PR-275 PAVEMENT PROFILER Daily Or 10 Hour Service Caterpillar

1. Check and service as required:

a. Engine oil level

b. Engine coolant level

c. Engine air cleaner

d. Fuel level

e. Fuel transfer pressure

f. Fuel system water separator

g. Hydraulic oil level

h. Hydraulic oil filter indicator

i. Hydraulic oil cooler and engine radiator

j. Cutter bits and flighting

k. Central lubrication reservoir

l. Moldboard cutting edges

m. Spray system water level and strainer

n. General machine for leaks, loose bolts, loose connectors, etc.

2. Lubricate in accordance with the Service Chart.

Checking Engine Oil Level

The dipstick is stamped on both sides of the blade. One side is marked and to be read when checking the oil level with the ENGINE STOPPED. The other side is marked and to be read with the ENGINE IDLING - HOT OIL. Each side is stamped to remind you not to OVERFILL the crankcase with oil.

Add oil until the oil level is at the FULL mark on the appropriate side of the dipstick. Do not overfill.

NOTE: BE SURE TO READ THE CORRECT SIDE OF THE DIPSTICK. THE ADD AND FULL LEVELS ARE NOT THE SAME WHEN CHECKING THE OIL WHILE STOPPED AND WHILE IDLING.

Checking Engine Coolant Level

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. Maintain coolant level at the base of the fillpipe. Never add coolant to an overheated engine, allow it to cool first.

4. Make-up coolant should be one of the following in order of preference:

a. Permanent anti-freeze and fresh water solution.

b. Drinkable water and rust inhibitor solution.

c. Drinkable water.

d. Any available fresh water.

If the engine is to be used in freezing weather, (a) must be used. (b) can be used if coolant temperature will remain above freezing. (c) or (d) should be used only as a temporary fix when coolant temperature will remain above freezing. As soon as possible, return system to (a) or (b).

Checking Engine Air Cleaner

Before starting the engine, check the window of the indicator. If the red piston is locked in the raised position, service the air cleaner as outlined below.

Changing Air Cleaner Element

1. Remove the air cleaner cover and element.

2. Cover the air inlet opening to prevent foreign objects from entering the engine.

3. Clean the inside of the air cleaner cover and the air cleaner body.

4. Inspect the replacement element for damage and cleanliness.

NOTE: HAVE A REPLACEMENT ELEMENT ON HAND TO INSTALL AND USE WHILE CLEANING THE DIRTY ELEMENT. THIS WILL SAVE YOU DOWN TIME.

5. Remove the covering from the air inlet opening.

6. Install the element.

7. Install the air cleaner cover.

8. Reset the service indicator button by pushing the reset button in.

9. Clean the used air cleaner element. See the instructions for cleaning in the AVSpare 3306 Industrial Engine Operation Guide.

Cleaning Air Cleaner Cap

1. Remove the cap from the air cleaner inlet.

2. Clean the bottom grill using pressure air (maximum 30 psi - 2.0 kg/cm²), or low sudsing detergent and water. Install the cap.

Show/hide table

PROTECTIVE EYE GLASSES MUST BE WORN WHEN USING PRESSURE AIR.

Checking Fuel Level

The fuel tank is equipped with a sight gauge for easy checking of the fuel level. The tank should be filled at the end of each work day to reduce the amount of water condensed out of the air as the tank cools during the night.

Checking Fuel Transfer Pressure

The fuel pressure gauge, located by the fuel filter housing, should register in the "Normal" (green) range whenever the engine is running. If the gauge registers outside the normal range with the engine running, change the fuel filter. See "Changing the Fuel Filter" on page 4-37 for procedures to change the fuel filter.

Draining The Fuel System Water Separator

The separator should be drained before the engine is started. Also, anytime the separator gets half-full of water, the engine should be shut down and the separator drained. If the inside of the glass cover gets so dirty that the water level cannot be seen, replace the filter element and clean the glass cover.

1. Stop the engine.

2. Close the fuel shutoff valve at the fuel tank.

3. Open the vent valve and the drain valve. Let all the water drain from the separator.

4. Close the vent valve and drain valve.

5. Open the shutoff valve at the fuel tank.

NOTE: USE THE PRIMING PUMP, IF NECESSARY, TO PRIME THE FUEL SYSTEM FOR RESTARTING.

Replacing The Fuel System Water Separator Filter Element

1. Thoroughly clean the water separator and the area around it.

2. Drain all the water from the separator, as described above, and then close the vent valve and drain valve.

3. Remove the clamp and pull the filter element off the base.

4. Use a clean cloth to clean the three sealing areas.

5. Install the new element on the base so the pin fits in the outlet passage at the bottom of the element.

6. Install the clamp so the lock tab fits into the slot on the bottom of the base, and the upper lock tab fits into the slot on top of the base.

NOTE: THE CLAMP MUST BE INSTALLED WITH THE FINGER TAB ON TOP AS SHOWN. MAKE SURE THE CLAMP HOLDS THE FILTER ELEMENT TIGHTLY AGAINST THE BASE.

USE THE PRIMING PUMP, IF NECESSARY, TO PRIME THE FUEL SYSTEM FOR RESTARTING.

Checking Hydraulic Oil Level

The hydraulic oil tank is equipped with a sight gauge for easy checking of the hydraulic oil level. The hydraulic oil level should be maintained halfway up the sight gauge, or higher. If the hydraulic oil level is low, use the replenishing hand pump to pump oil from the replenishing tank into the main hydraulic oil tank. Refill the replenishing tank with new water-free hydraulic oil conforming to the specification on page 4-1. Do not overfill either tank, allow for expansion of the oil and changes in the main tank level as the cylinders are operated.

Checking The Hydraulic Oil Filter Indicator

Push the test button and be sure the indicator light comes on. If the light does not come on, check the fuse and the light bulb. DO NOT OPERATE THE MACHINE IF THE INDIAVSOR WILL NOT FUNCTION.

Checking Hydraulic Oil Cooler And Radiator

Since the cooling air flows through the oil cooler and then through the radiator, any obstructions to air flow through either will also obstruct the air flow through the other. Any rags, paper, mud, dust, cuttings, bugs, etc. that may obstruct the air flow must be removed.

Checking Cutter Bits, Bit Holders And Flighting

NOTE: NEVER OPEN THE CUTTER DOORS WITH THE ENGINE RUNNING OR WITH THE WHEELS TURNED. IF THE JOG SWITCH WILL NOT TURN THE CUTTER, SEE PAGE 4-46.

The cutter bits should be checked for excessive wear and replaced anytime the distance from the holders to the tip of the bits (normal wear) or to the end of the supporting metal (carbide tip exposed) is 1 1/4inches or less.

At the same time the bits are checked, also check the cutter flighting and bit holders for breaks and cracks. Replace as necessary.

Replacing A Cutter Bit

Place the fork of the bit puller under the shoulder of the bit and then slide the weight sharply against the retainer to break the bit loose. Insert a new bit into the holder and hammer it into place so that the keeper spring is engaged with the holder.

Replacing A Damaged Bit Holder Or Flighting Section

1. Unbolt the damaged section of flighting or the section containing the damaged holder.

2. Thoroughly clean both the new flighting section and the cutter drum where the flighting section fits.

3. Position the new flighting section on the drum.

4. Position the wedges (CMI No. 1-2169) and lockwashers (CMI No. A00310) and install the bolts finger-tight. Be sure the bolts are clean and dry when installed. Use only CMI No. A02765 hex head bolts.

5. Use the torque wrench supplied with the machine to TIGHTEN THE LEADING BOLTS FIRST TO 290 ± 10 FT.-LBS. Then tighten the rear bolts to the same torque.

NOTE: DUE TO SOME "SEATING" OF THE BOLTS, IT IS IMPORTANT THAT THE BOLTS ALL BE RETORQUED AFTER THE FIRST FEW HOURS OF OPERATION.

Replacing A Broken Flighting Bolt

If a flighting bolt is broken off and therefore cannot be removed from the cutter drum:

1. Drill a hole into the center of the remainder of the bolt. Use a 1/4 inch drill bit for the smaller extractor or a 17/64inch bit for the larger extractor.

2. Insert one of the bolt extractors supplied with the machine into the hole and turn the extractor counterclockwise with a wrench. The extractor will thread itself into the hole and then turn the bolt to remove the bolt.

3. Check the threads in the bolt hole in the cutter drum. If the threads are satisfactory, install a new flighting section (see "Replacing a Damaged Bit Holder or Flighting Section" on page 4-17).

THREAD REPAIR PACK

4. If the bolt threads are damaged, use a 21/32 drill to drill out the bolt hole.

5. Use the tap supplied with the thread repair pack to tap the bolt hole.

6. Screw an insert onto the mandrel (both supplied in the thread repair pack) until the driving tang on the insert is fully engaged.

7. Use the mandrel to screw the insert into the bolt hole. The top of the insert must be 1/4 to 1/2 turn below the outside of the cutter drum.

8. Use a punch or rod that has a square end (no chamfer) and will fit snugly into the insert to break off the driving tang. Insert the punch or rod into the insert until it rests on the tang, hold the tool squarely and strike it with a hammer.

9. Install a new flighting section (see "Replacing a Damaged Bit Holder or Flighting Section" on page 4-17).

Checking The Central Lubrication Reservoir

The central lubrication reservoir is equipped with a low level alarm that flashes a light when the reservoir requires filling. However, a quick visual check of the transparent reservoir before starting operation may prevent running low on lubricant during operation.

To fill the reservoir:

1. Attach the delivery hose of a manually operated grease gun or filler pump to the grease fitting on the pump body.

2. Stroke the filler pump handle until weepage is present at the reservoir vent hole. The lower portion of the follower must rise above the vent hole to release any air entrapped in the lubricant.

NOTE: USE CARE WHEN FILLING THE RESERVOIR. EXCESSIVE PRESSURE CAN CAUSE DAMAGE TO THE RESERVOIR AND FOLLOWER.

Checking The Moldboard Cutting Edges

The moldboard cutting edges should be checked for excessive wear and for loose connecting bolts. Tighten any loose bolts and replace cutting edge sections as necessary.

Checking The Spray System Water Level

The water tank is equipped with a sight gauge for easy checking of the water level. Any water added should be as clean as possible to prevent damaging the water pump. If freezing temperatures are expected overnight drain the water tank, the filter, the hoses and the pump.

Servicing The Water Strainer

Open the valve on the strainer and allow the water to flush the accumulated dirt out. If very dirty water is used in the system, flushing of the strainer may be required more often.