Bit_KPF201_compl.jpg/Bit_KPF201_parts.jpg The three-part KPF 201 quick-change system comprises: - Bit (1) - Wearing sleeve (2) - Block (3). The wearing sleeve (2) is there to ensure that a worn planing tool does not cause wear to the block.
Page 180 SYSTEM KPF301 ( ) Bit_KPF301_compl.jpg/Bit_KPF301_parts.jpg The three-part KPF 301 quick-change system comprises: - Bit (1) - Wearing sleeve (2) - Block (3). The wearing sleeve (2) is there to ensure that a worn planing tool does not cause wear to the block. F 26...
Page 181 The condition of the bits and if necessary that of the wearing sleeve and bit blocks needs to be checked several times a day. Immediately replace worn or damaged bits, wearing sleeves and blocks. The machine capacity can only be fully utilised if planing / milling tools are in perfect condition.
Page 182 Wearing features of bit blocks New bit block Serious wear to locating faces of the planing bit or wearing sleeve - replace without delay Serious wear to locating bore on the planing bit or wearing sleeve - replace without delay Severe wear to flank - replace immediately The following safety precautions need to be taken, and the following action needs to be taken when inspecting and replacing the bits and, where necessary, to the wearing...
Page 183: System Kpf201 (O)
Dismantling the bits System KPF201 - Fit hammer punch into bore on re- verse side of bit box then drive out worn and damaged bits by striking with a hammer. Meißeldemon.cdr/Meisselh1.tif System KPF301 - Place the bit extractor (flat punch or similar) behind the bit plate, then drive out worn and damaged bits by striking the hammer punch.
Page 184: Dismantling The Wearing Sleeves
Dismantling the wearing sleeves System KPF201 Two different tools are available for dis- mantling the wearing sleeves: - Fit the sleeve driver (1) to the bore on the back of the bit block, then drive out worn and damaged wearing sleeves by striking with a hammer.
Page 185 System KPF301 Different tools are available for disman- tling the wearing sleeves: - Fit the sleeve extractor (1) to the two recesses, then unfasten the sleeve by hitting the striking surface of the sleeve extractor with a hammer - The sleeve extractor (2) can be used to press the loosened wearing sleeve out of its bore.
Page 186: Fitting The Wearing Sleeves
Fitting the wearing sleeves System KPF201 - Drive new wearing sleeves into the bit blocks by striking from the front with the sleeve driver. Only use the sleeve driver or the drawing tool to dismantle or fit the wearing sleeves! BIT_KPF201.jpg When installing new bits and wearing sleeves, always ensure that all bores and locating surfaces are free of dirt!
Page 187: Replacing The Bit Box
Replacing the bit box - The bit boxes arranged on the roller need to be so firmly and reliably weld- ed to the milling drum that they only very occasionally break off, and then only under extreme conditions (e.g. old steel rails lying concealed in the milling surface).
Page 188: Belt Drive
Belt drive Check the condition of belts on the cut- ting drive on a daily basis. Replace damaged and worn belts with- out delay. Clean material debris out of all grooves in the v-belts! Always replace these belts in pairs. The belt drive comprises 6 individual belts.
Page 189: Clutch
Clutch Check wear on clutch friction linings every 1000 operating hours. Replace worn friction linings immediate- The clutch is located behind the left- hand maintenance flap on the control panel. Ensure that the engine cannot be started accidentally! For inspection purposes, an inspection cover (1) needs to be removed from the clutch housing.
Page 190: Angular Gear
Angular gear Oil level check Check oil level every 50 operating hours. When checking the oil level or topping the oil up, the machine must be standing on level ground. - Unscrew and remove the filler and in- spection screw (1). The oil level should reach the lower edge of the bore for the screw plug.
Page 191 Oil changes First oil change after 50 hours of run- ning-in period, thereafter every 500 hours, but at least once a year. Always perform oil changes with the oil at operating temperature, immediately after the gearbox comes to a standstill. This ensures that suspended particles of solid matter do not have time to settle and form sediment.
Page 192: Milling Drum Gearbox
Milling drum gearbox Oil level check When checking the oil level or topping the oil up, the machine must be standing on level ground. - Unscrew and remove the filler and in- spection screw (1). The oil level should reach the lower edge of the bore for the screw plug.
Page 193 Oil changes Always perform oil changes with the oil at operating temperature, immediately after the gearbox comes to a standstill. This ensures that suspended particles of solid matter do not have time to settle and form sediment. Wear protective clothing when draining hot oil.
Page 194: Side Boards
Side boards Sliding shoes The side boards which slide over the ground (1) should be checked every 50 hours to ensure that they are still proper- ly attached. There is one side board on either side of the milling drum housing. The sliding shoes on the side boards are in continuous sliding contact with the as- phalt during planing operations, as a re-...
Page 195: Support Plates
Support plates There are several support plates on the internal surface of the side boards which ensure that the side boards can be raised or lowered in a sliding fashion. If the material on the support plates be- comes too thin, these must be replaced. Check the support plates on both side boards at regular intervals and replace if required.
Page 196: Moldboard / Scraper
Moldboard / Scraper Inspect the scrapers on the moldboard every 50 operating hours and replace if necessary. If surplus material is left in the milling lane, also check these components. The scrapers ensure that almost no cut material remains in the milling lane, thereby ensuring that waste material is collected up properly.
Page 197 Milling drum housing screw connections The connecting screws (1) attaching milling drum housing to vehicle chassis need to be checked with a torque wrench and, if necessary, retightened: Tightening torque: 1060 Nm Iso600_Complback.wmf/Boxscrew_PL1000.bmp F 43...
Page 198: Loading Unit
Loading unit Belt tension Check belt tension on the upper convey- or on a daily basis. If there is too much slack in the belt, adjust the tension. During the first weeks of operation, the belt may stretch excessively (residual and elastic elongation).
Page 199 In addition, perform visual check of belt and loading belt rollers for signs of damage or wear. Remove encrusted material from the drums on a regular basis. Inspect bolt connections on a regular basis. During all work on the upper conveyor, ensure that the conveyor drive cannot be start- F 45...
Page 200: Steel Cables
Steel cables Check the condition of the steel retaining cable on the upper conveyor on a daily basis. Always replace damaged steel cables immediately. Tearing steel cables constitute a serious threat to man and machine. Relieve tension on any damaged steel cables on the upper conveyor and re- place! During all work on the upper conveyor,...
Page 201: Water System
Water system Water tank Check the water tank level before start- ing work by inspecting the filler gauge (1) on the right-hand side of the water tank. If necessary, top up the tank. - Unscrew filler aperture (2), fill with wa- ter to top edge then close aperture properly.
Page 202: Remove Water Tank
Remove water tank If it is necessary to remove the water tank, proceed as follows: - Park machine in suitable location, open the drain valve (1) and complete- ly empty the water tank. - Remove hose connection from tank (2) by untightening the hose clamp. - Also remove the two horizontal tank screws (5) from behind the battery flap: these connect the tank to the ma-...
Page 203: Water Filter
Water filter Replace the filter cartridge daily after work, and whenever the contamination indicator shows that this is necessary! The machine’s accessories include an- other water filter to daily replacement is not a time-consuming operation. The water filter is located behind the right-hand maintenance flap of the en- gine compartment.
Page 204: Spray Nozzles
If there is a risk of frost, the filter housing must be emptied completely to protect it from damage. - Close the stop cock (1). - Shake out filter housing (2) and any water contained in it. - Reinstall drained filter housing. Spray nozzles The spray nozzles are located at the front end of the milling drum box.
Page 205: Power Supply
Power supply Batteries Check the charge level of the batteries every 250 operating hours and at least every 3 months. The two batteries are located behind the flap at the front of the machine. The batteries are factory-filled with the correct quantity of acid.
Page 206: Other
Other Emergency-stop button For your personal safety, the safety of other persons and of the machine, you should check the function of the emergency-stop button on a daily basis. Defective emergency-stop buttons must be replaced immediately. The emergency-stop button is located on the control panel. The engine, drives and steering system are shut down when the emergency-stop but- ton is pressed.
Page 207: Chassis Leg Guide
Chassis leg guide There are several sliding plates in the guides on both chassis legs through which the chassis legs can be guided when extending or retracting. The sliding surfaces on all sides of the square tube should always be prop- erly greased.
Page 208: Lubricating Points
Lubricating points Chassis leg, right side There is a grease nipple on the swivel joint on the chassis leg. Fill 5 strokes of grease using the grease press. Schwenk1_PL1000.wmf Steering system There are two grease nipples beside the steering system underneath the ma- chine.
Page 209: Belt Tensioner
Belt tensioner There is one grease nipple on the bear- ing point of the belt tensioner on the mill- ing drum drive. Fill 3 strokes of grease using the grease press. Riemen_PL1000.wmf Clutch bearing The grease nipple for the clutch bearing is located behind the belt disc.
Page 210: Hydraulic Cylinder
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 F 56...
Page 211: Inspections
Inspections General visual inspection A walk around the machine and the following inspections form part of the daily rou- tine: - Any damage to components or controls? - Any signs of leakage on engine, hydraulic system or gearbox, etc.? - All fastening points OK? Remedy defects immediately to prevent damage, danger of accidents and environ- mental contamination! Inspection by a specialist...
Page 212: Lubrication Agents And Fuel Substances
Lubrication agents and fuel substances Only use the specified greases or corresponding quality grades from well-known manufacturers. Only use containers which are clean on inside and outside for filling oil or fuel. Comply with specified filling volumes! Operating at the wrong oil or lubricant levels will accelerate the process of wear, cul- minating in machine breakdown.
Page 213: Hydraulic Oil
Hydraulic oil Preferred hydraulic oils: a) Synthetic hydraulic oil based on esthers, HEES Manufacturer ISO viscosity class VG 46 Shell Natural HF-E46 Panolin HLP SYNTH 46 Esso HE 46 b) Mineral oil pressurised fluids Manufacturer ISO viscosity class VG 46 Shell Tellus Oil 46 When changing from mineral oil pressurised fluids to bio-degradable pressure fluids,...
Page 214: Filling Volumes
Filling volumes Volume Fuel tank approx. 340 litres (up to max. fill level) Engine oil approx. 14 litres Hydraulic oil tank approx. 130 litres (up to max. fill level) Water tank approx. 1200 litres (up to max. fill level) Planetary gear on drive wheels approx.
Page 215: Electrical Fuses
Electrical fuses Main fuses (1) (behind the right-hand flap of the engine compartment) Hauptsch_PL1000.wmf 100 a - F1.1 Main fuse 100 a - F1.2 Main alternator fuse - F1.3 Ignition 30 a - F1.4 Heating system 100 a 60 a - F1.5 Hydr.
Page 216: Fuses On The Operating Panel
Fuses on the operating panel Panel1_500_1000.bmp Fuse holder (2) Fuse1.Tif F2.1 F2.8 Alternator Fittings Susmic travel drive Levelling unit Front/rear scraper, side board, cutting drive Conveyor belt, tilt alarm ( ) Rotary beacons F 62...
Page 217 Fuse holder (3) Fuse1.Tif F3.1 F3.8 Brake light Flashers Hazard flashers Left-hand low-beam headlights Right-hand low-beam headlights Left-hand high-beam headlights Right-hand high-beam headlights Left-hand parking lights Fuse holder (4) Fuse1.Tif F4.1 F4.8 Right-hand parking lights Working lights Horn Engine Engine Engine Engine Engine...
Page 218: Fuses In The Operating Panel
Fuses in the operating panel Panelkompl_500_1000.bmp/Deskfuse.eps F5.1 F5.2 Advance fuse protection, power supply Lights F 64...
Page 219: Tightening Torques
Tightening torques Maximum tightening torques for shaft screws with metric ISO standard threads 12.9 10.9 Tightening Tightening Tightening Preload force Preload force Preload force torque torque torque (Nm) (Nm) (Nm) 2250 3150 3800 3900 5450 6550 6350 8950 10700 9000 12600 15100 16500...
Page 220: Maintenance Log
Maintenance log To keep a proper record of all maintenance, service and repair work, please use the pre-printed forms on the following pages. Notes on how to fill in the maintenance logs properly: e.g.: 9.1 Assembly, engine, engine systems Result, name, Date Occasion Comments about scope of work...
Page 221: Assembly, Engine, Engine Systems
Assembly, engine, engine systems F 67...
Page 222: Hydraulic System
Hydraulic system F 68...
Page 223: Drive Wheels, Steering System, Brakes
Drive wheels, steering system, brakes F 69...
Page 224: Milling Section
Milling section F 70...
Page 225: Water System
Water system F 71...
Page 226: Electrical System
Electrical system F 72...
Page 227: Other Equipment
Other equipment F 73...
Page 229 INFORMATION The easiest way to solve a minor problem out in the field, is to contact your Dynapac dealer for trouble-shooting and advise. Make us a visit to inform yourself about the whole range of Dynapac equipment and...
Page 230 Don´t hesitate to contact your local dealer for: service spare parts documentation accessories information about the complete Dynapac paving and planing range...

Dynapac PL 1000 RS Operation & Maintenance Manual

A Intended Usage

B Vehicle Description

C Transport

D Operation

E Set-Up and Modification

F Maintenance

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