PR-275 PAVEMENT PROFILER 1000 Hour Or Annual Service Caterpillar

1. Complete 10, 50, 100, 250 and 500 Hour Services.

2. Set engine valve lash and check valve rotation. See the AVSpare 3306 Industrial Engine Operation Guide for procedures.

3. Drain, flush and refill engine cooling system.

4. Change fuel filter element.

5. Change hydraulic oil and filters.

6. Change oil in the pump drive gearbox, cutter gearbox, cutter chaincase, steering gearbox and wheel gear reducers.

Draining Engine Cooling System

1. Shut engine off.

2. Slowly turn pressure cap until pressure is fully released.

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NOTICE
BE CAREFUL. IF ENGINE IS WARM, STEAM MAY SPRAY OUTWARD UNDER HIGH PRESSURE.

3. Remove lower radiator hose.

4. Remove the engine block drain plug.

5. Allow coolant to drain.

6. Replace radiator hose and drain plug.

Flushing Engine Cooling System

To clean the cooling system, any good commercial radiator cleaning solution can be used. Follow the instructions included with the cleaner.

The cooling system can also be cleaned using oxalic acid and sodium carbonate as follows:

1. Fill the cooling system with a solution consisting of two pounds of oxalic acid or sodium bisulphate (NaHSO₂) with every 10 gallons of water.

2. Start engine and operate at operating temperatures for 1/2to 1 hour.

3. Stop engine and drain cooling system.

4. Flush system with clean water until draining water is clear.

5. Replace radiator hose.

6. Fill with solution consisting of 1/2 pound of sodium carbonate crystals (Na₂CO₃, 10H₂O) with every 10 gallons of water.

7. Start and run engine for 10 minutes.

8. Stop the engine and drain cooling system.

9. Flush cooling system with clean water.

10. Replace radiator hose and drain plug.

Filling Engine Cooling System

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NOTICE
WHEN FILLING THE COOLING SYSTEM, IT IS ESSENTIAL THAT AIR POCKETS WITHIN THE SYSTEM BE ABLE TO VENT TO THE ATMOSPHERE. AIR TRAPPED IN THE SYSTEM CAN CAUSE MAJOR ENGINE PROBLEMS.

1. Use water that is low in scale forming materials. Do not use softened water. Add either rust inhibitor or permanent type anti-freeze. DO NOT ADD BOTH.

2. While filling the cooling system, stop the filling procedure several times to allow the coolant level to stabilize and expel air from the system.

3. Add coolant until the coolant level reaches the base of the fill pipe. Allow space for coolant expansion.

4. Start the engine and allow it to idle several minutes with the filler cap off. Add coolant as necessary.

5. Install the filler cap.

6. Check the system for leaks. Have the engine cooling system repaired if necessary.

Changing The Fuel Filter

1. Stop the engine.

2. Close the diesel fuel supply valve.

3. Wipe the top of the filter element and filter base.

4. Unscrew and remove the filter.

5. Be certain the filter gasket does not remain attached to the filter base or leaking between the new and old filter gasket will result.

6. Clean the gasket sealing surface of the filter base.

7. Lubricate the new filter gasket with clean diesel fuel.

8. Tighten filter by hand until gasket contacts base and then tighten 1/2 turn more.

Priming The Fuel System

If air is trapped in the fuel system, the diesel engine will either not start, or will misfire.

1. Move the throttle lever to the shut-off position.

2. Open the vent valve.

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NOTICE
OPERATE THE PRIMING PUMP ONLY WHEN THE VENT VALVE IS OPEN.

3. Push in on the pump and turn counterclockwise to release the pump from the locked position.

4. Operate the fuel priming pump with rapid strokes until the stream of fuel pumped out the vent is free of air bubbles.

5. Push in on the pump and turn clockwise to lock in the closed position.

6. Close the vent valve.

7. Start the engine.

If the engine misfires or smokes:

8. Loosen a fuel injection line nut at the cylinder end of the line and allow fuel to flow until free of air bubbles.

9. Tighten the line nut and open the next line nut.

10. Vent each fuel line until the engine is running smoothly.

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NOTICE
AVOID BLEEDING EXCESSIVE AMOUNTS OF FUEL.

Changing The Hydraulic Oil

When changing the hydraulic oil, cleanliness must be kept in mind at all times. Perform the work in a clean area, use clean tools, keep your hands clean and clean up the outside of the hydraulic oil tank before starting.

1. Be sure the hydraulic oil is cool. If the machine has been operating, the oil can be hot enough to burn the hands.

2. Remove the drain plug at the bottom of the tank and allow the oil to drain.

3. Pump a gallon or two of oil from the replenishing tank to the hydraulic oil tank and allow it to drain from the oil tank in order to remove any water present in the replenishing tank.

4. Install the drain plug and refill the tank with hydraulic oil by pumping the oil from the replenishing tank and adding oil to the replenishing tank as needed. Use only hydraulic oil that conforms to the specification on page 4-1.

5. Loosen the hose at the suction port of each pump until air-free hydraulic oil flows from the connection.

6. Loosen the outlet connection on the auxiliary pump and crank the engine with the starter until air-free hydraulic oil flows from the connection. Tighten the connection.

7. Start the engine and run at a low idle for several minutes. Check for leaks and check the hydraulic oil level. Add oil as necessary.

Changing The Auxiliary Pump Pressure Filter Element

1. Be sure the hydraulic oil is cool enough that it will not burn the hands. If the machine has been operating, let it sit until the oil cools off.

2. Unscrew the bowl from the filter head and remove the bowl.

3. Flush the bowl with clean solvent and dry it with filtered air.

4. Insert a new filter element into the bowl and install the bowl on the head.

5. Loosen the pressure line at the outlet port in the filter head.

6. Crank the engine until air-free hydraulic oil comes from the outlet port.

7. Tighten the pressure line at the outlet port.

Changing The Replenishing, Return And Pump Suction Filter Elements (96102 & 96103)

1. Be sure the hydraulic oil is cool enough that it will not burn the hands. If the machine has been operating, let it sit until the oil cools off.

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.

NOTE: EXCESSIVE METAL PARTICLES IN THE OIL OR DISCOLORATION OF THE OIL ARE AN INDIAVSION OF AN IMPENDING COMPONENT FAILURE. LOAVSING THE CAUSE OF THE CONTAMINATION CAN HELP PREVENT FUTURE PROBLEMS. THE CMI FIELD ENGINEERING OFFICE AND/OR HYDRAULICS SHOP WILL GLADLY PROVIDE CONSULTATION ON APPROPRIATE ACTION IN SPECIFIC CASES.

5. Discard the old filter element.

6. If the inside of the filter housing is dirty, clean it with clean diesel fuel and blow it dry. DO NOT CLEAN HYDRAULIC COMPONENTS 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 FOR EACH FILTER.

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 FT.-LBS.

10. Repeat steps 2 through 9 for the other filter elements.

Changing The Replenishing, Return And Pump Suction Filter Elements (96104 And Subsequent)

Beginning with machine 96104, the filter arrangement is changed. The return filter and the auxiliary pump suction filter are the same type as on earlier machines and should be changed in the same way (see page 4-41). The suction filter for the cutter drive pump and the wheel drive pump is a single element, in-tank filter that should be changed as described below.

1. Unscrew the nut from the outside of the filter. This closes the check valve to keep oil from draining from the tank.

2. Remove the cover and filter element from the filter assembly.

3. Remove the self-locking nut and valve cap, and pull the element from the cover.

4. Check all O-rings for wear or deterioration. Replace as necessary.

5. Install a new element in the cover.

6. Install the valve cap and locknut.

7. Install the cover and element assembly in the filter assembly and tighten the nut.

Changing Oil In The Gearboxes And Cutter Chaincase

1. Remove the drain plug and allow the oil to drain.

2. Reinstall the drain plug.

3. Remove the check plug and breather.

CUTTER CHAINCASE

CUTTER CHAINCASE

CUTTER CHAINCASE

PUMP DRIVE GEARBOX

CUTTER GEARBOX

4. Add oil through the breather port until it reaches the check plug level.

5. Reinstall the check plug and breather.

Changing Oil In Wheel Gear Reducers

WHEEL GEAR REDUCER

1. Move the machine so that the drain plug in a gear reducer is at the bottom of the case.

2. Remove the drain plug and allow the oil to drain.

3. Install the drain plug and carefully move the machine until the fill plug is at the top of the case.

4. Remove the check plug and fill plug.

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

6. Install the check plug and fill plug.

7. Repeat 1 through 6 for the other wheels.