Dynapac PL 1000 RS Troubleshooting guide

502........................
02-0407
OPERATION
&
MAINTENANCE
Keep this manual for future reference
Order number for this manual: 900 98 12 29
Gültig ab Seriennummer:xxx.xxx
Cold Planer
PL 1000 RS

VALUE
QUALITY
THE ORIGINAL
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SPARE PARTS

V00.003.D V_PL1000RS_GB.fm- 02.04.07
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.
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 document various options. During operation and when
carrying out maintenance work, always ensure that the appropriate description for
that option is employed.
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 information and important explanations are identified by the following picto-
grams:
Stands for safety information which must be observed in order to prevent dangers af-
fecting operators.
$Stands for information which must be observed in order to prevent material damage.

Stands for information and explanations.
+ Identifies standard equipment.
& Identifies optional equipment.

V00.003.D V_PL1000RS_GB.fm- 02.04.07
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 further technical development, the manufacturer reserves the right
to undertake modifications while retaining the key features of the machine type de-
scribed and to do so without correcting these Operating Instructions.
Dynapac GmbH
Wardenburg
Ammerländer Strasse 93
D-26203 Wardenburg / Germany
Tel.: +49 / (0)4407 / 972-0
Fax: +49 / (0)4407 / 972-228
www.dynapac.com

1
PL1000RS_GBIVZ.fm 1-6 - 04.07
Table of contents
A Intended usage ........................................................................ 1
B Vehicle description ................................................................. 1
1 Description of usage ..................................................................................1
2 Descriptions of assemblies and functions ..................................................2
2.1 Vehicle ....................................................................................................... 3
Assembly ...............................................................................................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 ...................................................................................................... 9
4.3 Performance data ......................................................................................9
4.4 Engine ...................................................................................................... 10
4.5 Travel drive .............................................................................................. 10
4.6 Hydraulic system ...................................................................................... 10
4.7 Water system ............................................................................................ 11
4.8 Loading system.........................................................................................11
4.9 Electrical system ......................................................................................11
5 Identification points and type plates ......................................................... 12
5.1 Type plate and vehicle identification number ........................................... 12
Type plate, machine ........................................................................... 13
5.2 Identification points ..................................................................................14
6 European standards .................................................................................17
6.1 Permanent sound-pressure level .............................................................17
6.2 Operating conditions during the measurements ...................................... 17
6.3 Arrangement of measuring points ............................................................ 17
6.4 Vibration acting on the entire body .......................................................... 18
6.5 Vibration acting on the hand-arm .............................................................18
6.6 Electromagnetic compatibility (EMC) ....................................................... 18
C Transport ................................................................................. 1
1 Safety regulations for transport ..................................................................1
2 Fix points .................................................................................................... 2
3 Transport on trailers ................................................................................... 3
4 Normal on-road travel ................................................................................4
5 Loading by crane ....................................................................................... 5
6 Towing procedure ......................................................................................6
7 Secure before parking up ........................................................................... 7

2
PL1000RS_GBIVZ.fm 2-6 - 04.07
D Operation ................................................................................. 1
1 Safety regulations ......................................................................................1
2 Controls ......................................................................................................2
2.1 Control panel .............................................................................................. 2
3 Other controls ..........................................................................................32
3.1 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 ........................................................................... 35
Batteries ...............................................................................................35
Milling depth display ............................................................................ 36
Swivel-mounted chassis leg ................................................................37
Swivel-mounted chassis leg, hydraulic (o) ...........................................37
Retaining hook, moldboard .................................................................. 38
Water scales / inclination indicator ...................................................... 39
Throttle valve, levelling unit .................................................................40
Load relief of moldboard ...................................................................... 40
Direction of travel indicator .................................................................. 41
Working lights / rotary beacons ...........................................................42
Non-return valves for water spraying / drain valve on water tank ........43
Setting valve for water pressure (water spraying) ...............................44
Steps up to water tank ......................................................................... 44
Chocks .................................................................................................45
Vandalism protection ...........................................................................46
4 Levelling unit ............................................................................................47
4.1 MOBA-matic type .....................................................................................47
5 Operating the MOBA-matic ......................................................................48
6 Operating the MOBA-matic ......................................................................50
6.1 Liquid crystal display (M1) .......................................................................54
Activation message .............................................................................. 54
Sensor message ..................................................................................55
Changeover between height sensor and lateral slope .........................55
LED display .......................................................................................... 56
6.2 Actual value indicator (O) .........................................................................57
Connection: ..........................................................................................59
Connection of MOBA-matic, actual value indicator and sensors ......... 61
Button usage and possible button combinations on the digital
controller during milling ........................................................................ 63
automatic mode - „AUTO“ function lamp on. ......................................63
6.3 Basic settings ........................................................................................... 66
6.4 Calibration to zero ....................................................................................67
Initial situation for calibration to zero ...................................................67
Other tasks .......................................................................................... 67
Calibration to zero for cable tension and Digi-Sonic sensors
when sensing the ground via the side boards. ....................................68
6.5 Actual value calibration ............................................................................69
Digi-Slope sensor (lateral slope sensor) .............................................. 69
Initial situation for actual value calibration ........................................... 69
Other tasks .......................................................................................... 69
Height sensors (to correct the actual value to the value displayed) ....71

3
PL1000RS_GBIVZ.fm 3-6 - 04.07
7 Operation .................................................................................................72
7.1 Preparing for operation ............................................................................72
Devices and aids .................................................................................72
Before starting work ............................................................................. 72
Checklist for machine operator ............................................................73
7.2 Starting the machine ................................................................................ 74
Auxiliary starting (electrical starting aid) .............................................. 76
.............................................................................................................76
Allowing engine to „warm up“ .............................................................. 77
Driving the machine ............................................................................. 78
8 Milling instructions ....................................................................................79
„Driving“ position .................................................................................. 79
„Milling“ position ................................................................................... 79
Zero setting .......................................................................................... 80
Surface milling ..................................................................................... 80
Milling at the edge of the lane or at steps ............................................81
Milling at the curb (with deployed chassis leg) .................................... 81
Milling at the curb (with chassis leg swivelled in) .................................82
Planing without automatic levelling device ..........................................84
8.1 Operating the Moba-matic during milling .................................................86
Initial situation for operation ................................................................. 86
8.2 Other tasks for adopting the initial position for milling: ............................. 87
Milling with height sensors ...................................................................87
Milling with height sensors together with the transverse slope sensor 91
Ending the milling procedure ...............................................................93
Parking the machine ............................................................................ 94
Parking the machine for long periods of time ......................................95
9 Scope for using the small planers ............................................................96
Remedying longitudinal and transverse bumps in the road surface .... 96
Remedying cracks ...............................................................................96
Remedying potholes, frost damage ..................................................... 96
Remedying damage to edges and bumps ...........................................97
Producing adjoining edges .................................................................. 97
Producing slots, joints and cable trenches .......................................... 97
Removing embedded markings ........................................................... 98
Removing road markings ..................................................................... 98
Re-establishing surface grip ................................................................98
10 Malfunctions ............................................................................................. 99
10.1 Error code query for engine ..................................................................... 99
Output of the numerical code ...............................................................99
Error codes ........................................................................................ 101
10.2 Error messages for anti-slip control ....................................................... 109
10.3 Error message from travel drive ............................................................. 110
10.4 MOBA-Matic error messages ................................................................. 111
E Set-up and modification ......................................................... 1
1 Special safety instructions .........................................................................1
2 Planing without upper conveyor / Preparation for transport .......................2
2.1 Dismantling the upper conveyor ................................................................ 2

4
PL1000RS_GBIVZ.fm 4-6 - 04.07
F Maintenance ............................................................................ 1
1 Safety regulations for maintenance ........................................................... 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
Draining water from the fuel filter ......................................................... 12
Bleed 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
Pump-pedestal .....................................................................................20
3.3 Drive wheels, chassis legs .......................................................................21
Planetary gears ....................................................................................21
3.4 Milling section .......................................................................................... 23
Milling drum .........................................................................................23
Dismantling milling drum ...................................................................... 23
Bits, wearing sleeves, bit blocks .......................................................... 25
SYSTEM KPF201 (o) ........................................................................... 25
SYSTEM KPF301 (o) ........................................................................... 26
Dismantling the bits .............................................................................29
Installing the bits ..................................................................................29
Dismantling the wearing sleeves .........................................................30
.............................................................................................................30
Fitting the wearing sleeves .................................................................. 32
Replacing the bit box ........................................................................... 33
Belt drive ..............................................................................................34
Clutch ...................................................................................................35
Angular gear ........................................................................................ 36
Milling drum gearbox ...........................................................................38
Side boards ..........................................................................................40
Sliding shoes .......................................................................................40
Support plates ...................................................................................... 41
Moldboard / Scraper ............................................................................42
Fräskasten-Schraubenverbindungen ...................................................43

5
PL1000RS_GBIVZ.fm 5-6 - 04.07
3.5 Loading unit ............................................................................................. 44
Belt tension ..........................................................................................44
Steel cables .........................................................................................46
Rubber funnel gasket at transfer point and rubber seals / guides ....... 46
3.6 Water system ........................................................................................... 47
Water tank ........................................................................................... 47
Remove water tank ..............................................................................48
Water filter ........................................................................................... 49
Spray nozzles ......................................................................................50
3.7 Power supply ........................................................................................... 51
Batteries ...............................................................................................51
3.8 Other ........................................................................................................52
Emergency-stop button ........................................................................52
Limit switch on upper conveyor ...........................................................52
Chassis leg guide ................................................................................ 53
4 Lubricating points .....................................................................................54
Chassis leg, right side ..........................................................................54
Steering system ................................................................................... 54
Belt tensioner ....................................................................................... 55
Hydraulic cylinder ................................................................................56
5 Inspections ............................................................................................... 57
General visual inspection .....................................................................57
Inspection by a specialist .....................................................................57
6 Lubrication agents and fuel substances ................................................... 58
6.1 Hydraulic oil ............................................................................................. 59
6.2 Filling volumes .........................................................................................60
7 Electrical fuses .........................................................................................61
7.1 Main fuses (1) (behind the right-hand flap of the engine compartment) .. 61
7.2 Fuses on the operating panel .................................................................. 62
7.3 Fuses in the operating panel ....................................................................64
8 Tightening torques ...................................................................................65
9 Maintenance log .......................................................................................66
Notes on how to fill in the maintenance logs properly: ........................66
9.1 Assembly, engine, engine systems .......................................................... 67
9.2 Hydraulic system ...................................................................................... 68
9.3 Drive wheels, steering system, brakes ....................................................69
9.4 Milling section .......................................................................................... 70
9.5 Water system ........................................................................................... 71
9.6 Electrical system ......................................................................................72
9.7 Other equipment ...................................................................................... 73