Dynapac PL2000S User manual

900 98 04 83
Cold planer
PL2000S
PL2100S
Operating instructions Valid for:
02-10.01

V00.001.GB 1-2 10.01
Foreword
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.
In order to prevent misunderstanding when making inquiries, during consultations,
when placing orders etc. , please always use the terms specified in the Operating In-
structions.
These Operating Instructions document various options. During operation and when
undertaking maintenance work, ensure that the description appropriate for the option
in question is used.
The machine may only be operated by trained staff.
These Operating Instructions should be read and applied by everyone who has been
assigned tasks involving the operation, recondition (maintenance, repairs, inspec-
tion) or transport of the machine.
These Operating Instructions contain important specifications and information on
how to safely, economically, professionally and correctly use the machine. Compli-
ance with these instructions will help to prevent dangerous situations, reduce down-
times and repair costs, to increase reliability during usage and the service life and to
ensure compliance with the warranty terms.
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.

V00.001.GB 2-2 10.01
The Operating Instructions must always be available at the machine’s operating site.
They are valid in conjunction with the Dynapac safety manual, the information on in-
tended 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

I 1
PL2000_GBIVZ.fmI 1-4 - 10.01
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 .......................................................................................................4
Assembly ...............................................................................................4
3 Safety devices ..........................................................................................12
Emergency-stop button ........................................................................12
Horn ..................................................................................................... 13
Headlights, indicators rotary beacons ..................................................14
Hazard warning lights on side panels (O) ............................................15
Reverse lights and folding warning signs, reverse warning device, ....15
Traction unit supports ..........................................................................16
Steel retaining cables ..........................................................................17
Retaining hook of scraper flap .............................................................17
Limit switch of scraper flap ..................................................................17
Scraper flap safeguard .......................................................................18
Exit ladders, grab bars and guardrails .................................................18
Side shield ...........................................................................................18
4 Technical data, standard version .............................................................19
4.1 Dimensions .............................................................................................. 19
4.2 Weights ....................................................................................................21
4.3 Performance data ....................................................................................21
4.4 Loading system ......................................................................................21
4.5 Engine ......................................................................................................22
4.6 Travel drive .............................................................................................. 22
4.7 Hydraulic system ......................................................................................22
4.8 Water system ............................................................................................ 23
4.9 Compressed air system ............................................................................24
4.10 Electrical system ......................................................................................24
5 Identification points and type plates ......................................................... 25
5.1 Type plate and vehicle identification number ...........................................25
Type plate, machine ..........................................................................26
Serial number of discharge conveyor ................................................26
5.2 Identification points .................................................................................. 27
6 European standards .................................................................................33
6.1 Permanent noise level .............................................................................33
6.2 Operating conditions during the measurements ...................................... 33
6.3 Arrangement of measuring points ............................................................33
6.4 Vibration acting on the entire body .......................................................... 34
6.5 Vibration acting on the hand-arm .............................................................34
6.6 Electromagnetic compatibility (EMC) .......................................................34

I 2
PL2000_GBIVZ.fm 2-4 - 10.01
C Transport ................................................................................. 1
1 Safety regulations for transport ..................................................................1
2 Fix points .................................................................................................... 2
3 Transport on trailers ................................................................................... 3
4 Normal on-road travel ................................................................................6
5 Articulation procedure of foldable upper conveyor (O) .............................7
5.1 Folding in the upper conveyor ....................................................................7
5.2 Unfolding the upper conveyor ....................................................................9
6 Hydraulically foldable upper conveyor (O) ...............................................11
6.1 Folding out upper conveyor .....................................................................13
7 Loading by crane .....................................................................................14
8 Towing procedure ....................................................................................15
9 Secure before parking up .........................................................................16
D Operation ................................................................................. 1
1 Safety regulations ......................................................................................1
2 Controls ......................................................................................................2
3 Controls ......................................................................................................4
3.1 Control panel ..............................................................................................4
3.2 Switch panel ...............................................................................................8
Display indicator and menu operation .................................................34
Basic settings on the display ............................................................... 36
Operation, displays and setting options in the menu ...........................38
The basics of terminal operation ..........................................................39
Information and warning messages .....................................................41
Setting options ..................................................................................... 50
Other displays ......................................................................................55
Screen structure for setting and display options ..................................57
3.3 Error messages and warnings .................................................................58
Engine warnings (I) ..............................................................................58
Engine fault codes ...............................................................................59
Engine warnings (II) .............................................................................66
Warnings for hydraulic and water circuits ............................................69
Error messages, electrical system .......................................................70
Other possible error messages and warnings .....................................76
3.4 Lower rear control panel ..........................................................................79
3.5 Front lower control panel .........................................................................85

I 3
PL2000_GBIVZ.fmI 3-4 - 10.01
4 Controls ....................................................................................................91
4.1 Controls at operator’s control station .......................................................91
Driver’s seat on left / right ....................................................................91
Battery’s main switch ........................................................................... 92
Batteries ............................................................................................... 92
Windscreen wipers ..............................................................................93
Tilt display ............................................................................................ 93
Folding ladder ......................................................................................94
Guardrail ..............................................................................................95
Hydraulic folding roof operations ......................................................... 96
Hydraulic hood operations ...................................................................97
Throttle valves for deployment speed of hood and roof .......................98
Throttle valve for lowering speed of discharge conveyor .....................98
High pressure cleaner ..........................................................................99
4.2 Controls, vehicle frame .......................................................................... 100
Filling pump for water tank ................................................................ 100
Water filling (pressure fill) connection for water tank ......................... 101
Changeover for separate circuits of rear strut towers ........................ 102
Grading depth display ........................................................................ 103
Milling drum operational check .......................................................... 103
Ultrasonic sensor on side shield (optional) ........................................ 104
Reflector on ultrasonic sensor (optional) .......................................... 104
Interlock on scraper flap .................................................................... 105
Retaining hook of scraper flap ...........................................................105
Limit switch of scraper flap ................................................................106
Traction unit supports ........................................................................ 107
Support brackets ................................................................................ 107
"Scraper flap function changeover" valve .......................................... 108
Scraper flap throttle valves ................................................................ 109
"Upper conveyor function changeover" valve .................................... 109
Monitoring camera (o) ........................................................................ 110
Compressed air system ..................................................................... 111
Storage area and protective flaps ...................................................... 112
Plumbline fixture ................................................................................ 113
Swivel-mounted warning sign ............................................................114
Tool holder ......................................................................................... 114

I 4
PL2000_GBIVZ.fm 4-4 - 10.01
5 Levelling unit .......................................................................................... 115
5.1 MOBA-matic type ................................................................................... 115
6 Operating the MOBA-matic .................................................................... 116
6.1 Liquid crystal display (1) ........................................................................ 120
Activation message ............................................................................ 120
Sensor message ................................................................................ 121
LED display ........................................................................................ 122
Connection: ........................................................................................ 123
Equipping with other sensors / conversion ........................................ 125
Button usage and possible button combinations
on the digital controller during milling ................................................ 127
6.2 Basic settings ......................................................................................... 129
6.3 Calibration to zero .................................................................................. 130
Initial situation for calibration to zero .................................................130
Other tasks ........................................................................................ 130
Calibration to zero for cable tension and Digi-Sonic sensors
when sensing the ground via the side boards. .................................. 131
Calibration to zero for the Sonic-Ski during ground sensing .............. 132
Calibration to zero for the Sonic-Ski during cable sensing ................ 133
Calibration to zero of the Digi-Rotary sensor (rotary arm sensor)
during cable sensing .......................................................................... 134
Calibration to zero for the laser receiver LS 250 ...............................135
6.4 Actual value calibration .......................................................................... 136
Digi-Slope sensor (transverse slope sensor) ..................................... 136
Initial situation for actual value calibration ......................................... 136
Other tasks ........................................................................................ 136
Height sensors ................................................................................... 139
6.5 Other settings ......................................................................................... 140
6.6 Operating the Moba-matik during milling ...............................................142
Initial situation for operation ............................................................... 142
6.7 Other tasks for adopting the initial position for milling: ........................... 143
Milling with height sensors ................................................................. 143
Milling with height sensors together with the transverse slope sensor145
6.8 MOBA-Matic error messages ................................................................. 146
7 Operation ............................................................................................... 147
7.1 Preparing for operation .......................................................................... 147
Devices and aids ............................................................................... 147
Before starting work ........................................................................... 147
Checklist for machine operator .......................................................... 148
7.2 Starting the machine .............................................................................. 151
External starting (starting aid) ............................................................ 153
Allowing engine to "warm up" ............................................................ 154
Driving the machine ........................................................................... 155
Milling (preparation) ........................................................................... 157
Milling ................................................................................................. 159
Milling operations using set-up button ...............................................160
Ending the milling procedure ............................................................. 161
Parking the machine .......................................................................... 163
Parking the machine for long periods of time .................................... 164
8 Emergency steering unit ........................................................................ 165

A 1
A PL2000.GB 1-2 - 10.01
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.
The machine described in these Operating Instructions is a cold planer which can be
used as follows in enclosed building sites on roads:
- to partially or completely remove asphalt, asphalt based and cement layers
- to remove distortions in the form of track grooves, lateral bulges, lateral warps,
- to recreate a proper surface,
- to implement roughing up and stripping 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.
Obligations of the operator: An operator, as defined in these Operating Instruc-
tions, 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 used for its intended purpose
and that all kinds of risk to the life, limb and health of users or third parties are pre-
vented. Compliance must also be maintained with the accident prevention regula-
tions, all technical safety rules as well as the operating, maintenance and repair
guidelines. The operator must ensure that all users have read and understood these
Operating Instructions.

A 2
A PL2000.GB 2-2 - 10.01
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 va-
lues specified by the manufacturer. The manufacturer is not liable for damage
resulting from unauthorised changes to the assemblies, their removal or their repla-
cement with other, non-intended components or taking them completely or partially
out of operation.
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, approval should
be sought from the local authorities.
Consent from the authorities is however no substitute for approval from the manufac-
turer.