PR-105 PAVEMENT PROFILER 500 Hour Service Caterpillar

1. Change the engine fuel filter.

2. Change the suction and return hydraulic oil filter elements.

3. Change the cooling system return hydraulic oil filter elements.

4. Change the oil in the main cutter and auxiliary cutter gear reducers.

Changing The Fuel Filter

Show/hide table

FUEL LEAKED OR SPILLED ONTO HOT SURFACES CAN CAUSE A FIRE. ALLOW THE ENGINE TO COOL.

1. Move the battery disconnect switch to "Off".

2. If so equipped, close the fuel supply shutoff valve. Otherwise, either drain the fuel tank or disconnect the fuel supply line from the engine and cap the opening.

3. Unscrew the filter element. Throw the used element away.

4. Be sure all of the used element gasket is cleaned from the filter base.

5. Coat the gasket of the new element with clean diesel fuel.

6. Install the filter by hand. When the gasket contacts the base, tighten the filter 3/4 turn more. There are rotation marks 90° apart on the filter. Use these as a guide for proper tightening.

7. Either open the fuel supply shutoff valve, close the fuel tank drain valve, or reconnect the fuel supply line. If necessary, fill the tank with the recommended grade of fuel oil.

8. Turn the battery disconnect switch to "On".

9. Start the engine and check for leaks. If the engine will not start, prime the fuel system (see below).

Priming The Fuel System

1. Loosen each of the fuel line nuts at the cylinder head end.

2. Crank the engine with the starting motor until fuel flows, free of air bubbles, from each of the injection lines. Stop cranking the engine.

3. Tighten each of the fuel line nuts to a torque of 30 + 5 lb. ft. (41 + 7 Nm). Use a second wrench on the nozzle and/or adaptor.

4. Start the engine and check for leaks.

Changing The Suction, Return And Cooling System Return Hydraulic Oil Filter Elements

Show/hide table

THE HYDRAULIC OIL AT OPERATING TEMPERATURE CAN CAUSE SERIOUS BURNS. LET THE MACHINE STAND IDLE UNTIL THE HYDRAULIC OIL HAS COOLED AND THE FILTER HOUSING IS COMFORTABLE TO TOUCH.

Both elements of the cooling system return filter should be changed any time one is changed. To change an element:

1. Close the shutoff valve, if applicable.

2. Hold the filter housing to keep it from turning and loosen the center post.

3. Lower the center post and housing away from the body.

4. Check the filter element and note the types and amounts of contamination. If there is excessive contamination, the hydraulic oil should be drained from the tank, the tank refilled with clean oil and all the filter elements changed.

5. Discard the old filter element.

6. If the inside of the filter housing is dirty, clean it with clean non-flammable solvent and blow it dry. DO NOT CLEAN ANY O-RINGS OR SEALS WITH SOLVENT.

7. Examine all O-rings and seals. Replace any that appear faulty.

8. Reassemble the filter housing, spring, seals, O-rings and center post with a new filter element. BE SURE THE CORRECT ELEMENT IS USED.

9. Install the filter housing on the filter body. Hold the housing from turning while tightening the center post, or the O-ring between the housing and the body may be stretched out of shape and cause leaking. Tighten the center post to a MAXIMUM OF 20 lb.ft. (27 Nm).

10. Open the shutoff valve, if applicable.

Changing The Oil In The Cutter Gear Reducer

Show/hide table

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

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

Show/hide table

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 drain plug is at the bottom of the case.

5. Remove the drain plug and allow the oil to drain. Install the plug.

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

7. Remove the check plug and fill plug.

8. Add oil through the fill plug until check plug level is reached.

9. Install the check plug and fill plug.

10. Close the cutter housing and install the bolt.

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

12. Shut the engine down.

Changing The Oil In The Auxiliary Cutter Gear Reducer

Show/hide table

FAILURE OF THE HYDRAULIC CYLINDER OR 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 off the grade. Block up the cutter assembly.

Show/hide table

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 drain plug is at the bottom of the case.

4. Remove the drain plug and allow the oil to drain. Install the plug.

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

6. Remove the check plug and fill plug.

7. Add oil through the fill plug until check plug level is reached.

8. Install the check plug and fill plug.

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

10. Shut the engine down.