Caterpillar PM620 and PM622 Cold Planers Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Caterpillar PM620 and PM622 Cold Planers, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Caterpillar PM620 and PM622 Cold Planers workshop service repair manual includes:
* 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.
PM620 COLD PLANER 8RF
PM620 COLD PLANER FG4
PM620 COLD PLANER JB9
PM620 COLD PLANER LB8
PM620 COLD PLANER LH9
PM622 COLD PLANER EL6
PM622 COLD PLANER JCF
PM622 COLD PLANER JFC
PM622 COLD PLANER TPH
PM622 COLD PLANER XS6
M0067672 - Disassembly and Assembly (PM620 and PM622 Cold Planer Machine Systems).pdf
M0067686 - Disassembly and Assembly (PM-620 and PM-622 Cold Planer Engine Supplement).pdf
M0068306 - Systems Operation, Testing and Adjusting & Troubleshooting (PM310; PM312; PM313; PM620; PM622; PM820; PM822; PM825 Cold Planer Monitoring System_Grade & Slope).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
UENR6396 - Schematic (PM620 and PM622 Cold Planer Hydraulic System).pdf
UENR6397 - Schematic (PM620 and PM622 Cold Planer Electrical System; Power Distribution Circuit Board; Platform and Chassi..).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
PRODUCT DETAILS:
Total Pages: 2,061 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
M0067672 - Disassembly and Assembly (PM620 and PM622 Cold Planer Machine Systems)....1
Operator Console - Remove and Install....6
Seat - Remove and Install....11
Operator Platform - Remove and Install....14
Hood - Remove and Install - Left....17
Hood - Remove and Install - Right....20
Access Door - Remove and Install - Rotor Chamber....23
Fuel Tank - Remove and Install....27
Hydraulic Oil Filter (Return) - Remove and Install....31
Hydraulic Oil Tank - Remove and Install....34
Hydraulic Oil Filter (Hydraulic Tank and Travel) - Remove and Install....39
Hydraulic Cylinder (Hood Lift) - Remove and Install....41
Electric Drive Pump (Hood Lift) - Remove and Install....45
Rotor Drive Motor (Auxiliary) - Remove and Install....48
Piston Pump (Auxiliary) - Remove and Install....51
Piston Pump (Hydraulic Fan) - Remove and Install....54
Piston Pump (Hydraulic Fan) - Disassemble....61
Piston Pump (Hydraulic Fan) - Assemble....77
Piston Motor (Hydraulic Fan) - Disassemble....94
Piston Motor (Hydraulic Fan) - Assemble....103
Control Valve - Remove and Install - Rear....113
Bank Valve - Remove and Install - Bank 5....115
Piston Pump (Propel) - Remove and Install....119
Piston Pump (Propel) - Disassemble....122
Piston Pump (Propel) - Assemble....133
Piston Motor (Propel) - Remove and Install....145
Piston Motor (Propel) - Disassemble....149
Piston Motor (Propel) - Assemble....164
Flow Control Valve - Remove and Install - Right Rear Leg....179
Flow Control Valve - Remove and Install - Left Rear Leg....182
Flow Control Valve - Remove and Install - Front Leg....185
Final Drive Planetary - Remove and Install....188
Final Drive Planetary - Disassemble....191
Final Drive Planetary - Assemble....200
Rotor Drive Clutch - Remove and Install....210
Rotor Drive Clutch - Disassemble....213
Rotor Drive Clutch - Assemble....226
Rotor Drive Planetary - Remove and Install....239
Rotor Drive Planetary - Disassemble....242
Rotor Drive Planetary - Assemble....256
Belt Guard (Rotor Drive) - Remove and Install....271
V-Belt (Rotor Drive) - Remove and Install....275
Rotor Chamber - Remove and Install....277
Rotor - Remove and Install....288
Upper Sheave (Rotor Drive) - Remove and Install....293
Lower Sheave (Rotor Drive) - Remove and Install....295
Hydraulic Cylinder (Rotor Drive Idler Tensioner) - Remove and Install....297
Cutting Edge (Moldboard) - Remove and Install....300
Moldboard - Remove and Install....302
Wear Plate (Rotor Chamber) - Remove and Install....308
Side Plate - Remove and Install - Left Hand....310
Side Plate - Remove and Install - Right Hand....313
Antislab - Remove and Install....315
Hydraulic Cylinder - Remove and Install - Guide Ski....319
Hydraulic Cylinder - Remove and Install - Left Antislab....322
Hydraulic Cylinder - Remove and Install - Right Antislab....325
Hydraulic Cylinder (Moldboard Lift) - Remove and Install....328
Hydraulic Cylinder (Moldboard Lift) - Disassemble....332
Hydraulic Cylinder (Moldboard Lift) - Assemble....335
Hydraulic Cylinder (Rear Door) - Remove and Install....338
Hydraulic Cylinder (Left Rear Side Plate) - Remove and Install....341
Hydraulic Cylinder (Left Front Side Plate) - Remove and Install....344
Hydraulic Cylinder (Right Front Side Plate) - Remove and Install....347
Hydraulic Cylinder (Right Rear Side Plate) - Remove and Install....350
Hydraulic Cylinder (Side Plate) - Disassemble....353
Hydraulic Cylinder (Side Plate) - Assemble....356
Hydraulic Cylinder (Front Toe) - Remove and Install....359
Hydraulic Cylinder (Rear Toe) - Remove and Install....362
Hydraulic Cylinder (Front Steering) - Remove and Install....365
Hydraulic Cylinder (Rear Steering) - Remove and Install....368
Hydraulic Cylinder (Rear Steering) - Disassemble....371
Hydraulic Cylinder (Rear Steering) - Assemble....374
Counterbalance Valve - Remove and Install - Steering Valve....377
Steering Bearing and Mounting - Remove and Install....380
Hydraulic Cylinder (Elevation) - Remove and Install - Rear....384
Hydraulic Cylinder (Elevation) - Remove and Install - Front....389
Hydraulic Cylinder (Elevation) - Disassemble....393
Hydraulic Cylinder (Elevation) - Assemble....397
Air Compressor - Remove and Install....401
Air Tank - Remove and Install....405
Pump Drive - Remove and Install....408
Pump Drive - Disassemble....417
Pump Drive - Assemble....431
Coupling - Remove and Install....445
Gear Pump (Charge) - Remove and Install....448
Gear Pump (Charge) - Disassemble....450
Gear Pump (Charge) - Assemble....454
Hydraulic Cylinder (Conveyor Fold) - Remove and Install....458
Conveyor Idler (First Stage) - Remove and Install....462
Conveyor Roller (First Stage) - Remove and Install....464
Conveyor Pulley (Head; First Stage) - Remove and Install....466
Conveyor Pulley (Tail; First Stage) - Remove and Install....469
Conveyor (First Stage) - Remove and Install....471
Conveyor Belt (Second Stage) - Remove and Install....477
Conveyor Idler (Second Stage) - Remove and Install....490
Conveyor Roller (Second Stage) - Remove and Install....492
Conveyor Pulley (Head; Second Stage) - Remove and Install....494
Conveyor Pulley (Tail; Second Stage) - Remove and Install....495
Conveyor (Second Stage) - Remove and Install....497
Conveyor Pivot - Remove and Install....503
Flashing (Conveyor) - Remove and Install....507
Gerotor Motor (Second Stage Conveyor) - Remove and Install....509
Gerotor Motor (Second Stage Conveyor) - Disassemble....513
Gerotor Motor (Second Stage Conveyor) - Assemble....517
Hydraulic Cylinder (Conveyor Swing) - Remove and Install....522
Hydraulic Cylinder (Conveyor Lift) - Remove and Install....525
Gerotor Motor (First Stage Conveyor) - Remove and Install....528
Piston Pump (Conveyor) - Remove and Install....531
Piston Pump (Conveyor) - Disassemble....534
Piston Pump (Conveyor) - Assemble....545
Track - Separate....557
Track - Connect....561
Track Roller Frame - Remove and Install....564
Track Roller - Remove and Install....569
Hydraulic Cylinder (Track_Belt Tension) - Remove and Install....571
Hydraulic Cylinder (Track_Belt Tension) - Disassemble....573
Hydraulic Cylinder (Track_Belt Tension) - Assemble....577
Track Idler - Remove and Install....582
Wear Pad (Track Frame) - Remove and Install....584
Drive Sprocket - Remove and Install....586
Water Spray Pump - Remove and Install....589
Washdown Hose Reel - Remove and Install - High Pressure....592
Washdown Hose Reel - Remove and Install - Low Pressure....594
Spray Bar - Remove and Install - Rotor Chamber....596
Gear Motor - Remove and Install - Ventilation....598
Control Manifold - Remove and Install - Auxiliary Power Unit....600
Control Manifold - Remove and Install - Right Side....603
Control Manifold - Remove and Install - Conveyor....607
Control Manifold - Remove and Install - Cutter Box....610
Control Manifold - Remove and Install - Grade Control Ski....614
Blower Fan - Remove and Install - Conveyor Fumes Extractor....617
M0067686 - Disassembly and Assembly (PM-620 and PM-622 Cold Planer Engine Supplement)....620
Battery - Remove and Install....621
Alternator - Remove and Install....624
Electric Starting Motor - Remove and Install....627
Air Cleaner - Remove and Install....629
Muffler - Remove and Install....631
Fuel Priming Pump and Primary Filter (Water Separator) - Remove and Install....634
Expansion Tank - Remove and Install....637
Fan - Remove and Install....639
Engine - Remove and Install....642
M0068306 - Systems Operation, Testing and Adjusting & Troubleshooting (PM310; PM312; PM313; PM620; PM622; PM820; PM822; PM825 Cold Planer Monitoring System_Grade & Slope)....651
Systems Operation....652
Display Navigation....653
Left Hand Buttons....665
Grade and Slope....678
Display Settings....733
Menu Navigation....746
Machine Settings Menu....763
Service Test Menu....777
Pop-Up Messages....799
Testing and Adjusting....807
Troubleshooting....814
General Information....815
Service Tools....816
Diagnostic Capabilities....818
Determining Diagnostic Trouble Codes....822
Diagnostic Trouble Codes....827
Event Codes....828
CAN Data Link - Test....832
UENR6291 - Specifications (PM620; PM622; PM820 and PM822 and PM825 Cold Planer Power Train)....842
Hydraulic Tank....843
Hydraulic Oil Filter....844
Propel Lines....847
Piston Motor (Propel)....850
Drive Sprocket....853
Track....854
Idlers (Track)....856
Speed Sensor (Wheel) - Auto Differential Lock....858
Speed Sensor and Mounting....859
UENR6292 - Systems Operation (PM620; PM622; PM820; PM822 and PM825 Cold Planer Propel Systems)....861
Propel System....862
Operator Controls (Propel System)....864
Undercarriage Components....870
Location of Electrical Components....872
Location of Components (Propel System)....874
Piston Pump (Propel)....879
Piston Motor (Propel)....885
Electrical Schematic (Propel System)....887
Hydraulic Schematic (Propel System)....897
UENR6292 - Testing and Adjusting (PM620; PM622; PM820; PM822 and PM825 Cold Planer Propel Systems)....907
Machine Preparation for Troubleshooting....908
Visual Inspection (Power Train)....911
Propel System Troubleshooting....914
System Pressure - Release....917
Hydraulic Oil Contamination - Test....925
Travel Speed - Test....935
Propel Pump Pressure Override - Calibrate....941
Propel Current - Calibrate....955
Relief Valve (Main; Propel Pump) - Test and Adjust....969
Relief Valve (Charge) - Test and Adjust - Propel....987
Case Drain Flow for Piston Motor (Propel) - Test....999
UENR6293 - Specifications (PM620; PM622; PM820 and PM822 and PM825 Cold Planer Machine Systems)....1017
Hydraulic Oil Filter....1019
Lines (Conveyor) - Motor....1022
Lines (Conveyor)....1024
Pump Rotating (Hydraulic Fan)....1027
Lines (Hydraulic Fan)....1029
Fan Drive Motor....1030
Control Manifold....1032
Control Valve....1036
Bank Valve - Two....1039
Bank Valve (Four)....1043
Control Valve (Rear Auxiliary Manifold)....1045
Moldboard....1050
Hydraulic Cylinder (Conveyor Lift)....1052
Hydraulic Cylinder (Conveyor Swing)....1053
Hydraulic Cylinder (Hood Tilt)....1054
Hydraulic Cylinder....1055
Hydraulic Cylinder - Lines....1068
Hydraulic Oil Lines - Clutch....1072
Water Spray Pump....1074
Water Spray Group - Lines....1076
Water Spray Lines....1078
Fuel Tank....1082
Air Cleaner....1087
Operator Console....1089
Electronic Control Module....1093
Conveyor System....1100
Solenoid Valve....1112
Hydraulic Cylinder (Steering)....1113
Access Door....1115
Frame....1117
Undercarriage Frame....1119
Swing Cylinder Lines....1123
Lines (Lift Cylinder)....1125
Hydraulic Lines - Cylinder....1126
Pump Lines - Auxiliary....1127
Return Lines....1131
Steering Lines....1135
Track Tension Lines....1136
Mounting Bracket - Control....1138
Hydraulic Pump and Mounting....1140
Track Roller (Single Flange)....1141
Rotor Drive Group....1143
Rotor....1145
Rotor - Plate Group....1149
Steering Control Group....1151
Steering Guide....1152
Check Valve....1154
Control Valve and Mounting....1157
Steering Cylinder....1160
Machine Electronic Control Module Mounting....1161
Display Module....1163
Sensor Mounting....1169
Antislab and Mounting....1171
Mixing Chamber....1173
UENR6294 - Systems Operation (PM620; PM622; PM820; PM822 and PM825 Cold Planer Machine System)....1175
Graphic Color Codes....1177
General Information (Auxiliary Hydraulic System)....1179
Operator Controls (Auxiliary Hydraulic System)....1181
Location of Components (Auxiliary Hydraulic System)....1196
Control Valve (Rear Auxiliary Manifold)....1205
Control Valve (Cutter Box)....1207
Control Valve (Left Auxiliary)....1210
Control Valve (Right Auxiliary)....1212
Control Valve (Conveyor)....1214
Hydraulic Cylinder....1217
Electrical Schematic (Auxiliary Hydraulic System)....1222
Hydraulic Schematic (Auxiliary Hydraulic System)....1241
Pump Control....1262
General Information (Rotor Drive System)....1265
Operator Controls (Rotor Drive System)....1266
Location Of Components (Rotor Drive System)....1268
Rotor Clutch....1277
Electrical Schematic (Rotor Drive System)....1280
Hydraulic Schematic (Rotor Drive System)....1285
General Information (Conveyor System)....1288
Operator Controls (Conveyor System)....1290
Piston Pump (Conveyor System)....1293
Gerotor Motor (Conveyor System)....1298
Electrical Schematic (Conveyor System)....1300
Hydraulic Schematic (Conveyor System)....1305
General Information (Fan Drive Hydraulic System)....1311
Electrical System (Cooling)....1312
Cooling Package (Cooling System)....1315
Piston Pump (Fan Drive)....1316
Piston Motor (Fan Drive)....1319
Electrical Schematic (Hydraulic Fan)....1323
Hydraulic Schematic (Hydraulic Fan)....1325
General Information (Water Spray System)....1335
Location of Components (Water Spray System)....1336
Operator Controls (Water Spray System)....1346
Electrical Schematic (Water Spray System)....1350
Hydraulic Schematic (Water Spray System)....1356
General Information (Steering System)....1359
Location of Components (Steering System)....1360
Operator Controls (Steering System)....1367
Hydraulic Schematic (Steering System)....1374
UENR6294 - Testing and Adjusting (PM620; PM622; PM820; PM822 and PM825 Cold Planer Machine System)....1379
Machine Preparation for Troubleshooting....1380
Visual Inspection (Auxiliary Hydraulic System)....1383
Auxiliary Hydraulic System Troubleshooting....1386
System Pressure - Release....1388
Hydraulic Oil Contamination - Test....1396
Relief Valve (Auxiliary) - Test and Adjust - Pump....1406
Relief Valve (Auxiliary) - Test and Adjust - Auxiliary Power Unit....1418
Fan Pump - Test and Adjust....1430
Fan Speed (Ventilation) - Test....1443
Main Relief Valve - Test and Adjust - Front Right Steering....1453
Fan Speed - Calibrate....1463
Control Valve (Moldboard) - Test and Adjust - Downward Pressure....1479
Relief Valve (Charge) - Test - Conveyor....1491
Pressure Reducing Valve - Test and Adjust - Rear Side Plates....1501
Pressure Reducing Valve - Test and Adjust - Moldboard Lower....1512
Pressure Reducing Valve - Test and Adjust - Auxiliary Brake Release....1524
Pressure Reducing Valve - Test and Adjust - Front Side Plate....1536
Pressure Reducing Valve - Test and Adjust - Antislab Lower....1546
Pressure Reducing Valve - Test and Adjust - Left Grade Control Ski....1556
Pressure Reducing Valve - Test and Adjust - Right Grade Ski Control....1565
Pressure Reducing Valve - Test and Adjust - Rotor Belt Tension....1575
Pressure Reducing Valve - Test and Adjust - Track Tension....1586
Pressure Reducing Valve - Test and Adjust - Rotor Clutch....1598
Conveyor (First Stage) - Test - Case Drain Flow for Piston Motor....1609
Conveyor Current - Calibrate....1619
Relief Valve (First Stage Conveyor) - Test and Adjust - Main....1631
Conveyor (Second Stage) - Test - Case Drain Flow for Piston Motor....1644
Relief Valve (Second Stage Conveyor) - Test and Adjust....1655
Steering Angle - Calibrate....1665
UENR6396 - Schematic (PM620 and PM622 Cold Planer Hydraulic System)....1676
Feature....1676
Cover Page....1678
Information....0
Component Location....0
Main Hydraulic System....1679
Implement Hydraulic System....1680
Tap Location....0
Main Hydraulic System....1681
Implement Hydraulic System....1682
Schematics....0
Main Hydraulic System....1683
Implement Hydraulic System....1684
Machine Views....0
Main Hydraulic System....0
Charge Pump And Cooler Bypass ....1685
Conveyor ....1686
Cooling Fan....1687
Hydraulic Pump Comp. (View A) ....1688
Hydraulic Pump Comp. (View B)....1689
Hydraulic Tank ....1690
LF Track Gp ....1691
LR Track Gp ....1692
RH Track Gp ....1693
RR Track Gp....1694
Implement Hydraulic System....0
Canopy....1695
Conveyor Fold / Ventilation....1696
Conveyor Valve....1697
Cutter Belt Tensioner....1698
Cutter Box Compartment....1699
Cutter Box Control Valve....1700
Front Legs / Conveyor Top View ....1701
Left Front Compartment ....1702
Left Rear Compartment....1703
Left Rear Leg....1704
Right Front Compartment....1705
Right Rear Compartment....1706
Steering Cylinders....1707
Track Tensioners ....1708
UENR6397 - Schematic (PM620 and PM622 Cold Planer Electrical System; Power Distribution Circuit Board; Platform and Chassi..)....1709
Feature....1709
Cover Page....1711
Information....0
Component Location....0
Vol 1 - Power Distribution Circuit Board....1712
Vol 2 - Platform and Chassis....0
Page 1 of 2....1713
Page 2 of 2....1714
Vol 3 - Control Cabinet and Power Distribution....1715
Vol 4 - Engine and Aftertreatment....1716
Connector Location....0
Vol 1 - Power Distribution Circuit Board....1717
Vol 2 - Platform and Chassis....1718
Vol 3 - Control Cabinet and Power Distribution....1719
Vol 4 - Engine and Aftertreatment....1720
Schematics....0
Vol 1 - Power Distribution Circuit Board....1721
Vol 2 - Platform and Chassis....1722
Vol 3 - Control Cabinet and Power Distribution....1723
Vol 4 - Engine and Aftertreatment....1724
Machine Views....0
Vol 1 - Power Distribution Circuit Board....0
PDB Fuse Loactions....1725
PDB Relay Locations ....1726
PDB Rear View....1727
Vol 2 - Platform and Chassis....0
Center Panel....1728
Conveyor....1729
Left Front Compartment ....1730
Left Front Components ....1731
Left Front Track / Steering ....1732
Left Rear Compartment ....1733
Left Rear Leg....1734
Left Rear Track....1735
Left Side Of Conveyor Valve....1736
Left Side View....1737
LH Operator Controls ....1738
RH Operator Controls....1739
Right / Left Rear Component Locations....1740
Right Front Compartment....1741
Right Front Component Locations ....1742
Right Front Leg....1743
Right Front Track ....1744
Right Mid Component Locations....1745
Right Rear Track / Steering....1746
Rotor Compartment Components ....1747
Rotor Rotation Components....1748
SKI Attachment Components....1749
Vol 3 - Control Cabinet and Power Distribution....0
Battery Power Circuit....1750
Engine Compartment....1751
Engine Components ....1752
Machine Rear View....1753
Operator Monitor....1754
PDB Enclosure Rear View ....1755
PDB Enclosure ....1756
PDB Rear View....1757
Product Link Attachment....1758
Vol 4 - Engine and Aftertreatment....1745
Cutter Box Valve....1759
Engine And AftertreatMent Component Locations....1760
Engine Compartment....1761
Engine Components Left Side View ....1762
Engine RT Side View....1763
Engine Top View....1764
Hyd Pump / Valves Component Locations....1765
LH Rear Compartment....1766
Pump Drive....1767
UENR6406 - Systems Operation (PM620; PM622; PM820; PM822 and PM825 Cold Planers Electronic System)....1768
General Information....1769
Features....1774
Location of Electrical Components....1782
Electrical Input Components....1790
Electronic Control Module (ECM) - ECM Locations....1798
Electrical Output Components....1810
UENR6406 - Troubleshooting (PM620; PM622; PM820; PM822 and PM825 Cold Planers Electronic System)....1817
General Information....1818
Service Tools....1820
Connector Locations....1823
Diagnostic Capabilities....1827
Determining Diagnostic Trouble Codes....1830
Diagnostic Trouble Codes....1834
Event Codes....1854
Symptom Troubleshooting....1863
Emerging Symptom Information....1865
CAN Data Link - Test....1866
Condition Switch (Switch to Ground) - Test....1882
ECM Location Code - Test....1888
Electrical Connector - Inspect....1895
Sensor (Data Link Type) - Test....1902
Sensor Signal (Analog; Active) - Test....1905
Sensor Signal (Analog; Passive) - Test....1913
Sensor Signal (PWM) - Test....1919
Sensor Supply - Test....1947
Solenoid Return - Test....1969
Solenoid Valve - Test....1973
Speed Sensor (Dual Signal) - Test....2006
Speed Signal - Test....2012
Switch Circuits - Test....2016
Wiring Harness (Open Circuit) - Test....2041
Wiring Harness (Short Circuit) - Test....2042
ECM Software - Install....2043
ECM - Configure....2045
ECM - Replace....2047
Connector Contact Description....2049
System Schematic....2059
Caterpillar PM620 and PM622 Cold Planers Repair Service Manual
