PM820, PM822, and PM825 Cold Planer Machine Systems Caterpillar

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1. Remove second stage conveyor.

Removal Procedure

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and 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.

Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes to help prevent fluid loss and keep contaminants from entering the system.

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Illustration 1	g06098997

1. Disconnect hose assembly (1), hose assembly (2), and hose assembly (4). Disconnect harness assembly (3).
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   Illustration 2	g06099011

2. Remove six bolts (5). Repeat process for opposite side of bent plate (6). Remove bent plate (6).
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   Illustration 3	g06099021

3. Disconnect hose (7) and hose (8). Remove four bolts (9).

4. Remove blower (10).
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   Illustration 4	g06099295

5. Remove nuts (11). Remove bolts (12) and place the bracket assembly out of the way. Cut cable strap (14) and place the camera assembly out of the way.

6. Remove four bolts (13). Repeat process on opposite side of the second stage conveyor.
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   Illustration 5	g06099327

7. Remove three bolts (15). Remove retaining plate (16). Repeat process for opposite side of the second stage conveyor.

8. With the assistance of another person, remove second stage conveyor cover (17). The weight of second stage conveyor cover (17) is approximately 45 kg (100 lb)
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   Illustration 6	g06099386

9. Remove sheet cover (18). Repeat process for opposite side of the second stage conveyor.
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   Illustration 7	g06099418

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   Illustration 8	g06099422

10. Remove four bolts (20). Remove retaining plate (21). Remove four bolts (19). Repeat process on opposite side of the second stage conveyor.

11. Use suitable lifting device to remove second stage conveyor cover (22). The weight of second stage conveyor cover (22) is approximately 68 kg (150 lb)

12. Repeat Step 10 and Step 11 for the remaining two second stage conveyor covers.
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    Illustration 9	g06099462

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    Illustration 10	g06099468

13. Remove four bolts (23). Repeat process for opposite side of the second stage conveyor.

14. Use a suitable lifting device to remove hopper assembly (24). The weight of hopper assembly (24) is approximately 73 kg (160 lb).
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    Illustration 11	g06099526

15. Use suitable lifting devices to rotate second stage conveyor (25) 90° onto the right side and place on suitable cribbing. The weight of second stage conveyor (25) is approximately 2086 kg (4600 lb)
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    Illustration 12	g06099544

16. Remove bolts (26). Repeat process for opposite side of the second stage conveyor. Remove return idler (27).

17. Repeat Step16 for the remaining two return idler rollers.
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    Illustration 13	g06099976

18. Remove retaining clip (29). Remove linkage pin (28). Repeat process for opposite side of the second stage conveyor.
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    Illustration 14	g06100513

19. Use a suitable lifting device to rotate the head end of second stage conveyor (25) as shown to a 90°angle from the tail end of second stage conveyor (25) to allow slack in conveyor belt (30). The weight of second stage conveyor (25) is approximately 2086 kg (4600 lb)
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    Illustration 15	g06100515

20. Use a suitable lifting device to remove conveyor belt (30). The weight of conveyor belt (30) is approximately 181 kg (400 lb).

Installation Procedure

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Illustration 16	g06100515

1. Use a suitable lifting device to install conveyor belt (30). The weight of conveyor belt (30) is approximately 181 kg (400 lb).
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   Illustration 17	g06100513

2. Use a suitable lifting device to rotate the head end of second stage conveyor (25) as shown to straighten second stage conveyor (25). The weight of second stage conveyor (25) is approximately 2086 kg (4600 lb)
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   Illustration 18	g06099976

3. Install linkage pin (28). Install retaining clip (29). Repeat process for opposite side of the second stage conveyor.
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   Illustration 19	g06099544

4. Install return idler roller (27). Install bolts (26). Repeat process for opposite side of the second stage conveyor.

5. Repeat Step 4 for the remaining two return idler rollers.
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   Illustration 20	g06099526

6. Use suitable lifting devices to rotate second stage conveyor (25) 90° so that top of conveyor belt faces up. Place second stage conveyor on suitable cribbing. The weight of second stage conveyor (25) is approximately 2086 kg (4600 lb)
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   Illustration 21	g06099468

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   Illustration 22	g06099462

7. Use a suitable lifting device to install hopper assembly (24). The weight of hopper assembly (24) is approximately 73 kg (160 lb).

8. Install four bolts (23). Repeat process for opposite side of the second stage conveyor.
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   Illustration 23	g06099422

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   Illustration 24	g06099418

9. Use a suitable lifting device to install second stage conveyor cover (22). The weight of second stage conveyor cover (22) is approximately 68 kg (150 lb)

10. Install four bolts (19). Install retaining plate (21). Install four bolts (20) and tighten to a torque of 30 ± 7 N·m (266 ± 62 lb in). Repeat process on opposite side of second stage conveyor.

11. Repeat Step 9 and Step10 for the remaining two second stage conveyor covers.
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    Illustration 25	g06099386

12. Install sheet cover (18). Repeat process for opposite side of the second stage conveyor.
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    Illustration 26	g06099327

13. With the assistance of another person, install second stage conveyor cover (17). The weight of second stage conveyor cover (17) is approximately 45 kg (100 lb)

14. Install retaining plate (16). Install three bolts (15) and tighten to a torque of 30 ± 7 N·m (266 ± 62 lb in). Repeat process for opposite side of the second stage conveyor.
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    Illustration 27	g06099295

15. Install four bolts (13). Repeat process on opposite side of the second stage conveyor.

16. Install the cable strap on harness assembly (14). Install the bracket and bolts (12). Install the camera and nuts (11).
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    Illustration 28	g06099021

17. Install blower (10).

18. Install four bolts (9). Connect hose (7) and hose (8).
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    Illustration 29	g06099011

19. Install bent plate (6). Install six bolts (5). Repeat process for opposite side of bent plate (6).
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    Illustration 30	g06098997

20. Connect hose assembly (1), hose assembly (2), and hose assembly (4). Connect harness assembly (3).