PR-1000 PAVEMENT PROFILER 500 Hour Service Caterpillar

1. Check the valve lash on the AVSpare 3208 engine (engine B). See the AVSpare 3208 Operation and Maintenance Manual for procedures.

2. Clean the crankcase breathers on the AVSpare 3412 engine (engine A).

3. Clean the breathers on:

a. Pump drive gearbox.

b. Lower conveyor chaincase.

c. Cutter drive sheaves.

d. Cutter gear reducers.

4. Clean the breather, fill cap and screen on the fuel tank.

5. Clean the breather, fill cap and screen on the hydraulic oil replenishing tank.

6. Change the oil in the track and cutter planetary gear reducers and, if installed, the high pressure water pump.

7. Change the hydraulic oil. (After the first 500 hours only. See the 1000 Hour or Annual Service for procedures.)

Cleaning The AVSpare 3412 Engine (Engine A) Crankcase Breathers

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SHUT THE ENGINE DOWN BEFORE WORKING ON THE BREATHERS. STAY CLEAR OF HOT EXHAUST DUCTING.

1. Release the hose clamp and disconnect the fumes disposal tube.

2. Remove the breather assembly.

3. Wash the breather in non-flammable solvent.

4. Allow the breather to drain dry and then wipe.

5. Inspect the gasket. Install a new gasket if necessary.

6. Install the breather.

7. Connect the fumes disposal tube.

8. Clean the second breather in the same manner.

Cleaning The Breathers On The Pump Drive Gearbox, Lower Conveyor Chaincase, Power Take-Off Sheave, Cutter Takeup Sheave, Cutter Drive Sheaves And Cutter Planetary Gear Reducers

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SHUT BOTH ENGINES DOWN AND SET THE MAIN BATTERY DISCONNECT SWITCH AT "OFF" WHILE REMOVING OR INSTALLING THE BREATHERS. INADVERTENT STARTING OF THE ENGINES COULD CAUSE SERIOUS INJURIES.

1. Remove the breather and wash it in clean non-flammable solvent.

2. Blow the breather dry with clean air or allow it to drain dry.

3. Reinstall the breather.

Cleaning The Fuel Tank Breather, Fill Cap And Screen

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

1. Remove the breather, fill cap and screen and wash them in clean non-flammable solvent.

2. Blow the components dry with clean air or allow them to drain dry.

3. Reinstall the components.

Cleaning The Breather, Fill Cap And Screen On The Hydraulic Oil Replenishing Tank

1. Remove the breather, fill cap and screen and wash them in clean non-flammable solvent.

2. Blow the components dry with clean air or allow them to drain dry.

3. Reinstall the components.

Changing The Oil In The Track Planetary Gear Reducers

1. Move the machine so that the drain (fill) plug in a planetary gear reducer is at the bottom of the case.

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SHUT THE AVSpare 3208 ENGINE (ENGINE B) DOWN BEFORE WORKING ON A PLANETARY GEAR REDUCER. INADVERTENT ENGAGEMENT OF THE TRACK COULD CAUSE SERIOUS INJURIES.

2. Remove the drain plug and allow the oil to drain. Install the plug.

3. Move the machine so the fill plug is at the top of the case.

4. Remove the check plug and fill plug.

5. Add oil through the fill plug until check plug level is reached.

6. Install the check plug and fill plug.

7. Repeat steps 1 through 6 for the other tracks.

Changing The Oil In The Cutter Planetary Gear Reducers

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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. Open the cutter belt drive cover and remove the two cover plates.

2. Rotate the cutter so that a gear reducer plug is centered in the lower cover plate opening and one plug is at the bottom of the reducer.

3. Remove both plugs and let the oil drain out.

4. Rotate the cutter to position the gear reducer check plug port 2 inches below the cutter centerline and the fill plug port in the upper cover plate opening.

5. Add oil through the fill plug port until it reaches check plug port level, wait several minutes for the oil level to even out throughout the reducer, then add more oil. Repeat until the oil remains at check plug port level.

6. After the correct oil level is assured, install the plugs and cover plates, and close the belt drive cover.

7. Repeat the procedure for the planetary gear reducer at the other end of the cutter.

Changing The Oil In The Optional High Pressure Water Pump

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SHUT THE AVSpare 3208 ENGINE (ENGINE B) DOWN BEFORE WORKING UNDER THE MACHINE.

1. Remove the drain plug and allow the oil to drain.

2. Install the drain plug, remove the dipstick, and add oil through the dipstick port until the oil level reaches the full mark on the dipstick. USE ATF TYPE F HYDRAULIC OIL.

3. Install the dipstick.