Testing and Ajsting 111

QENR2017-01
December 2008
2005
Testing and Adjusting

PM200 Cold Planer
P1C0271-Up (Machine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should
also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
WARNING
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in this
publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Caterpillar is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Caterpillar dealers have the most current information available.
WARNING
When replacement parts are required for this
product Caterpillar recommends using
Caterpillar replacement parts or parts with
equivalent specifications including, but not
limited to, physical dimensions, type, strength
and material.
Failure to heed this warning can lead to

premature failures, product damage, personal
injury or death.
3
PM200 Cold Planer
Table of Contents
Table of Contents Accumulator Pressure—Test ...............................

Rotor Brake (Negative Rotor Brake)—Test and
74
Adjust ............................................................... 78
Testing and Adjusting Section Rotor Brake (Positive Rotor Brake)—Test ............ 80
Relief Valve (Belt Tensioner)—Test and Adjust ... 82
Testing and Adjusting Relief Valve (Rotor Transmission)—Test and
Testing and Adjusting.............................................. 4 Adjust ............................................................... 86
Machine Preparation for Testing and Adjusting .... 4
Visual Inspection .................................................... 4 Conveyor System
Hydraulic Oil Contamination—Test ........................ 6 Conveyor System................................................... 88
Relief Valve (Conveyor Charge)–Test .................. 88
Propulsion System Pressure Limiter Valve (Conveyor Pump)—Test and
Propulsion System ................................................... 7 Adjust ............................................................... 92
Relief Valve (Charge)–Test .................................... 7 Conveyor Speed—Test ....................................... 96
Pressure Limiter Valve (Propel Pump)—Test and Piston Pump Neutral—Test and Adjust ............... 98
Adjust ............................................................... 11
Differential Lock Engagement—Test ................... 15 Fan Control System
Piston Pump Neutral—Test and Adjust ............... 18 Fan Control System ............................................. 101
Relief Valve (Fan)—Test and Adjust .................. 101
Auxiliary Hydraulic System Fan Speed—Test ............................................... 104
Auxiliary Hydraulic System .................................... 21
Relief Valve (Auxiliary System Main)—Test and
Adjust ............................................................... 21
Relief Valve (Right Side Plate)—Test and Adjust 24
Relief Valve (Left Side Plate)—Test and Adjust ... 27
Side Plate Cycle Times—Test .............................. 31
Conveyor Cycle Time (Swing)—Test and Adjust . 33
Conveyor Cycle Time (Raise and Lower)—Test and
Adjust ............................................................... 35
Standard Water Pump RPM—Test ...................... 38
Optional Water Pump RPM—Test ........................ 40
Water Pressure (Optional Washdown Pump)—Test
and Adjust ........................................................ 43
Optional Water Loading Pump RPM—Test and
Adjust ............................................................... 46
Rear Column Lower Cycle Time—Test and
Adjust ............................................................... 50
Moldboard Pressure—Test .................................. 52
Steering Wheel Rotation—Test ............................ 53
Electronic Controls
Electronic Controls................................................. 55
Engine Antistall—Calibrate .................................. 55
Grade and Slope Offset—Calibrate ..................... 57
Rear Steering Potentiometer—Calibrate .............. 59
Steering Sensor (Front)—Replace ....................... 62
Steering Sensor (Front)—Calibrate ...................... 63
Steering Sensor (Rear)—Replace ....................... 65
Steering Sensor (Rear)—Calibrate ...................... 66
Rotor Clutch
Rotor Clutch ........................................................... 68
Relief Valve (Negative Rotor Brake)—Test and
Adjust ............................................................... 68
Relief Valve (Positive Rotor Brake)—Test and
Adjust ............................................................... 71
4
PM200 Cold Planer
Testing and Adjusting Section
Testing and Adjusting This list will only provide an indication of the location
of a problem and the repairs that are required.
Section Remember that a problem is not necessarily caused
by one part, but by the relation of one part with other
parts. This list can not provide all possible problems
and corrections. Service personnel must find the
Testing and Adjusting problem and the source of the problem. Then,
complete the necessary repairs.
Machine Preparation for Perform a visual inspection first. If the visual checks
Testing and Adjusting are completed but the problem has not been
identified, perform operational checks. If the
problem is not understood, perform instrument tests.
WARNING This procedure will help to identify problems in the
machine systems.
Do not operate or work on this machine unless
you have read and understand the instructions Visual Inspection
and warnings in the Operation and Maintenance
Manual. Failure to follow the instructions or heed
the warnings could result in injury or death.
Contact any Caterpillar dealer for replacement
WARNING
manuals. Proper care is your responsibility. Do not operate or work on this machine unless
you have read and understand the instructions
and warnings in the Operation and Maintenance
1. Move the machine to a smooth, horizontal Manual. Failure to follow the instructions or heed
location that is away from operating machines the warnings could result in injury or death.
and away from personnel. Contact any Caterpillar dealer for replacement
manuals. Proper care is your responsibility.
NOTE: Permit only one operator on the machine at
a time. Keep all other personnel away from the
machine or in the operator’s sight.
WARNING
2. Raise the machine and install the leg lift locks.
Diesel engine exhaust contains products of
3. Engage the parking brake. Place blocks around combustion which may cause personal injury.
the tracks.
Always start and operate the engine in a well-
ventilated area, and, if in an enclosed area, vent
4. Stop the engine.
the exhaust to the outside.
5. Make sure that all of the hydraulic pressure is
released before any hydraulic components are
altered. WARNING
Correct oil flow and pressure are necessary for Personal injury can result from hydraulic oil
correct operation. The output of the pump (oil flow) pressure and hot oil.
increases with an increase in engine speed (RPM).
The output of the pump decreases when engine Hydraulic oil pressure can remain in the
speed (RPM) is decreased. Oil pressure is caused hydraulic system after the engine has been
by resistance to the flow of oil. stopped. Serious injury can be caused if this
pressure is not released before any service is
Visually inspect the complete hydraulic system for oil done on the hydraulic system.
leaks and damaged parts before you test the
machine. For some of the tests, a magnet and a Make sure all of the attachments have been
measuring rule are usable tools. lowered, and that the oil is cool before removing
any components or lines. Remove the oil filler
The hydraulic oil must be at the normal temperature cap only when the engine is stopped, and the
for operation before any tests are performed. filler cap is cool enough to touch with your bare
hand.
Troubleshooting can be complex.Some of the
possible problems and corrections are listed on the
following pages.
5
PM200 Cold Planer
d. Aluminum particles indicate a pump group

WARNING failure.
Personal injury or death can result from NOTE: When foreign particles are found, all
improperly checking for a leak. hydraulic systems on the machine must be
thoroughly flushed. Each hydraulic system must be
Always us a board or cardboard when checking filtered independently. Do not reuse damaged parts.
for a leak. Escaping air or fluid under pressure.
even a pin-hole side leak, can penetrate body 5. Inspect the control linkages for damaged
tissue causing serious injury, and possible components.
death.
6. Inspect the tracks for wear. Inspect the tracks for
If fluid is injected into your skin, it must be damage. The tracks may show the following
treated immediately by a doctor familiar with this signs of wear or damage:
type of injury.
• loose tracks
NOTICE
Care must be taken to ensure that fluids are • broken parts
contained during performance of inspection,
maintenance, testing, adjusting and repair of the • worn rollers and wheels
machine. Be prepared to collect the fluid in suitable
containers before opening any compartment or • damaged tracks.
disassembling any component containing fluids.
Repair the tracks if the tracks are worn or
Refer to Special Publication, NENG2500, “Caterpillar damaged.
Tools and Shop Products Guide,” for tools and
supplies suitable to collect and contain fluids from 7. Check the machine for loose wiring. Check the
Caterpillar machines. machine for frayed wiring.
Dispose of all fluids according to local regulations. 8. Inspect the lights for broken bulbs. Inspect the
lights for broken lenses. Replace the bulbs or the
lenses if the bulbs or the lenses are broken.
A visual inspection of the hydraulic system and its
components is the first step when a diagnosis of a 9. Inspect the following for damage or wear: the
problem is made. Stop the engine, and make the steps, the walkways, and the hand holds. Repair
following inspections. any damaged or worn components. Inspect
these areas for cleanliness. Clean the
1. Measure the oil level in the hydraulic oil tank. components.
2. Use a clear container to obtain an oil sample Checks During Operation

from the hydraulic tank immediately after the
engine is stopped. Examine the sample for air
bubbles. Operation checks can be used in order to find a
valve or a pump that is not working. The speed of
3. Check all oil lines and check all connections for rod movement or the torque on a motor can be used
damage. Look for oil on the ground under the to check the condition of the cylinders, motors, and
machine. pumps.
4. Remove the hydraulic oil filter and examine the 1. Monitor the extension and monitor the retraction
filter element for debris. of the cylinders. The movement of the cylinders
should be smooth.
a. Shiny steel particles indicate a pump failure or
pump deterioration. Shiny steel particles can 2. Listen for irregular noise that may come from the
also indicate a motor failure or motor pumps.
deterioration.
3. Listen to the relief valves. Low pressure in the
b. Rubber particles indicate seal failures or hose relief valves may cause an increase in oil
failures. temperature. Also, cycle time of the cylinders
may increase.
c. Bronze-colored particles indicate pump port
plate failure.
6
PM200 Cold Planer
NOTE: High pressure in the hydraulic system may

decrease the service life of hydraulic system NOTICE
components. Care must be taken to ensure that fluids are
4. Observe the drift rates of the cylinders. maintenance, testing, adjusting and repair of the
Excessive drift rates can be caused by the machine. Be prepared to collect the fluid with suitable
following: containers before opening any compartment or
• cylinder leakage
Refer to Special Publication, NENG2500, “Caterpillar
• damaged o-ring seals on the control valves Tools and Shop Products Guide,” for tools and
supplies suitable to collect and contain fluids in
• improper adjustment of the relief valves. Caterpillar machines.
Dispose of all fluids according to local regulations

Hydraulic Oil Contamination— and mandates.
Test
If the oil becomes contaminated, premature
component failure could result. Contaminated oil
WARNING can also contribute to overheating.
Escaping fluid under pressure, even a pinhole Use the following procedure to determine the
size leak, can penetrate body tissue, causing
contamination of the oil in the hydraulic system.
serious injury, and possible death. If fluid is
injected into your skin, it must be treated
immediately by a doctor familiar with this type of
injury.
Always use a board or cardboard when checking

for a leak.
WARNING
Personal injury can result from hydraulic oil
pressure and hot oil.
Hydraulic oil pressure can remain in the IMG_1075_2_4
hydraulic system after the engine has been

stopped. Serious injury can be caused if this Illustration 1
pressure is not released before any service is 1. Obtain a hydraulic oil sample from S•O•S tap (1)
done on the hydraulic system. in the auxiliary manifold.
Make sure all of the attachments have been
lowered, and that the oil is cool before removing
any components or lines. Remove the oil filler
cap only when the engine is stopped, and the
filler cap is cool enough to touch with your bare
hand.
IMG_0941_2_4
Illustration 2
2. Obtain a hydraulic oil sample from S•O•S tap (2)

on the brake and shift manifold.
7
PM200 Cold Planer
NOTE: For the correct procedure, refer to Operation

and Maintenance Manual, “Sampling Interval and WARNING
Location of Sampling Valve.”
Personal injury can result from rotating and
3. Check the hydraulic filter elements for foreign moving parts.
materials.
Moving fan blades and moving parts will throw or
a. Bronze-colored particles give an indication of cut any object or tool that falls or is pushed into
pump failure or motor port plate failure. them.
Make sure no one is working on, underneath or

b. Shiny steel particles give an indication of
close to an engine that is running. Make sure the
pump failure or motor piston failure.
area is free of personnel.
c. Rubber particles indicate a seal failure or a
hose failure. NOTICE
Care must be taken to ensure that fluids are
d. Aluminum particles give an indication of contained during performance of inspection,
steering pump failure. maintenance, testing, adjusting and repair of the
machine. Be prepared to collect the fluid with suitable
NOTE: If any of these particles are found in the containers before opening any compartment or
hydraulic filter elements, all components of the disassembling any component containing fluids.
hydraulic oil system must be cleaned. Do not use
any damaged parts. Any damaged parts must be Refer to Special Publication, NENG2500, “Caterpillar
removed, and new parts must be installed. Tools and Shop Products Guide,” for tools and
Caterpillar machines.
Propulsion System Dispose of all fluids according to local regulations
and mandates.
Relief Valve (Charge)–Test
Table 1
WARNING Required Tools

Sudden movement of the machine or release of Tool Part Description Qty
oil under pressure can cause serious injury to Number
persons on or near the machine. Pressure Gauge
A 8T-0855 2
0–4000 kPa (0–580 psi)
To prevent injury or death, make sure that the
area around the machine is clear of personnel 177-7860 Hose Assembly 2
and obstructions before operating the machine. B 8T-41889 Adapter–Union 2
6V-4143 Valved Coupler 2
WARNING C 4C-6500 Digital Thermometer 1
Injury to personnel can result if they are not in

the operator’s view. Allow only essential
personnel near the machine, and make sure the
personnel are in the operator’s view when
testing, to prevent injury. Make sure checks are
done in an open area.
8
PM200 Cold Planer
Table 2
Optional Tools(1)
Part
Tool Description Qty
Number
(2)
D 198-4234 Digital Pressure Indicator 1
(2)
E 198-4236 Extension Cable 2
Pressure Sensor
F(2) 198-4237 0–3500 kPa 2
(0–500 psi)
(1) The optional tools can be used in place of the analog pressure
IMG_0836_2_4
measurement tools which are specified in the required tool list.
(2) Tool D, Tool E, and one Tool F are part of the 198-4240 Digital
Pressure Indicator Group. Illustration 4
11. Open the compartment which is located under

1. Drive the machine to a smooth, horizontal the left steering wheel. Move engine
surface. compartment switch (12) to the RAISE position.
Hold the switch until the compartment is
completely open.
! " #
!
$ % & ' IMG_0781_2_4
Illustration 3
IMG_1009_2_4
2. Move propulsion lever (6) to the NEUTRAL
position. Illustration 5
12. Install prop rod (13).

3. Move parking brake switch (2) to the ON
position. 13. Move engine compartment switch (12) to the
LOWER position. Release the switch when prop
4. Make sure rotor switch (9) is in the OFF position. rod (13) is seated.
5. Make sure conveyor switch (11) is in the OFF
position.
"
#
6. Make sure water spray switches (4, 5, and 10)
are in the OFF position.
NOTE: Water spray switches (4 and 5) are optional. $
7. If necessary, move engine control switch (3) to

the MANUAL position.
8. Press decrease engine RPM switch (1). Hold the

switch until the engine reaches low idle.
IMG_1027_2_4
9. Move drive selector switch (8) to the OFF
10. Move key switch (7) to the OFF position.

9
PM200 Cold Planer
14. Unlock two locking mechanisms (14 and 16). 18. Move key switch (7) to the START position.
Open cover (15). Release the key switch when the engine starts.
15. Assemble two sets of Tool B. Connect one Tool A 19. Operate the engine for a few minutes at low idle.
to each Tool B. Push increase engine RPM switch (19).

%
IMG_1024_2_4 IMG_1026_2_4
Illustration 7 Illustration 10
16. Connect one Tool B to charge port (17) on the 20. Monitor engine speed value (20) on the digital
propulsion pump. display at the center of the instrument panel.
Release increase engine RPM switch (19) when
the engine speed reaches 1500 rpm.
21. Monitor the hydraulic oil temperature with Tool C.

Operate the machine until the oil temperature
reaches 45 ± 5 °C (110 ± 10 °F).
22. With propulsion lever (6) in the NEUTRAL

position and the engine at 1500 rpm, record the
pressure at charge tap (17).
23. Record the pressure at M2-port (18).
& 24. Subtract the pressure recorded in Step 23 from

IMG_1021_2_4
the pressure recorded in Step 22. The differential
pressure should be 2200 –0/+200 kPa (320 –0/
Illustration 8
+30 psi).
17. Connect the second Tool B to M2-port (18) on
the return manifold. 25. If the pressure is not within the specified range,
go to Step 26. If the pressure is within the
specified range, go to Step 29.
26. Press decrease engine RPM switch (1) until the

' engine reaches low idle. Move key switch (7) to
the OFF position.
% IMG_0781_2_5
Illustration 9
10
PM200 Cold Planer
33. Move propulsion lever (6) slightly out of the

NEUTRAL position into the FORWARD range.

"
IMG_0965_2_4
Illustration 11
IMG_0805_2_4
27. Loosen locknut (22) on the charge relief valve. In
order to increase pressure, rotate adjustment Illustration 13
screw (21) clockwise. In order to decrease
pressure, rotate the adjustment screw 34. Push propulsion enable switch (24) on top of
counterclockwise. propulsion lever (6). Slowly move the propulsion
lever forward until the pressure charge tap (17)
28. Hold adjustment screw (21) in place, and tighten stabilizes.
locknut (22). Go to Step 18.
35. Read the pressure at charge tap (17). The
pressure should be 200 ± 100 kPa (29 ± 15 psi)
less than the pressure recorded in Step 22.
' 36. Move propulsion lever (6) to the NEUTRAL
position.
37. If the pressure recorded in Step 35 is outside the

specified range, components in the propulsion
system may have excessive case drain leakage.

$ ! & IMG_0781_2_6
position.
Illustration 12

WARNING 41. Remove the tooling.
The machine will move during the next steps. In
order to prevent injury or death, make sure that 42. Use engine compartment switch (12) to close the
the area around the machine is clear of personnel engine compartment cover.
and clear of obstructions before operating the
machine. 43. Close cover (15). Lock the cover with locking
mechanisms (14 and 16).
29. Press increase engine RPM switch (19) until the
engine reaches high idle.
30. Move electrical controls master switch (23) to the

ON position.
31. Move drive selector switch (8) to the ON position.
32. Move parking brake switch (2) to the OFF

position.
11
PM200 Cold Planer
Pressure Limiter Valve (Propel Table 3
Pump)—Test and Adjust Required Tools

Part
Number
WARNING Pressure Gauge
Sudden movement of the machine or release of A 8T-0861 0–60 000 kPa 1
(0–8700 psi)
oil under pressure can cause serious injury to
persons on or near the machine. 177-7860 Hose Assembly 1
To prevent injury or death, make sure that the B 8T-4188 Adapter–Union 1

area around the machine is clear of personnel 6V-4143 Valved Coupler 1
and obstructions before operating the machine.
C 4C-6500 Digital Thermometer 1
WARNING Table 4
Optional Tools(1)
the operator’s view. Allow only essential Part
personnel near the machine, and make sure the Number
D(2) 198-4234 Digital Pressure Indicator 1
done in an open area. E (2)
198-4236 Extension Cable 1
Pressure Sensor
F(2) 198-4239 0–69 000 kPa 1
WARNING (0–10 000 psi)
moving parts. (2) Tool A, Tool B, and Tool C are part of the 198-4240 Digital Pressure
Indicator Group.
cut any object or tool that falls or is pushed into 1. Drive the machine to a smooth, horizontal
them. surface.
! " #
NOTICE
maintenance, testing, adjusting and repair of the
containers before opening any compartment or
Refer to Special Publication, NENG2500, “Caterpillar $ % & ' IMG_0781_2_7

supplies suitable to collect and contain fluids in Illustration 14
Dispose of all fluids according to local regulations position.
and mandates.
position.
4. Make sure rotor switch (9) is in the OFF position.

position.
12
PM200 Cold Planer

are in the OFF position. "
#
NOTE: Water spray switches (4 and 5) are optional.

the MANUAL position. $


position.
IMG_1027_2_5

Illustration 17
14. Unlock two locking mechanisms (14 and 16).

Open cover (15).
%
IMG_0836_2_5
Illustration 15
IMG_1031_2_4
the left steering wheel. Move engine
Illustration 18
compartment switch (12) to the RAISE position.
Hold the switch until the compartment is 15. Unplug the connector from parking brake
completely open. solenoid (17).
16. Assemble Tool B. Connect Tool A to Tool B.
!
&
IMG_1009_2_5
Illustration 16 IMG_1028_2_4

Illustration 19
13. Move engine compartment switch (12) to the 17. Connect Tool B to M1-port (18) on the propulsion
LOWER position. Release the switch when prop pump.
rod (13) is seated.
13
PM200 Cold Planer
'
% IMG_0781_2_8
$ & IMG_0781_2_9
18. Move key switch (7) to the START position. 22. Move travel mode switch (22) to the TRAVEL
Release the key switch when the engine starts. position.
19. Operate the engine for a few minutes at low idle. 23. Move electrical controls master switch (21) to the
Push increase engine RPM switch (19). ON position.

position.
IMG_1026_2_5
Illustration 21
20. Monitor engine speed value (20) on the digital

display at the center of the instrument panel.
IMG_0805_2_5
the engine speed reaches 1500 rpm. Illustration 23
21. Monitor the hydraulic oil temperature with Tool C. 26. Move propulsion lever (6) slightly out of the
Operate the machine until the oil temperature NEUTRAL position and into the FORWARD
reaches 45 ± 5 °C (110 ± 10 °F). range.
27. Push propulsion enable switch (23) on top of

WARNING propulsion lever (6).
The travel mode switch must be in the TRAVEL
position during this test. If the travel mode switch
is in the WORK position or in the DIFFERENTIAL
LOCK position, the machine may drive through
the parking brake.
If the machine moves at any time during this test,

immediately move the propulsion lever to
NEUTRAL. Stop the machine and repair the
parking brakes before this test is continued and/
or before the machine is placed back in service.
14
PM200 Cold Planer
"
$
IMG_0794_2_4 IMG_0973_2_4
28. Slowly move propulsion lever (6) forward until the 39. Loosen locknut (25) on the forward multifunction
pressure on gauge (24) on the instrument panel valve. In order to increase pressure, rotate
stabilizes. Record the pressure shown on the adjustment screw (26) clockwise. In order to
gauge as “forward pressure.” Forward pressure decrease pressure, rotate the adjustment screw
should be 420 -0/+10 bar. counterclockwise.
NOTE: The units on gauge (24) are bar; 420 –0/+10 NOTE: One revolution of adjustment screw (26)
bar is equivalent to 42 000 –0/+100 kPa (6100 -0/ changes the pressure by approximately 9300 kPa
+150 psi). (1350 psi).
29. Move propulsion lever (6) to the NEUTRAL 40. Hold adjustment screw (26), and tighten locknut
position. (25).
30. Move propulsion lever (6) slightly out of the 41. If the reverse pressure is outside the specified
NEUTRAL position and into the REVERSE range. range, go to Step 42. If the reverse pressure is
inside the specified range, go to Step 44.
propulsion lever (6).
32. Slowly move propulsion lever (6) reverse until the

pressure reading on Tool A stabilizes. Record the
pressure shown on the Tool A as “reverse
pressure.” Reverse pressure should be 42 000 -
0/+1000 kPa (6100 -0/+150 psi).
33. Move the propulsion lever (6) to the NEUTRAL %

position.

position. &
IMG_0973_2_5

Illustration 26
42. Loosen locknut (27) on the reverse multifunction
36. Move drive selector switch (8) to the OFF valve. In order to increase pressure, rotate
position. adjustment screw (28) clockwise. In order to
decrease pressure, rotate the adjustment screw
37. Move key switch (7) to the OFF position. counterclockwise.
38. If the forward pressure is outside the specified NOTE: One revolution of adjustment screw (28)
range, go to Step 39. If the forward pressure is changes the pressure by approximately 9300 kPa
inside the specified range, go to Step 41. (1350 psi).
43. Hold adjustment screw (28), and tighten locknut

(27).
15
PM200 Cold Planer
44. If an adjustment was made in Step 39 or in Step

42, go to Step 18. NOTICE
45. Remove the tooling. contained during performance of inspection,
46. Reconnect parking brake solenoid (17). machine. Be prepared to collect the fluid with suitable
47. Use engine compartment switch (12) to close the disassembling any component containing fluids.
engine compartment.
48. Close cover (15). Lock the cover with locking Tools and Shop Products Guide,” for tools and
mechanisms (14 and 16). supplies suitable to collect and contain fluids in
Differential Lock Dispose of all fluids according to local regulations
Engagement—Test and mandates.
NOTE: Perform the procedure entitled “Pressure

Table 5
Limiter Valve (Propulsion Pump)—Test and Adjust”
before the following test is performed. Required Tools
Part
WARNING Number
Pressure Gauge
Sudden movement of the machine or release of A 8T-0861 0–60 000 kPa 1
oil under pressure can cause serious injury to (0–8700 psi)
persons on or near the machine. 177-7860 Hose Assembly 1
To prevent injury or death, make sure that the B 8T-41889 Adapter–Union 1
area around the machine is clear of personnel
Male Quick Disconnect
6V-3965 1
C Fitting
WARNING 3J-1907 O-Ring Seal 1
Injury to personnel can result if they are not in D 4C-6500 Digital Thermometer 1
personnel near the machine, and make sure the Table 6
testing, to prevent injury. Make sure checks are Optional Tools(1)
done in an open area. Part
Number
E(2) 198-4234 Digital Pressure Indicator 1
WARNING F (2)
198-4236 Extension Cable 1
Pressure Sensor
moving parts. G(2) 198-4239 0–69 000 kPa 1
(0–10 000 psi)
cut any object or tool that falls or is pushed into (1) The optional tools can be used in place of the analog pressure
them. measurement tools which are specified in the required tool list.
(2) Tool E, Tool F, and Tool G are part of the 198-4240 Digital Pressure
Indicator Group.
area is free of personnel. 1. Drive the machine to a smooth, horizontal
surface.
16
PM200 Cold Planer
! " #
%
$ % & ' IMG_0781_2_10 IMG_1031_2_5
2. Move propulsion lever (6) to the NEUTRAL 12. Unplug the connector from parking brake
position. solenoid (17).
3. Move parking brake switch (2) to the ON 13. Assemble Tool B. Connect Tool A to Tool B.
position.

position.


&
IMG_0940_2_4

Illustration 30
14. Remove the plug from port (18) in differential
9. Move drive selector switch (8) to the OFF lock manifold.
position.
" &
#
$
IMG_1033_2_4
Illustration 31
IMG_1027_2_6
15. Install Tool C in port (18).
Illustration 28
16. Connect Tool B to Tool C.
Open cover (15).
17
PM200 Cold Planer
'
% IMG_0781_2_11
$ & IMG_0781_2_12
17. Move key switch (7) to the START position. 21. Move electrical controls master switch (21) to the
Release the key switch when the engine starts. ON position.
18. Operate the engine for a few minutes at low idle. 22. Move drive selector switch (8) to the ON position.
Push increase engine RPM switch (19).
position.
24. Move travel mode switch (22) to the

DIFFERENTIAL LOCK position.
WARNING
If the parking brake is not functioning properly,
the machine may move during this test.
If the machine moves at any time during this test,

immediately move the propulsion lever to
IMG_1026_2_6 NEUTRAL. Stop the machine and repair the
parking brakes before this test is continued and/
Illustration 33 or before the machine is placed back in service.
display at the center of the instrument panel. 25. Move propulsion lever (6) slightly out of the
Release increase engine RPM switch (19) when NEUTRAL position and into the FORWARD
the engine speed reaches 1500 rpm. range.
20. Monitor the hydraulic oil temperature with Tool D.

reaches 45 ± 5 °C (110 ± 10 °F).
18
PM200 Cold Planer
Piston Pump Neutral—Test

!
and Adjust
WARNING
Sudden movement of the machine or release of
persons on or near the machine.

IMG_0805_2_6 and obstructions before operating the machine.
Illustration 35

propulsion lever (6). Read the pressure on Tool
WARNING
A. The pressure should be case drain pressure. Injury to personnel can result if they are not in
27. Move travel mode switch (22) to the WORK personnel near the machine, and make sure the
position. Read the pressure on Tool A. The personnel are in the operator’s view when
pressure should be 42 000 -0/+1000 kPa (6100 - testing, to prevent injury. Make sure checks are
0/+150 psi). done in an open area.

position.
WARNING
29. Depress decrease engine RPM switch (1). Personal injury can result from rotating and
Release the switch when the engine reaches low moving parts.
idle.
30. Move parking brake switch (2) to the ON cut any object or tool that falls or is pushed into
position. them.
31. Move drive selector switch (8) to the OFF Make sure no one is working on, underneath or
position. close to an engine that is running. Make sure the
33. If the pressure is outside the specified range, go NOTICE

to Step 34. If the pressure is inside the specified Care must be taken to ensure that fluids are
range, go to Step 35. contained during performance of inspection,
34. Inspect the flow divider solenoid on the machine. Be prepared to collect the fluid with suitable
differential lock manifold and/or the shuttle valve containers before opening any compartment or
on the brake and shift manifold. Make necessary disassembling any component containing fluids.
repairs, and go to Step 17.
35. Remove the tooling, and replace the plug in port Tools and Shop Products Guide,” for tools and
(18). supplies suitable to collect and contain fluids in
36. Reconnect parking brake solenoid (17).
37. Use engine compartment switch (12) to close the and mandates.
engine compartment.
38. Close cover (15). Lock the cover with locking

19
PM200 Cold Planer
Table 7
Required Tools
Part
Number
Pressure Gauge
A 8T-0862 0–500 kPa 2
(0–70 psi)
B 6V-4144 Coupler 2
C 6V-3965 Nipple 2
D 3J-1907 O-Ring Seal 2
IMG_0836_2_6
E 4C-6500 Digital Thermometer 1
Illustration 37
1. Drive the machine to a smooth, horizontal 11. Open the compartment which is located under
surface. the left steering wheel. Move engine
Hold the switch until the compartment is
completely open.
! " #
!
$ % & ' IMG_0781_2_13
Illustration 36
2. Move propulsion lever (6) to the NEUTRAL IMG_1009_2_6

position.
Illustration 38
3. Move parking brake switch (2) to the ON 12. Install prop rod (13).
position.
13. Move engine compartment switch (12) to the
4. Make sure rotor switch (9) is in the OFF position. LOWER position. Release the switch when prop
rod (13) is seated.
position.




position.

20
PM200 Cold Planer
18. Move key switch (7) to the START position.

Release the key switch when the engine starts.
19. Operate the engine for a few minutes at low idle.

" Push increase engine RPM switch (17).
#
&
IMG_0973_2_6
Illustration 39
14. Remove the plug from M4 port (15). Remove

plug from M5 port (14).
IMG_1026_2_7
15. Install Tool C and Tool D in M4 port (15). Install
Tool C and Tool D in M5 port (14). Illustration 42
16. Install Tool B on Tool A. Connect Tool A to M4 20. Monitor engine speed value (18) on the digital
port (15), and connect Tool A in M5 port (14). display at the center of the instrument panel.
21. Monitor the hydraulic oil temperature with Tool E.

reaches 45 ± 5 °C (110 ± 10 °F).
22. Read the pressure on the gauge in M4 port (15).

Read the pressure on the gauge in M5 port (14).
The pressure at the M4 port and the pressure at
the M5 port should be equal. If the pressure is
$ equal, go to Step 26. If the pressure is not equal,
go to Step 23.
IMG_0962_2_4
Illustration 40
17. Disconnect connector (16) for the propulsion '

pump EDC.
%

IMG_0961_2_4
Illustration 43
NOTE: Make sure not to adjust the pressure beyond

the rating of the gauges during the next two steps.
% IMG_0781_2_14
Illustration 41
21
PM200 Cold Planer
23. Loosen locknut (19) on the pump adjustment

mechanism. Turn adjustment screw (20) until the WARNING
pressure at M4 port (15) starts to increase over
the pressure at M5 port (14). Record the Injury to personnel can result if they are not in
pressure reading on the gauge which is attached the operator’s view. Allow only essential
to the M4 port, and note the angular position of personnel near the machine, and make sure the
the wrench. personnel are in the operator’s view when
24. Rotate adjustment screw (20) the opposite done in an open area.
direction until the pressure at M5 port (14) is
equal to the pressure which was recorded during
Step 23. Note the angular position of the wrench. WARNING
25. Rotate adjustment screw (20) to the center of the Personal injury can result from rotating and
two positions which were noted in Step 23 and moving parts.
Step 24. Hold the adjustment screw in place,
and tighten locknut (19). Go to Step 22. Moving fan blades and moving parts will throw or
cut any object or tool that falls or is pushed into
26. Depress decrease engine RPM switch (1). them.
Release the switch when the engine reaches low
idle. Make sure no one is working on, underneath or
27. Move key switch (7) to the OFF position. area is free of personnel.
28. Allow the oil to cool. Remove the tooling, and NOTICE
replace the plugs in M4-port (15) and M5-port Care must be taken to ensure that fluids are
(16). contained during performance of inspection,
29. Connect connector (16) to the propulsion pump machine. Be prepared to collect the fluid with suitable
EDC. containers before opening any compartment or
30. Use engine compartment switch (12) to close the
engine compartment. Refer to Special Publication, NENG2500, “Caterpillar
Auxiliary Hydraulic System Caterpillar machines.

Relief Valve (Auxiliary System and mandates.
Main)—Test and Adjust
Table 8
WARNING Required Tools
Sudden movement of the machine or release of Part

Number
persons on or near the machine. Pressure Gauge
A 8T-0859 0–25 000 kPa 1
To prevent injury or death, make sure that the (0–3600 psi)
area around the machine is clear of personnel 177-7860 Hose Assembly 1
B 8T-41889 Adapter–Union 1
22
PM200 Cold Planer
Table 9
Optional Tools(1)
Part
Number
(2)
(2)
Pressure Sensor
F(2) 198-4239 0–69 000 kPa 1
(0–10 000 psi)
IMG_0836_2_7
(2) Tool D, Tool E, and Tool F are part of the 198-4240 Digital Pressure
Indicator Group. Illustration 45

Hold the switch until the hood is completely
open.
! " #
!
$ % & ' IMG_0781_2_15
Illustration 44
IMG_1009_2_7


position.
"
#
NOTE: Water spray switches (4 and 5) are optional. $


IMG_1027_2_7

23
PM200 Cold Planer
14. Unlock two locking mechanisms (14 and 16). 19. Monitor engine speed value (19) on the digital
Open cover (15). display at the center of the instrument panel.
15. Assemble Tool B. Connect Tool A to Tool B. the engine speed reaches 1500 rpm.

reaches 45 ± 5 °C (110 ± 10 °F).
%
IMG_1034_2_4
Illustration 48
16. Connect Tool B to tap (17) in the M-port of the % IMG_0781_2_17

auxiliary manifold.
Illustration 51

ON position.
&
22. Read the pressure on Tool A. The pressure
should be 17 000 -0/+1000 kPa (2470 -0/+140
psi).
23. Press decrease engine RPM switch (1). Release

the switch when the engine reaches low idle.

% IMG_0781_2_16
25. If the pressure is inside the specified range go to
Step 30. If the pressure is outside the specified
Illustration 49
range go to Step 26.

'
IMG_0866_2_4
Illustration 52
26. Remove the cap (21).

IMG_1026_2_8
Illustration 50
24
PM200 Cold Planer
WARNING
moving parts.

them.

! IMG_0867_2_4
Illustration 53 NOTICE
27. Loosen locknut (22) on the relief valve. In order contained during performance of inspection,
to increase pressure, rotate adjustment screw maintenance, testing, adjusting and repair of the
(23) clockwise. In order to decrease pressure, machine. Be prepared to collect the fluid with suitable
rotate the adjustment screw counterclockwise. containers before opening any compartment or
(22). Refer to Special Publication, NENG2500, “Caterpillar
29. Go to Step 17. supplies suitable to collect and contain fluids in
30. Remove the tooling.
31. Use engine compartment switch (12) to close the and mandates.
engine compartment.
32. Close cover (15). Lock the cover with locking Table 10
Required Tools
Relief Valve (Right Side Tool Part

Number Description Qty
Plate)—Test and Adjust Pressure Gauge
A 8T-0855 0–4000 kPa 1
(0–580 psi)
WARNING 177-7860 Hose Assembly 1
Sudden movement of the machine or release of 8T-41889 Adapter–Union 1
oil under pressure can cause serious injury to B
persons on or near the machine. 6V-4143 Valved Coupler 1
4D-6475 90-Degree Elbow 1
area around the machine is clear of personnel C 4C-6500 Digital Thermometer 1
WARNING
25
PM200 Cold Planer
Table 11
Optional Tools(1)
Part
Number
(2)
(2)
Pressure Sensor
F(2) 198-4237 0–3500 kPa 1
(0–500 psi)
IMG_0836_2_8
(2) Tool D, Tool E, and Tool F are part of the 198-4240 Digital Pressure

open.
! " #
!
$ % & ' IMG_0781_2_18
Illustration 54
IMG_1009_2_8


position.




position.

26
PM200 Cold Planer
"
# '
$
IMG_1027_2_8 IMG_1026_2_9
14. Unlock two locking mechanisms (14 and 16). 19. Monitor engine speed value (19) on the digital
Open cover (15). display at the center of the instrument panel.
15. Assemble Tool B. Connect Tool A to Tool B. the engine speed reaches 1500 rpm.

reaches 45 ± 5 °C (110 ± 10 °F).

% IMG_0864_2_5
Illustration 58
16. Connect Tool B to right side plate tap (17) in the % ! IMG_0781_2_20
auxiliary manifold.
Illustration 61

ON position.
&
WARNING
Ensure that the conveyor and/or the canopy will
not contact any obstacles when the machine is
raised.
22. If necessary, use conveyor joystick (21) to lower

% IMG_0781_2_19
the conveyor.
Illustration 59 23. Move all legs joystick (23) to the ALL LEGS UP
position. Release the joystick when the machine
17. Move key switch (7) to the START position. is completely raised.
24. Momentarily move right side plate switch (20) to
18. Operate the engine for a few minutes at low idle. the RAISE position. Release the switch.
27
PM200 Cold Planer

should be 1200 -0/+50 kPa (174 -0/+7 psi).

28. If the pressure is inside the specified range go to %

&
IMG_0869_2_4
"
# Illustration 64
31. Loosen locknut (27) on the relief valve. In order

to increase pressure, rotate adjustment screw
# (28) clockwise. In order to decrease pressure,
rotate the adjustment screw counterclockwise.

(27).
33. Go to Step 17.

IMG_1027_2_9
Illustration 62
29. Close cover (15). Remove two bolts (24 and 25) 35. Close cover (15). Install bolts (24 and 25) and
and washers. Open the cover. the washers. Lock the cover with locking

engine compartment.
Relief Valve (Left Side Plate)—

Test and Adjust
WARNING
$ oil under pressure can cause serious injury to
IMG_0868_2_4 persons on or near the machine.
Illustration 63 To prevent injury or death, make sure that the
30. Remove the cap (26). area around the machine is clear of personnel
WARNING
28
PM200 Cold Planer
WARNING Table 13
Optional Tools(1)
moving parts. Part
Number
Moving fan blades and moving parts will throw or D(2) 198-4234 Digital Pressure Indicator 1
cut any object or tool that falls or is pushed into (2)
them. E 198-4236 Extension Cable 1
Pressure Sensor
Make sure no one is working on, underneath or F(2) 198-4237 0–3500 kPa 1
close to an engine that is running. Make sure the (0–500 psi)
NOTICE (2) Tool D, Tool E, and Tool F are part of the 198-4240 Digital Pressure
Indicator Group.
maintenance, testing, adjusting and repair of the 1. Drive the machine to a smooth, horizontal
machine. Be prepared to collect the fluid with suitable surface.
Refer to Special Publication, NENG2500, “Caterpillar ! " #


and mandates.
Table 12
$ % & '
Required Tools IMG_0781_2_21
Part Illustration 65
Number
Pressure Gauge position.
A 8T-0855 0–4000 kPa 1
(0–580 psi)
177-7860 Hose Assembly 1 position.
position.




position.

29
PM200 Cold Planer

Open cover (15).
15. Assemble Tool B. Connect Tool A to Tool B.

%
IMG_0836_2_9
Illustration 66

IMG_1037_2_4
Hold the switch until the hood is completely Illustration 69
open.
16. Connect Tool B to left side plate tap (17) in the
auxiliary manifold.
!
&
IMG_1009_2_9
Illustration 67 % IMG_0781_2_23
12. Install prop rod (13). Illustration 70
13. Move engine compartment switch (12) to the 17. Move key switch (7) to the START position.
LOWER position. Release the switch when prop Release the key switch when the engine starts.
rod (13) is seated.
"
#
$
IMG_1027_2_10
Illustration 68
30
PM200 Cold Planer

should be 600 -0/+50 kPa (87 -0/+7 psi).
'

IMG_1026_2_10
"
Illustration 71
#

Release increase engine RPM switch (18) when #

reaches 45 ± 5 °C (110 ± 10 °F).
IMG_1027_2_11
Illustration 73
29. Close cover (15). Remove two bolts (24 and 25)
and washers. Open the cover.
% ! IMG_0781_2_22
Illustration 72

ON position.
$ IMG_0868_2_5
WARNING Illustration 74
Ensure that the conveyor and/or the canopy will 30. Remove the cap (26).
not contact any obstacles when the machine is
raised.
22. If necessary, use conveyor joystick (20) to lower

the conveyor.
23. Move all legs joystick (23) to the ALL LEGS UP

is completely raised.
24. Momentarily move left side plate switch (22) to

the RAISE position. Release the switch.
31
PM200 Cold Planer
WARNING
moving parts.

% them.

& area is free of personnel.
IMG_0870_2_4
Illustration 75 Table 14
31. Loosen locknut (27) on the relief valve. In order Required Tools
to increase pressure, rotate adjustment screw Part
(28) clockwise. In order to decrease pressure, Tool Description Qty
Number
A 4C-6500 Digital Thermometer 1
(27). 1. Drive the machine to a smooth, horizontal
surface.
33. Go to Step 17.

! " # $
35. Close cover (15). Install bolts (24 and 25) and
the washers. Lock the cover with locking

engine compartment.
Side Plate Cycle Times—Test

% & '
WARNING
IMG_0781_2_24
Illustration 76
oil under pressure can cause serious injury to 2. Move propulsion lever (7) to the NEUTRAL
persons on or near the machine. position.
To prevent injury or death, make sure that the 3. Move parking brake switch (3) to the ON
area around the machine is clear of personnel position.
4. Make sure rotor switch (10) is in the OFF
position.
WARNING 5. Make sure conveyor switch (12) is in the OFF

position.
personnel near the machine, and make sure the 6. Make sure water spray switches (5, 6, and 11)
personnel are in the operator’s view when are in the OFF position.
done in an open area. NOTE: Water spray switches (5 and 6) are optional.

32
PM200 Cold Planer
8. Press decrease engine RPM switch (1) or

increase engine RPM switch (2).
%
!
IMG_0773_2_4
Illustration 79
IMG_1026_2_11
14. Move left side plate switch (17) to the RAISE
Illustration 77
position. Hold the switch in this position.
9. Monitor engine speed value (13) on the digital 15. When the left side plate is fully raised, release left
display at the center of the instrument panel. side plate switch (17), and start the stopwatch.
Release the engine RPM switch when the engine Record the time required for the slide plate to
speed reaches 1500 rpm. reach the full down position. The time should be
2.5 ± 1 sec.
10. Monitor the hydraulic oil temperature with Tool A.
Operate the machine until the oil temperature 16. Move left slide plate switch (17) to the LOCK
reaches 45 ± 5 °C (110 ± 10 °F). position.
&
" # $ IMG_0781_2_25 IMG_0778_2_4
11. If necessary, move electrical controls master 17. Move right side plate switch (18) to the RAISE
switch (15) to the ON position. position. Hold the switch in this position.
18. When the right side plate is fully raised, release

WARNING right side plate switch (18), and start the
stopwatch. Record the time required for the slide
Ensure that the conveyor and/or the canopy will plate to reach the full down position. The time
not contact any obstacles when the machine is should be 2.5 ± 1 sec.
raised.
19. Move right side plate switch (18) to the LOCK
12. If necessary, use conveyor joystick (14) to lower position.
the conveyor.
20. Place blocks under the front and rear of the side
13. Move all legs joystick (16) to the ALL LEGS UP plates. The blocks should be approximately 254
position. Release the joystick when the machine mm (10 in).
is completely raised.
33
PM200 Cold Planer
26. Momentarily move right side plate switch (18) on

the right front ground control station to the RAISE
position. Release the switch and start the stop
watch. Record the time required for the side
plate cylinder to fully retract. The time should be
' 21 ± 3 sec.
27. Use a suitable lifting device to lift the left side

plate. Connect cable (24) to the left side plate
cylinder with pin (22) and cotter key (23).
Remove the lifting device.
IMG_0774_2_4
Conveyor Cycle Time
Illustration 81
(Swing)—Test and Adjust
21. Simultaneously move front legs switches (19 and
20) and rear legs switch (21) on rear left ground WARNING
control station to the LOWER position. Release
the switches when the side plates touch the Sudden movement of the machine or release of
blocks and the side plate cable has a small oil under pressure can cause serious injury to
amount of slack. persons on or near the machine.

WARNING
! Injury to personnel can result if they are not in
" personnel near the machine, and make sure the
IMG_1040_2_4
Illustration 82
22. Remove cotter key (23). Remove pin (22) from

WARNING
the rod end of the side plate cylinder. Allow cable Personal injury can result from rotating and
(24) to fall free. Repeat this step for the side plate moving parts.
cylinder on the other side of the machine.
23. Momentarily move left side plate switch (17) on cut any object or tool that falls or is pushed into
the left ground level control station to the RAISE them.
position. Release the switch and start the stop
watch. Record the time required for the side Make sure no one is working on, underneath or
plate cylinder to fully retract. The time should be close to an engine that is running. Make sure the
15 ± 2 sec. area is free of personnel.
24. Move left side plate switch (17) to the LOCK

position. Table 15
Required Tools
25. Use a suitable lifting device to lift the left side
plate. Connect cable (24) to the left side plate Part
cylinder with pin (22) and cotter key (23). Number
Remove the lifting device. A 4C-6500 Digital Thermometer 1
1. Drive the machine to a smooth, horizontal

surface.
34
PM200 Cold Planer
11. Press increase engine RPM switch (2) until the

engine reaches high idle.
! " # $
% & ' IMG_0781_2_26
Illustration 83
! " IMG_0781_2_27
3. Move parking brake switch (3) to the ON 12. If necessary, move electrical controls master
position. switch (14) to the ON position.

WARNING
position. Ensure that the conveyor will not contact any
obstacles when the conveyor is moved.
6. Make sure water spray switches (5, 6, and 9) are
in the OFF position. 13. Move conveyor control joystick (13) to the RIGHT
position. Release the joystick when the conveyor
NOTE: Water spray switches (5 and 6) are optional. is in the full right position.
7. If necessary, move engine control switch (4) to 14. Simultaneously start the stop watch and move
the MANUAL position. conveyor control joystick (13) to the FULL LEFT
position. Record the amount of time required for
8. Press decrease engine RPM switch (1) or the conveyor to reach the full left position.
increase engine RPM switch (2). Release the joystick. The time should be 18 ±3
sec.
15. Simultaneously start the stop watch and move

conveyor control joystick (13) to the RIGHT
position. Record the amount of time required for
the conveyor to reach the full right position.
Release the joystick. The time should be 18 ±3
sec.

Move key switch (12) to the OFF position. If either
time is outside the specified range, go to Step
IMG_1026_2_12
17. If both times are inside the specified range,
go to Step 26.
Illustration 84

Release the engine RPM switch when the engine
speed reaches 1500 rpm.

reaches 45 ± 5 °C (110 ± 10 °F).
35
PM200 Cold Planer
#
$
%
&
!
'
IMG_1027_2_12 IMG_0873_2_4
17. Unlock two locking mechanisms (15 and 17). 23. Loosen locknut (22) on the flow control valve. In
order to decrease the speed, rotate adjustment
18. Remove two bolts (18 and 19) and the washers. screw (23) clockwise. In order to increase the
Open cover (16). speed, rotate the adjustment screw
counterclockwise.
19. If the swing left time is out of specification, go to
Step 20. If the swing left time is inside the 24. Hold adjustment screw (23), and tighten locknut
specified range, go to Step 22. (22).
25. Move key switch (12) to START. Release the

switch when the engine starts. Go to Step 7.
26. If necessary, close cover (16). Install bolts (18

and 19) and the washers. Lock the cover with
locking mechanisms (15 and 17).
Conveyor Cycle Time (Raise

and Lower)—Test and Adjust
PIN: P1C406-Up
IMG_0862_2_4
Illustration 87 WARNING
20. Loosen locknut (20) on the flow control valve. In Sudden movement of the machine or release of
order to decrease the speed, rotate adjustment oil under pressure can cause serious injury to
screw (21) clockwise. In order to increase the persons on or near the machine.
speed, rotate the adjustment screw
counterclockwise. To prevent injury or death, make sure that the
21. Hold adjustment screw (21), and tighten locknut and obstructions before operating the machine.
(20).
Table 16
22. If the swing right time is outside the specified
range, go to Step 23. If the swing right time is Required Tools
Part
Number
A 1U-7839 Stopwatch 1

surface.
36
PM200 Cold Planer
! " # $

% & ' IMG_0781_2_69

! ! IMG_0781_2_98
2. Move propulsion lever (7) to the NEUTRAL 11. Press decrease engine RPM switch (1). Release
position. the switch when the engine reaches low idle.
4. Make sure rotor switch (8) is in the OFF position. 13. Move conveyor position joystick (13) to the
LOWER position.
position. 14. Release conveyor position joystick (13) when the
conveyor is fully lowered.
in the OFF position. 15. Move conveyor position joystick (13) to the
RAISE position. Record the amount of time
NOTE: Water spray switches (5 and 6) are optional. required for the conveyor to fully raise. The time
required to fully raise the conveyor should be 17
7. If necessary, move engine control switch (4) to ± 2 seconds.
16. Move conveyor position joystick (13) to the
8. Push increase engine RPM switch (2) or LOWER position. Record the amount of time
decrease engine RPM switch (1). required for the conveyor to fully lower. The time
required to fully lower the conveyor should be 17
± 2 seconds.
17. If the cycle times are outside the specified

range, the pump is not operating within design
parameters. Go to Step 18 in order to adjust the
appropriate solenoid valve.
If the cycle times are within the specified range,

go to Step 25.
IMG_1026_2_29
Illustration 90

10. Monitor the hydraulic oil temperature with Tool

(A). Operate the machine until the oil
temperature reaches 45 ± 5 °C (110 ± 10 °F).
37
PM200 Cold Planer
'
"
IMG_0836_2_13 IMG_7567_2_4
18. Open the compartment that is located under the Conveyor Raise Solenoid Adjustment Screw
left steering wheel. Move engine compartment
switch (14) to the RAISE position. Hold the switch 22. If the time required to fully raise the conveyor
until the hood is completely open. was out of specification, rotate adjustment screw
(19), Rotate the adjustment screw clockwise to
increase the time to fully raise the conveyor.
Rotate the adjustment screw counterclockwise to
decrease the time to fully raise the conveyor.
#
IMG_1009_2_13
Illustration 93

IMG_7566_2_4

LOWER position. Release the switch when prop Illustration 96
rod (23) is seated. Conveyor Lower Solenoid Adjustment Screw
23. If the time required to fully lower the conveyor

$
% was out of specification, rotate adjustment screw
(20), Rotate the adjustment screw clockwise to
increase the time to fully lower the conveyor.
rotate adjustment screw counterclockwise to
& decrease the time to fully lower the conveyor.
24. Go to Step 13 and retest.
25. Remove the tooling and close the covers.
IMG_1027_2_19
Illustration 94

Open cover (17).
38
PM200 Cold Planer
Standard Water Pump RPM—

Test ! " #
WARNING

and obstructions before operating the machine. $ % & ' IMG_0781_2_28
Illustration 97
WARNING 2. Move propulsion lever (6) to the NEUTRAL

position.
the operator’s view. Allow only essential 3. Move parking brake switch (2) to the ON
personnel near the machine, and make sure the position.
testing, to prevent injury. Make sure checks are 4. Make sure rotor switch (9) is in the OFF position.
position.
WARNING 6. Make sure water spray switches (4, 5, and 10)
Personal injury can result from rotating and are in the OFF position.
moving parts.
cut any object or tool that falls or is pushed into 7. If necessary, move engine control switch (3) to
them. the MANUAL position.
Make sure no one is working on, underneath or 8. Press decrease engine RPM switch (1). Hold the
close to an engine that is running. Make sure the switch until the engine reaches low idle.
position.
Table 17
Required Tools 10. Move key switch (7) to the OFF position.
Tool Part Description Qty 11. Open the water pump compartment on the front-
Number left side of the machine.
A(1) 1U-7771 Tachometer 1
(1)
B 1U-6605 Reflective Tape 1
(1) Tool A and Tool B are part of the 1U-6602 Photo-Tach Group.

surface.
!
IMG_1045_2_4
Illustration 98
39
PM200 Cold Planer
12. Remove two screws (12) and remove grill (13). 16. Monitor engine speed value (16) on the digital

" reaches 45 ± 5 °C (110 ± 10 °F).
IMG_1047_2_4
Illustration 99
13. Place reflective tape on the motor output shaft

(14).
% % IMG_0781_2_30
# Illustration 102

ON position.
19. Move water spray switch (10) to the MANUAL

position.
20. Use Tool A to measure the speed of the motor

output shaft (14). The speed should be 2900 -
% 100/+0 RPM.
IMG_0781_2_29
21. Move water spray switch (10) to the OFF

Illustration 100
position.
Release the key switch when the engine starts. 22. Press decrease engine RPM switch (1). Release
Push increase engine RPM switch (15). 23. Move key switch (7) to the OFF position.
24. If the speed is outside the specified range, go to

Step 25. If the speed is inside the specified
range, go Step 30.
$
IMG_1026_2_13
Illustration 101
40
PM200 Cold Planer
Optional Water Pump RPM—

&
' Test

WARNING

IMG_1027_2_13 and obstructions before operating the machine.
Illustration 103
25. Unlock two locking mechanisms (18 and 20). WARNING

26. Remove two bolts (21 and 22) and the washers. Injury to personnel can result if they are not in
Open cover (19). the operator’s view. Allow only essential
!
WARNING
moving parts.

" them.
IMG_0872_2_4

Illustration 104
27. Loosen locknut (23) on the flow control valve. In area is free of personnel.
screw (24) clockwise. In order to increase the
speed, rotate the adjustment screw Table 18
counterclockwise. Required Tools
28. Hold adjustment screw (24), and tighten locknut Part

(23). Number
29. Go to Step 14. (1)
B 1U-6605 Reflective Tape 1
30. If necessary, close cover (19). Install bolts (21 C 4C-6500 Digital Thermometer 1
and 22) and the washers. Lock the cover with
locking mechanisms (18 and 20). (1) Tool A and Tool B are part of the 1U-6602 Photo-Tach Group.
31. Place grill (13) on the motor, and install two 1. Drive the machine to a smooth, horizontal
screws (12). surface.
41
PM200 Cold Planer
! " #
!
$ % & ' IMG_0781_2_31 IMG_1049_2_4
2. Move propulsion lever (6) to the NEUTRAL 12. Remove two screws (12) and remove grill (13).
position.

position.

position.
"

IMG_1051_2_4

Illustration 107
13. Place reflective tape on motor output shaft (14).

position. #
11. Open the water pump compartment on the front-

left side of the machine.
% IMG_0781_2_32
Illustration 108


42
PM200 Cold Planer
&
$ '
IMG_1026_2_14 IMG_1027_2_14
16. Monitor engine speed value (16) on the digital 25. Unlock two locking mechanisms (18 and 20).
Release increase engine RPM switch (15) when 26. Remove two bolts (21 and 22) and the washers.
the engine speed reaches 1500 rpm. Open cover (19).

reaches 45 ± 5 °C (110 ± 10 °F).
!
"
"
IMG_0872_2_5
Illustration 112
% % 27. Loosen locknut (23) on the flow control valve. In

IMG_0781_2_33
Illustration 110
18. Move electrical controls master switch (17) to the counterclockwise.
ON position.
19. Move water spray switch (4) to the MANUAL (23).
position.
29. Go to Step 14.
20. Use Tool A to measure the speed of the motor
output shaft. The speed should be 2900 -100/+0 30. If necessary, close cover (19). Install bolts (21
RPM. and 22) and the washers. Lock the cover with
locking mechanisms (18 and 20).
21. Move water spray switch (4) to the OFF position.
31. Place grill (13) on the motor, and install two
22. Press decrease engine RPM switch (1). Release screws (12).
24. If the speed is outside the specified range, go to

Step 25. If the speed is inside the specified
range, go Step 30.
43
PM200 Cold Planer
Water Pressure (Optional

Washdown Pump)—Test and ! " # $
Adjust
WARNING
To prevent injury or death, make sure that the % & ' IMG_0781_2_41
and obstructions before operating the machine. Illustration 113
WARNING
position.

position.
position.

WARNING in the OFF position.
Personal injury can result from rotating and NOTE: Water spray switches (5 and 6) are optional.
moving parts.
Moving fan blades and moving parts will throw or the MANUAL position.
them. 8. Press decrease engine RPM switch (1) or
increase engine RPM switch (2).

Table 19
Required Tools
Part
Number

surface.
IMG_1026_2_15
Illustration 114


reaches 45 ± 5 °C (110 ± 10 °F).
44
PM200 Cold Planer
"
IMG_1053_2_4 IMG_1059_2_5
13. Connect hose (14) to the outlet port on the

NOTICE pump.
In order to prevent possible pump damage, make
sure that the water tank contains enough water to NOTE: Hose (14) should be stored in the water
complete this test. pump compartment.
11. Use water sight gauge (12) to check the water

level in the water tank. Add water to the tank if
necessary.
#
"
$
!
IMG_1060_2_3
Illustration 118
14. Connect spray gun (15) to hose (14) and

IMG_1061_2_4 connect nozzle (16) to the spray gun.
Illustration 116
12. Open gate valve (13) for the high-pressure

system.
NOTE: The valve is open when the lever is in-line

with the hose, as shown in the above illustration.
%
IMG_1056_2_3
Illustration 119
15. Move key switch (17) on the rear left ground

control station to the ON position.
45
PM200 Cold Planer
19. Move water washdown switch (18) on the front

left ground control station to the OFF position.

control station to the OFF position.
&

IMG_0771_2_4
Illustration 120
16. Move water washdown switch (18) on the front

left ground control station to the ON position.

IMG_0781_2_43
Illustration 123

22. Move key switch (21) on the instrument panel to

the OFF position.
23. If the pressure is outside the specified range, go

' to Step 24. If the pressure is inside the specified
range, go to Step 33.
IMG_1060_2_4
Illustration 121
!
17. Actuate trigger (19) on spray gun (15).
"

IMG_1027_2_15
Illustration 124

Open cover (23).
IMG_1059_2_6
Illustration 122
18. Read the maximum pressure on gauge (20). The

pressure should be 160 ± 10 bar (2320 ± 140
psi).
NOTE: The unit of measure on pressure gauge (20)

is bar. One bar equals 100 KPa.
46
PM200 Cold Planer
Optional Water Loading Pump

RPM—Test and Adjust
#
WARNING
$
IMG_0862_2_5
Illustration 125 and obstructions before operating the machine.
WARNING
to decrease the pressure, rotate adjustment
pressure, rotate the adjustment screw
counterclockwise.
(25).
the START position. Release the switch when the
engine starts.
WARNING
Push increase engine RPM switch (2). Personal injury can result from rotating and
moving parts.
display at the center of the instrument panel. Moving fan blades and moving parts will throw or
Release increase engine RPM switch (2) when cut any object or tool that falls or is pushed into
the engine speed reaches 1500 rpm. them.

reaches 45 ± 5 °C (110 ± 10 °F).
NOTICE Table 20
In order to prevent possible pump damage, make Required Tools
sure that the water tank contains enough water to
complete this test. Part
Number
31. Check the level in water sight gauge (12). Add
water to the tank if necessary. B (1)
1U-6605 Reflective Tape 1
32. Go to Step 15. C 4C-6500 Digital Thermometer 1

33. Close gate valve (13). Remove water hose (14).
Close the covers. 1. Drive the machine to a smooth, horizontal
surface.
47
PM200 Cold Planer

reaches 45 ± 5 °C (110 ± 10 °F).
! " # $
% & ' IMG_0781_2_42
Illustration 126

IMG_1053_2_5
position.
Illustration 128
position.
NOTICE
4. Make sure rotor switch (8) is in the OFF position. In order to prevent system overflow, the water tank
must not be over filled.
position. 11. Check the level in water sight gauge (12). The
water tank must not be full.
in the OFF position.


Push increase engine RPM switch (2) or
decrease engine RPM switch (1). !
IMG_1071_2_4

Illustration 129
12. Open the front right compartment. Open gate

valve (13) for the water loading pump.
NOTE: The valve is open when the lever is in line

with the hose, as shown.
IMG_1026_2_20
Illustration 127

48
PM200 Cold Planer
"
#
IMG_1065_2_4 IMG_1067_2_4
13. Connect hose (14) to inlet port (15) on the pump. 16. Place Tool B on motor output shaft (20).
Place the other end of the hose in a clean water
source.
NOTE: Hose (14) should be stored in the water

pump compartment.
IMG_1056_2_4
$
Illustration 134

IMG_1069_2_4
Illustration 131
14. Close valve (16).
22
%
&
IMG_0778_2_5
Illustration 135
'
18. Move water loading switch (22) on the front right
IMG_1066_2_4
ground control station to the ON position.
Illustration 132
19. Use Tool A to measure the speed of the shaft.
15. Remove two screws (17 and 19) and remove grill The speed should be 2800 ± 50 rpm.
(18) that covers the pump drive shaft.
20. Move water loading switch (22) on the front right
ground control station to the OFF position.
49
PM200 Cold Planer
21. Move key switch (21) on rear left ground control

station to the OFF position.

%
&
IMG_0862_2_6
!
IMG_0781_2_44 Illustration 138
Illustration 136 26. Loosen locknut (27) on the relief valve. In order
to decrease the speed, rotate adjustment screw
22. Depress decrease engine RPM switch (1). (28) clockwise. In order to increase the speed,
Release the switch when the engine reaches low rotate the adjustment screw counterclockwise.
idle.
23. Move key switch (23) on the instrument panel to (27).
the OFF position.
24. If the speed is outside the specified range, go to the START position. Release the switch when the
Step 25. If the speed is inside the specified engine starts.
range, go to Step 34.
"
# 30. Monitor engine speed value (11) on the digital
$
reaches 45 ± 5 °C (110 ± 10 °F).
NOTICE
IMG_1027_2_16 In order to prevent system overflow, the water tank
must not be over filled.
Illustration 137
25. Unlock two locking mechanisms (24 and 26). 32. Check the level in water sight gauge (12). The
Open cover (25). water tank must not be full.
33. Go to Step 17.
34. Close gate valve (13). Remove water hose (14).

Close the covers.
50
PM200 Cold Planer
Rear Column Lower Cycle

Time—Test and Adjust ! " #
NOTE: The rear column lower time can be adjusted.
The rear column raise time cannot be adjusted.
WARNING
$ % & ' IMG_0781_2_45
area around the machine is clear of personnel Illustration 139
and obstructions before operating the machine. 2. Move propulsion lever (6) to the NEUTRAL
position.
WARNING 3. Move parking brake switch (2) to the ON

position.
the operator’s view. Allow only essential 4. Make sure rotor switch (9) is in the OFF position.
personnel are in the operator’s view when 5. Make sure conveyor switch (11) is in the OFF
testing, to prevent injury. Make sure checks are position.
WARNING NOTE: Water spray switches (4 and 5) are optional.
moving parts. 7. If necessary, move engine control switch (3) to
cut any object or tool that falls or is pushed into 8. Depress increase engine RPM switch (1).
them. Release the switch when the engine reaches
high idle.
close to an engine that is running. Make sure the 9. Monitor the hydraulic oil temperature with Tool A.
area is free of personnel. Operate the machine until the oil temperature
reaches 45 ± 5 °C (110 ± 10 °F).
Table 21 10. If necessary, move electrical controls master

Required Tools switch (7) to the ON position.
Tool Part Description Qty 11. Move all legs joystick (8) to the ALL UP position.
Number Release the joystick when the machine stops.

surface.
51
PM200 Cold Planer
$
%
&

! IMG_0774_2_5 IMG_1027_2_17
12. Move moldboard switch (12) on the rear left 17. Unlock two locking mechanisms (16 and 18).
ground control station to the LIFT position. Open cover (17).
Release the switch when the rotor tips are visible.
Do not open the rear door.
13. Simultaneously start the stop watch and move

the rear legs switch (13) on the left rear ground
control station to the LOWER position. Record
the amount of time required to lower the machine
until the tips of the rotor just touch the ground.
Release the switch. The time should be 16 ± 1
seconds.
'
IMG_0864_2_4
" Illustration 143
18. Loosen locknut (19) on the flow control valve. In

counterclockwise.
# 19. Hold adjustment screw (20), and tighten locknut

IMG_0781_2_46
(19).
Illustration 141
14. Depress decrease engine RPM switch (14). Release the switch when the engine starts.
idle. 21. Go to Step 7.
15. Move key switch (15) to the OFF position. 22. If necessary, close the machine.
16. If the time is outside the specified range, go to

Step 17. If the time is inside the specified range,
go to Step 22.
52
PM200 Cold Planer
Moldboard Pressure—Test
! " # $
WARNING

% & ' IMG_0781_2_47
WARNING Illustration 144
Injury to personnel can result if they are not in 2. Move propulsion lever (7) to the NEUTRAL
the operator’s view. Allow only essential position.
personnel are in the operator’s view when 3. Move parking brake switch (3) to the ON

WARNING position.
Personal injury can result from rotating and 6. Make sure water spray switches (5, 6, and 9) are
moving parts. in the OFF position.
Moving fan blades and moving parts will throw or NOTE: Water spray switches (5 and 6) are optional.
them. 7. If necessary, move engine control switch (4) to
8. Depress increase engine RPM switch (2) or
decrease engine RPM switch (1).
Table 22
Required Tools

Part
Number

surface.
IMG_1026_2_22
Illustration 145


reaches 45 ± 5 °C (110 ± 10 °F).
53
PM200 Cold Planer
!
$
IMG_0781_2_48 IMG_0781_2_49
11. If necessary, move electrical controls master 19. Depress decrease engine RPM switch (1).
switch (12) to the ON position. Release the switch when the engine reaches low
idle.
12. Move moldboard switch (13) on the instrument
panel to the FLOAT position. 20. Move key switch (16) to the OFF position.
Steering Wheel Rotation—Test
WARNING
"
# area around the machine is clear of personnel
IMG_0946_2_4

13. Rotate moldboard pressure valve (14) fully Injury to personnel can result if they are not in
counterclockwise. the operator’s view. Allow only essential
14. Read the pressure on moldboard pressure personnel are in the operator’s view when
gauge (15) on the instrument panel. The testing, to prevent injury. Make sure checks are
pressure should be 0 to 2 bar. done in an open area.
NOTE: The unit of measure on moldboard pressure
gauge (15) is bar. One bar equals 100 KPa.
WARNING
15. Rotate moldboard pressure valve (14) fully
clockwise. Personal injury can result from rotating and
moving parts.
16. Read the pressure on moldboard pressure
gauge (15) on the instrument panel.
them.
17. The pressure should be 42 ± 2 bar.
NOTE: Moldboard pressure must be less than 10 close to an engine that is running. Make sure the
bar during normal machine operation. area is free of personnel.
18. Rotate moldboard pressure valve (14) until the
pressure is 0-to-10 bar.
54
PM200 Cold Planer
Table 23
Required Tools

Part
Number

surface.
IMG_1026_2_23
! " # $
Illustration 150


% & ' IMG_0781_2_50
reaches 45 ± 5 °C (110 ± 10 °F).
Illustration 149

position.

position.
!


position.
! "
6. Make sure water spray switches (5, 6, and 9) are IMG_0781_2_51

Illustration 151
NOTE: Water spray switches (5 and 6) are optional. 11. If necessary, move electrical controls master
switch (14) to the ON position.
the MANUAL position. 12. If necessary, move steering mode switch (12) on
instrument panel to the FRONT STEER position.
8. Depress increase engine RPM switch (2) or
decrease engine RPM switch (1). 13. Rotate the steering wheel to the full left position.
14. Rotate the steering wheel to the full right position.

Record the number of rotations required to move
from stop to stop. The required rotations should
be 14.5 ± 1 revolutions.
15. Rotate the steering wheel to the full left position.

Record the number of rotations required to move
from stop to stop. The required rotations should
be 14.5 ± 1 revolutions.
16. Rotate the steering wheel so the front tracks are

in the straight travel position.
55
PM200 Cold Planer
17. Depress decrease engine RPM switch (1).

idle.
! "
Electronic Controls
Engine Antistall—Calibrate
# $ % &
WARNING
IMG_0781_2_52
Illustration 152
oil under pressure can cause serious injury to 2. Move propulsion lever (5) to the NEUTRAL
To prevent injury or death, make sure that the 3. Make sure rotor switch (6) is in the OFF position.
and obstructions before operating the machine. 4. Make sure conveyor switch (8) is in the OFF
position.
WARNING 5. Make sure water spray switches (3, 4, and 7) are

the operator’s view. Allow only essential NOTE: Water spray switches (3 and 4) are optional.
personnel are in the operator’s view when 6. If necessary, move engine control switch (2) to
testing, to prevent injury. Make sure checks are the MANUAL position.
WARNING
moving parts. '

them.

1. Drive the machine to a smooth, horizontal IMG_1026_2_24
surface. The machine must be driven during this

Illustration 153
test. Ensure that the area around the machine is
clear. 8. Monitor engine speed value (9) on the digital
9. Monitor the engine oil temperature (10) on the

digital display. Operate the machine until the oil
56
PM200 Cold Planer

%
! #
IMG_0781_2_53 IMG_0781_2_54
10. Depress the increase engine RPM switch (1).

Release the switch when the engine is at high WARNING
idle. If necessary, move electrical controls
master switch (11) to the ON position. The machine will move in the following steps.
Make sure the area around the machine is clear
11. If necessary, move the drive selector switch (12) of personnel and obstructions before the next
to the ON position. step is completed.
12. If necessary move travel speed switch (13) to 14. Move propulsion lever (5) to the full forward
the WORK position. position and depress the propulsion enable
switch (17).
$
" #
IMG_0800_2_4
&
IMG_0800_2_5
Illustration 155
13. Move antistall switch (16) to the AUTO position. Illustration 157
Move antistall speed selector switch (14) to the 15. The machine should move. If the machine
HI position. Place antistall dial (15) in the center moves, go to Step 17. If the machine does not
position. move, remove plug (18).
NOTE: Maximum speed is 10 km/h (6 mph) when

antistall speed selector switch (14) is in the HI
position.
57
PM200 Cold Planer
NOTE: Maximum speed is 3 km/h (2 mph) when

antistall speed selector switch (14) is in the LOW
position.
22. Depress decrease engine RPM switch (20) once.

The engine speed should be 1800 RPM. The
machine should stop when the engine speed is
1800 RPM.
23. If the machine did not operate as described

above, depress increase engine RPM switch (1).
' Release the switch when the engine is at high
idle. Move antistall speed selector switch (14) to
IMG_1119_2_4
the HI position. Go to Step 15.
Illustration 158
24. If necessary, replace plug (18).
16. Rotate potentiometer (19) counterclockwise until
the machine begins to move. 25. Depress decrease engine RPM switch (20).
idle.

Grade and Slope Offset—

Calibrate
WARNING
IMG_0781_2_55 persons on or near the machine.
Illustration 159 To prevent injury or death, make sure that the
17. Depress decrease engine RPM switch (20)
twice. The engine speed should decrease to
1800 RPM.
18. The machine should stop when the engine

speed is 1800 RPM. If the machine stops before
WARNING
the engine speed reaches 1800 RPM, rotate Injury to personnel can result if they are not in
adjustment potentiometer (19) counterclockwise the operator’s view. Allow only essential
until the machine begins to move. Then rotate personnel near the machine, and make sure the
the adjustment potentiometer clockwise until the personnel are in the operator’s view when
machine just stops. testing, to prevent injury. Make sure checks are
19. Move antistall speed selector switch (14) to the
MED position. The machine should not move
when the engine is at 1800 RPM.
WARNING
NOTE: Maximum speed is 6 km/h (4 mph) when Personal injury can result from rotating and
antistall speed selector switch (14) is in the MED moving parts.
position.
20. Depress increase engine RPM switch (1) once. cut any object or tool that falls or is pushed into
The machine should move when the engine them.
speed is greater than 1800 RPM.
21. Move antistall speed selector switch (14) to the close to an engine that is running. Make sure the
LOW position. The machine should move when area is free of personnel.
the engine speed is greater than 1800 RPM.
58
PM200 Cold Planer
Table 24
Required Tools Release increase engine RPM switch (1) when
Part the engine speed reaches 1500 rpm.
Number
A 4C-6500 Digital Thermometer 1 Operate the machine until the oil temperature
reaches 45 ± 5 °C (110 ± 10 °F).
surface.

! "
IMG_0781_2_57
# $ % & IMG_0781_2_56 Illustration 162
Illustration 160 10. Depress decrease engine RPM switch (10).

release the switch when the engine is at low idle.
position. 11. Remove a grade and slope unit from its storage
location. The grade and slope units are stored in
3. Make sure rotor switch (6) is in the OFF position. a compartment under the instrument panel.

position.



IMG_1120_2_4
Illustration 163
12. Open the compartment at the rear right side of

'
the machine. Connect the two cables from the
grade and slope unit to connectors (11 and 12).
IMG_1026_2_25
Illustration 161
59
PM200 Cold Planer
21. Press auto switch (17). Watch the right front leg.
Rotate dial (19) clockwise until the right side of
the machine lowers. Rotate the dial
counterclockwise until the right side of the
machine just stops. Record the number in
display. Rotate the dial counterclockwise until the
new value in the display is 15 less than the
recorded value.
22. Press auto switch (17).
23. Press set switch (20).

! " # IMG_0781_2_58
24. Move power switch (19) to the OFF position.
Illustration 164
25. Move grade and slope switch (15) on the
13. If necessary, move electrical controls master instrument panel to the OFF position.
switch (13) to the ON position.
26. Disconnect the two cables from the grade and
14. Move the drive selector switch (14) to the ON slope unit from connectors (11 and 12).
position.
27. Repeat the procedure for the left side of the
15. Move grade and slope switch (15) on the machine.
instrument panel to the MANUAL position.
28. Place the grade and slope unit in its storage
16. Mount the grade and slope unit in the holder at location.
the right corner of the machine.
29. Stop the engine.
Rear Steering Potentiometer—

$ Calibrate
%
WARNING
& oil under pressure can cause serious injury to

' area around the machine is clear of personnel
IMG_1133_2_4
Illustration 165
17. Move power switch (18) to the ON position. Wait

for the system to initialize. WARNING
18. Depress and hold set switch (20). Cycle power Injury to personnel can result if they are not in
switch (18) to the OFF position and then back to the operator’s view. Allow only essential
the ON position. Release the set switch. personnel near the machine, and make sure the
19. Rotate dial (19) until “OFS” appears in display testing, to prevent injury. Make sure checks are
(16). done in an open area.
20. Press auto switch (17). Watch the right front leg.
Rotate dial (19) clockwise until the right side of
the machine rises. Rotate the dial
counterclockwise until the right side of the
machine just stops. Record the number in
display (16). Rotate the dial counterclockwise
until the new value in the display is 15 less than
the recorded value.
60
PM200 Cold Planer
WARNING
moving parts.

them.

IMG_1026_2_16
1. Drive the machine to a smooth, horizontal Illustration 167

surface.
10. Press “8” key (11) on the display twice.
! " # !
" #
$ % & ' IMG_0781_2_35

IMG_1499_2_4
Illustration 166
Illustration 168
position. 11. Press “1” key (12). Press “5” key (13). Press “2”
key (14). Press “6” key (15).
position.


position.


IMG_1501_2_4
Illustration 169
8. Push decrease engine RPM switch (1). Release
the switch when the engine reaches low idle. 12. Press “1” key (12) in order to choose “rear steer
potentiometer.”
position.
61
PM200 Cold Planer
$ &
% '
IMG_1503_2_4 IMG_1506_2_4
13. Rotate rear steering potentiometer (16) to the NOTE: If a value in any of the boxes on the display
MINIMUM position. is red, go to Step 13. If the value is still red after a
second calibration attempt, record the values from
the display unit. Then, test the potentiometer with a
multimeter. If the values on the multimeter
correspond with the values from the display, replace
the rear steering potentiometer. If the values on the
multimeter do not match the values on the display,
the display unit may have a fault.
16. Depress “OK” key (19) in order to save the

currently displayed values.
NOTE: If “7” key (18) is chosen, the values on the

$ display will be replaced with default values which
are stored in the software memory. If “ESC” key (17)
IMG_1504_2_4
is chosen, the display returns to the previous menu
without the currently displayed values being saved.
Illustration 171
14. Rotate rear steering potentiometer (16) to the

MAXIMUM position.
%
$
IMG_0781_2_36
Illustration 174
IMG_1505_2_4
17. After the values have been saved, press “ESC”
key (17) in order to return to the previous screen
Illustration 172
and perform other calibrations. If no other
15. Rotate rear steering potentiometer (16) to the “0” calibrations are to be performed, move key start
position. switch (20) to the OFF position.
62
PM200 Cold Planer
Steering Sensor (Front)— 3. Move propulsion lever (6) to the NEUTRAL

position.
Replace
position.
WARNING 5. Make sure rotor switch (8) is in the OFF position.
oil under pressure can cause serious injury to 6. Make sure conveyor switch (10) is in the OFF
To prevent injury or death, make sure that the 7. Make sure water spray switches (4, 5, and 9) are
area around the machine is clear of personnel in the OFF position.
WARNING 8. If necessary, move engine control switch (3) to

the operator’s view. Allow only essential 9. Depress decrease engine RPM switch (1).
personnel near the machine, and make sure the Release the switch when the engine reaches low
personnel are in the operator’s view when idle.
done in an open area. 10. Move key switch (7) to the OFF position.
11. If the machine is equipped with an existing

WARNING sensor and the mounting brackets for the sensor
and the sensor cable are correctly placed, go to
Personal injury can result from rotating and Step 21. If one or both of the mounting brackets
moving parts. are missing or incorrectly placed, go to Step 12.

them. "
!
area is free of personnel. #

surface.
$ %
2. Rotate the steering wheel so the front tracks are
in the straight travel position. IMG_0917_2_4
Illustration 176
12. Attach steering sensor mounting bracket (12) to

! " # the cylinder tube. Leave the bracket loose
enough on the cylinder tube so the bracket can
slide when the mounting distance is adjusted.
13. Attach cable bracket (14) to the rod end of the

cylinder.
14. Attach cable clip (17) to the end of sensor cable

(16). Extend the sensor cable and measure the
maximum length from the face of the sensor to
$ % & ' IMG_0781_2_87 the tip of cable clip (17).
Illustration 175 15. Attach steering sensor (15) to steering sensor

mounting bracket (12).
63
PM200 Cold Planer
16. Connect sensor cable (16) to cable bracket (14)

with cable clip (17). WARNING
NOTICE the operator’s view. Allow only essential
Make sure that the position of the steering sensor personnel near the machine, and make sure the
does not interfere with other components of the personnel are in the operator’s view when
machine. testing, to prevent injury. Make sure checks are
17. Position steering sensor (15) so that the distance
from the face of the sensor to cable bracket (14)
is equal to approximately one half of the WARNING
maximum cable length that was measured in
Step 14. Personal injury can result from rotating and
moving parts.
18. Securely attach steering sensor mounting
bracket (12) to the cylinder. Moving fan blades and moving parts will throw or
19. Connect wiring harness (13) to steering sensor them.
(15).
20. Go to Step 26. close to an engine that is running. Make sure the
21. Disconnect wiring harness (13) from existing
steering sensor (15). 1. Drive the machine to a smooth, horizontal
surface.
22. Disconnect cable clip (17) from cable bracket
(14) and sensor cable (16).
23. Remove existing steering sensor (15) from

mounting bracket (12) and attach the new ! " #
steering sensor in its place.
24. Connect wiring harness (13) to steering sensor

(15).

with cable clip (17).
26. Complete the replacement by performing the $ % & '

“Steering Sensor (Front)—Calibrate” procedure. IMG_0781_2_37
Illustration 177
Steering Sensor (Front)—
Calibrate position.

WARNING position.
Sudden movement of the machine or release of 4. Make sure rotor switch (8) is in the OFF position.
persons on or near the machine. 5. Make sure conveyor switch (10) is in the OFF
position.

64
PM200 Cold Planer
8. Push decrease engine RPM switch (1). Release 13. Rotate the steering wheel to the full right position.
the switch when the engine reaches low idle. Rotate the steering wheel to the full left position.
Rotate the steering wheel to the straight travel
9. Move drive selector switch (7) to the OFF position.
position.

%
$ &
IMG_1509_2_4
IMG_1026_2_17
Illustration 181
Illustration 178
NOTE: If a value in any of the boxes on the display
10. Press “8” key (11) on the display twice. is red, go to Step 13. If the value is still red after a
the display unit. Then, test the sensor with a
! multimeter. If the values on the multimeter
correspond with the values from the display, attempt
" # to adjust the position of the steering sensor. Refer to
“Steering Sensor (Front)—Replace.” If the front
steering sensor cannot be calibrated after the
sensor is adjusted and/or replaced, the display unit
may have a fault.
14. Depress “OK” key (18) in order to save the


IMG_1499_2_5
display will be replaced with default values which
are stored in the software memory. If “ESC” key (16)
Illustration 179
is chosen, the display returns to the previous menu
11. Press “1” key (12). Press “5” key (13). Press “2” without the currently displayed values being saved.
key (14). Press “6” key (15).
$
"
' IMG_0781_2_38
IMG_1501_2_7
Illustration 182
Illustration 180
12. Press “2” key (14) in order to choose “front steer

sensor.”
65
PM200 Cold Planer
15. After the values have been saved, press “ESC”

key (16) in order to return to the previous screen
and perform other calibrations. If no other
! " # $
calibrations are to be performed, move key start
switch (19) to the OFF position.
Steering Sensor (Rear)—

Replace
WARNING
% & '
Sudden movement of the machine or release of IMG_0781_2_88

persons on or near the machine. Illustration 183
2. Move rear steering joystick (1) to the FULL LEFT

To prevent injury or death, make sure that the position.
position.
WARNING 4. Move parking brake switch (3) to the OFF

position.
moving parts. 8. If necessary, move engine control switch (4) to
cut any object or tool that falls or is pushed into 9. Depress decrease engine RPM switch (2).
them. Release the switch when the engine reaches low
idle.
close to an engine that is running. Make sure the 10. Move key switch (8) to the OFF position.

surface.
66
PM200 Cold Planer
WARNING
! personnel near the machine, and make sure the
" testing, to prevent injury. Make sure checks are
WARNING
#
moving parts.
$ IMG_0918_2_4 Moving fan blades and moving parts will throw or
Illustration 184
them.
11. If necessary, disconnect wiring harness (15) and
remove existing steering sensor (12). Make sure no one is working on, underneath or
NOTICE
Make sure that the cable bracket does not contact
nearby hoses or other equipment on the machine. 1. Drive the machine to a smooth, horizontal
surface.
12. If necessary, install cable bracket (16) on the tie

rod and position it near the hoses.
13. Install new steering sensor (12) on the machine. ! " #
14. Connect wiring harness (15) to steering sensor

(12).

with cable clip (14).
16. Complete the replacement by performing the

“Steering Sensor (Rear)—Calibrate” procedure. $ % & ' IMG_0781_2_39
Steering Sensor (Rear)— Illustration 185

Calibrate 2. Move propulsion lever (6) to the NEUTRAL
position.
WARNING 3. Move parking brake switch (2) to the OFF

position.
oil under pressure can cause serious injury to 4. Make sure rotor switch (8) is in the OFF position.
To prevent injury or death, make sure that the position.
and obstructions before operating the machine. 6. Make sure water spray switches (4, 5, and 9) are

67
PM200 Cold Planer
8. Push decrease engine RPM switch (1). Release

9. Move drive selector switch (7) to the OFF %

position.
IMG_0791_2_4
Illustration 189
13. Move rear steering joystick (17) to the FULL

LEFT position.
IMG_1026_2_18
14. Move rear steering joystick (17) to the FULL
Illustration 186
RIGHT position.
10. Press “8” key (11) on the display twice.

&
! '
" #
IMG_7621C1_2_4
Illustration 187
15. Use rear steering joystick (17) to return the rear
tracks to the center position. The tracks are in the
11. Press “1” key (12). Press “5” key (13). Press “2” center position when pointer (18) is aligned with
key (14). Press “6” key (15). the center-punched mark on support (19).
$
IMG_1501_2_6
Illustration 188
12. Press “3” key (16) in order to choose “rear steer

sensor.”
68
PM200 Cold Planer
Rotor Clutch
Relief Valve (Negative Rotor
Brake)—Test and Adjust
NOTE: This procedure tests the spring-engaged,
hydraulically released rotor brake.

WARNING
IMG_1512_2_4 Sudden movement of the machine or release of
Illustration 191 persons on or near the machine.
NOTE: If a value in any of the boxes on the display
is red, go to Step 13. If the value is still red after a
the display unit. Then, test the joystick and test the and obstructions before operating the machine.
sensor with a multimeter. If the joystick is operating
correctly and the values on the multimeter for the
sensor correspond with the values from the display,
attempt to adjust the position of the steering sensor.
WARNING
Refer to “Steering Sensor (Rear)—Replace.” If the Injury to personnel can result if they are not in
rear steering sensor cannot be calibrated after the the operator’s view. Allow only essential
sensor is adjusted and/or replaced, the display unit personnel near the machine, and make sure the
may have a fault. personnel are in the operator’s view when
16. Depress “OK” key (22) in order to save the done in an open area.

display will be replaced with default values which
WARNING
are stored in the software memory. If “ESC” key (20) Personal injury can result from rotating and
is chosen, the display returns to the previous menu moving parts.
without the currently displayed values being saved.
them.
NOTICE
! IMG_0781_2_40 containers before opening any compartment or
Illustration 192
17. After the values have been saved, press “ESC” Tools and Shop Products Guide,” for tools and
key (20) in order to return to the previous screen supplies suitable to collect and contain fluids in
and perform other calibrations. If no other Caterpillar machines.
calibrations are to be performed, move key start
switch (23) to the OFF position. Dispose of all fluids according to local regulations
and mandates.
69
PM200 Cold Planer
Table 25
position.
Required Tools
Part 6. Make sure water spray switches (4, 5, and 10)
Tool Description Qty are in the OFF position.
Number
Pressure Gauge NOTE: Water spray switches (4 and 5) are optional.
A 8T-0859 0–25 000 kPa 1
(0–3600 psi)
177-7860 Hose Assembly 1 the MANUAL position.
8. Depress decrease engine RPM switch (1). Hold
6V-4143 Valved Coupler 1 the switch until the engine reaches low idle.
position.
Table 26
10. Move engine start switch (7) to the OFF position.
Optional Tools(1)
Part
Number
!
Digital Pressure
D(2) 198-4234 Indicator 1
E(2) 198-4236 Extension Cable 1

"
Pressure Sensor
F 198-4238 0–35 000 kPa 1
(0–5000 psi)
(2) Tool D and Tool E, are part of the 198-4240 Digital Pressure
Indicator Group. IMG_1027_2_18

surface.
Open cover (13).
12. Assemble Tool (B). Connect Tool (A) to Tool (B).

! " #
#
$ % & ' IMG_0781_2_59
Illustration 193

position.
Illustration 195
position. 13. Connect Tool (B) to the rotor brake pressure tap
(15) in the auxiliary manifold.
70
PM200 Cold Planer
$

% IMG_0781_2_61 & IMG_0781_2_60
14. Move engine start switch (7) to the START 18. Depress decrease engine RPM switch (1).
position. Release the engine start switch when release the switch when the engine is at low idle.
the engine starts. Move electrical controls master switch (18) to the
ON position.
Depress increase engine RPM switch (16). 19. Read the pressure on Tool (A). The pressure
should be 7000 -0/+200 kPa (1015 -0/+29 psi).

%
!
IMG_1026_2_26
Illustration 197
'

IMG_1027_2_20
17. Monitor the hydraulic oil temperature with Tool Illustration 199
(C). Operate the machine until the oil
temperature reaches 45 ± 5 °C (110 ± 10 °F). 22. Remove two bolts (19 and 20) and washers.
Open cover (13).
71
PM200 Cold Planer
Relief Valve (Positive Rotor

NOTE: This procedure tests the hydraulically
engaged rotor brake.
WARNING
IMG_0868_2_6
Illustration 200 area around the machine is clear of personnel
23. Remove cap (21). and obstructions before operating the machine.
WARNING
!
WARNING
IMG_0871_2_4
Illustration 201 moving parts.
24. Loosen locknut (22) on the relief valve. In order Moving fan blades and moving parts will throw or
to increase pressure, rotate adjustment screw cut any object or tool that falls or is pushed into
(23) clockwise. In order to decrease pressure, them.
25. Hold adjustment screw (23), and tighten locknut close to an engine that is running. Make sure the
(22). area is free of personnel.
26. Go to Step 14.

NOTICE
27. Remove the tooling and close the covers. Care must be taken to ensure that fluids are


and mandates.
72
PM200 Cold Planer
Table 27
position.
Required Tools
Number
A 8T-0859 0–25 000 kPa 1
(0–3600 psi)
6V-4143 Valved Coupler 1 the switch until the engine reaches low idle.
position.
Table 28
Optional Tools(1)
Part
Number
Digital Pressure
D(2) 198-4234 Indicator 1

Pressure Sensor
F 198-4238 0–35 000 kPa 1
(0–5000 psi)
(2) Tool D and Tool E, are part of the 198-4240 Digital Pressure
Indicator Group. IMG_0836_2_11

surface.
11. Open the compartment that is located under the
switch (12) to the RAISE position. Hold the switch
until the hood is completely open.
! " #
!
$ % & ' IMG_0781_2_59
Illustration 202

position.
Illustration 204
position. 12. Install prop rod (13).
4. Make sure rotor switch (9) is in the OFF position. 13. Move engine compartment switch (22) to the
rod (23) is seated.
73
PM200 Cold Planer

" Depress increase engine RPM switch (18).
#
$ '
IMG_1027_2_10
Illustration 205
IMG_1026_2_36
Open cover (15). Illustration 208
15. Assemble Tool (B). Connect Tool (A) to Tool (B). 19. Monitor engine speed value (19) on the digital

% (C). Operate the machine until the oil
IMG_7585_2_5
Illustration 206
16. Connect Tool (B) to the rotor brake pressure tap

(17) in port “A” of the brake manifold.
IMG_0781_2_95
& Illustration 209

Release the switch when the engine is at low
idle. Move electrical controls master switch (20)
to the ON position.
22. Read the pressure on Tool (A). The pressure

should be 7000 -0/+200 kPa (1015 -0/+29 psi).
% 23. Move engine start switch (7) to the OFF position.

IMG_0781_2_94

Illustration 207
17. Move engine start switch (7) to the START range go to Step 25.
position. Release the engine start switch when
the engine starts.
74
PM200 Cold Planer
WARNING

moving parts.

them.

IMG_7588_2_5
Illustration 210 NOTICE

25. Loosen locknut (21) on the relief valve. In order contained during performance of inspection,
to increase pressure, rotate adjustment screw maintenance, testing, adjusting and repair of the
(22) clockwise. In order to decrease pressure, machine. Be prepared to collect the fluid with suitable
rotate the adjustment screw counterclockwise. containers before opening any compartment or
(21). Refer to Special Publication, NENG2500, “Caterpillar
27. Go to Step 17. supplies suitable to collect and contain fluids in
Accumulator Pressure—Test and mandates.
NOTE: The “Relief Valve (Rotor Brake)—Test and

Adjust” procedure must be performed before this
procedure is performed.
WARNING

WARNING
75
PM200 Cold Planer
Table 29
Required Tools
! " #
Part
Number
Pressure Gauge
A 8T-0859 0–25 000 kPa 1
(0–3600 psi)
177-7860 Hose Assembly 1
6V-4143 Valved Coupler 1 $ % & ' IMG_0781_2_62
124-2114 Coupling 2
Illustration 211
122-6889 Hose 72 in
6V-8397 O-Ring 1
C position.
6V-8364 Adapter–Union 1
3K-0360 O-Ring 1 position.
6V-8634 Tee Valve 1
8T-8902 Tee 1
214-7568 O-Ring 1 5. Make sure conveyor switch (11) is in the OFF
D position.
6V-3965 Quick Disconnect Nipple 1
6V-8337 O-Ring 1 6. Make sure water spray switches (4, 5, and 10)
6V-9508 Plug 1
E NOTE: Water spray switches (4 and 5) are optional.
6V-8397 O-Ring 1
F 4C-6500 Digital Thermometer 1 7. If necessary, move engine control switch (3) to
Table 30
Optional Tools(1) switch until the engine reaches low idle.
Part
Tool Number Description Qty 9. Move drive selector switch (8) to the OFF
position.
Digital Pressure
G(2) 198-4234 Indicator 1
H(2) 198-4236 Extension Cable 1
Pressure Sensor
J 198-4238 0–35 000 kPa 1
(0–5000 psi)

(2) Tool G and Tool H are part of the 198-4240 Digital Pressure
Indicator Group. "
surface.
!
IMG_1113_2_4
Illustration 212
11. Remove two bolts (12 and 13) and the washers.
Open door (14).
76
PM200 Cold Planer
%
#
$
IMG_1114_2_4 IMG_7609_2
12. Remove three bolts (15 and 16 two shown) and 16. Attempt to rotate upper sheave (20). If the
the washers, and remove cover (17). sheave can be rotated, check the negative
brake. Refer to “Rotor Brake (Negative Brake)—
Test and Adjust.” If the negative brake wear is
within specification, the accumulator manifold is
& faulty. In this case, remove the nitrogen charge
from the brake accumulator, and repair the
problem before continuing with this procedure.
'

IMG_7595_2_4
Illustration 214
13. Remove four bolts (19) and the washers, and

remove cover (18).
IMG_7604_2_4
Illustration 216
15. Assemble Tool (C).
17. Disconnect hose (21). Plug the hose with Tool
(E).
18. Connect Tool (C) to the fitting in port “C” of the

manifold. Make sure the needle valve in Tool (C)
is completely closed.
19. Place the outlet of Tool (C) into a suitable

container.
20. Move engine start switch (7) to the ON position.

Do not start the engine.

77
PM200 Cold Planer
WARNING
The next step may release high-pressure oil. !
Make sure the outlet of Tool C is directed into a
suitable container. Do not allow the stream of
high-pressure oil to contact personnel.
22. With the outlet of the needle valve in Tool (C) in a

suitable container, slowly open the needle valve
in order to release the hydraulic oil pressure from
the accumulator. After the pressure has been
released, firmly close the needle valve in Tool % IMG_0781_2_96
(C).
Illustration 219
position. 28. Move engine start switch (7) to the START
24. Move engine start switch (7) to the OFF position. the engine starts.

Depress increase engine RPM switch (23).
"
IMG_7598_2_4
Illustration 217
IMG_1026_2_37
25. Disconnect hose (22) from port “ACC” in the
manifold. Illustration 220

, the engine speed reaches 1500 rpm.

(F). Operate the machine until the oil temperature
reaches 45 ± 5 °C (110 ± 10 °F).

idle.
IMG_7607_2_4 33. Move engine start switch (7) on instrument panel

to the OFF position.
Illustration 218
26. Install Tool (D) in port “ACC” of the manifold. 34. Read the pressure on Tool (A). The pressure
should be 9500 -0/+500 kPa (1380 -0/+72 psi).
27. Connect hose (22) to Tool (D). Connect Tool (B) Wait for 10 minutes. The pressure should not
to Tool (D). decrease.
35. Move engine start switch (7) to the ON position.

Do not start the engine.
78
PM200 Cold Planer

WARNING
37. Read the pressure on Tool (A). The pressure
should be approximately 1000 kPa (145 psi) less Personal injury can result from rotating and
than the pressure recorded in Step 34. moving parts.

WARNING cut any object or tool that falls or is pushed into
them.
The next step may release high-pressure oil.
Make sure the outlet of Tool C is directed into a Make sure no one is working on, underneath or
suitable container. Do not allow the stream of close to an engine that is running. Make sure the
high-pressure oil to contact personnel. area is free of personnel.
38. Place the outlet of the needle valve in Tool (C) Table 31
into a suitable container. Slowly open the needle
valve in order to release the hydraulic oil Required Tools
pressure from the accumulator. After the Part
pressure has been released, firmly close the Tool Description Qty
Number
needle valve in Tool (C).
A 8H-8581 Feeler Gauge 1
39. Move engine start switch (7) on instrument panel
to the OFF position. 1. Drive the machine to a smooth, horizontal
surface.
position.
41. Remove the tooling and close the covers. If the ! " #
pressure is below the specified range, the circuit
may contain hydraulic leakage or the nitrogen
charge in the accumulator is incorrect.
Rotor Brake (Negative Rotor

NOTE: The “Relief Valve (Rotor Brake)—Test and
Adjust” procedure and the “Accumulator Pressure— $ % & ' IMG_0781_2_64
Test” procedure must be performed before this
procedure is performed. Illustration 221

WARNING position.
Sudden movement of the machine or release of 3. Move parking brake switch (2) to the ON
oil under pressure can cause serious injury to position.
area around the machine is clear of personnel 5. Make sure conveyor switch (11) is in the OFF
and obstructions before operating the machine. position.

WARNING are in the OFF position.
Injury to personnel can result if they are not in NOTE: Water spray switches (4 and 5) are optional.
personnel near the machine, and make sure the 7. If necessary, move engine control switch (3) to
personnel are in the operator’s view when the MANUAL position.
done in an open area. 8. Depress decrease engine RPM switch (1). Hold
the switch until the engine reaches low idle.
79
PM200 Cold Planer
9. Move drive selector switch (8) to the OFF 14. Move engine start switch (7) on instrument panel
position. to the ON position. Do not start the engine.
"

IMG_0774_2_7
!
Illustration 222
15. Move engine start switch (20) on rear left
ground-level control station to the ON position.
11. Remove two bolts (12 and 13) and the washers. Do not start the engine.
Open door (14).
%
#
$ IMG_1077_2_5
IMG_1114_2_5
Illustration 226
Illustration 223
16. Depress brake release switch (21), on the left
12. Remove three bolts (15 and 16 two shown) and side of the rotor housing.
the washers, and remove cover (17).
17. Use Tool (A) to measure the distance between
the outside brake pad and the outside face of the
rotor. The gap should be 1.5 -0/+0.2 mm (0.059 -
0/+0.008 in).
&
18. Use Tool (A) to measure the distance between
the inside brake pad and the inside face of the
rotor. The gap should be 1.5 -0/+0.2 mm (0.059 -
0/+0.008 in).
19. Move engine start switch (20) on rear left

' ground-level control station to the OFF position.
20. Move engine start switch (7) on instrument panel

IMG_7595_2_4 to the OFF position.
Illustration 224
13. Remove four bolts (19) and the washers, and

remove cover (18).
80
PM200 Cold Planer
21. If the measurement recorded in Step 17 and the

measurement recorded in Step 18 are within the
Rotor Brake (Positive Rotor
specified range, go to Step 24. If the Brake)—Test
measurement recorded in Step 17 and/or the
measurement recorded in Step 18 are outside NOTE: The “Relief Valve (Positive Rotor Brake)—
the specified range, go to Step 22. Test and Adjust” procedure must be performed
before this procedure is performed.
WARNING

IMG_7611_2_4
WARNING
Illustration 227
Outside Plate Shown, Inside Plate Similar the operator’s view. Allow only essential
22. Rotate plate (22) of the brake assembly personnel are in the operator’s view when
clockwise in order to decrease the gap between testing, to prevent injury. Make sure checks are
the brake pad and the rotor. Rotate the plate done in an open area.
counterclockwise in order to increase the gap
between the brake pad and the rotor.
NOTE: One complete rotation of plate (22) changes

WARNING
the gap by approximately 1.0 mm (0.04 in). Personal injury can result from rotating and
moving parts.
23. Go to Step 14.
24. Subtract the measurement recorded in Step 17 cut any object or tool that falls or is pushed into
from the measurement recorded in Step 18. The them.
difference between the readings should be less
than 0.2 mm (0.008 in). If the difference is within Make sure no one is working on, underneath or
the specified range, go to Step 25. If the close to an engine that is running. Make sure the
difference between the gaps is greater than the area is free of personnel.
specification, make an adjustment to the brake
pistons. Go to Step 22.
Table 32
25. Replace cover (18) and replace the bolts and the Required Tools
washers.
Part
Number
26. Replace cover (17) and replace the bolts and the
washers. A 4C-6500 Digital Thermometer 1
27. Close door (14) and replace the bolts and the 1. Drive the machine to a smooth, horizontal
washers. surface.
81
PM200 Cold Planer
%
! " #
#
$ % & ' $
IMG_0781_2_64 IMG_1114_2_5
2. Move propulsion lever (6) to the NEUTRAL 12. Remove three bolts (15 and 16 two shown) and
position. the washers, and remove cover (17).

position.
&

position.


% IMG_0781_2_94
Illustration 231
8. Depress decrease engine RPM switch (1). Hold 13. Move engine start switch (7) to the START
the switch until the engine reaches low idle. position. Release the engine start switch when
the engine starts.
position. 14. Operate the engine for a few minutes at low idle.
Depress increase engine RPM switch (18).
"
!
IMG_1113_2_5
Illustration 229
11. Remove two bolts (12 and 13) and the washers.
Open door (14).
82
PM200 Cold Planer
'

IMG_1026_2_36 IMG_7613_2_5
15. Monitor engine speed value (19) on the digital Outside Caliper Shown, Inside Caliper Similar
Release increase engine RPM switch (18) when 18. Measure the distance between inside face (21)
the engine speed reaches 1500 rpm. of the brake housing to the end of pin (22). The
distance should be greater than 3.0 mm (0.12
16. Monitor the hydraulic oil temperature with Tool in).
temperature reaches 45 ± 5 °C (110 ± 10 °F). 19. Move drive selector switch (8) to the OFF
position.
21. If the distance measured in Step 18 is within

specification, go to Step 22. If the distance is
outside the specified range, replace the brake
pads.
22. Replace cover (17) and replace the bolts and the
washers.
23. Close door (14) and replace the bolts and the
IMG_0781_2_97
washers.
Illustration 233 Relief Valve (Belt Tensioner)—

17. Depress decrease engine RPM switch (1). Test and Adjust
release the switch when the engine is at low idle.
Move electrical controls master switch (20) to the
ON position. WARNING

83
PM200 Cold Planer
WARNING Table 34
Optional Tools(1)
the operator’s view. Allow only essential Part
Number
personnel are in the operator’s view when D(2) 198-4234 Digital Pressure 1
testing, to prevent injury. Make sure checks are Indicator
done in an open area. E(2) 198-4236 Extension Cable 1
Pressure Sensor
WARNING
F 198-4238 0–35 000 kPa 1
(0–5000 psi)
Personal injury can result from rotating and (1) The optional tools can be used in place of the analog pressure
moving parts. measurement tools which are specified in the required tool list.
(2) Tool D and Tool E are part of the 198-4240 Digital Pressure
Moving fan blades and moving parts will throw or Indicator Group.
them. 1. Drive the machine to a smooth, horizontal
surface.
! " #
NOTICE

$ % & '
Tools and Shop Products Guide,” for tools and IMG_0781_2_66

Caterpillar machines. Illustration 235

Dispose of all fluids according to local regulations position.
and mandates.
position.
Table 33
Required Tools 4. Make sure rotor switch (9) is in the OFF position.
Part 5. Make sure conveyor switch (11) is in the OFF
Number
position.
Pressure Gauge
A 8T-0859 0–25 000 kPa 2 6. Make sure water spray switches (4, 5, and 10)
(0–3600 psi) are in the OFF position.
6V-4143 Valved Coupler 2 7. If necessary, move engine control switch (3) to

position.
84
PM200 Cold Planer
"

IMG_7087_2_5
Illustration 236
15. Connect Tool (B) to clutch pressure tap (14),
near the clutch filter.
open. #
!
% IMG_0781_2_67
Illustration 239
16. Move engine start switch (7) to the START

IMG_1009_2_11
the engine starts.
Illustration 237
12. Install prop rod (13). Push increase engine RPM switch (15).

rod (13) is seated.
$
IMG_1026_2_28
Illustration 240
85
PM200 Cold Planer

the engine speed reaches 1500 rpm. &
19. Monitor the hydraulic oil temperature with Tool '


21. Read the pressure on Tool (A) at the filter. The

IMG_7593_2_5
pressure should be 4000 -0/+400 kPa (580 -0/
+58 psi).
Illustration 242
22. Press increase engine RPM switch (15). Release 28. Loosen locknut (19) on the relief valve. In order
the switch when the engine reaches high idle. to increase pressure, rotate adjustment screw
(18) clockwise. In order to decrease pressure,
23. Read the pressure on Tool (A). The pressure rotate the adjustment screw counterclockwise.
should be 4000 -0/+400 kPa (580 -0/+58 psi).
24. Press decrease engine RPM switch (1). Release (19). Replace cap (17).
30. Go to Step 16.
26. If the pressure is outside the specified range go

to Step 27. If the pressure is inside the specified
%
IMG_7594_2_4
Illustration 243
31. Remove cap and connect Tool (B) to M2-tap

(20), near the clutch filter.
IMG_7085_2_5
Illustration 241
27. Remove cap (17).

86
PM200 Cold Planer
Relief Valve (Rotor

# Transmission)—Test and
Adjust
WARNING
% ' IMG_0781_2_68
Illustration 244 and obstructions before operating the machine.
WARNING
the engine starts.
ON position.
34. Move all legs up joystick (22) to the ALL UP
stops moving.
35. Move rotor switch (9) to the ON position. Wait for

the rotor to engage. WARNING
36. Depress increase engine RPM switch (15). Personal injury can result from rotating and
Release the switch when the engine is at high moving parts.
idle.
37. Read the pressure on Tool (A) in M2 tap (20). The cut any object or tool that falls or is pushed into
pressure should be 3500 ± 200 kPa (510 ± 30 them.
psi). If this pressure is outside the specified
range, the system has an internal problem
downstream from the relief valve.
38. Press decrease engine speed switch (1).
Release the switch when the engine reaches low Table 35
idle.
Required Tools
39. Move rotor switch (9) to the OFF position.
Part
Number
surface.
87
PM200 Cold Planer
! " # $ "

% & ' IMG_0781_2_69 # ! & IMG_0781_2_70
2. Move propulsion lever (7) to the NEUTRAL 11. Press decrease engine RPM switch (1). Release
position. the switch when the engine reaches low idle.
4. Make sure rotor switch (8) is in the OFF position. 13. Move all legs joystick (13) to the ALL UP position.
Release the joystick when the machine stops
5. Make sure conveyor switch (10) is in the OFF moving.
position.
14. Move rotor switch (8) to the ON position. Wait for
6. Make sure water spray switches (5, 6, and 9) are the rotor to engage.
15. Press increase engine RPM switch (2). Release
NOTE: Water spray switches (5 and 6) are optional. the switch when the engine is at high idle.
7. If necessary, move engine control switch (4) to 16. Read the pressure on the rotor transmission
the MANUAL position. gauge (14) on the instrument panel. The
pressure should be 11.5 ± 0.5 bar (167 ± 7 psi)
8. Push increase engine RPM switch (2) or
decrease engine RPM switch (1). NOTE: The unit of measure on pressure gauge 14 is
bar. One bar equals 100 kPa.
17. Press decrease engine speed switch (1).


idle.
18. Move rotor switch (8) to the OFF position. Wait for
the rotor to stop.
19. Move engine start switch (15) to the OFF

position.

IMG_1026_2_29
Illustration 246


(A). Operate the machine until the oil
88
PM200 Cold Planer

to increase pressure, rotate adjustment screw
(19) clockwise. In order to decrease pressure,
$
(18).

position. Release the switch when the engine
starts. Go to Step 14.
27. If necessary, close the covers.

IMG_0836_2_12
Illustration 248

Conveyor System
compartment switch (16) to the RAISE position. Relief Valve (Conveyor
open. Charge)–Test
WARNING
% persons on or near the machine.

IMG_1009_2_12
WARNING
Illustration 249 the operator’s view. Allow only essential
22. Install prop rod (17). personnel near the machine, and make sure the
23. Move engine compartment switch (16) to the testing, to prevent injury. Make sure checks are
LOWER position. Release the switch when prop done in an open area.
rod (17) is seated.
'
WARNING
& Personal injury can result from rotating and
moving parts.

them.

IMG_7085_2_4
Illustration 250
89
PM200 Cold Planer
NOTICE
contained during performance of inspection, !

" # $ % IMG_0781_2_71
and mandates. Illustration 251

position.
Table 36
Required Tools 3. Move parking brake switch (1) to the ON

position.
Part
Number
Pressure Gauge
A 8T-0855 0–4000 kPa 2 5. Make sure conveyor switch (7) is in the OFF
(0–580 psi)
position.
B 8T-41889 Adapter–Union 2 in the OFF position.
7. If the conveyor is extended, go to Step 11. If the
Table 37 conveyor is folded, go to Step 8.
Optional Tools(1)
Part
Number
D(2) 198-4234 Digital Pressure Indicator 1
Pressure Sensor
F(2) 198-4237 0–3500 kPa 2
(0–500 psi)
&
(2) Tool D, Tool E, and one Tool F are part of the 198-4240 Digital
Pressure Indicator Group. IMG_0774_2_8

surface. 8. Move key switch (8) on the rear left ground-level
90
PM200 Cold Planer
WARNING
The conveyor will move during the next steps. In
order to prevent injury or death, make sure that
the area around the machine is clear of personnel "
conveyor.
IMG_0836_2_13
' Illustration 255

until the hood is completely open.
IMG_0771_2_5
Illustration 253
9. Move conveyor fold switch (9) on the front left

ground-level control station to the UNFOLD
position. Hold the switch in this position until the #
second-stage conveyor is completely unfolded.
10. Move key switch (8) on the left rear ground

control station to the OFF position.
IMG_1009_2_13
Illustration 256

rod (15) is seated.
$
%
! IMG_0781_2_72
Illustration 254
&
12. Press decrease engine RPM switch (11). Hold

13. Move drive selector switch (12) to the OFF IMG_1027_2_19

position.
Illustration 257
Open cover (17).
91
PM200 Cold Planer
19. Assemble two sets of Tool B. Connect one Tool A 23. Operate the engine for a few minutes at low idle.
to each Tool B. Depress increase engine RPM switch (21).
'
IMG_1109_2_4 IMG_1026_2_30
20. Connect one Tool B to charge port (19) on the 24. Monitor engine speed value (22) on the digital
conveyor pump. display at the center of the instrument panel.

reaches 45 ± 5 °C (110 ± 10 °F).
26. Record the pressure at charge port (19).
27. Record the pressure at M2-port (20).
28. Subtract the pressure recorded in Step 27 from

the pressure recorded in Step 26. The differential
pressure should be 2200 ± 200 kPa (320 ± 30
IMG_1021_2_5
psi).
Illustration 259
29. If the pressure is not within the specified range,
21. Connect the second Tool B to M2-port (20) on go to Step 30. If the pressure is within the
the return manifold. specified range, go to Step 34.
30. Depress decrease engine RPM switch (1) until

the engine reaches low idle.

! IMG_0781_2_73
Illustration 260

92
PM200 Cold Planer
38. Read the pressure at charge pressure port (19).

The pressure should be 200 ± 100 kPa (29 ± 15
psi) less than the pressure recorded in Step 26.
NOTE: If the pressure recorded in Step 38 is

outside the specified range, components in the
conveyor system may have excessive case drain
leakage.
" 39. Move conveyor switch (26) to the OFF position.
Wait for the conveyor to stop operating.
!
IMG_1109_2_5
Illustration 262
32. Loosen locknut (23) on charge relief valve. In position.
order to increase pressure, rotate adjustment
screw (24) clockwise. In order to decrease 42. Move key switch (13) to the OFF position.
pressure, rotate the adjustment screw
counterclockwise. 43. Remove the tooling and replace the covers.
33. Hold adjustment screw (24) in place, and tighten Pressure Limiter Valve
locknut (23). Go to Step 22.
(Conveyor Pump)—Test and
Adjust

% WARNING

! # $ IMG_0781_2_74

34. Depress increase engine RPM switch (21) until Injury to personnel can result if they are not in
the engine reaches high idle. the operator’s view. Allow only essential
35. Move electrical controls master switch (25) to the personnel are in the operator’s view when
ON position. testing, to prevent injury. Make sure checks are
WARNING
The conveyor will move during the next steps. In
WARNING
the area around the machine is clear of personnel Personal injury can result from rotating and
and clear of obstructions before operating the moving parts.
conveyor.
36. Move conveyor switch (26) to the MANUAL them.
position.
37. Rotate conveyor speed potentiometer (27) to the close to an engine that is running. Make sure the
MAXIMUM position. area is free of personnel.
93
PM200 Cold Planer
NOTICE
contained during performance of inspection, ! " #

$ % & ' IMG_0781_2_75
and mandates. Illustration 264

position.
Table 38
Required Tools 3. Move parking brake switch (2) to the ON

position.
Part
Number
Pressure Gauge
A 8T-0861 0–60 000 kPa 1 5. Make sure conveyor switch (11) is in the OFF
(0–8700 psi)
position.
B 8T-41889 Adapter–Union 1 are in the OFF position.
C 6V-9833 Cap 1
D 150-3073 Plug With O-Ring Seal 1 7. If necessary, move engine control switch (3) to
Table 39
Optional Tools(1) 9. Move drive selector switch (8) to the OFF

Part position.
Number
F(2) 198-4234 Digital Pressure Indicator 1
G(2) 198-4236 Extension Cable 1
Pressure Sensor
H(2) 198-4239 0–69 000 kPa 1
(0–10 000 psi)
(2) Tool F, Tool G, and Tool H are part of the 198-4240 Digital Pressure
Indicator Group.

surface.
94
PM200 Cold Planer
15. Install Tool B in M1-port (14) on the conveyor

pump.

#
IMG_0836_2_14
Illustration 265
IMG_1106_2_4
left steering wheel. Move engine compartment Illustration 268
until the hood is completely open. 16. Disconnect coupler (15) at second-stage
conveyor motor. Use Tool C to cap the port. Use
Tool D to plug the hose.
! $
IMG_1009_2_14
Illustration 266 % IMG_0781_2_76
12. Install prop rod (13). Illustration 269
13. Move engine compartment switch (12) to the 17. Move key switch (7) to the START position.
LOWER position. Release the switch when prop Release the key switch when the engine starts.
rod (13) is seated.
14. Assemble Tool B. Connect Tool A to Tool B. Push increase engine RPM switch (16).
%
"
IMG_1107_2_4 IMG_1026_2_31

95
PM200 Cold Planer
19. Monitor engine speed value (17) on the digital 25. Depress decrease engine RPM switch (1).
display at the center of the instrument panel. Release the switch when the engine reaches low
Release increase engine RPM switch (16) when idle.
Operate the machine until the oil temperature 27. If the forward pressure is outside the specified
reaches 45 ± 5 °C (110 ± 10 °F). range, go to Step 28. If the forward pressure is

&

IMG_0974_2_4
! IMG_0976_2_4
Illustration 271
Illustration 273
21. Push manual override lever (18) on the conveyor
pump EDC towards the rear of the machine (to NOTE: Pump shown removed from machine.
the left in the photo).
28. Loosen locknut (20) on the forward multifunction
NOTE: Pump shown removed from machine. valve. In order to increase pressure, rotate
adjustment screw (21) of the multifunction valve
clockwise. In order to decrease pressure, rotate
' the adjustment screw counterclockwise.
NOTE: One revolution of the adjustment screw

changes the pressure by approximately 9300 kPa
(1350 psi).

(20) on the forward multifunction valve.
30. If the reverse pressure is outside the specified

range, go to Step 31. If the reverse pressure is
IMG_0794_2_5
31. Loosen locknut (22) on the reverse multifunction

Illustration 272
valve. In order to increase pressure, rotate
22. Record the pressure shown on gauge (19) on adjustment screw (23) of the multifunction valve
instrument panel as “forward pressure.” Forward clockwise. In order to decrease pressure, rotate
pressure should be 290 ± 10 Bar. the adjustment screw counterclockwise.
NOTE: The units on gauge (19) are bar; 290 ± 10 NOTE: One revolution of the adjustment screw
bar is equivalent to 29 000 ± 1000 kPa (420 ±140 changes the pressure by approximately 9300 kPa
psi). (1350 psi).
23. Push manual override lever (18) on the conveyor 32. Hold adjustment screw (23), and tighten locknut
pump EDC towards the front of the machine. (22) on the reverse multifunction valve.
24. Record the pressure on Tool A as “reverse 33. If an adjustment was made in Step 28 or Step
pressure.” Reverse pressure should be 29 000 ± 31, go to Step 17; otherwise, go to Step 34.
1000 kPa (4200 ± 140 psi).
96
PM200 Cold Planer
35. Reconnect coupler (15) at second-stage

conveyor motor.
!
36. Lower the engine cover.
Conveyor Speed—Test
WARNING
persons on or near the machine. " # $ % IMG_0781_2_77
To prevent injury or death, make sure that the Illustration 274

position.
WARNING 3. Move parking brake switch (1) to the ON

position.

Personal injury can result from rotating and 7. If the conveyor is extended, go to Step 11. If the
moving parts. conveyor is folded, go to Step 8.
them.

Table 40
Required Tools &
Part
Number
IMG_0774_2_9

Illustration 275
B(1) 1U-6605 Reflective Tape 1
8. Move key switch (8) on the left rear ground
C 4C-6500 Digital Thermometer 1 control station to the ON position.

surface.
97
PM200 Cold Planer

WARNING position.
The conveyor will move during the next steps. In 15. Move key switch (14) to the OFF position.
the area around the machine is clear of personnel
conveyor.
#
'
IMG_1111_2_4
Illustration 278
16. Install a piece of Tool B on idler (15) at the top of

IMG_0771_2_6 the first-stage conveyor.
Illustration 276
9. Move conveyor fold switch (9) on the front left

ground control station to the UNFOLD position.
Hold the switch in this position until the second-
stage conveyor is completely unfolded.

control station to the OFF position. $
IMG_1112_2_4

Illustration 279
17. Install a piece of Tool B on idler (16) at the top of

the second-stage conveyor.
" ! IMG_0781_2_78
%
Illustration 277
11. If necessary, move conveyor position joystick

(10) to the LOWER position. Release the joystick
when the end of the second-stage conveyor can
be reached from the ground.

the MANUAL position. " IMG_0781_2_79
13. Depress decrease engine RPM switch (12). Hold Illustration 280
98
PM200 Cold Planer
19. Operate the engine for a few minutes at low idle. 25. Rotate conveyor speed potentiometer (20) to the
Depress increase engine RPM switch (17). MAXIMUM position.
26. Use Tool A to record the speed of idler (15) at the

top of the first-stage conveyor. The speed of the
idler should be 303 ± 10 RPM.
&
%
27. Use Tool A to record the speed of idler (16) at the
top of the second-stage conveyor. The speed of
the idler should be 320 ± 10 RPM.
28. Move conveyor switch (7) to the OFF position.

Wait for the conveyor to stop operating.

IMG_1026_2_32

Illustration 281
position.
display at the center of the instrument panel. 31. Move key switch (7) to the OFF position.
the engine speed reaches 1500 rpm. Piston Pump Neutral—Test
21. Monitor the hydraulic oil temperature with Tool C. and Adjust
reaches 45 ± 5 °C (110 ± 10 °F).
WARNING
%
WARNING
' % IMG_0781_2_80 the operator’s view. Allow only essential
Illustration 282 personnel are in the operator’s view when
22. Depress increase engine RPM switch (17) until testing, to prevent injury. Make sure checks are
the engine reaches high idle. done in an open area.

ON position. WARNING
WARNING moving parts.
The conveyor will move during the next steps. In Moving fan blades and moving parts will throw or
order to prevent injury or death, make sure that cut any object or tool that falls or is pushed into
the area around the machine is clear of personnel them.
conveyor. Make sure no one is working on, underneath or
24. Move conveyor switch (7) to the MANUAL
position.
99
PM200 Cold Planer

NOTICE are in the OFF position.
contained during performance of inspection, NOTE: Water spray switches (4 and 5) are optional.
machine. Be prepared to collect the fluid with suitable 7. If necessary, move engine control switch (3) to
containers before opening any compartment or the MANUAL position.
Refer to Special Publication, NENG2500, “Caterpillar switch until the engine reaches low idle.
supplies suitable to collect and contain fluids in 9. Move drive selector switch (8) to the OFF
Caterpillar machines. position.
Dispose of all fluids according to local regulations 10. Move key switch (7) to the OFF position.
and mandates.
Table 41
Required Tools
Part
Number
Pressure Gauge
A 8T-0862 2
0–500 kPa (0–70 psi)
B 6V-4144 Coupler 2
C 6V-3965 Nipple 2
D 3J-1907 O-Ring Seal 2 IMG_0836_2_15

Illustration 284
1. Drive the machine to a smooth, horizontal 11. Open the compartment that is located under the
surface. left steering wheel. Move engine compartment
until the compartment is completely open.
! " #
!
$ % & ' IMG_0781_2_81
Illustration 283 IMG_1009_2_15
2. Move propulsion lever (6) to the NEUTRAL Illustration 285

position.

position.
100
PM200 Cold Planer
"
&
%
#
IMG_0976_2_5
% IMG_0781_2_82
NOTE: The above photo shows the conveyor pump 18. Move key switch (7) to the START position.
removed from the machine. Release the key switch when the engine starts.
14. Remove the plug from M4 port (15). Remove 19. Operate the engine for a few minutes at low idle.
plug from M5 port (14). Push increase engine RPM switch (17).
15. Install Tool C and Tool D in M4 port (15). Install

Tool C and Tool D in M5 port (14).
&
16. Install Tool B on Tool A. Connect Tool A to M4
port (15), and connect Tool A in M5 port (14).
$
IMG_1026_2_33
Illustration 289

IMG_0976_2_6
Illustration 287
NOTE: The above photo shows the conveyor pump Operate the machine until the oil temperature
removed from the machine and a cover over the reaches 45 ± 5 °C (110 ± 10 °F).
connector.
22. Read the pressure on the gauge in M4 port (15).
17. Disconnect cable at connector (16) from the Read the pressure on the gauge in M5 port (14).
conveyor pump EDC. The pressure at the M4 port and the pressure at
the M5 port should be equal. If the pressure is
equal, go to Step 26. If the pressure is not equal,
go to Step 23.
101
PM200 Cold Planer
Fan Control System

Relief Valve (Fan)—Test and
' Adjust
WARNING
IMG_0975_2_4
Illustration 290 area around the machine is clear of personnel
NOTE: The above photo shows the conveyor pump
removed from the machine.
NOTE: Make sure not to adjust the pressure beyond

the rating of the gauges during the next two steps.
WARNING
23. Loosen locknut (19) on the pump adjustment the operator’s view. Allow only essential
mechanism. Turn adjustment screw (20) until the personnel near the machine, and make sure the
pressure at M4 port (15) starts to increase over personnel are in the operator’s view when
the pressure at M5 port (14). Record the testing, to prevent injury. Make sure checks are
pressure reading on the gauge which is attached done in an open area.
to the M4 port, and note the angular position of
the wrench.
24. Rotate adjustment screw (20) the opposite

WARNING
direction until the pressure at M5 port (14) is Personal injury can result from rotating and
equal to the pressure which was recorded during moving parts.
Step 23. Note the angular position of the wrench.
25. Rotate adjustment screw (20) to the center of the cut any object or tool that falls or is pushed into
two positions which were noted in Step 23 and them.
Step 24. Hold the adjustment screw in place,
and tighten locknut (19). Go to Step 22. Make sure no one is working on, underneath or
26. Depress decrease engine RPM switch (1). area is free of personnel.
idle.
NOTICE
28. Allow the oil to cool. Remove the tooling, and
replace the plugs in M4-port (15) and M5-port
(16).
29. Connect connector (16) to the conveyor pump
EDC.
engine compartment.
31. If an adjustment was made, recalibrate the initial
and mandates.
current setting to the electronic control module
(ECM) for the pump.
102
PM200 Cold Planer
Table 42
position.
Required Tools
Number
A 8T-0859 0–25 000 kPa 2
(0–3600 psi)
6V-4143 Valved Coupler 2 switch until the engine reaches low idle.
D 164-5581 Plug with O-ring 1 position.
E 6V-9832 Cap 1 10. Move key switch (7) to the OFF position.
Table 43
Optional Tools(1)
Part
Number
F(2) 198-4234 Digital Pressure Indicator 1
G(2) 198-4236 Extension Cable 2
Pressure Sensor
H 198-4238 0–35 000 kPa 2
(0–5000 psi)
measurement tools which are specified in the required tool list. IMG_0836_2_16
(2) Tool F and Tool G are part of the 198-4240 Digital Pressure

surface.
open.
! " #
!
$ % & ' IMG_0781_2_83
Illustration 291
IMG_1009_2_16

position.
rod (13) is seated.
103
PM200 Cold Planer
14. Assemble two sets of Tool B. Connect one Tool A

to each Tool B.
'
%
$
"
% IMG_0781_2_84
#
Illustration 296
IMG_1096_2_4
Illustration 294
15. Connect one Tool B to M1-port (14) in fan 19. Depress increase engine RPM switch (19).
manifold. Connect a second Tool B to M2-port
(15).
16. Remove fitting (16). Plug hose with Tool D. Cap

P1-port (17) with Tool E.
&
IMG_1026_2_34
Illustration 297

IMG_1093_2_4
Illustration 295
NOTE: Valve shown removed from machine. 21. Monitor the hydraulic oil temperature with Tool C.
17. Rotate valve (18) clockwise until the valve is reaches 45 ± 5 °C (110 ± 10 °F).
completely closed.
22. Read the M1 pressure on the gauge. The
pressure should be 23 000 ± 500 kPa (3340 ± 70
psi).

idle.
25. If the M1 pressure is inside the specified range,

go to Step 28. If the M1 pressure is outside the
specified range, go to Step 26.
104
PM200 Cold Planer
"

IMG_1100_2_4 ! IMG_1100_2_5

26. Loosen locknut (21) on relief valve. In order to 37. Loosen locknut (23) on relief valve. In order to
increase pressure, rotate adjustment screw (22) increase pressure, rotate adjustment screw (24)
clockwise. In order to decrease pressure, rotate clockwise. In order to decrease pressure, rotate
the adjustment screw counterclockwise. the adjustment screw counterclockwise.
27. Hold adjustment screw (22) in place, and tighten 38. Hold adjustment screw (24) in place, and tighten
locknut (21). Go to Step 18. locknut (23). Go to Step 29.
28. Rotate the valve (18) counterclockwise to 39. Remove Tool D and Tool E. Reconnect fitting
completely open the valve. (16) to P1-port (17).
29. Move key switch (7) to the START position. 40. Remove Tool B from M1-port (14). Remove Tool B
Release the key switch when the engine starts. from M2-port (15). Replace caps on port M1 and
M2.
30. Depress increase engine RPM switch (19).
41. Completely close valve (18).
display at the center of the instrument panel. 42. Close the covers.
Fan Speed—Test
WARNING
reaches 45 ± 5 °C (110 ± 10 °F).
33. Read the M2 pressure on the gauge. The oil under pressure can cause serious injury to
pressure should be 13 500 ± 500 kPa (1960 ± 70 persons on or near the machine.
psi).
34. Depress decrease engine RPM switch (1). area around the machine is clear of personnel
Release the switch when the engine reaches low and obstructions before operating the machine.
idle.

WARNING
36. If the M2 pressure is inside the specified range,
go to Step 39. If the M2 pressure is outside the Injury to personnel can result if they are not in
specified range, go to Step 37. the operator’s view. Allow only essential
105
PM200 Cold Planer

WARNING the MANUAL position.
Personal injury can result from rotating and 8. Depress decrease engine RPM switch (1). Hold
moving parts. the switch until the engine reaches low idle.
Moving fan blades and moving parts will throw or 9. Move drive selector switch (8) to the OFF
cut any object or tool that falls or is pushed into position.
them.
Table 44

Required Tools
Part
Number
B(1) 1U-6605 Reflective Tape 1
IMG_0836_2_4
Illustration 301
surface. 11. Open the compartment which is located under
open.
! " #
!
$ % & ' IMG_0781_2_85
Illustration 300

position.
Illustration 302
position. 12. Install prop rod (13).
4. Make sure rotor switch (9) is in the OFF position. 13. Move engine compartment switch (12) to the
5. Make sure conveyor switch (11) is in the OFF rod (13) is seated.
position.


106
PM200 Cold Planer

reaches 45 ± 5 °C (110 ± 10 °F).
" 19. Depress decrease engine RPM switch (1).

idle.
20. Read the fan speed with Tool A. The speed

should be 630 ± 50 rpm.

Release the switch when the engine is at high
IMG_1104_2_4
idle.
Illustration 303
22. Read the fan speed with Tool A. The speed
14. Place a piece of Tool B on a fan blade (14). should be 1250 -0/+50 rpm.
23. Depress the decrease engine RPM switch (1).

idle.
#
24. Move the key switch (17) to the OFF position.
25. If the fan speed is outside the specified range,

check the fan pressure. Refer to “Relief Valve
(Fan)—Test and Adjust.” If the pressure is within
specification but the speed is still outside the
specified range, the hydraulic system has a fault.
26. Close the engine compartment.

% IMG_0781_2_86
Illustration 304

$
IMG_1026_2_35
Illustration 305

107
PM200 Cold Planer
Index Section
Index Adjust ................................................................. 46

Optional Water Pump RPM—Test ........................ 40
A P
Accumulator Pressure—Test ................................ 74 Piston Pump Neutral—Test and Adjust .......... 18, 98
Auxiliary Hydraulic System ................................... 21 Pressure Limiter Valve (Conveyor Pump)—Test and
Adjust ................................................................. 92
Pressure Limiter Valve (Propel Pump)—Test and
C Adjust ................................................................. 11
Propulsion System .................................................. 7
Checks During Operation
Visual Inspection .................................................. 5
Conveyor Cycle Time (Raise and Lower)—Test and R
Adjust ................................................................. 35
Conveyor Cycle Time (Swing)—Test and Adjust .. 33 Rear Column Lower Cycle Time—Test and Adjust ..
Conveyor Speed—Test ......................................... 96 50
Conveyor System .................................................. 88 Rear Steering Potentiometer—Calibrate .............. 59
Relief Valve (Auxiliary System Main)—Test and
Adjust ................................................................. 21
D Relief Valve (Belt Tensioner)—Test and Adjust ... 82
Relief Valve (Charge)–Test .................................... 7
Differential Lock Engagement—Test .................... 15 Relief Valve (Conveyor Charge)–Test .................. 88
Relief Valve (Fan)—Test and Adjust .................. 101
Relief Valve (Left Side Plate)—Test and Adjust ... 27
E Relief Valve (Negative Rotor Brake)—Test and
Adjust ................................................................. 68
Electronic Controls ................................................ 55 Relief Valve (Positive Rotor Brake)—Test and
Engine Antistall—Calibrate ................................... 55 Adjust ................................................................. 71
Relief Valve (Right Side Plate)—Test and Adjust . 24
Relief Valve (Rotor Transmission)—Test and
F Adjust ................................................................. 86
Rotor Brake (Negative Rotor Brake)—Test and
Fan Control System ............................................ 101 Adjust ................................................................. 78
Fan Speed—Test ................................................ 104 Rotor Brake (Positive Rotor Brake)—Test and
Adjust ................................................................ 80
Rotor Clutch .......................................................... 68
G
Grade and Slope Offset—Calibrate ...................... 57 S
Slide Plate Cycle Times—Test ............................. 31

H Standard Water Pump RPM—Test ....................... 38
Steering Sensor (Front)—Calibrate ...................... 63
Hydraulic Oil Contamination—Test ......................... 6 Steering Sensor (Front)—Replace ....................... 62
Steering Sensor (Rear)—Calibrate ....................... 66
Steering Sensor (Rear)—Replace ........................ 65
I Steering Wheel Rotation—Test ............................ 53
Important Safety Information ................................... 2

T
M Testing and Adjusting ............................................. 4

Testing and Adjusting Section ................................ 4
Machine Preparation for Testing and Adjusting ...... 4
Moldboard Pressure—Test ................................... 52
V
O Visual Inspection ..................................................... 4
Optional Water Loading Pump RPM—Test and

108
PM200 Cold Planer
Index Section
Water Pressure (Optional Washdown Pump)—Test

and Adjust .......................................................... 43
© 2008 Caterpillar
All Rights Reserved Printed in USA

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QENR2017-01

Testing and Adjusting

Attention! Become Alert! Your Safety is Involved.

Failure to heed this warning can lead to

Table of Contents Accumulator Pressure—Test ...............................

d. Aluminum particles indicate a pump group

2. Use a clear container to obtain an oil sample Checks During Operation

NOTE: High pressure in the hydraulic system may

Dispose of all fluids according to local regulations

Always use a board or cardboard when checking

Hydraulic oil pressure can remain in the IMG_1075_2_4

hydraulic system after the engine has been

2. Obtain a hydraulic oil sample from S•O•S tap (2)

NOTE: For the correct procedure, refer to Operation

Make sure no one is working on, underneath or

WARNING Required Tools

WARNING C 4C-6500 Digital Thermometer 1

Injury to personnel can result if they are not in

11. Open the compartment which is located under

$ % & '   IMG_0781_2_4

12. Install prop rod (13).

NOTE: Water spray switches (4 and 5) are optional. $

7. If necessary, move engine control switch (3) to

8. Press decrease engine RPM switch (1). Hold the

10. Move key switch (7) to the OFF position.

21. Monitor the hydraulic oil temperature with Tool C.

22. With propulsion lever (6) in the NEUTRAL

23. Record the pressure at M2-port (18).

& 24. Subtract the pressure recorded in Step 23 from

26. Press decrease engine RPM switch (1) until the

33. Move propulsion lever (6) slightly out of the

37. If the pressure recorded in Step 35 is outside the

38. Press decrease engine RPM switch (1). Hold the

40. Move key switch (7) to the OFF position.

30. Move electrical controls master switch (23) to the

31. Move drive selector switch (8) to the ON position.

32. Move parking brake switch (2) to the OFF

Pressure Limiter Valve (Propel Table 3

Pump)—Test and Adjust Required Tools

To prevent injury or death, make sure that the B 8T-4188 Adapter–Union 1

Refer to Special Publication, NENG2500, “Caterpillar $ % & '   IMG_0781_2_7

4. Make sure rotor switch (9) is in the OFF position.

5. Make sure conveyor switch (11) is in the OFF

6. Make sure water spray switches (4, 5, and 10)

7. If necessary, move engine control switch (3) to

8. Press decrease engine RPM switch (1). Hold the

9. Move drive selector switch (8) to the OFF

10. Move key switch (7) to the OFF position.

14. Unlock two locking mechanisms (14 and 16).

16. Assemble Tool B. Connect Tool A to Tool B.

12. Install prop rod (13).

24. Move drive selector switch (8) to the ON position.

25. Move parking brake switch (2) to the OFF

20. Monitor engine speed value (20) on the digital

27. Push propulsion enable switch (23) on top of

If the machine moves at any time during this test,

32. Slowly move propulsion lever (6) reverse until the

33. Move the propulsion lever (6) to the NEUTRAL %

34. Move parking brake switch (2) to the ON

35. Press decrease engine RPM switch (1). Hold the

43. Hold adjustment screw (28), and tighten locknut

44. If an adjustment was made in Step 39 or in Step

NOTE: Perform the procedure entitled “Pressure

WARNING 3J-1907 O-Ring Seal 1

$ % & ' IMG_0781_2_4

NOTE: Water spray switches (4 and 5) are optional. $

& 24. Subtract the pressure recorded in Step 23 from

Refer to Special Publication, NENG2500, “Caterpillar $ % & ' IMG_0781_2_7

$ % & ' IMG_0781_2_10 IMG_1031_2_5

$ % & ' IMG_0781_2_13

17. Disconnect connector (16) for the propulsion '

$ % & ' IMG_0781_2_15

NOTE: Water spray switches (4 and 5) are optional. $

16. Connect Tool B to tap (17) in the M-port of the % IMG_0781_2_17

$ % & ' IMG_0781_2_18