PR-105 PAVEMENT PROFILER 50 Hour Service Caterpillar

1. Check the following items and service as required.

a. Pump drive gearbox oil level.

b. Cutter gear reducer oil level.

c. Auxiliary cutter gear reducer oil level.

d. Engine air inlet and exhaust system.

e. Diesel fuel.

2. Lubricate the cutter sheave drive shaft.

3. Service the spray system Y-strainer.

4. Lubricate those points shown in the 50 hour column of the service chart.

Checking The Pump Drive Gearbox Oil Level

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INADVERTENT STARTING OF THE ENGINE CAN CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH.

1. Remove the check plug.

2. Add oil, if necessary, to bring the level up to the check plug port.

3. Replace the check plug.

Checking The Cutter Gear Reducer Oil Level

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FAILURE OF THE HYDRAULIC CYLINDER OR A HOSE WILL ALLOW THE CUTTER ASSEMBLY TO DROP AND POSSIBLY CAUSE PERSONAL INJURY. INSTALL THE SAFETY PIN.

1. Start the engine and raise the cutter assembly until the safety pin can be installed through the cutter slide.

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INADVERTENT ENGAGEMENT OF THE CUTTER CAN CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH.

2. Shut the engine down.

3. Remove the bolt from the rear of the cutter housing, then swing the housing open.

4. Turn the cutter by hand until the gear reducer check plug is at the same level as the center of the case.

5. Allow time for the oil to settle to the bottom of the gear reducer, then remove the check plug.

6. If the oil does not trickle from the check plug port, remove the fill plug and add oil until check plug level is reached.

7. Install the check plug and fill plug.

8. Close the cutter housing and install the bolt.

9. Start the engine, raise the cutter assembly enough to remove the pin, then lower the cutter assembly.

10. Shut the engine down.

Checking The Auxiliary Cutter Gear Reducer Oil Level

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FAILURE OF THE HYDRAULIC CYLINDER OR A HOSE WILL ALLOW THE AUXILIARY CUTTER ASSEMBLY TO DROP AND POSSIBLY CAUSE PERSONAL INJURY. BLOCK THE CUTTER UP.

1. Start the engine and raise the cutter until the teeth are just above grade. Block up the cutter assembly.

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INADVERTENT ENGAGEMENT OF THE CUTTER CAN CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH.

2. Shut the engine down.

3. Use a bar to turn the cutter until the gear reducer check plug is at the same level as the center of the case.

4. Allow time for the oil to settle to the bottom of the gear reducer, then remove the check plug.

5. If the oil does not trickle from the check plug port, remove the fill plug and add oil until check plug level is reached.

6. Install the check plug and fill plug.

7. Start the engine, raise the cutter assembly, remove the blocks, then lower the cutter assembly.

8. Shut the engine down.

Checking The Engine Air Inlet And Exhaust System

Check all clamps, bolts, hoses and ducting on the engine air inlet and exhaust systems and service as necessary to prevent any leaks and to ensure that the air cleaner is securely mounted.

Checking The Diesel Fuel

Allow the machine to stand for at least 10 minutes before checking the diesel fuel. This will allow time for any water in the fuel to separate out.

Open the drain valve located beneath the fuel tank and drain at least one pint of fuel into a clear glass bottle and visually check for sediment and water. If sediment and/or water are present, drain fuel until it is clear. If excessive amounts of sediment and/or water are present, completely drain the tank and refill it with clean fuel.

Lubricating The Cutter Sheave Drive Shaft

Each of the slip joint drive shafts has two universal joints (U-joints) and a sliding spline section. Each U-joint has four bearings. All eight bearings and the sliding spline section must be properly lubricated if trouble is to be avoided.

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INADVERTENT STARTING OF THE ENGINE CAN CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH.

To ensure proper lubrication of all four bearing assemblies in the universal joints, it is essential that lubricant be added until it appears at all journal cross bearing seals. This assures removal of dirt particles and other contaminants that may find their way into the bearings and indicates that the bearings are fully lubricated.

Do not assume that bearing cavities have been filled with new lubricant unless flow is noticed around all four bearing seals!

The journal cross seals are designed to relieve. However, if not all the seals "pop" when being lubed, move the drive shaft laterally in all four directions and pull or push on the drive shaft in the direction opposite to the journal cross seal not relieving, while lube gun pressure is being applied to the lubrication fitting. An increase in line pressure may also be necessary.

To ensure proper lubrication of the sliding spline section, apply grease gun pressure to the lubrication fitting until lubricant appears at the pressure relief hole in the welch plug at the sleeve end of the spline.

Then cover the pressure relief hole with a finger and continue to apply grease until it appears at the sleeve yoke seal.

Servicing The Spray System Y-Strainer

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INADVERTENT STARTING OF THE ENGINE CAN CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH.

1. Empty the water tank.

2. Remove the bushing, pipe coupling and ball valve as a unit from the strainer.

3. Remove the screen from the strainer and thoroughly clean the screen in water. If necessary, use soap or detergent.

4. Reinstall the screen, bushing, pipe coupling and valve on the strainer.

5. Fill the tank.