Dynapac PL 500/20 S Troubleshooting guide

503........................
02-0407
Operation
&
Maintenance
Keep for later use in document compartment
Order no. for this handbook: 900 98 12 71
Valid from serial number: 503.173
Cold planer
PL 500/20 S

VALUE
QUALITY
THE ORIGINAL
Your authorised Dynapac dealer:
SPARE PARTS

V00.001.GB 1-2 01-04.07
Preface
If the machines are to be operated safely, the information provided in these Operating
Instructions will be required. The information is provided in a concise, clearly struc-
tured form. The individual chapters are arranged in alphabetical order. Every chapter
starts on page 1. The designation of pages consists of a letter denoting the chapter
and a numeral denoting the page number in that chapter.
Example: Page B 2 is the second page of chapter B.
To avoid misunderstandings relating to enquiries, consultation sessions, orders, etc.,
always use the terms defined in these Operating Instructions.
These operating instructions cover various machine options. Make sure that during
operation and maintenance work the description appropriate to the machine option is
used.
The machine may only be operated by trained staff.
These Operating Instructions must be read and applied by every person engaged in
the operation, upkeep (maintenance, repair, servicing) or transport of this device.
These Operating Instructions contain important specifications and information on
how to safely, economically, professionally and correctly use the machine. Compli-
ance helps to prevent dangerous incidents, downtime and repair costs, while also im-
proving operational reliability, extending service life and safeguarding warranty cover.
Safety instructions and important notes are identified by the following pictograms:
Precedes safety instructions that must be observed in order to prevent danger to per-
sonnel.
$Precedes notes that must be observed to prevent damage to equipment.

Precedes general notes and explanations.
+ Used to indicate standard equipment.
& Used to indicate optional equipment.

V00.001.GB 2-2 01-04.07
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.
In the interest of continued development, the manufacturer reserves the right to make
changes to the machine (which will not, however, change the essential features of the
type of machine described) without updating the present operating instructions at the
same time.
Dynapac GmbH
Niederlassung Lingen
Darmer Esch 81
D-49811 Lingen/Germany
Tel.: +49 / (0)591 / 91275-0
Fax: +49 / (0)591 / 91275-99
www.dynapac.com

1
PL500/16S.GB 1-6 - 06.05
Table of Contents
A Correct use and application ................................................... 1
B Vehicle description ................................................................. 1
1 Application ................................................................................................. 1
2 Descriptions of assemblies and functions ..................................................2
2.1 Vehicle .......................................................................................................3
Construction ...........................................................................................3
3 Safety devices ............................................................................................5
Emergency-stop button ..........................................................................5
Horn .......................................................................................................5
Headlights, flashers, rotary beacons .....................................................6
Retaining hook, moldboard ....................................................................6
Limit switch on upper conveyor .............................................................7
4 Technical data, standard version ...............................................................8
4.1 Dimensions ................................................................................................8
4.2 Weights .................................................................................................... 10
4.3 Performance data ....................................................................................10
4.4 Engine ...................................................................................................... 11
4.5 Travel drive ..............................................................................................11
4.6 Hydraulic system ......................................................................................11
4.7 Water system ............................................................................................ 12
4.8 Loading system.........................................................................................12
4.9 Electrical system ......................................................................................12
5 Identification points and type plates .........................................................13
5.1 Type plate and vehicle identification number ........................................... 13
Type plate, machine ...........................................................................14
5.2 Identification points .................................................................................. 15
6 EN standards ...........................................................................................18
6.1 Continuous sound pressure level .............................................................18
6.2 Operating conditions during measurement ..............................................18
6.3 Arrangement of measuring points ............................................................18
6.4 Vibration acting on the entire body ..........................................................19
6.5 Vibrations acting on hands and arms .......................................................19
6.6 Electromagnetic compatibility (EMC) .......................................................19
C Transport ................................................................................. 1
1 Safety regulations for transport ..................................................................1
2 Fix points ....................................................................................................2
3 Transportation on low-bed trailers .............................................................3
4 Normal on-road travel ................................................................................ 4
5 Loading by crane .......................................................................................5
6 Towing .......................................................................................................6
7 Safely parking the vehicle ..........................................................................7

2
PL500/16S.GB 2-6 - 06.05
D Operation ................................................................................. 1
1 Safety regulations ...................................................................................... 1
2 Controls ......................................................................................................2
2.1 Operating panel ......................................................................................2
Sockets and interfaces on the operating panel ....................................32
3 Other controls ..........................................................................................34
3.1 Controls at operator’s control station .......................................................34
Setting up the control panel ................................................................ 34
Driver’s seat .........................................................................................35
Weather protecting sun roof ................................................................36
Side roof ..............................................................................................36
Weather-protecting sun roof, hydraulic (O) ..........................................37
Battery’s main switch ........................................................................... 38
Batteries ...............................................................................................38
Milling depth indicator ..........................................................................39
Swivel-mounted chassis leg ................................................................ 40
Swivel-mounted chassis leg, hydraulic (O) .......................................... 41
Retaining hook, moldboard ..................................................................42
Water scales / inclination indicator ...................................................... 43
Pressure gauge
Relief pressure for moldboard .............................................................43
Loading on sliding shoe ....................................................................... 44
Throttle valve, levelling unit .................................................................45
Direction of travel indicator .................................................................. 46
Working lights / rotary beacons ...........................................................47
Water system .......................................................................................48
Steps up to water tank .........................................................................49
Chocks .................................................................................................49
Non-return valve
Freewheel on milling drum ...................................................................49
Vandalism protection ...........................................................................50
4 Levelling unit ............................................................................................ 51
4.1 MOBA-matic type ..................................................................................... 51
5 Operating the MOBA-matic ......................................................................52
6 Operating the MOBA-matic ......................................................................54
6.1 Liquid crystal display (M1) ....................................................................... 58
Activation message .............................................................................. 58
Sensor message ..................................................................................59
Changeover between height sensor and lateral slope ......................... 59
LED display ..........................................................................................60
6.2 Actual value indicator (O) .........................................................................61
Connection: .......................................................................................... 63
Connection of MOBA-matic, actual value indicator and sensors .........65
Button usage and possible button combinations
on the digital controller during milling .................................................. 67
6.3 Basic settings ........................................................................................... 70
6.4 Calibration to zero ....................................................................................71
Initial situation for calibration to zero ................................................... 71
Other tasks .......................................................................................... 71
Calibration to zero for cable tension and Digi-Sonic sensors
when sensing the ground via the side boards. ....................................72

3
PL500/16S.GB 3-6 - 06.05
6.5 Actual value calibration ............................................................................ 73
Digi-Slope sensor (lateral slope sensor) ..............................................73
Initial situation for actual value calibration ........................................... 73
Other tasks .......................................................................................... 73
Height sensors (to correct the actual value to the value displayed) ....75
7 Operation .................................................................................................76
7.1 Preparing for operation ............................................................................76
Devices and aids .................................................................................76
Before starting work ............................................................................. 76
Checklist for machine operator ............................................................ 77
7.2 Starting the machine ................................................................................79
Auxiliary starting (electrical starting aid) .............................................. 81
............................................................................................................. 81
Allowing engine to „warm up“ .............................................................. 82
Driving the machine .............................................................................83
8 Milling instructions ....................................................................................84
„Driving“ position ..................................................................................84
„Milling“ position ................................................................................... 84
Zero setting .......................................................................................... 85
Surface milling .....................................................................................85
Milling on edge of road surface or on offsets ....................................... 86
Milling at the curb (with deployed chassis leg) ....................................86
Milling at the curb (with chassis leg retracted) ..................................... 87
Milling without automatic levelling device ............................................89
8.1 Operating the Moba-matic during milling .................................................91
Initial situation for operation .................................................................91
8.2 Other tasks for adopting the initial position for milling: ............................. 92
Milling with height sensors ...................................................................92
Milling with height sensors together with the transverse slope sensor 96
Ending the milling operation ................................................................98
Parking the machine ............................................................................99
Parking the machine for long periods of time .................................... 100
9 Scope for using the small planers .......................................................... 101
Remedying longitudinal and transverse bumps in the road surface .. 101
Remedying cracks ............................................................................. 101
Remedying potholes, frost damage ................................................... 101
Remedying damage to edges and bumps ......................................... 102
Producing adjoining edges ................................................................ 102
Producing slots, joints and cable trenches ........................................ 102
Removing embedded markings ......................................................... 103
Removing road markings ................................................................... 103
Re-establishing surface grip .............................................................. 103
10 Malfunctions ........................................................................................... 104
10.1 Error code retrieval for engine ............................................................... 104
Output of numerical code ................................................................... 104
Error codes ........................................................................................ 106
10.2 Error messages for anti-slip control ....................................................... 114
10.3 Travel drive error message ................................................................... 115
10.4 MOBA-Matic error messages ................................................................. 116

4
PL500/16S.GB 4-6 - 06.05
E Set-up and modification ......................................................... 1
1 Special notes on safety .............................................................................. 1
2 Planing without upper conveyor / Preparation for transport ....................... 2
2.1 Dismantling the upper conveyor ................................................................ 2
F Maintenance ............................................................................ 1
1 Notes regarding safety ............................................................................... 1
2 Liability is rendered null and void if non-genuine spares or wearing
parts or incorrect fuel substances are used. ..............................................2
3 Maintenance intervals ...............................................................................2
3.1 Power unit - engine ....................................................................................9
Fuel tank ................................................................................................ 9
Diesel engine ......................................................................................10
Oil changes ..........................................................................................11
Oil filter ................................................................................................. 11
Fuel filter ..............................................................................................12
Water drain point in fuel filter ...............................................................12
Bleeding the fuel system ...................................................................... 13
Air cleaner ...........................................................................................14
Radiator ...............................................................................................14
Radiator ...............................................................................................15
Drive belt ..............................................................................................16
3.2 Hydraulics ................................................................................................ 17
Hydraulic oil tank .................................................................................17
Changing the hydraulic oil ...................................................................18
Suction-return hydraulic filter ..............................................................19
Hydraulic hoses ...................................................................................19
3.3 Drive wheels, chassis legs ....................................................................... 20
Planetary gears ....................................................................................20
3.4 Milling section .......................................................................................... 22
Milling drum .........................................................................................22
Dismantling milling drum ......................................................................22
Milling bits, wearing sleeves, bit boxes ................................................24
SYSTEM KPF201 (o) ...........................................................................24
SYSTEM C10, C10HD (o) ...................................................................25
Dismantling the bits ............................................................................. 28
Installing the bits ..................................................................................28
Dismantling the wearing sleeves .........................................................29
Fitting the wearing sleeves ..................................................................30
Replacing the bit box ........................................................................... 31
Belt drive ..............................................................................................32
Clutch ................................................................................................... 33
Angle drive ........................................................................................... 34
Milling drum gear box ..........................................................................36
Side boards .......................................................................................... 38
Sliding shoes ....................................................................................... 38
Support plates ......................................................................................39
Moldboard / Scraper ............................................................................40
Milling box screw connections .............................................................41

5
PL500/16S.GB 5-6 - 06.05
3.5 Loading unit ............................................................................................. 42
Belt tension .......................................................................................... 42
Steel cables .........................................................................................44
Rubber funnel gasket at transfer point and rubber seals / guides .......44
3.6 Water system ........................................................................................... 45
Water tank ........................................................................................... 45
Remove water tank .............................................................................46
Water filter ...........................................................................................47
Spray nozzles ......................................................................................48
3.7 Power supply ........................................................................................... 49
Batteries ...............................................................................................49
3.8 Other ........................................................................................................50
Emergency-stop button ........................................................................ 50
Limit switch on upper conveyor ........................................................... 50
Chassis leg guide ................................................................................ 51
4 Lubricating points .....................................................................................52
Chassis leg, right ................................................................................. 52
Steering ...............................................................................................52
Belt tightener ........................................................................................53
Upper conveyor - swivel console ......................................................... 54
Hydraulic cylinder ................................................................................ 55
5 Inspections ............................................................................................... 56
General visual checks .......................................................................... 56
Checks by a specialist ......................................................................... 56
6 Lubrication agents and fuel substances ................................................... 57
6.1 Hydraulic oil .............................................................................................58
6.2 Filling volumes .........................................................................................59
7 Electric fuses ............................................................................................ 60
7.1 Main fuses (1) (behind the right-hand flap of the engine compartment) .60
7.2 Fuses and relays in the control panel ...................................................... 61
Fuses (2.) .............................................................................................62
Relays (3.) ...........................................................................................63
8 Tightening torques ...................................................................................64
9 Maintenance log ....................................................................................... 65
Notes on how to fill in the maintenance logs properly: ........................65
9.1 Assembly, engine, engine systems .......................................................... 66
9.2 Hydraulic system ......................................................................................67
9.3 Drive wheels, steering system, brakes ....................................................68
9.4 Milling section .......................................................................................... 69
9.5 Water system ........................................................................................... 70
9.6 Electrical system ......................................................................................71
9.7 Other equipment ......................................................................................72

A 1
A PL500/20S.GB 1-2 - 04.07
A Correct use and application

The Dynapac „Guideline for the intended and correct usage of cold planers“ falls with-
in the scope of supply of this machine. The guidelines are part of the present operat-
ing instructions and must always be heeded. National regulations are fully applicable.
The machine described in these Operating Instructions is a cold planer which can be
used as follows in enclosed building sites on roads:
- for partial removal of asphalt, asphalt-cement and layers of concrete
- to remove distortions in the form of track grooves, lateral bulges, lateral warps,
- to recreate a proper surface,
- to perform roughing and demarcation work,
- for use in preparatory work in pipeline and cable-laying work.
For this, the underlying base layer must be robust enough to withstand movement of
the cold planer.
The transportation of outsiders is expressly forbidden, as is using the cold planer as
a traction mechanism, winch or lifting device.
The intended usage also includes compliance with the operating, transport, mainte-
nance and repair conditions specified in the Operating Instructions.
The machine is not designed for any type of usage not described in the intended us-
age section. The manufacturer is not liable for such instances of use. The operator
alone bears all risks for such usage. When in doubt, contact the manufacturer.
Duties of the user: An operator, as defined in these Operating Instructions, is any
natural or judicial person who uses the cold planer himself or on whose behalf it is
used. In special circumstances (e.g. leasing, rental), the operator is that person who
is to observe the specified operating obligations in accordance with the contractual
agreements made between the owner and user of the cold planer.
The operator must ensure that the cold planer is only ever used for its intended pur-
pose and that risks of all kind to the health and safety at work of the operator or third
parties are prevented. In addition to this, it must be ensured that the relevant accident
prevention regulations and other safety-related provisions as well as the operating,
servicing and maintenance guidelines are observed. The user must also ensure that
all persons operating the paver finisher have read and understood the present oper-
ating instructions.

A 2
A PL500/20S.GB 2-2 - 04.07
Technical modifications, attachments and conversions: The cold planer may on-
ly be operated with the extension parts, optional equipment and accessories, protec-
tion and safety devices authorised by the manufacturer as well as the setting values
specified by the manufacturer. Autonomous changes to assemblies, their removal or
replacement with other unauthorised parts and any attempt to take these out of serv-
ice either completely or partially render null and void the manufacturer’s liability for
any resultant damage.
The attachment or installation of additional devices, which are used to intervene in
the function of the cold planer or with which its functions are supplemented, is only
permitted with the written approval of the manufacturer. If necessary, the approval of
local authorities has to be obtained.
Any approval obtained from local authorities does not, however, make the approval
by the manufacturer unnecessary.

B 1
B PL500/20S.GB 1-20 - 04.07
B Vehicle description
1 Application
The DYNAPAC PL 500/20 S cold planer is a compact and very manoeuvrable cold
planer with all-wheel drive and, depending on equipment standard, can be fitted with
either three or four drive wheels.
This cold planer was designed for tasks such as the partial removal of asphalt and
concrete and for preparatory work in pipeline and cable-laying operations.
The right-hand chassis leg can be folded in to allow for precision edge milling.
The extremely small turning circle means that the planer can work around drain cov-
ers.
The PL500/20 S meets European safety standards and complies with very high
standards in terms of reliability, cost-effectiveness and environmental compatibility.
Iso500_compl.wmf

B 2
B PL500/20S.GB 2-20 - 04.07
2 Descriptions of assemblies and functions
Item Designation
1Frame
2 Operator’s control station
3 Driver’s seat
4 Drive wheel
5 Chassis leg
6 Swivel-mounted chassis leg
7 Milling depth indicator
8 Water tank
9 Water spraying system
10 Weather protecting sun roof ( & )
11 Upper conveyor
PL500_compl.wmf
1
2
3
7
8
9
11
4
6
10
5
7

B 3
B PL500/20S.GB 3-20 - 04.07
2.1 Vehicle
Construction
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.
From the operator’s control station on the right-hand side of the machine, the planer
is easy and safe to operate, affording good visibility and corresponding ease of mon-
itoring for the milling process.
Controls at operator’s control station: A convenient operating and control element
comprising all the requisite switching and display elements.
The securely arranged controls are obviously marked for all applications.
The steering system involves the use of a steering wheel while travel is controlled by
means of a drive lever.
All requisite machine settings such as milling depth and slope control can be per-
formed comfortably from the operator’s control station.
Access to all major switching and connection points, as well as to all maintenance lo-
cations, can be locked.
Engine: The machine is fitted with a powerful 4-cylinder Cummins turbo diesel en-
gine which effortlessly covers the power requirements of the large planer.
The emission levels defined in the U.S. EPA and the European COM2 exhaust stand-
ards are all achieved. The engine covers are insulated from noise as standard, ena-
bling noise emissions to personnel and the surrounding area to be reduced to a
minimum.
Milling section: The hydraulically powered milling drum is located between the two
rear chassis legs. The right-hand chassis leg can be swivelled in front of the milling
drum.
The milling drum rotates in the opposite direction to the machine’s direction of travel.
The special-purpose bit arrangement equipped with the best bits ensures rapid and
clean cutting as well as high bit life.
On the standard drum, with a milling width of 500mm, bits can be replaced via the rear
milling drum flap, thereby keeping downtime to a minimum for replacement purposes.
The milling drum is bolted to the housing of the mechanical drive and can be replaced
easily and quickly after removing the right-hand housing plate.

B 4
B PL500/20S.GB 4-20 - 04.07
Milling depth control: milling depth control is performed hydraulically, and separate-
ly for each chassis leg.
To the left and right sides of the operator’s control station are two clearly legible mill-
ing depth indicators.
Traction unit, steering system, travel drive, brake: The suspension for both front
wheels takes the form of a parallel rocker arm arrangement which delivers an opti-
mum locating surface at all times.
The right-hand chassis leg can be swivelled in front of the milling drum.
The hydraulic all-wheel travel drive has continuously variable adjustment across two
speed ranges. The hydraulic travel drives are connected to the wheel hubs by means
of planetary gears. This ensures optimum feed and high gradeability.
A multi-disc brake on the rear wheels acts as brake.
Water system: The water system comprises a water spraying and cooling system.
The water spraying and cooling system operates in the low pressure range. This sys-
tem is used for cooling and jetting the milling bits.
The spray nozzles can be easily replaced.
The water tank has a high capacity and has good access for filling from the top.
Loading unit: The cold planer attachment is designed as a rear-loading unit and fea-
tures a one-piece load transfer system.
Final loading of material occurs from the upper conveyor to the transport container or
some other loading area outside the milling lane. The belt is wide and its transport
speed can be varied. As part of this process, the operating speed of the upper con-
veyor can be varied across an infinite range from zero to maximum setting.
The belt can then be changed quickly and easily.
The height of the upper conveyor can be adjusted hydraulically over a wide range of
heights and the conveyor can also be swivelled to quite a sharp angle on both sides.
The full-length cover substantially reduces the dust burden.
The upper conveyor can be dismantled / assembled very rapidly and can be erected
on four integrated legs.
As an option, a short version of this loading belt can be supplied which can be used
for applications such as the loading of material straight into the shovel on a wheel
loader.
Hydraulic system: The drive unit, actuator functions and steering system are oper-
ated by independent hydraulic circuits ideally suited to the machine.
Electrical system: 24 volt system with two in-line cold-start high-performance batter-
ies and a 3-phase alternator.
The power supply can be interrupted to ground/earth by the battery’s main switch.

B 5
B PL500/20S.GB 5-20 - 04.07
3 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-
tem are shut down when the emergen-
cy-stop button is pressed. Any
countermeasures which may be re-
quired (manoeuvring, deploying the
chassis legs) are then no longer pos-
sible! Danger of accidents!
$The EMERGENCY STOP button is not
used for normal shut-down of the engine
and should only be used in emergencies
or for inspection purposes.

The traction unit brakes are applied whenever an emergency stop button is pressed!
Horn
- On the control panel
Before starting up the machine, press
the horn button to issue a warning sig-
nal.
Panel2_500_20S_v2.bmp
Panel3_V2.bmp

B 6
B PL500/20S.GB 6-20 - 04.07
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.
The function of the headlights and warn-
ing lamps should be checked on a daily
basis before starting work.

The headlights are easy to remove and
should therefore, as a safety precaution,
be removed at the end of work and
stored in a safe location.
$Headlight contacts which are not used
should be protected using rubber caps.
Retaining hook, moldboard
- Retaining tab on moldboard and re-
taining hook on machine frame en-
gage with one another in raised
position.

Secures the moldboard to prevent it
from being lowered accidentally.
Panel2_500_20S_v2.bmp/Iso500_compl_short.wmf
Scraper_safety_pl600

B 7
B PL500/20S.GB 7-20 - 04.07
Limit switch on upper conveyor
A limit switch on the frame of the upper
conveyor prevents unfavourable load
levels arising from excessive raising ac-
tion.
Limit_PL600.wmf

B 8
B PL500/20S.GB 8-20 - 04.07
4 Technical data, standard version
4.1 Dimensions
PL500_measure_side_long.wmf, PL500_measure_top_long.wmf