PR-1000 PAVEMENT PROFILER Daily Or 10 Hour Service Caterpillar

Check the following items and service as required.

1. On the AVSpare 3208 engine (engine B):

a. Crankcase oil level.

b. Coolant level.

c. Radiator.

d. Air cleaner.

e. Fuel water separator.

2. On the AVSpare 3412 engine (engine A):

a. Crankcase oil level.

b. Coolant level.

c. Radiator.

d. Air cleaners.

e. Fuel filters.

3. Drain any water and sediment from the fuel tank and check the fuel level.

4. Water level in the water system tanks.

5. Hydraulic oil level.

6. Hydraulic oil cooler.

7. Control (auxiliary) hydraulic system pressure filter.

8. Compressed air system.

9. Power take-off clutch clearance.

10. Cutter sheave and planetary gear reducer oil levels.

11. Moldboard blade.

12. Cutter bits, bit holders and flighting.

13. Cutter drum water level.

14. Water spray system filters and nozzles.

15. Optional high pressure water pump oil level, if installed.

16. General machine for missing shields and guards, leaks, loose bolts, loose connectors, etc.

Lubricate those points shown in the 10 hour column of the service chart.

Checking The AVSpare 3208 (Engine B) Oil Level

CHECK THE OIL LEVEL BEFORE STARTING THE ENGINE. Maintain the oil level between the FULL and ADD marks on the dipstick.

Checking The AVSpare 3208 (Engine B) Coolant Level

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

1. Slowly turn the radiator pressure cap to the first stop and release any pressure.

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

3. Maintain the coolant level at the base of the fillpipe. If a loss of coolant is noticable, check for leaks in the system. After filling the system, leave the radiator cap off, start the engine and recheck the coolant level after normal operating temperature is reached. Running the engine at operating temperature will permit the temperature regulator to open and allow the coolant to circulate through the entire system and purge air from the engine.

4. Install the radiator cap.

Make-up coolant should be water that is free as possible of scale forming minerals (not softened water), a permanent type antifreeze and AVSpare Cooling System Conditioner. Follow the recommendations given on the container.

Maintain a 3% concentration of AVSpare Cooling System Conditioner. Make-up water added without the proper proportions of cooling system conditioner can cause excessive lime deposits and corrosion.

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NOTICE
DO NOT USE AVSpare CORROSION INHIBITOR WITH DOWTHERM 209 FULLFILL COOLANT. DO NOT ADD COOLANT TO AN OVERHEATED ENGINE, ALLOW THE ENGINE TO COOL FIRST. ADD COOLANT SLOWLY TO A HOT ENGINE TO PREVENT POSSIBLE CRACKING OR DISTORTING OF THE CYLINDER HEAD.

Checking The AVSpare 3208 (Engine B) Radiator

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NEVER WORK NEAR THE COOLING FAN WITH ENGINE B (AVSpare 3208) RUNNING. THE FAN BLADES OR BELT DRIVE CAN CAUSE SERIOUS INJURIES.

Check that the radiator is clear of any obstructions to air flow through the cooling fins. Any rags, paper, mud, DUST, bugs, etc. that may obstruct the air flow must be removed. Carefully straighten any bent fins on the radiator.

Checking The AVSpare 3208 (Engine B) Engine Air Cleaner

AIR CLEANER

The engine air cleaner is equipped with an indicator that shows a red signal when the main element should be serviced. If the red signal is locked in view, the main element should be serviced as soon as possible to prevent possible engine damage. See "Changing the AVSpare 3208 (Engine B) Air Cleaner Element" below for procedures.

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NOTICE
SHUT THE ENGINE DOWN BEFORE SERVICING THE AIR CLEANER.

The air cleaner also has a dust cup that collects the dust from the pre-cleaner. Empty the dust cup as required to prevent the dust from building up closer than one inch from the baffle. Remove and inspect the dust cup daily until a regular service interval can be established.

When reinstalling the dust cup, be sure it seals all the way around the air cleaner body.

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NOTICE
THIS IS A DRY TYPE AIR CLEANER - DO NOT USE OIL.

Changing The AVSpare 3208 (Engine B) Air Cleaner Element

The main element should be cleaned or replaced with a new element anytime the air cleaner red indicator is locked in view. Replace the main element after three cleanings or one year of use, whichever occurs first. Change the safety element every third time the main element is cleaned or replaced. (See the Maintenance Manual for cleaning procedures.)

Although it is possible to clean the safety element using the procedures described for the main element, it is not recommended except in an emergency situation. Maximum engine protection is achieved by replacing the plugged safety element with a new element.

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NOTICE
SHUT THE ENGINE DOWN BEFORE CHANGING AN AIR CLEANER ELEMENT.

To replace the main element:

1. STOP THE ENGINE, remove the dust cup and clean it.

2. Remove the main element. DO NOT REMOVE THE SAFETY ELEMENT.

3. Immediately inspect the main element for any dust streaks on the inside. If there are any dust streaks, the element is damaged, THROW IT AWAY.

4. Inspect the main element gasket. If the element gasket is not smooth and flat or is damaged in any way that might allow dust to get by, THROW THE ELEMENT AWAY.

5. Install a new or cleaned main element and tighten the wing nut securely.

6. Install the dust cup.

To replace the safety element:

1. STOP THE ENGINE, remove the dust cup and clean it.

2. Remove the main element.

3. Remove the safety element and clean out any dust dislodged into the cleaner outlet.

4. Install a new safety element.

5. Inspect the gasket washer on the wing nut and replace it if a good air seal cannot be guaranteed.

6. Tighten the wing nut securely.

7. Install the main element and tighten the wing nut securely.

8. Install the dust cup.

Checking The AVSpare 3208 (Engine B) Fuel Water Separator

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NEVER SMOKE OR HAVE AN OPEN FLAME WHEN SERVICING THE FUEL WATER SEPARATOR. THE DIESEL FUEL COULD IGNITE OR EXPLODE, CAUSING SERIOUS BURNS AND INJURIES FROM FLYING OBJECTS.

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. NEVER RUN THE ENGINE WITH THE SEPARATOR MORE THAN HALF-FULL OF WATER. If the inside of the glass cover gets so dirty that the water level cannot be seen, replace the filter element. To drain the separator:

1. SHUT THE ENGINE DOWN.

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.

6. Use the priming pump, if necessary, to prime the fuel system (see page 5-23).

Replacing The AVSpare 3208 (Engine B) Fuel Water Separator Element

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NEVER SMOKE OR HAVE AN OPEN FLAME WHEN SERVICING THE FUEL WATER SEPARATOR. THE DIESEL FUEL COULD IGNITE OR EXPLODE, CAUSING SERIOUS BURNS AND INJURIES FROM FLYING OBJECTS.

1. SHUT THE ENGINE DOWN and close the fuel shutoff valve at the fuel tank.

2. Clean all dirt from the separator and the surrounding area.

3. Depress the extended tab with the heel of the hand, lift the slotted tab from the locking slot at the top of the base by pulling on the finger tab with the fingers, then pull the element off the base. Discard the old element.

4. Clean the three sealing surfaces on the base with a clean cloth.

5. Insert the roll pin into the outlet passage at the bottom of the base, align the filter holes with the base holes, then push the element into place.

6. Place the lower tab of the clamp in the bottom locking slot of the base and push the upper tab into the locking slot at the top of the base. Make sure the clamp is securely engaged in both locking slots.

7. Open the fuel shutoff valve and start the engine. It may be necessary to prime the fuel system if the engine does not start (see below). Check for fuel leaks.

Priming The AVSpare 3208 Engine (Engine B)

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NEVER SMOKE OR HAVE AN OPEN FLAME WHILE PRIMING THE ENGINE. THE DIESEL FUEL COULD IGNITE OR EXPLODE, CAUSING SERIOUS BURNS AND INJURIES FROM FLYING OBJECTS.

1. Open the vent valve on the fuel injection pump housing.

2. Operate the priming pump until the flow of fuel from the vent valve is continuous, and free of air bubbles.

3. Close the vent valve and lock the fuel priming pump.

4. Start the engine. If the engine continues to misfire or smoke, further bleeding is necessary.

5. With the engine running, loosen the fuel lines at the cylinder head, one at a time, and allow the fuel to run until free of air bubbles.

6. Tighten the fuel line nuts.

Checking The AVSpare 3412 (Engine A) 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.

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NOTICE
BE SURE TO READ THE CORRECT SIDE OF THE DIPSTICK. THE ADD AND FILL LEVELS ARE NOT THE SAME WHEN CHECKING THE OIL WHILE STOPPED OR WHILE IDLING.

Checking The AVSpare 3412 (Engine A) Coolant Level

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

1. Slowly turn the pressure cap to the first stop and release any pressure.

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

3. Maintain the coolant level at the base of the fillpipe. If a loss of coolant is noticeable, check for leaks in the system. After filling the system, start the engine and recheck the coolant level after normal operating temperature is reached. Running the engine at operating temperature will permit the temperature regulator to open and allow the coolant to circulate through the entire system and purge air from the engine.

Make up coolant should be water that is free as possible of scale forming minerals (not softened water), a permanent type antifreeze and AVSpare Corrosion Inhibitor. Follow the recommendations given on the container.

Maintain a 3% concentration of AVSpare Corrosion Inhibitor. Makeup water added without the proper proportions of coolant corrosion inhibitor can cause excessive lime deposits and corrosion.

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NOTICE
DO NOT USE AVSpare CORROSION INHIBITOR WITH DOWTHERM 209 FULLFILL COOLANT. DO NOT ADD COOLANT TO AN OVERHEATED ENGINE, ALLOW THE ENGINE TO COOL FIRST. ADD COOLANT SLOWLY TO A HOT ENGINE TO PREVENT POSSIBLE CRACKING OR DISTORTING OF THE CYLINDER HEAD.

Checking The AVSpare 3412 (Engine A) Radiator

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NEVER WORK NEAR THE COOLING FAN WITH ENGINE B (AVSpare 3208) RUNNING. THE FAN BLADES OR BELT DRIVE CAN CAUSE SERIOUS INJURIES.

Check that the radiator is clear of any obstructions to air flow through the cooling fins. Any rags, paper, mud, DUST, bugs, etc. that may obstruct the air flow must be removed. Carefully straighten any bent fins on the radiator.

Checking The AVSpare 3412 (Engine A) Air Cleaners

Each of the two engine air cleaners is equipped with an indicator that shows a red signal when the main element should be serviced. If the red signal is locked in view, the main element should be serviced as soon as possible to prevent possible engine damage. See "Changing the AVSpare 3412 (Engine A) Air Cleaner Elements" below for procedures.

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NOTICE
SHUT THE ENGINE DOWN BEFORE SERVICING THE AIR CLEANERS.

Each air cleaner also has a dust cup that collects the dust from the pre-cleaner. Empty the dust cup when the dust builds up to within one and one-quarter inches from the top of the cup. Remove and inspect the dust cup daily until a regular service interval can be established.

When replacing the dust cup, be sure a seal is made between the cup and the body to maintain high pre-cleaner efficiency. Replace the gasket if it is not smooth and clean.

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NOTICE
THIS IS A DRY TYPE AIR CLEANER - DO NOT USE OIL.

Changing The AVSpare 3412 (Engine A) Air Cleaner Elements

The main element should be cleaned or replaced with a new element anytime the air cleaner red indicator is locked in view. Replace the main element after three cleanings or one year of use, whichever occurs first. Change the safety element every third time the main element is cleaned or replaced. (See the Maintenance Manual for cleaning procedures.)

Although it is possible to clean the safety element using the procedures described for the main element, it is not recommended except in an emergency situation. Maximum engine protection is achieved by replacing the plugged safety element with a new element.

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NOTICE
SHUT THE ENGINE DOWN BEFORE CHANGING AN AIR CLEANER ELEMENT.

To replace the main element:

1. STOP THE ENGINE, clean the dust off the access cover and unlatch it.

2. Remove the access cover and main element. DO NOT REMOVE THE SAFETY ELEMENT.

3. Immediately inspect the main element for any dust streaks on the inside. If there are any dust streaks, the element is damaged. THROW IT AWAY.

4. Inspect the main element gasket. If the element gasket is not smooth and flat or is damaged in any way that might allow dust to get by, THROW THE ELEMENT AWAY.

5. Install a new or cleaned main element and tighten the wing nut securely.

6. Install the access cover.

To replace the safety element:

1. STOP THE ENGINE, clean the dust off the access cover and remove it.

2. Loosen the wing nut and remove the main element.

3. Remove the locking pin from the nut, and remove the nut that secures the safety element.

4. Remove the safety element and clean out any dust dislodged into the cleaner outlet.

5. Install a new safety element.

6. Inspect the gasket washer on the nut and replace it if a good air seal cannot be guaranteed.

7. Tighten the nut securely and replace the locking pin.

8. Install the main element and tighten the wing nut securely.

9. Install the access cover.

Checking The AVSpare 3412 (Engine A) Fuel Filters

The fuel pressure gauge should register in the NORMAL (green or approximately 30 PSI) range with the engine running and with clean primary and final fuel filter elements. As the filter elements become clogged, the gauge indicator will gradually move toward the OUT (red or approximately 20 PSI) range. If the gauge indication reaches the OUT range, the primary fuel filter element should be removed and cleaned (see below). If the indication is still in the OUT range after cleaning the primary element, replace the final fuel filter element (see page 5-30).

Cleaning The AVSpare 3412 (Engine A) Primary Fuel Filter Element

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NEVER SMOKE OR HAVE AN OPEN FLAME WHEN CLEANING THE PRIMARY FUEL FILTER ELEMENT. THE DIESEL FUEL COULD IGNITE OR EXPLODE, CAUSING SERIOUS BURNS AND INJURIES FROM FLYING OBJECTS.

1. SHUT THE ENGINE DOWN and close the fuel shutoff valve.

2. Loosen the nut on the filter cover and lower the filter case.

3. Remove the element and wash it in clean solvent or diesel fuel.

4. Reinstall the element and open the fuel shutoff valve.

5. If the engine will not start or misfires, prime the fuel system as described on page 5-30.

Replacing The AVSpare 3412 (Engine A) Final Fuel Filters

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NEVER SMOKE OR HAVE AN OPEN FLAME WHEN CHANGING THE FINAL FUEL FILTERS. THE DIESEL FUEL COULD IGNITE OR EXPLODE, CAUSING SERIOUS BURNS AND INJURIES FROM FLYING OBJECTS.

1. SHUT THE ENGINE DOWN and close the fuel shutoff valves.

2. Unscrew and remove the filters.

3. Clean the gasket sealing surfaces on the filter bases.

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

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NOTICE
DO NOT POUR FUEL INTO THE NEW FILTER ELEMENT BEFORE INSTALLING. PRIME THE SYSTEM AS DESCRIBED BELOW.

5. Tighten the filters by hand until the gasket contacts the base, then tighten 1/2 to 3/4 turn more.

6. Open the fuel shutoff valves, start the engine and run it at 1000 RPM for several minutes. Check for leaks. If the engine fails to start, prime the fuel system as described below.

Priming The AVSpare 3412 (Engine A) Fuel System

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NEVER SMOKE OR HAVE AN OPEN FLAME WHEN PRIMING THE FUEL SYSTEM. THE DIESEL FUEL COULD IGNITE OR EXPLODE, CAUSING SERIOUS BURNS AND INJURIES FROM FLYING OBJECTS.

1. Be sure the fuel shutoff valves are open and the engine ignition switch is at "Off".

2. Unlock the fuel priming pump.

3. Operate the priming pump until increased resistance is felt.

4. Lock the fuel priming pump.

5. Start the engine.

If the engine fails to start or continues to misfire or smoke, further bleeding is necessary. With the engine running, or with the use of the priming pump, loosen the fuel line nuts one at a time several times in succession and allow fuel to flow until free of air bubbles. Tighten the fuel line nuts.

Checking The Fuel Level

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NEVER HAVE EITHER ENGINE RUNNING AND NEVER SMOKE OR HAVE AN OPEN FLAME WHEN REFUELING THE MACHINE. HOLD THE FUNNEL OR SPOUT AGAINST THE TANK FILLER NECK TO AVOID A STATIC ELECTRICITY SPARK. DIESEL FUEL IS VOLATILE AND COULD IGNITE OR EXPLODE, CAUSING SERIOUS BURNS AND INJURIES FROM FLYING OBJECTS.

The fuel tank has 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.

Before filling the fuel tank the last time for the day, open the drain valve under the tank. Allow any accumulated water and sediment to drain, then close the valve. In cold weather, drain the water immediately after stopping the engines, to prevent the water from freezing in the bottom of the tank.

Checking The Water Level In The Water Tanks

The water level can be checked by looking at the sight gauge located on the outer face of the right rear water tank. Fill all the tanks before starting operation. To fill the tanks from ground level, connect a water supply hose with a 3 inch female, automatic check, quick connect coupling half to the fitting on either side of the machine. The tanks can also be filled through the uncapped top fill openings. Use the cleanest water possible to avoid rapid clogging of the filters.

If the machine is to be parked overnight or left idle for a period of time, the water tanks, lines, filters and pumps should all be drained to avoid damage from freezing water.

Draining The Water System

If the water system must be drained to avoid damage from freezing water:

1. Open the water tank drain valve and check that the gate valves near the lower conveyor spray bar are not closed.

2. Remove the filter bowls, remove the filter elements from the bowls, dump the water from the bowls and reinstall the bowls. Store the filter elements in a warm place.

3. Disconnect one end of each hose loop at the water filters and drain the water from the loops.

4. Open the petcocks near the optional high pressure water pump, near the lower conveyor spray bar and on the spray system pump.

5. With engine B (AVSpare 3208) running, use the spray bar control to turn the spray system pump momentarily to clear any water from the pump, then return the control to "Off". If a high pressure water pump is installed, clear any water from it also. Shut engine B down.

6. With both engines shut down, move the spray bar control to "Spray Bar" and leave it for two or three minutes to open the solenoid valve and allow any water to drain. Move the spray bar control to "Off".

Checking The Hydraulic Oil Level

The hydraulic oil tank is equipped with a sight gauge for easy checking of the oil level which should be maintained at least halfway up the gauge. If the oil level is low, use the replenishing hand pump to transfer oil from the replenishing tank to the main tank. Refill the replenishing tank 2/3 to 3/4 full with new water-free hydraulic oil conforming to the specification on page 5-2. Do not overfill either tank, allow for expansion of the oil.

Checking The Hydraulic Oil Cooler

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NEVER WORK NEAR THE COOLING FAN WITH ENGINE B (AVSpare 3208) RUNNING. THE FAN BLADES OR BELT DRIVE CAN CAUSE SERIOUS INJURIES.

Check that the oil cooler is clear of any obstructions to air flow through the cooling fins. Any rags, paper, mud, DUST, bugs, etc. that may obstruct the air flow must be removed. Carefully straighten any bent fins on the oil cooler.

Checking The Control (Auxiliary) Hydraulic System Pressure Filter

The control system filter is equipped with a pressure differential indicator to show when the element should be changed. The indicator will show all yellow when a new filter element is installed. As the filter element becomes clogged, more and more of the yellow will be replaced by red until only red is visible.

Two persons are required to check the condition of the control system filter, one to operate the controls and one to watch the filter indicator.

1. Be sure the hydraulic oil temperature is at or above 140°F.

2. Set the AVSpare 3208 (engine B) at high idle.

3. Actuate a steering or elevation control valve and watch the auxiliary pressure gauge on the forward console for a drop in pressure.

4. Watch the filter indicator while the control valve is actuated. If the indicator signal becomes all red with no yellow showing, CHANGE THE FILTER ELEMENT. See below for procedures.

Changing The Control (Auxiliary) Hydraulic System Filter Element

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LET THE MACHINE STAND IDLE UNTIL THE HYDRAULIC OIL HAS COOLED. THE OIL AT OPERATING TEMPERATURE CAN CAUSE SERIOUS BURNS. THE FILTER BOWL SHOULD BE COMFORTABLE TO TOUCH BEFORE REMOVING IT. BE SURE HYDRAULIC OIL PRESSURE IS RELIEVED BY ACTUATING A STEERING OR ELEVATION CONTROL VALVE UNTIL THE CYLINDER WILL NOT RESPOND IN EITHER DIRECTION.

1. Remove the filter bowl and element. Throw the element away and empty the bowl.

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

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

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

5. Leave the fuel switch at "Off" and crank the AVSpare 3208 (engine B) with the starter until air-free hydraulic oil comes from the filter outlet port.

6. Tighten the pressure line at the outlet port.

Servicing The Compressed Air System

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STAY CLEAR OF AIR ESCAPING FROM THE SYSTEM. IT CAN CAUSE INJURIES.

1. Open the drain valve at the bottom of the reservoir and the petcock at the bottom of the filter regulator. Let the air flow until accumulated moisture is removed.

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DISCHARGE ALL AIR PRESSURE FROM THE LUBRIAVSOR BEFORE ADDING OIL.

2. Check the lubricator oil level and add 10W non-detergent engine oil as needed. Before adding oil, close the shutoff valve and open the petcock at the bottom of the filter regulator until all air pressure is discharged.

Checking The Power Take-Off Clutch Clearance

The clutch clearance is the axial distance the pressure plate moves along the output shaft when the clutch is first engaged. As the clutch plates and friction discs wear, the clearance will increase. A new clutch will have a clearance of 3/32 to 1/8 inch. When the clearance increases to 1/2 inch, the friction discs should be replaced. See the Maintenance Manual for procedures to change the friction discs.

NOTE: TO ENSURE PROPER OPERATION AND MAXIMUM CLUTCH LIFE, IT IS ESSENTIAL THAT THE CLUTCH FRICTION DISCS BE REPLACED BEFORE THE CLEARANCE EXCEEDS 1/2INCH. SINCE THE RAPIDITY OF CLUTCH WEAR IS PRIMARILY DEPENDENT UPON THE NUMBER OF CLUTCH ENGAGEMENTS AND DISENGAGEMENTS, CLUTCH WEAR WILL VARY NOT ONLY FROM MACHINE TO MACHINE BUT WILL VARY ON A GIVEN MACHINE DUE TO CHANGING JOB REQUIREMENTS. IT IS ADVISABLE, THEREFORE, TO INITIALLY CHECK AND NOTE THE CLEARANCE DAILY UNTIL EXPERIENCE IS GAINED ON THE AMOUNT OF CLUTCH WEAR RESULTING FROM VARIOUS JOB REQUIREMENTS. THE FREQUENCY OF THE CLUTCH CLEARANCE CHECKS CAN THEN BE ADJUSTED AS DESIRED.

1. SHUT THE CUTTER ENGINE (ENGINE A) DOWN.

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SHUT THE CUTTER ENGINE (ENGINE A) DOWN BEFORE WORKING NEAR THE POWER TAKE-OFF. SERIOUS INJURIES CAN RESULT FROM INADVERTENT ENGAGEMENT OF THE CLUTCH WITH THE CUTTER ENGINE RUNNING.

2. Check that the clutch control is at "Out".

3. Use an engineering scale to carefully measure the distance between the clutch pressure plate and the drive ring. Record the measurement.

4. BE SURE EVERYONE IS CLEAR OF THE POWER TAKE-OFF AND THE CUTTER ENGINE IS NOT RUNNING. Check for at least 90 PSI of air pressure, then move the cutter control to "In".

5. Measure the distance between the pressure plate and drive ring. Record the measurement.

6. Move the cutter control to "Out".

7. Subtract the second measurement from the first measurement. The result is the clutch clearance.

8. If the clearance is 1/2 inch or more, replace the clutch friction discs (see the Maintenance Manual).

Checking The Cutter Sheave Oil Levels

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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.

The oil level must be checked in six sheaves, the P.T.O. sheave, the takeup sheave, and two sheaves at each end of the cutter. The machine must be on level ground when the oil levels are checked.

. Open the cutter belt cover.

2. Remove the check plug. If oil trickles from the check plug port, reinstall the check plug. If a large amount of oil flows from the port, allow the oil to drain, then reinstall the check plug. If no oil is apparent at the check plug port, add oil as described below.

3. To add oil, remove the breather or plug, or disconnect the hose, then add oil through the port until the oil reaches check plug level. Wait several minutes for the oil level to even out throughout the sheave, then add more oil.

4. After the correct oil level is assured, install the check plug and breather or hose.

5. Close the cutter belt cover if no other work is to be done that requires the cover to be open.

Checking The Cutter Planetary Gear Reducer Oil Levels

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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.

The oil level must be checked in two planetary reducers, one at each end of the cutter. The machine must be on level ground when the oil levels are checked.

1. Open the cutter belt cover.

2. Remove a bolt from each cover plate and loosen the other bolt, use the cutter auxiliary drive motor to position the plugs with the check plug 2 inches below the cutter centerline, then remove the check plug. If oil trickles from the check plug port, reinstall the check plug. If a large amount of oil flows from the port, allow the oil to drain, then reinstall the check plug. If no oil is apparent at the check plug port, add oil as described below.

3. To add oil, remove the fill plug, then add oil through the fill plug port until the oil reaches check plug level. Wait several minutes for the oil level to even out throughout the reducer, then add more oil.

4. After the correct level is assured, install the check plug, the fill plug and the cover plates.

5. Close the cutter belt cover if no other work is to be done that requires the cover to be open.

Checking The Moldboard Blade

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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. REMEMBER TO LOWER THE SAFETY STOPS IF THE CUTTER WILL BE MORE THAN ONE-HALF INCH ABOVE GRADE (SEE PAGE 5-3).

The moldboard blade sections should be checked for excessive wear and for loose connecting bolts. Tighten any loose bolts and replace the blade sections as necessary. Replace all the blade sections at the same time or loose material will pass underneath the worn sections. Use the mechanical stops to adjust the amount of moldboard downward travel possible.

Checking Cutter Bits, Bit Holders And Flighting

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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. REMEMBER TO LOWER THE SAFETY STOPS IF THE CUTTER WILL BE MORE THAN ONE-HALF INCH ABOVE GRADE (SEE PAGE 5-3).

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, mounting blocks and bit holders for breaks or cracks. Replace or repair as necessary.

Replacing A Cutter Bit

When the bits get worn they should be changed as a group so that all the bits are approximately the same length. If a single bit is longer than the bits around it, the long bit may be broken off or the bit holder torn out when the bit hits the concrete. Keep several worn bits on hand to replace any bits that break.

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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. DO NOT TOUCH THE BIT HOLDER OR CUTTER FLIGHTING UNTIL THEY ARE COOL. REMEMBER TO LOWER THE SAFETY STOPS IF THE CUTTER WILL BE MORE THAN ONE-HALF INCH ABOVE GRADE (SEE PAGE 5-3).

An air operated hammer and a punch for the hammer are supplied with each machine. To remove a bit:

1. Connect the air hammer hose to the air system quick disconnect.

2. Insert the tip of the punch into the opening in the bit holder and use the air hammer to drive the bit out.

3. Position the new bit in the holder and drive it into place with a hammer or with the slide hammer supplied with the machine. Be sure the keeper spring is engaged with the holder.

A manual bit puller is also supplied with each machine. To remove a bit, hook the puller on the shoulder of the bit and strike the puller sharply with a hammer.

A drift pin and hammer can also be used to remove a bit, if necessary. Insert the drift pin into the opening in the bit holder and strike the drift pin sharply with a hammer.

Replacing A Damaged Bit Holder

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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. REMEMBER TO LOWER THE SAFETY STOPS IF THE CUTTER WILL BE MORE THAN ONE-HALF INCH ABOVE GRADE (SEE PAGE 5-3). DO NOT TOUCH THE BIT HOLDER OR CUTTER FLIGHTING UNTIL THEY ARE COOL.

1. Cut the bit holder free of the block and remove the holder.

2. Grind the surface of the holder mounting block smooth.

3. Position the new bit holder the same as the other bit holders and slide the bit holder onto the dowels so the bit holder is flush with the block.

4. Weld the bit holder to the holder mounting block. The welding process used should be CO-2 shielded fluxcored arc welding using an .052 E70T-1 electrode and electrode positive polarity. The contact tip to work distance should be 1", gas flow set at 30-40 CFH, voltage at 28V, and amperage at 280A. Two passes.

Checking The Cutter Drum Water Level

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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. REMEMBER TO LOWER THE SAFETY STOPS IF THE CUTTER WILL BE MORE THAN ONE-HALF INCH ABOVE GRADE (SEE PAGE 5-3).

1. Stop the cutter with the cutter teeth off the ground and open the cutter door.

2. Connect the auxiliary cutter drive motor to the cutter shaft and rotate the cutter to place the plug 5 inches above the centerline of the cutter.

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LET THE CUTTER DRUM COOL UNTIL IT IS COMFORTABLE TO TOUCH BEFORE REMOVING THE PLUG. THE WATER CAN BE HOT ENOUGH TO CAUSE WATER AND STEAM TO SPRAY OUTWARD WHEN THE PLUG IS REMOVED. SERIOUS BURNS CAN RESULT.

3. Remove the plug. If water does not flow from the port, add a 50% solution of water and ethylene glycol type permanent antifreeze until the liquid level reaches the port.

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NOTICE
THE MACHINE IS SHIPPED FROM THE FACTORY WITH A 50% SOLUTION OF WATER AND ETHYLENE GLYCOL TYPE PERMANENT ANTIFREEZE IN THE CUTTER DRUM. THIS SOLUTION MUST BE MAINTAINED IF THE CUTTER DRUM AND PLANETARY GEAR REDUCERS ARE TO BE PROTECTED.

Checking The Water Spray System Filters

The water spray system has two pressure gauges that should be checked periodically during operation and as part of the daily service. The gauges, mounted on the inlet and outlet of the water system filters, should be checked with the spray system operating. If the pressure gauge on the outlet of the filters falls below 40 PSI, or the difference between the two pressures is more than 20 PSI, the filter elements should be changed. If the pressure gauge on the inlet to the filters falls below 55 PSI, the spray system pump should be checked.

To change a water filter:

1. Check the pressure gauges to be sure there is no pressure in the system.

2. Unscrew the filter body from the filter head.

3. Remove the element.

4. Clean the inside of the body.

5. Place a new element in the body and install the body on the head.

Checking The Water Spray System Nozzles

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NOTICE
IT IS EXTREMELY IMPORTANT THAT THE SPRAY NOZZLES OPERATE PROPERLY AT ALL TIMES. IF THEY DO NOT, LARGE AMOUNTS OF DUST WILL LEAVE THE CUTTER AREA AND BE DRAWN INTO THE RADIATORS AND OIL COOLER CAUSING OVERHEATING OF THE ENGINES AND/OR HYDRAULIC OIL.

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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 INADVERTENT ENGAGEMENT OF THE CUTTER CLUTCH.

To check the spray nozzles:

1. Check the water tank level to be sure there is plenty of water.

2. Open the cutter door and install the safety chain.

3. With the AVSpare 3208 (engine B) running, move the spray bar switch to "Start".

4. Visually check the cutter spray pattern from the front. Check the conveyor spray nozzles from the top of the lower conveyor.

5. If a nozzle is not spraying properly, SHUT THE ENGINE DOWN and then remove the nozzle.

6. Disassemble, clean and reassemble the nozzle.

7. Reinstall the nozzle and check its operation as in 3 and 4 above.

Checking The Optional High Pressure Pump Water Level

Stop the pump before checking the oil level. Maintain the oil level in accordance with the markings on the dipstick. USE ATF TYPE F HYDRAULIC OIL.