PR-1000 PAVEMENT PROFILER Preparing The Machine For Operation Caterpillar

DISENGAGE THE CUTTER CLUTCH, LOCK THE CLUTCH CONTROL AT "OUT" AND SHUT THE CUTTER ENGINE (ENGINE A) DOWN BEFORE WORKING NEAR THE CUTTER AREA OF THE MACHINE. SERIOUS INJURIES CAN RESULT FROM INADVERENT ENGAGEMENT OF THE CUTTER CLUTCH.

1. Park the machine on level ground with engine B (AVSpare 3208) running and the emergency and park brake control at "On". Move the cutter on the shipping skid near to the left front side of the machine.

2. Raise the mainframe enough to clear the cutter, turn the front track to the far left limit, use the lower conveyor lift control valve to raise the front of the conveyor, then move the cutter into position.

3. Carefully lower the mainframe onto the cutter, install the pins that connect the cutter to the mainframe, and lower the front of the lower conveyor until it engages the cutter.

4. Connect the u-joint drives, one at each end of the power unit drive.

5. Connect the quick-disconnect couplings in the hoses for the moldboard cylinders, the cutter door cylinder and the spray bars on the cutter.

6. Plug in the cutter housing light wires.

7. Install the elevation sensors, grade sensing wheels and averaging skis, as needed (see below).

Installing The Elevation Sensors And Grade Sensing Wheels Or Optional Averaging Skis

The machine is shipped from the factory with the elevation sensors installed in the shipping mounts on the handrails and with the elevation sensors already plumbed into the HYDRA-MATION system. The sensor on the right side of the machine controls the right rear elevation cylinder and the sensor on the left side controls the front elevation cylinder. To help prevent dirt from entering the HYDRA-MATION system and damaging it, the hoses should never be disconnected from the sensors unless it is necessary for repair of system components.

Installing a Grade Sensing Wheel and Sensor

1. Position the machine on level grade with the cutter lowered onto the grade and both engines shut down.

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DISENGAGE THE CUTTER CLUTCH, LOCK THE CLUTCH CONTROL AT "OUT" AND SHUT THE CUTTER ENGINE (ENGINE A) DOWN BEFORE WORKING ON THE CUTTER. SERIOUS INJURIES CAN RESULT FROM INADVERTENT STARTING OF THE CUTTER.

2. Bolt the slide tube mounting bracket to the cutter housing with the flanges to the outside of the housing.

GRADE SENSING WHEEL ASSEMBLY

3. Position the slide tube mount and install the bolt that holds the slide tube mount in the slide tube mounting bracket.

4. Bolt the swivel caster to the bracket, slide the rod holder onto the bracket, and install the wand guide in the rod holder.

5. Position the bracket near the slide tube mount, with the wand guide toward the front of the machine, slide the slide tube onto the bracket, then bolt the slide tube to the slide tube mount.

6. Slide the crank mounting bracket into the collar in the slide tube, insert the wand through the wand guide, and tighten the setscrew.

OPTIONAL AVERAGING SKI ASSEMBLY

Installing an Optional Averaging Ski

1. Install the beam mounting bracket on the track yoke and slide a retainer onto the bracket.

2. Lift the beam into position and slide the end onto the beam mounting bracket.

3. Slide the beam guide onto the beam from the front and bolt the beam guide to the mainframe.

4. Center the beam in the guide, slide a second retainer onto the beam mounting bracket, move both retainers lightly against the beam, then tighten the setscrews in the retainers.

5. Install the swivel casters on the channel and the channel on the strut arm.

6. Position the strut near the front of the beam and install the support brackets.

7. Slide the sensor arm into the sensor mount, then slide the crank mounting bracket into the collar in the sensor arm.

8. Install the feeler rod on the beam and the wand guide on the feeler rod, then insert the wand through the wand guide.

Installing The Steering Indicator

The steering indicator is used to give the operator a reference to steer by during the cutting operation. The support arm mounts in a bracket on the front track guard and can be slid in or out to position the vertical rod. The rod runs through the support arm and can be moved up or down as needed.

Checking Calibration Of The Optional Cross Slope Sensor

NOTE: THE CROSS SLOPE SENSOR IS A PRECISION INSTRUMENT THAT IS ACCURATELY CALIBRATED AT THE FACTORY. DO NOT ADJUST OR CHANGE THE POSITION OF THE POINTER, THE ADJUSTMENT GUIDE BLOCK, THE ADJUSTMENT SHAFT BEARINGS OR THE BELT THAT EXTENDS FROM THE ADJUSTMENT SHAFT TO THE SLOPE INDIAVSOR. IF NECESSARY, ADJUST BELT TENSION BY MOVING THE INDIAVSOR SUPPORT BRACKET. DO NOT MOVE THE ADJUSTMENT SHAFT BEARINGS.

The optional cross slope sensor is accurately calibrated to the cutter before the machine leaves the factory and will not normally require any further adjustment. If the machine is not cutting to the slope set in the slope indicator, the calibration of the cross slope sensor can be checked as follows:

1. Check the cutter bits for even wear. If the bits are not evenly worn, replace all the bits (see page 5-42).

2. Position the machine on a level slab or compacted dirt grade with the cutter above grade, set the emergency and park brake control at "On" and open the cutter door. Leave engine B running.

3. Set the slope indicator at "0", the right rear elevation selectors at "Auto" and "Cross Slope". Leave the front elevation selector at "Manual".

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STAY WELL CLEAR OF THE CUTTER WHILE IT IS TURNING. THE CUTTER CAN CAUSE SERIOUS INJURIES.

4. Start the cutter engine (engine A) and engage the cutter clutch.

5. Use the front and left rear elevation controls to manually lower the mainframe evenly until the cutter bits on the left end of the cutter are just contacting the slab and the mainframe is level fore and aft. If the cutter bits are all just contacting the slab, the cutter is level. Proceed with normal operation of the machine.

6. If the cutter is not level, remove the pendulum cover and set an 8 inch mechanic's level (Starret No. 98 with ground and graduated main vial, or equal) on top of the adjustment guide yoke.

7. Move the right rear elevation selector to "Manual" and use the elevation controls to adjust the cutter so that the bits are all just contacting the slab, then disengage the cutter.

8. Loosen the jam nuts on the bolts in the bottom of the pendulum frame. Use the adjusting nuts to level the adjustment guide yoke. Tighten the jam nuts.

9. Loosen the setscrew in the pulley on the slope indicator shaft, hold the pulley so it will not turn and then turn the slope indicator shaft to set the slope indicator at "0". Tighten the pulley setscrew.

10. Install the pendulum cover and proceed with normal operation of the machine. If the machine does not cut "Slope Right" or "Slope Left" according to the slope indicator, see "Calibrating the Cross Slope Sensor" in the Maintenance Manual.