Caterpillar PM820 PM822 PM825 Cold Planer Workshop Repair Service Manual PDF - MCATPM820PM825.zip
A full factory-style service and repair guide, complete with Electrical Wiring Diagrams, covering the Caterpillar PM820, PM822, and PM825 Cold Planers — packed with every technical detail needed to service, troubleshoot, fix, and rebuild these machines just like a seasoned technician would.
Inside the workshop service and repair manual for the Caterpillar PM820, PM822, and PM825 Cold Planers, you'll find:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PM820 COLD PLANER AK5
PM820 COLD PLANER AN8
PM820 COLD PLANER HN8
PM820 COLD PLANER RL3
PM820 COLD PLANER TLZ
PM822 COLD PLANER E8S
PM822 COLD PLANER EE2
PM822 COLD PLANER H6S
PM822 COLD PLANER JB7
PM822 COLD PLANER SL8
PM825 COLD PLANER 3C6
PM825 COLD PLANER 626
PM825 COLD PLANER 627
PM825 COLD PLANER ESE
PM825 COLD PLANER HC8
M0068306 - Systems Operation (PM310; PM312; PM313; PM620; PM622; PM820; PM822; and PM825 Cold Planer Monitoring System_Grade and Slope).pdf
M0068306 - Systems Operation, Testing and Adjusting & Troubleshooting (PM310; PM312; PM313; PM620; PM622; PM820; PM822; PM825 Cold Planer Monitoring System_Grade & Slope).pdf
M0068306 - Testing and Adjusting (PM310; PM312; PM313; PM620; PM622; PM820; PM822; and PM825 Cold Planer Monitoring System_Grade and Slope).pdf
M0068306 - Troubleshooting (PM310; PM312; PM313; PM620; PM622; PM820; PM822; and PM825 Cold Planer Monitoring System_Grade and Slope).pdf
M0082957 - Disassembly and Assembly (PM820; PM822; and PM825 Cold Planer Machine Systems).pdf
M0082958 - Disassembly and Assembly (PM820; PM822; and PM825 Cold Planer Engine Supplement).pdf
UENR6291 - Specifications (PM620; PM622; PM820 and PM822 and PM825 Cold Planer Power Train).pdf
UENR6292 - Systems Operation (PM620; PM622; PM820; PM822 and PM825 Cold Planer Propel Systems).pdf
UENR6292 - Testing and Adjusting (PM620; PM622; PM820; PM822 and PM825 Cold Planer Propel Systems).pdf
UENR6293 - Specifications (PM620; PM622; PM820 and PM822 and PM825 Cold Planer Machine Systems).pdf
UENR6294 - Systems Operation (PM620; PM622; PM820; PM822 and PM825 Cold Planer Machine System).pdf
UENR6294 - Testing and Adjusting (PM620; PM622; PM820; PM822 and PM825 Cold Planer Machine System).pdf
UENR6406 - Systems Operation (PM620; PM622; PM820; PM822 and PM825 Cold Planers Electronic System).pdf
UENR6406 - Troubleshooting (PM620; PM622; PM820; PM822 and PM825 Cold Planers Electronic System).pdf
UENR8361 - Schematic (PM820; PM822 and PM825 Cold Planer Hydraulic System).pdf
UENR8362 - Schematic (PM820; PM822 and PM825 Cold Planer Electrical System; Power Distribution Circuit Board; Platform and Chassis; Control Cabinet and Power Distribution; Machine; Engine).pdf
PRODUCT DETAILS:
Total Pages: 2,221 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
M0068306 - Systems Operation (PM310; PM312; PM313; PM620; PM622; PM820; PM822; and PM825 Cold Planer Monitoring System_Grade and Slope)....1
Display Navigation....2
Left Hand Buttons....14
Grade and Slope....27
Display Settings....83
Menu Navigation....96
Machine Settings Menu....113
Service Test Menu....138
Pop-Up Messages....160
M0068306 - Systems Operation, Testing and Adjusting & Troubleshooting (PM310; PM312; PM313; PM620; PM622; PM820; PM822; PM825 Cold Planer Monitoring System_Grade & Slope)....168
Systems Operation....169
Display Navigation....170
Left Hand Buttons....182
Grade and Slope....195
Display Settings....250
Menu Navigation....263
Machine Settings Menu....280
Service Test Menu....294
Pop-Up Messages....316
Testing and Adjusting....324
Troubleshooting....331
General Information....332
Service Tools....333
Diagnostic Capabilities....335
Determining Diagnostic Trouble Codes....339
Diagnostic Trouble Codes....344
Event Codes....345
CAN Data Link - Test....349
M0068306 - Testing and Adjusting (PM310; PM312; PM313; PM620; PM622; PM820; PM822; and PM825 Cold Planer Monitoring System_Grade and Slope)....359
M0068306 - Troubleshooting (PM310; PM312; PM313; PM620; PM622; PM820; PM822; and PM825 Cold Planer Monitoring System_Grade and Slope)....366
General Information....367
Service Tools....368
Diagnostic Capabilities....370
Determining Diagnostic Trouble Codes....374
Diagnostic Trouble Codes....379
Event Codes....380
CAN Data Link - Test....384
M0082957 - Disassembly and Assembly (PM820; PM822; and PM825 Cold Planer Machine Systems)....394
Operator Console - Remove and Install....399
Seat - Remove and Install....404
Operator Platform - Remove and Install....407
Hood - Remove and Install - Left....410
Hood - Remove and Install - Right....412
Access Door - Remove and Install - Rotor Chamber....415
Fuel Tank - Remove and Install....419
Hydraulic Oil Filter (Return) - Remove and Install....423
Hydraulic Oil Tank - Remove and Install....426
Hydraulic Oil Filter (Hydraulic Tank and Travel) - Remove and Install....432
Hydraulic Cylinder (Hood Lift) - Remove and Install....434
Electric Drive Pump (Auxiliary) - Remove and Install....436
Rotor Drive Motor (Auxiliary) - Remove and Install....439
Piston Pump (Auxiliary) - Remove and Install....442
Piston Pump (Hydraulic Fan) - Remove and Install....445
Piston Pump (Hydraulic Fan) - Disassemble....451
Piston Pump (Hydraulic Fan) - Assemble....467
Piston Motor (Hydraulic Fan) - Disassemble....484
Piston Motor (Hydraulic Fan) - Assemble....493
Control Valve - Remove and Install - Rear....502
Piston Pump (Propel) - Remove and Install....504
Piston Pump (Propel) - Disassemble....507
Piston Pump (Propel) - Assemble....518
Piston Motor (Propel) - Remove and Install....530
Piston Motor (Propel) - Disassemble....534
Piston Motor (Propel) - Assemble....549
Flow Control Valve - Remove and Install - Front....563
Flow Control Valve - Remove and Install - Rear....566
Final Drive Planetary - Remove and Install....569
Final Drive Planetary - Disassemble....572
Final Drive Planetary - Assemble....581
Rotor Drive Clutch - Remove and Install....591
Rotor Drive Clutch - Disassemble....594
Rotor Drive Clutch - Assemble....606
Rotor Drive Planetary - Remove and Install....619
Rotor Drive Planetary - Disassemble....621
Rotor Drive Planetary - Assemble....635
Belt Guard (Rotor Drive) - Remove and Install....650
V-Belt (Rotor Drive) - Remove and Install....653
Rotor Chamber - Remove and Install....654
Rotor - Remove and Install....664
Upper Sheave (Rotor Drive) - Remove and Install....669
Lower Sheave (Rotor Drive) - Remove and Install....671
Hydraulic Cylinder (Rotor Drive Idler Tensioner) - Remove and Install....673
Cutting Edge (Moldboard) - Remove and Install....675
Moldboard - Remove and Install....677
Wear Plate (Rotor Chamber) - Remove and Install....682
Side Plate - Remove and Install - Left Hand....683
Side Plate - Remove and Install - Right Hand....686
Antislab - Remove and Install....688
Hydraulic Cylinder - Remove and Install - Rear Door....692
Hydraulic Cylinder - Remove and Install - Left Antislab....694
Hydraulic Cylinder - Remove and Install - Right Antislab....697
Hydraulic Cylinder (Moldboard Lift) - Remove and Install....700
Hydraulic Cylinder (Moldboard Lift) - Disassemble....703
Hydraulic Cylinder (Moldboard Lift) - Assemble....706
Hydraulic Cylinder (Rear Door) - Remove and Install....709
Hydraulic Cylinder (Left Rear Side Plate) - Remove and Install....711
Hydraulic Cylinder (Left Front Side Plate) - Remove and Install....713
Hydraulic Cylinder (Right Front Side Plate) - Remove and Install....715
Hydraulic Cylinder (Right Rear Side Plate) - Remove and Install....717
Hydraulic Cylinder (Side Plate) - Disassemble....719
Hydraulic Cylinder (Side Plate) - Assemble....722
Hydraulic Cylinder (Front Toe) - Remove and Install....725
Hydraulic Cylinder (Rear Toe) - Remove and Install....728
Hydraulic Cylinder (Front Steering) - Remove and Install....731
Hydraulic Cylinder (Rear Steering) - Remove and Install....734
Hydraulic Cylinder (Rear Steering) - Disassemble....737
Hydraulic Cylinder (Rear Steering) - Assemble....740
Counterbalance Valve - Remove and Install - Steering Valve....743
Steering Bearing and Mounting - Remove and Install....745
Hydraulic Cylinder (Elevation) - Remove and Install - Rear....749
Hydraulic Cylinder (Elevation) - Remove and Install - Front....754
Hydraulic Cylinder (Elevation) - Disassemble....758
Hydraulic Cylinder (Elevation) - Assemble....761
Pump Drive - Remove and Install....764
Pump Drive - Disassemble....773
Pump Drive - Assemble....787
Coupling - Remove and Install....800
Gear Pump (Charge) - Remove and Install....803
Gear Pump (Charge) - Disassemble....805
Gear Pump (Charge) - Assemble....808
Hydraulic Cylinder (Conveyor Fold) - Remove and Install....812
Conveyor Idler (First Stage) - Remove and Install....816
Conveyor Roller (First Stage) - Remove and Install....817
Conveyor Pulley (Head; First Stage) - Remove and Install....818
Conveyor Pulley (Tail; First Stage) - Remove and Install....820
Conveyor (First Stage) - Remove and Install....821
Conveyor Belt (Second Stage) - Remove and Install....827
Conveyor Idler (Second Stage) - Remove and Install....839
Conveyor Roller (Second Stage) - Remove and Install....841
Conveyor Pulley (Head; Second Stage) - Remove and Install....842
Conveyor Pulley (Tail; Second Stage) - Remove and Install....843
Conveyor (Second Stage) - Remove and Install....845
Conveyor Pivot - Remove and Install....850
Flashing (Conveyor) - Remove and Install....854
Gerotor Motor (Second Stage Conveyor) - Remove and Install....855
Gerotor Motor (Second Stage Conveyor) - Disassemble....858
Gerotor Motor (Second Stage Conveyor) - Assemble....862
Hydraulic Cylinder (Conveyor Swing) - Remove and Install....866
Hydraulic Cylinder (Conveyor Lift) - Remove and Install....869
Gerotor Motor (First Stage Conveyor) - Remove and Install....871
Piston Pump (Conveyor) - Remove and Install....874
Piston Pump (Conveyor) - Disassemble....876
Piston Pump (Conveyor) - Assemble....887
Track - Separate....899
Track - Connect....903
Track Roller Frame - Remove and Install....906
Track Roller - Remove and Install....911
Hydraulic Cylinder (Track_Belt Tension) - Remove and Install....913
Hydraulic Cylinder (Track_Belt Tension) - Disassemble....914
Hydraulic Cylinder (Track_Belt Tension) - Assemble....918
Track Idler - Remove and Install....922
Wear Pad (Track Frame) - Remove and Install....924
Drive Sprocket - Remove and Install....926
Water Spray Pump - Remove and Install....928
Washdown Hose Reel - Remove and Install - High Pressure....931
Washdown Hose Reel - Remove and Install - Low Pressure....933
Spray Bar - Remove and Install - Rotor Chamber....935
Gear Motor - Remove and Install - Ventilation....937
Control Manifold - Remove and Install - Auxiliary Power Unit....939
Control Manifold - Remove and Install - Right Side....941
Control Manifold - Remove and Install - Conveyor....945
Control Manifold - Remove and Install - Cutter Box....948
Control Manifold - Remove and Install - Grade Control Ski....952
Blower Fan - Remove and Install - Conveyor Fumes Extractor....955
M0082958 - Disassembly and Assembly (PM820; PM822; and PM825 Cold Planer Engine Supplement)....958
Battery - Remove and Install....959
Belt Tensioner - Remove and Install....962
Electric Starting Motor - Remove and Install....965
Engine Enclosure (Hood) - Remove and Install....968
Air Cleaner - Remove and Install....971
Fuel Filter Base (Secondary) - Remove and Install....975
Fuel Priming Pump and Primary Filter (Water Separator) - Remove and Install....977
Fuel Transfer Pump - Remove and Install....979
Fumes Disposal Filter - Remove and Install....981
Coolant Temperature Sensor - Remove and Install....983
Expansion Tank - Remove and Install....985
Fan - Remove and Install....988
Piston Motor (Fan) - Remove and Install....991
Cooling Package - Remove and Install....994
Cooling Package - Disassemble....1003
Cooling Package - Assemble....1008
Clean Emissions Module - Remove and Install....1013
Engine - Remove and Install....1017
Engine Oil Pan - Remove and Install....1026
Engine Oil Filter and Base - Remove and Install....1029
Air Compressor - Remove and Install....1031
Air Tank - Remove and Install....1033
UENR6291 - Specifications (PM620; PM622; PM820 and PM822 and PM825 Cold Planer Power Train)....1036
Hydraulic Tank....1037
Hydraulic Oil Filter....1038
Propel Lines....1041
Piston Motor (Propel)....1044
Drive Sprocket....1047
Track....1048
Idlers (Track)....1050
Speed Sensor (Wheel) - Auto Differential Lock....1052
Speed Sensor and Mounting....1053
UENR6292 - Systems Operation (PM620; PM622; PM820; PM822 and PM825 Cold Planer Propel Systems)....1055
Propel System....1056
Operator Controls (Propel System)....1058
Undercarriage Components....1064
Location of Electrical Components....1066
Location of Components (Propel System)....1068
Piston Pump (Propel)....1073
Piston Motor (Propel)....1079
Electrical Schematic (Propel System)....1081
Hydraulic Schematic (Propel System)....1091
UENR6292 - Testing and Adjusting (PM620; PM622; PM820; PM822 and PM825 Cold Planer Propel Systems)....1101
Machine Preparation for Troubleshooting....1102
Visual Inspection (Power Train)....1105
Propel System Troubleshooting....1108
System Pressure - Release....1111
Hydraulic Oil Contamination - Test....1119
Travel Speed - Test....1129
Propel Pump Pressure Override - Calibrate....1135
Propel Current - Calibrate....1149
Relief Valve (Main; Propel Pump) - Test and Adjust....1163
Relief Valve (Charge) - Test and Adjust - Propel....1181
Case Drain Flow for Piston Motor (Propel) - Test....1193
UENR6293 - Specifications (PM620; PM622; PM820 and PM822 and PM825 Cold Planer Machine Systems)....1211
Hydraulic Oil Filter....1213
Lines (Conveyor) - Motor....1216
Lines (Conveyor)....1218
Pump Rotating (Hydraulic Fan)....1221
Lines (Hydraulic Fan)....1223
Fan Drive Motor....1225
Control Manifold....1227
Control Valve....1231
Bank Valve - Two....1234
Bank Valve (Four)....1238
Control Valve (Rear Auxiliary Manifold)....1240
Moldboard....1245
Hydraulic Cylinder (Conveyor Lift)....1247
Hydraulic Cylinder (Conveyor Swing)....1248
Hydraulic Cylinder (Hood Tilt)....1249
Hydraulic Cylinder....1250
Hydraulic Cylinder - Lines....1265
Hydraulic Oil Lines - Clutch....1269
Water Spray Pump....1271
Water Spray Group - Lines....1273
Water Spray Lines....1275
Fuel Tank....1279
Air Cleaner....1284
Operator Console....1286
Electronic Control Module....1290
Conveyor System....1297
Solenoid Valve....1309
Hydraulic Cylinder (Steering)....1310
Access Door....1312
Frame....1319
Undercarriage Frame....1321
Pump Drive....1325
Swing Cylinder Lines....1331
Lines (Lift Cylinder)....1333