52 PM102 Cold Planer Testing and Adjusting Section Mustation 118 4, Make sure conveyor switch (3} is in the OFF position, 5. Make cure water spray switch (4) is in the OFF position, 6. Make sure rotor switch (5) is in the OFF position. Musation 116 7. Move parking brake switch (6) to the ON position 8. If necessary, move engine control switch (7) to the “O° position. 9. Rotate engine speed dial (8) to the HIGH-IDLE position, station 117 10. Monitor hydraulic oil temperature (9) on the digital display. Operate the machine unti the oil temperature reaches 45 4 5 °C (110 + 10°F), oe ‘wustraion 118 11. Use lett rear leg switch (10) and right rear teg switch (11) in order to level the rear of the machine. Use these switches in order to position the rear of the machine so that the rotor is. ‘approximately 250 mm (10 in) above the ground. Release tne rear legs switches. Imugvation 119JI d d IJIJIII 53 M102 Cold Planer Testing and Adjusting Section 12. Move auto-stop override switch (12) to the ‘OVERRIDE position. Move al-legs joystick (14) to the FRONT-LOWER position, Release the joystick when the front of the machine is completely lowered 13, Simultaneously start Too! A and move all-legs. joystick (14) to the FRONTERAISE position. Record the amount of time required to completely raise the front of the machine, Release the joystick, The time should be 16 +3 seconds. 14, Simultaneously start Too! A and move all-iegs, joystick (14) to the FRONT-LOWER position. Record the amount of time required to ‘completely lower the front of the machine. Release the joystick. The time should be 16 + 3 seconds. 15, Move all-logs joystick (14) to the FRONT-RAISE position. Release the joystick when the front of the machine has lifted approximately 200 mm (12in), 16. Simultaneously move left rear leg switch (10) and Tight rear leg Switch (11) to the LOWER postion. Release the switches when the rotor tips just touch the ground. 17, Simultaneously start Tool A and move all-legs joystick (14) to the REAR-RAISE position. Record the amount of time required to completely ifthe rear of the machine. Release the joystick. The time should be 16 = 3 seconds. 18. Simultaneously start Tool A and move leftrear teg switen (10) and right rear leg switch (11) to the LOWER position, Record the amount of time required to lower the machine until the rotor tips just touch the ground. Reloase the joystick. The time should be 16 = 9 seconds. 19, Move all-legs joystick (14) to the REAR-RAISE position, Release the joystick when the machine islevel 20. Rotate engine speed dial (8) to the LOW-IOLE. position 21. Move key switch (13) to the OFF position. Conveyor Swing Time—Test rae 18 [ze Required Tools Tool Description ay a ‘Stop Waich 1 4. Drive the machine to a smooth, horizontal surface. ustation #20 2, Move propulsion lever (1) fo the NEUTRAL position, 3. Move drive selector switch (2) to the OFF position ostraion 121 4, Make sure conveyor switch (3) is in the OFF position, 5. Make sure water spray switch (4) is in the OFF position. 6. Make sure rotor switch (5) is in the OFF position.d ) 54 PM102 Cold Planer Testing and Adjusting Section IMastaton 122 Move parking brake switch (6) to the ON position 8. If necessary, move engine control switch (7) 1o the "O* position. 9. Rotate engine speed dial (8) to the HIGH-IDLE position. ustation 128 10. Monitor hydraulic oil temperature (9) on the digital display. Operate the machine unt the oll temperature reaches 45 = 5°C (110 + 10°F). Imusuation 128 11. Depress electrical controls master switch (10). Mustation 125 POW es Ensure that the conveyor will not contact any obstacles when the conveyor is moved. 12. Move conveyor joystick (11) to the FULL-RIGHT position, Release the joystick when the conveyor ig in the Tul-right position. 1. Simultaneously start Tool A and move conveyor joystick (11) to the FULL-LEFT position. Record the amount of time required for the conveyor to reach the ful-left position. Release the joystick. The time should be 16 + 2 seconds. 14, Simultaneously start Tool A and move conveyor Conttol joystick (11) to the FULL-RIGHT position. Record the amount of time required for the Conveyor to reach the iul-right position, Release the joystick, The time should be 15 = 2 seconds. 45, Rotate engine speed dial (8) to the LOW-IOLE position 16. Move key switch (7) to the OFF position.a es J 2 Sane due! ore! eet sete ners 55 PM102 Cold Planer Testing and Adjusting Section Clutch Engagement Pressure—Test and Adjust NOTE: Perform the procedure entitled "Relief Valve (Main)—Test and Adjust” before the following test is performed. FN ilc} ‘Sudden movement of the machine or release of ol under pressure can cause serious injury to persons on or near the machine. To provent injury or death, make sure that the ‘area around the machine is clear of personnel and obstructions before operating the machine. A WARNING 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 ar zror7s | Wose Assery, 4 | 280-0168 | Nipple Fitting i 1 3 | SVK05 Bowy Seal GFTIIO Adapter Urion 1 | an1007 "| O-Ring Seal arene 164-5567 | Nippie Fiting nal Tools! Description ay G# | 198-4254 | Digtal Pressure indicator) 1 A WARNING Personal injury can result from rotating and moving parts. Moving fan blades and moving parts will throw or “cut any object or tool that falls or Is pushed into no one is working on, underneath or close to an engine that is running. Make sure the area is free of personnel. NOTICE Care must be taken to ensure that fluids are ‘contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable Containers before opening any compartment of isassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar ‘Tools and Shop Products Guide," for tools and supplies suitable to collect and contain fluids in Caterpillar machines, Dispose of all fluids according to local regulations and mandates, D® | 186-4286 | Extension Cable 2 Pressure Sensor | 8 | 1984237 | 0-500 kPa 2 (0-500 psi | (9) Te eponal els can be wad place o he analog pressure Imeasremant Tol A whi spetod i fe requed els. (2 Tat, Too 0, anc one Tool are rt ci 18-4240 Dg Presi Indes Gru, 1, Drive the machine to a smooth, horizontal surface, station 126 2. Move propulsion lever (1) to the NEUTRAL position 3. Move drive selector switch (2) to the OFF position,) ) 3 JIVDIIIIII 3 56 PM102 Cold Planer Testing and Adjusting Section ‘station 127 4, Mako sure conveyor switch (3) is in the OFF position, 5. Make sure water spray switch (4) is in the OFF position, 6. Make sure rotor switch (5) is in the OFF position. ‘station 128 7. Move parking brake switch (6) to the ON positon, 8. If necessary, move engine control switch (7) to the "O* position, 9, Rotate engine speed dial (8) to the LOW-IDLE position. 10. Move key switch (8) to the OFF position, Imastation 129 11. Assemble Tool A, Assemble Too! B. Connect Too! Ato Tool B. Iwsstrason 100 12, Open compartment (10} station 131 13, Remove the cap from rotor clutch pressure tap any3 ED ) ) ) ) 87 PMtt02 Cold Planer Testing and Adjusting Section Mustation 132 14, Connect Too! B to rotor clutch pressure tap (11). 18. Move key switch (9) to the START position. Releaso the key siwitch when the engine starts. 16, Operate the engine at low idle for a few minutes. station 139 17. Monitor engine speed value (12) on the digital isplay. Rotate engine speed cial (8) until the ‘engine speed reaches 1500 rom. 18. Monitor hydraulic cil temperature (13) on the digital display Operate the machine until the oil temperature reaches 45 + 5 °C (110 = 10°F), 19, Rotate engine speed cial (8) to the LOW-IDLE position, Wostaion 194 20. Depress electrical controls master switch (14). 21. 1f necessary, use all-legs joystick (15) to lift the machine, Release the joystick when the machine |g at the maximum height, tasraton 135, 22, Move moldboard switch (16) to the FLOAT position, 23, Move rotor switch (6) 0 the ON position. 24, Read the pressure on Too! A. The pressure ‘should be 2790 + 100 kPa (405 = 15 psi). 25. Move rotor switch (6) to the OFF pos ion 26. Rotate engine speed dial (8) to the LOW-IDLE position, 27. Move key switch (9) to the OFF position. 28. Ifthe pressure is outside the specified range, go to Step 29. If the pressure is inside the specified range, go to Step 32.58 PM102 Cold Planer Testing and Adjusting Section station 136 Valve Removed Fiem Machine 29. Remove cap (17). A WARNING Sudden movement of the machine or release of oll under pressure can cause serious injury to persons on or near the machin To prevent injury or death, make sure that the area around the machine is clear of personnel ‘and obstructions before operating the machine. PONE es 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. Virani sonal injury can result from rotating and moving parts. z a ‘Moving fan blades and moving parts will throw or ‘cut any object or tool that falls or is pushed into them, Make sure no one is working on, underneath or close to an engine that is running. Make sure the area is free of personnel. ustation 137 Valve Removed From Machine 80. Loosen locknut (18) on the relief valve. In order to increase the pressure, rotate adjustment screw (19) clockwise. in order to decrease the pressure, rotate tho adjustment screw counterclockwise. 31. Hold adjusiment screw (19), and tighten locknut (18). Goto Step 18 ‘32, Remove the tooling. Close compartment (10) Relief Valve (Belt Tensioner)— Test and Adjust NOTE: Perform the procedure entitled “Clutch Engagement Pressure—Test and Adjust" before the folowing test is performed, NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, ‘maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable ‘containers beiore opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide’’ for tools and ‘supplies suitable to collect and contain fluids in Caterpillar machines. Dispose of all uids according to local regulations and mandates.IIIIIIIZ JJ 59 PMt102 Cold Planer Testing and Adjusting Section must iss Required Tools EEE HEH Dene oot | Pat, | Deserption | Pressure Gauge sroass | Seo %ee 1 A (0-680 psi) | wards [come Hose Assay 272-0775. | +000 mm (39 in) u [ peotes” | Nooe Fring 7 | 64-0405 | Domy Seal 1 eation 130 grre10 | adeptr-Usion i 4. Make sute conveyor switch (8) inthe OFF | $J-1907 | O-Ring Seal 1 Pee 1685867 | Nise Fiting i 5. Make sure water sprey owt (4) 8 nthe OFF poston. eee - 6. Make sure rotor switch (5) is in the OFF position. ‘Optional Tools” Toot | Path, | bescrption | ay P| 864238" Digal Presi iatr | 7 DB | qoe-a058 [Extension able | HH Pressure Sensor Hee 198-4237 | 0-3500 kPa 1 | (0-500 psi) (9) The opal ol carbo ted in pace he analog presse renauroment Too A wie ped ne required els. (2) Tol, Tot, end Too Ear pt the 166-4240 Dig Pressure seater Grove. 4. Drive the machine to a smooth, horizontal surface. Iwuevaton 138 2, Move propulsion lever (1) to the NEUTRAL, position. 3. Move drive solector switch (2) to the OFF position, Wasration 140 7. Move parking brake switch (6) to the ON position. 8. lf necessary, move engine control switch (7) t0 the “©” position. 9. Rotate engine speed dial (8) to the LOW-IDLE position. 10. Move key switch (9) 10 the OFF position.~ J j » 60 PM102 Cold Planer Testing and Adjusting Section wis Cats OE y ed tmustation 141 11. Assemble Tool A. Assemble Too! B. Connect Too! ‘Ato Tool B. 13, Remove cap (11) from the belt tensioner pressure tap. istration 14a 14. Connect Too! B to the belt tensioner pressure tap. 18, Move key switch (9) to the START position Release the key switch when the engine starts. 16. Operate the engine at low idle for a few minutes, Mustation 145 47. Monitor engine speed value (12) on the digital display. Rotate engine speed dial (8) until the engine spead reaches 1500 rpm, 18. Monitor hydraulic oil temperature (13) on the digital display. Operate the machine until the oll temperature reaches 45 + 5°C (110 4 10°F), 19, Rotate engine speed dial (8) to the LOW-IOLE, position,a J J JID tre 61 PM102 Cold Planer ‘Testing and Adjusting Section t : i ‘station 166 20. Depress olectrical controls master switch (14). 21. necessary, use al-legs joystick (15) to fit the machine. Release the joystick when the machine ig at the maximum height. tnustaton 147 22. Mave mioidboard switch (16) to the FLOAT position. 28. Move rotor switch (5) to the ON positon. 24, Read the pressure on Too! A. The pressure should be 2000 + 100 kPa (290 + 15 psi) 25. Move rotor switch (5) to the OFF position. 26. Rotate engine speed dial (8) to the LOW-IDLE postion, 27. Move key switch (9) to the OFF position 28. i te pressure is outside the specitieg range, go to Step 29. Ifthe pressure is inside the specified range, go to Step 31 Metration 148 29. Loosen locknut (17) an the differential pressure valve. In order to increase the pressure, rotate adjustment screw (18) clockwise. In order to decrease the pressure, rotate the adjustment screw counterclackwise. 90. Hold adjustment screw (18), and tighten focknut (17), Go to Step 15, 31, Remove the tooling. Close compartment (10). Relief Valve (Right Rear Column)—Test and Adjust Sudden movement of the machine or release of oll under pressure can cause serious injury to persons on or near the machine To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine. PRG Injury to personnel can result if they are not in the operator's view. Allow only essenti 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.J JID 62 M102 Cold Planer Testing and Adjusting Section Personal injury can result from rotating and moving parts. ‘Moving fan blades and moving parts will throw or cut any object or tool that falls or is pushed into them. Make sure no one is working on, underneath or close to an engine that is running. Make sure the area is free of personnel. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine, Be prepared to collec! the fluid with suitable ‘containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar ‘Tools and Shop Products Guide’ for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose of all fluids according to local regulations and mandates. Tae 18 ~ Required Tools Toot | Pater Description — | aty i Pressure Gauge 6F-0858 | 0-16 000 kPa 1 {0-2300 ps) ‘ev-a144 | Coupler 1 27.0775 | Hoge Assembly, 1 280-9168 | Nipple Fitting 1 | 8¥0405 | Dowiy Sal 7 ‘77910 | AdapierUnion 7 | su-1907 | O-Ring Seal 1 645567 | Nipple Fiting 4 Tae 19 Optional Tools Tool | Pate, Description ty | o® | 196-4036 | Digtal Pressure necator) 1 | | 1984296 | Extension Gable 1 I Pressure Sensor & | 198238 | 0438 000 KPa + | | {0°5000 ps L (9) The aptonl els can be wean pace a fe aralog pressure measurement oo A wi species Me requred ce. (2) Teal Cand To! Owe part one 198-4240 ipa Pressure resent Group, 1. Drive the machine to a smooth, horizontal surface. ‘Wuetraton 149 2, Move propulsion lever (1) to the NEUTRAL position 3, Move drive selector switch (2) to the OFF position, ttustration 10 4, Make sure conveyor switch (3) is in the OFF position.63 PM102 Cold Planer Testing and Adjusting Section 5, Make sure water spray switch (4) in the OFF position, 6. Make sure rotor switch (5) isin the OFF position Mustration 153 12. Open compartment (10). IWastraton 169 7. Move parking breke switch (6) to the ON position. 8. Iinecessary, move engine control switch (7 the “O" position. 9, Rotate engine speed dial (8) to the LOW-IDLE position. 10. Move key switch (9) to tha OFF position. 13. Remove the cap from pressure tap (11). 14. Connect Too! B to pressure tap (1). 18. Move key switch (9) to the START position. Release the ky switch when the engine starts, 16. Operate the engine at low idle for a fow minutes. Wustration 152 11, Assemble Tool A. Assemble Too! B, Connect Too! Ato Tool B. Iwastation 455 17. Monitor engine speed value (12) on the digital display. Rotate engine speed dial (8) until the engine speed reaches 1500 rpm.