PR-1000 PAVEMENT PROFILER 200 Hour Service Caterpillar

1. Change the AVSpare 3208 engine (engine B) crankcase oil and filters.

2. Change the hydraulic oil tank breather filter element.

3. Clean the AVSpare 3412 engine (engine A) primary fuel filter element. See page 5-29 for procedures.

4. Check all drive belts.

5. Check the electrolyte level in the battery cells and, if needed, clean the batteries.

6. Check electrical connections and wiring.

7. Lubricate those points shown in the 200 hour column of the service chart.

Changing The AVSpare 3208 (Engine B) Crankcase Oil And Filters

1. Remove the crankcase drain plug.

2. Unscrew and remove the filters. Be sure that neither old filter gasket remains attached to the filter base, or leaking between the new and old filter gaskets will result.

3. Wipe the filter base.

4. Apply a thin coat of clean oil to the gasket of each new filter.

5. Install the new filters. Hand tighten each filter 1/2 turn after the gasket contacts the filter base.

6. Install the drain plug. Fill the crankcase with clean oil.

7. Check the oil level before starting the engine.

8. Start and run the engine until it is warm; check for oil leaks.

9. Recheck the oil level

Changing The Hydraulic Oil Tank Breather Filter Element

The hydraulic oil tank breather has a spin-on type element. To change the element:

1. OPEN THE VALVE BY THE BREATHER TO RELIEVE THE PRESSURE IN THE TANK.

2. Unscrew the filter element from the filter body.

3. Check the condition of the O-ring at the base of the filter body. Replace the O-ring, if necessary.

4. Coat the O-ring with clean hydraulic oil and screw the element onto the filter body until it contacts the O-ring.

5. Turn the element about 1/2 turn more.

6. Close the valve by the breather.

Checking Drive Belts

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SHUT BOTH ENGINES DOWN BEFORE WORKING IN THE ENGINE COMPARTMENTS. STAY CLEAR OF HOT EXHAUST DUCTING.

Check all the drive belts for signs of wear or fraying and replace any belts that show such signs. Also check and adjust the belt tension.

Replace all belts in a set when one is worn. Single belts of similar size should not be used as a substitute for a matched set; premature belt wear can result because of belt length variation. All belts in a matched set are within .032 inch of their specified center distances.

New standard V-belts will stretch after the first few hours of operation Run the engine for 15 seconds to set the belts then retighten them. Retighten the fan drive, water pump drive, battery-charging alternator and other accessory drive belts after 1/2 hour and again after 8 hours of operation. Thereafter, check the tension of the drive belts every 200 hours and adjust, if necessary. Too tight a belt is destructive to the bearings of the driven part; a loose belt will slip.

NOTE: NEVER PRY A BELT OVER A PULLEY.

To check the tension of the V-belts apply a force midway between the two pulleys and check the belt deflection. The correct force and deflection for each V-belt is given below. Check each belt of a set separately.

Checking Battery Electrolyte Level

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DO NOT SMOKE OR HAVE AN OPEN FLAME WHEN NEAR BATTERIES. HYDROGEN GAS FROM THE BATTERY COULD IGNITE AND CAUSE SERIOUS BURNS, OR INJURIES FROM FLYING PARTICLES.

1. Shut the engine down and turn the main battery disconnect switch to "Off".

2. Maintain electrolyte level at the base of each vent well.

3. Make-up water must be one of the following (in order of preference):

a. Distilled water.

b. Odorless, tasteless drinking water.

c. Iron free water.

d. Any available water.

4. Turn the main battery disconnect switch to "On".

Cleaning Batteries

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DO NOT SMOKE OR HAVE AN OPEN FLAME WHEN NEAR BATTERIES. HYDROGEN GAS FROM THE BATTERY COULD IGNITE AND CAUSE SERIOUS BURNS, OR INJURIES FROM FLYING PARTICLES.

1. Shut the engine down and turn the main battery disconnect switch to "Off".

2. Mix a solution of baking soda and water (1/4 pound to a quart of water). Apply the solution to the batteries, battery box and cable clamps with a bristle brush.

3. Thoroughly rinse the battery and battery box with clean water.

4. Apply grease to the battery cable clamps and terminals and to all threads.

5. Turn the main battery disconnect switch to "On".

Checking Electrical Connections and Wiring

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SHUT THE AVSpare 3208 (ENGINE B) DOWN AND TURN THE MAIN BATTERY DISCONNECT SWITCH TO "OFF" BEFORE CHECKING THE CONNECTIONS AND WIRING. THE ALTERNATOR DRIVE SYSTEM CAN CAUSE PERSONAL INJURY. SHORTING OF HOT WIRES CAN CAUSE BODILY BURNS AND DAMAGE TO THE ALTERNATOR.

1. Check for loose, broken or corroded connections.

2. Check wiring insulation for breaks, cracks, fraying or other defects.

3. Repair or replace components as necessary to maintain tight, uncorroded connections and sound wiring.

4. Turn the main battery disconnect switch to "On".