PR-1000 PAVEMENT PROFILER 100 Hour Service Caterpillar

5. Check the valve lash on the AVSpare 3208 (engine B). (After the first 100 hours only.) See the AVSpare 3208 Operation and Maintenance Manual for procedures.

6. Lubricate those points shown in the 100 hour column of the service chart.

Checking Pump Drive Gearbox And Lower Conveyor Chaincase Oil Levels

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SHUT BOTH ENGINES DOWN BEFORE CHECKING THE OIL LEVELS. ACCIDENTAL ENGAGEMENT OF THE GEARBOX OR CHAINCASE COULD CAUSE SERIOUS INJURIES.

1. Remove the top plug on the right side of the gearbox for checking the oil level.

2. Maintain the oil level to the bottom of the fill opening. Add oil if necessary.

3. Install the check plug.

Checking The Track Planetary Gear Reducer Oil Levels

1. Position the machine so that the fill plug in a gear reducer is at the top of the case and the check plug is at the same level as the center of the case.

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SHUT THE AVSpare 3208 (ENGINE B) DOWN BEFORE WORKING NEAR THE TRACKS. INADVERTENT ENGAGEMENT OF THE TRACKS COULD CAUSE SERIOUS INJURIES.

2. Allow time for the oil to settle to the bottom of the gear reducer, then remove the check plug.

3. If the oil does not trickle from the check plug port, remove the fill plug and add oil until check plug port level is reached.

4. Install the check plug and fill plug.

5. Repeat steps 1 through 4 for the other tracks.

Changing Oil In The P.T.O. Sheave, Takeup Sheave And Upper Cutter Drive Sheaves

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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. Position a suitable container under one sheave drain, remove the drain plug and let the oil drain into the container. If any oil gets onto the belts, be sure to thoroughly wipe the oil off but DO NOT use a solvent to clean the belts. Oil and/or solvents will weaken the belts.

2. Check the magnetic drain plug for metal particles. If there is an excessive amount of metal particles present, the sheave should be removed and the bearings inspected and/or replaced (see the Maintenance Manual). Continued operation could lead to complete failure of the bearings which would cause damage to other components.

3. Install the drain plug, remove the check plug and breather, then and SAE 90 gear lubricant until it reaches check plug port level

4. Install the check plug and breather.

Changing The Oil In The Cutter (Lower) Sheaves

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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 nuts on the takeup ONLY ENOUGH TO ALLOW THE TAKEUP TO SLIDE, then loosen the jam nut on the drive sheave adjusting bolt and turn the bolt to loosen the belt band tension.

2. Remove the belt bands from the sheaves.

3. Attach a lifting device to the cutter sheave, remove the mounting nuts, then insert a 1/2-13 NC bolt into each of the three threaded holes in the sheave. Turn the bolts evenly and alternately to free the sheave, then move the sheave away.

4. Position a suitable container under the spindle, remove the drain plug and let the oil drain into the container.

5. Check the magnetic drain plug for metal particles. If there is a excessive amount of metal particles present, the drive shaft should be removed and the bearings inspected and/or replaced (see the Maintenance Manual). Continued operation could lead to complete failure of the bearings which would cause damage to other components.

6. Install the drain plug, remove the check plug, disconnect the breather hose, then add SAE 90 gear lubricant until it reaches check plug port level.

7. Install the check plug and connect the breather hose.

8. Move the sheave onto the spindle and install the mounting nuts.

9. Slide the belt bands onto the sheaves and adjust the belt tension (see page 5-50).

10. Change the oil in the other sheave in the same way.

Checking The Track Chain Tension

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SHUT THE AVSpare 3208 (ENGINE B) DOWN BEFORE WORKING NEAR THE TRACKS. INADVERTENT ENGAGEMENT OF THE TRACKS COULD CAUSE SERIOUS INJURIES.

For new tracks:

1. Loosen the jam nuts on the adjusting bolts, then turn the adjusting bolts alternately and evenly until the tensioning spring begins to compress.

2. Loosen the adjusting bolts alternately and evenly until the sprocket moves back 1/4 inch.

3. Hold the adjusting bolts and tighten the jam nuts.

For tracks with more than 40 hours of operation:

1. With engine B running and the emergency and park brake control at "On", raise the mainframe and block the mainframe up at the track to be checked.

2. Raise the track off the ground by holding the elevation control for the leg at "DN" (Down), the SHUT ENGINE B DOWN.

3. Hold a straightedge across the tread faces of the two center rollers, then measure from the straightedge to the contact face of the center chain link. The measurement should be between 3 and 3 1/2 inches.

4. If the measurement is not correct, loosen the jam nuts on the adjusting bolts, then turn the adjusting bolts alternately and evenly to obtain the correct measurement. Hold the adjusting bolts and tighten the jam nut.

5. Start engine B, hold the elevation control for the leg at "Up" to lower the track, then remove the blocks from under the mainframe.

Checking The Track Pads

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SHUT THE AVSpare 3208 (ENGINE B) DOWN BEFORE WORKING NEAR THE TRACKS. INADVERTENT ENGAGEMENT OF THE TRACKS COULD CAUSE SERIOUS INJURIES.

Check for any broken or bent track pads and replace any found. Operating the machine with broken or bent pads will overload the chain and damage it. Tighten all pad mounting bolts with a torque wrench. If the nuts and bolts are dry and unlubricated, tighten them to a torque of 200 to 250 Ft.-Lbs. If the nuts and bolts have grease or oil on them, tighten them to only 165 to 200 Ft.-Lbs.