PR-105 PAVEMENT PROFILER 150 Hour Service Caterpillar

1. Change the engine oil and oil filter element.

2. Clean the engine crankcase breather.

3. Add conditioner to the engine coolant.

4. Check the drive belts.

5. Check the battery electrolyte level and clean the battery or batteries, if needed.

6. Check the machine wiring and connections.

7. Check the engine governor. After the first 150 hours only, thereafter every 2000 hours.

8. Check the engine valve lash. After the first 150 hours only, thereafter every 1000 hours. See the AVSpare 3204 Operation and Maintenance Manual for procedures.

9. Lubricate those points shown in the 150 hour column of the service chart.

Changing The Engine Oil

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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.

With the engine stopped and the oil warm:

1. Remove the engine oil drain plug.

2. Drain the oil.

3. Install the drain plug and tighten it to 50 ± 10 lb.ft. (70 ± 14 Nm).

4. Fill the engine with oil meeting the specification on page 5-1.

5. Before starting the engine, check the oil level.

6. Start and run the engine at low idle for two minutes. Inspect for oil leaks.

7. Shut the engine down.

8. Wait 10 minutes to allow the oil to drain into the crankcase, then recheck the oil level.

Changing The Engine Oil Filter Element

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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. Drain the engine oil (see above).

2. Use a strap wrench to remove the oil filter. Throw the old filter away.

3. Wipe the sealing surface of the filter element mounting base. Be sure all of the old gasket is removed.

4. Apply a small amount of clean engine oil to the new filter element gaskets.

5. Install the new filter by hand until the gasket contacts the base.

6. Tighten the filter 3/4 of a turn more. Do not overtighten.

7. Fill the crankcase (see page 5-25).

Cleaning The Engine Crankcase Breather

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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. Loosen the clamps and slide the hose on the tube.

2. Remove the bolt, then remove the breather and seal.

3. Wash the breather in clean nonflammable solvent, then dry the breather.

4. Install a new seal and the clean breather on the engine. Tighten the bolt to 10 ± 2 lb.ft. (14 ± 3 Nm).

5. Slide the hose onto the breather and tighten the hose clamps.

Adding Conditioner To The Engine Coolant

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IF THE ENGINE IS WARM, STEAM MAY SPRAY OUTWARD UNDER HIGH PRESSURE WHEN THE RADIATOR CAP IS LOOSENED. SERIOUS BURNS MAY RESULT. CHECK THE COOLANT LEVEL ONLY WHEN THE ENGINE IS STOPPED AND THE RADIATOR CAP IS COOL ENOUGH TO TOUCH. COOLING SYSTEM CONDITIONER CONTAINS ALKALI AND CAN CAUSE CHEMICAL BURNS. WEAR EYE PROTECTION AND AVOID LETTING THE CONDITIONER TOUCH YOUR SKIN.

1. Slowly turn the pressure cap to the first stop and release the pressure fully before proceeding.

2. Push the cap down and turn it until released.

3. If necessary, drain enough coolant from the radiator to allow the cooling system conditioner to be added.

4. Add 1/2 pint (0.24 Liters) of conditioner to the cooling system.

5. Inspect the radiator cap gaskets. Replace the cap if the gaskets are damaged.

6. Install the radiator cap.

Checking The Drive Belts

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

Check all the drive belts for signs of wear or fraying and replace any belts that show such signs. Also check and adjust the belt tension.

To check the tension of the V-belts apply a force midway between the two pulleys and check the belt deflection. The correct force and deflection for each V-belt is given below.

New standard V-belts will stretch after the first few hours of operation. Run the engine for 15 seconds to set the belts then retighten them. Retighten the belts after 1/2 hour and again after 8 hours of operation. Thereafter, check the tension of the drive belts every 150 hours and adjust, if necessary. Too tight a belt is destructive to the bearings of the driven part; a loose belt will slip.

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NOTICE
NEVER PRY A BELT OVER A PULLEY. THE BELT WILL BE DAMAGED.

Adjusting The Engine Drive Belt

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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 fan guard.

2. Loosen the mounting bolt and the adjusting bracket bolt.

3. Move the alternator in or out as necessary to obtain the correct belt tension. A 25 pound (110 N) force produces a deflection of 1/2 to 3/4 inch (13-19 mm).

4. Tighten the bolts.

5. Replace the fan guard.

Adjusting The Water Pump Drive Belt

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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. Loosen the pump mounting bolts.

2. Move the pump as necessary to obtain the correct belt tension. A 3 to 5 pound (13.2-22 N) force produces a deflection of 1/4inch (6 mm).

3. Tighten the mounting bolts.

Adjusting The Accessory Pump Drive Belt

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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. Hold the adjustment nut with a wrench.

2. Turn the adjustment bolt as necessary to obtain the correct belt tension. A 5 to 7 pound (22 to 30.8 N) force produces a deflection of 1/4 inch (6 mm). Turning the bolt clockwise tightens the belt. Turning the bolt counterclockwise loosens the belt.

Adjusting The Cutter Drive Belt

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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. Loosen the slide adjustment jam nut.

2. Turn the adjustment nut as necessary to obtain the correct belt tension. A 14 to 20 pound (61.6-88 N) force produces a deflection of 1/16 inch (1.5 mm). Turning the nut clockwise tightens the belt. Turning the nut counterclockwise loosens the belt.

3. Tighten the jam nut.

Checking The Battery Electrolyte Level

The PR-105 is equipped with a maintenance-free battery or batteries at the factory. These batteries do not have vent caps and the electrolyte level does not have to be checked. If a battery is replaced with a battery with vent caps, the following procedures for checking the electrolyte level should be performed.

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BATTERIES GIVE OFF A FLAMMABLE GAS. IF THE GAS WERE TO IGNITE, SERIOUS BURNS COULD RESULT. NEVER SMOKE OR HAVE AN OPEN FLAME WHEN NEAR THE BATTERY.

1. Maintain electrolyte level to base of each vent well.

2. Make-up water must be one of following (in order of preference):

a. Distilled water

b. Odorless, tasteless drinking water

c. Iron free water

d. Any available water

Cleaning The Battery

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BATTERIES GIVE OFF A FLAMMABLE GAS. IF THE GAS WERE TO IGNITE, SERIOUS BURNS COULD RESULT. NEVER SMOKE OR HAVE AN OPEN FLAME WHEN NEAR THE BATTERY.

1. Mix a solution of baking soda and water, 1/4 pound (55 grams) to a quart (.95 L) of water. Apply with a bristle brush.

2. Thoroughly rinse battery and battery box with clean water.

3. Apply grease to battery cable clamps and terminals and to all threads.

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NOTICE
BE CAREFUL TO KEEP ANY OF THE BAKING SODA FROM GETTING INTO THE BATTERY CELLS.

Checking Machine Wiring And Connections

Visually check the machine wiring for damage such as broken insulation and frayed wires. Check for loose or corroded connections. Repair as necessary.

Checking The Engine Governor

The engine governor should be checked and the necessary adjustments made by an authorized AVSpare engine dealer or a mechanic that has the correct training. The correct low and high idle rpm and the measurements for adjustment of the fuel setting are available from your AVSpare dealer.