PR-1000 PAVEMENT PROFILER 50 Hour Service Caterpillar

4. Change the oil in the track and cutter planetary gear reducers. (After the first 50 hours only. Thereafter change every 500 hours. See the 500 Hour Service for procedures).

Checking The Engine Air Inlet And Exhaust Systems

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IF THE ENGINE BEING CHECKED HAS BEEN RUNNING, LET IT COOL FIRST. THE EXHAUST DUCTING CAN BE HOT ENOUGH TO CAUSE SERIOUS BURNS.

3208 ENGINE

3412 ENGINE

With the engine shut down, check all clamps, bolts and ducting on the engine air inlet and exhaust system. Service as necessary to prevent any leaks and to ensure that the air cleaners are securely mounted. Be sure to check the systems on both engines.

Servicing The Compressed Air System

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SHUT THE AVSpare 3208 (ENGINE B) DOWN BEFORE WORKING IN THE ENGINE COMPARTMENT. STAY CLEAR OF HOT EXHAUST DUCTING.

1. Shut the engine down and check the air distribution system for leaks. Repair any leaks found.

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COMPLETELY DISCHARGE THE AIR PRESSURE BEFORE ATTEMPTING TO REPAIR ANY LEAKS. A WEAK FITTING OR LINE UNDER AIR PRESSURE CAN FAIL WITH EXPLOSIVE FORCE.

2. Clean the finned cooling surfaces of the compressor.

Checking The Drive Sheave To Cutter Sheave Belt Bands

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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.

1. Check both sets of belt bands (one set at each end of the cutter) for breaks, cracks, burned spots, separation from the tie band, or excessive wear. Check the tie bands for fraying, holes or blisters. If the condition of any belt band is questionable, replace all the belt bands in that set.

2. Check each belt band for proper tension by placing a rigid bar across the width of the belt band, halfway between the drive sheave and the cutter sheave (approximately 20 inches from the center of either sheave), then depressing the band evenly. A 60 pound force should produce a deflection of 5/8 inch.

3. If the belt band tension is not correct, adjust the tension as described below.

Adjusting The Cutter Drive Sheave To Cutter Sheave Belt Bands

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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.

1. Loosen the four takeup plate nuts ONLY ENOUGH TO ALLOW THE TAKEUP PLATE TO SLIDE. If the nuts are loosened enough to allow a gap to form between the takeup plate and the end plate, the tension in the belt bands will be increased when the nuts are tightened.

2. Loosen the jam nut on the drive sheave adjusting bolt, turn the bolt until the tension is correct, then tighten the jam nut and the takeup plate nuts.

3. Check the belt band tension as described above and repeat steps 1 and 2 if necessary. If the belt bands are too tight, the bearings and/or seals will be damaged. If the belt bands are too loose, they will slip and be damaged.

Checking The P.T.O. Belt Bands

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1. Check the belt bands for breaks, cracks, burned spots, separation from the tie band, or excessive wear. Check the tie bands for fraying, holes or blisters. If the condition of any belt band is questionable, replace all the belt bands.

2. Check EACH belt band for proper tension with a belt tension gauge. The gauge should read 62 pounds for a belt deflection of .58 inch.

3. If the belt tension is not correct, adjust the tension as described below.

Adjusting The P.T.O. Belt Bands

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1. Remove the retaining caps from both U-joints, then slide the U-joints off the takeup sheave shaft.

2. Remove the belt cover.

3. Connect the belt tensioner assembly pump to the cylinder.

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BE SURE THE BELT TENSIONER IS SECURELY INSTALLED. IF THE TENSIONER IS LOOSE IT COULD FLY OFF WITH GREAT FORCE WHEN THE INTERNAL PRESSURE IS PUMPED UP.

4. Pump the tensioner until the piston rod contacts the angled plate on the takeup.

5. Loosen the four bolts that hold the takeup in place until the takeup can easily slide on the support but is not loose.

6. Pump the tensioner until the pressure gauge indicates 8000 to 8500 PSI, hold the pressure and tighten the four 1"-8NC bolts that hold the takeup in place.

7. Loosen the jam nuts on the two takeup bolts, turn the takeup bolts until they firmly contact the angled plate, then hold each bolt and tighten the jam nut.

8. Use a belt tension gauge to check the tension in EACH belt band. The gauge should read 62 pounds for a belt band deflection of .58 inch.

9. Install the U-joints on the takeup sheave shaft.

10. Install the belt cover and drive shaft covers.