PR-1000 PAVEMENT PROFILER 1000 Hour Or Annual Service Caterpillar

1. Refer to the AVSpare 3208 Operation and Maintenance Manual for instructions and complete the following on engine B.

a. Change the fuel filter element.

b. Replace the PCV valve diaphragm.

c. Drain, flush and refill the engine cooling system.

2. Refer to the AVSpare 3412 Operation Guide for instructions and complete the following on engine A.

a. Check the cold weather starting aids.

b. Inspect the coolant pump and temperature regulators.

c. Drain, flush and refill the engine cooling system.

d. Clean the primary fuel filter element and change the final fuel filter elements.

e. Check the fuel injection nozzles.

f. Check the valve lash and rotation.

3. Change the hydraulic oil, clean the tank strainer and change all filter elements.

4. Change the oil in the pump drive gearbox.

5. Inspect the air compressor.

Changing The Hydraulic Oil

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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 HYDRAULIC OIL TANK SHOULD BE COMFORTABLE TO TOUCH BEFORE DRAINING THE OIL.

When changing the hydraulic oil, cleanliness must be kept in mind at all times. Perform the work in a clean area, use clean tools, keep your hands clean and clean the outside of the hydraulic oil tank before starting.

1. Close the two hydraulic oil shutoff valves.

2. Thoroughly clean around a hose connection at the rear shutoff valve, disconnect the hose from the valve, and immediately cap or plug the hose.

3. Attach a clean hose long enough to reach a suitable container, place the other end of the hose in the container, then open the shutoff valve and allow the oil to drain.

4. While the oil is draining, use the replenishing pump to empty the replenishing tank.

5. After the oil has drained, disconnect the drain hose from the shutoff valve and connect the original suction hose to the valve.

6. Unbolt the replenishing pump from the tank cover and move the pump to a place where it will be out of the way and will not be damaged.

7. Thoroughly clean the tank cover and surrounding area of the tank, remove the bolts from the tank cover and pull the cover from the tank.

8. Remove the strainer from the pipe nipple.

9. If there is dirt or sediment in the tanks or on the cover, thoroughly clean the tanks and/or cover.

10. Wash the strainer in clean non-flammable solvent and blow it dry with clean air or allow it to drain dry. Also clean off the flexible magnets.

11. Install the cleaned strainer on the pipe nipple.

12. Thoroughly clean the mating surfaces of the tank and cover, coat both surfaces with a liquid sealant such as Permatex, position the gasket and install the cover.

13. Install the replenishing pump on the main tank.

14. Replace the elements in all the hydraulic oil filters (see pages 5-80 and 5-81.

15. Refill the tank with clean hydraulic oil by pumping the oil from the replenishing tank and adding oil to the replenishing tank as needed. Use only hydraulic oil conforming to the specification on page 5-2.

16. Open the two hydraulic oil shutoff valves.

17. Loosen the hose at the suction port of each pump until air-free hydraulic oil flows from the connection, then tighten the connection.

18. Loosen the outlet connection on the control (auxiliary) system pump, leave the fuel switch at "Off", and crank the AVSpare 3208 engine (engine B) with the starter until air-free hydraulic oil flows from the connection, then tighten the connection.

19. Start the engine and run it at low idle for several minutes. Check for leaks and check the hydraulic oil level. Add oil as necessary.

Cleaning The Hydraulic Oil Tank Strainer

See "Changing the Hydraulic Oil" on page 5-78.

Changing The Charge Oil Filter Element And The System Filter Elements

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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 HYDRAULIC OIL TANK SHOULD BE COMFORTABLE TO TOUCH BEFORE DRAINING THE OIL.

Both elements of the system filter should be changed any time one is changed.

1. Unscrew the element from the filter head. If the filter has a gasket between the element and the head, be sure the gasket comes off with the element.

2. Coat the gasket or O-ring of the new element with clean hydraulic oil.

3. Screw the element onto the filter head until the element contacts the head.

4. Turn the element 1/2 to 3/4 turn more.

5. If applicable, change the other filter element.

6. Check the hydraulic oil level and add oil as necessary.

CONTROL (AUXILIARY) SYSTEM FILTER

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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.

Changing The Oil In The Pump Drive Gearbox

1. Shut the AVSpare 3208 engine (engine B) down.

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

3. Reinstall the drain plug.

4. Remove the top plug on the right side of the gearbox.

5. Add oil until the level is to the plug opening.

6. Install the check/fill plug.

Inspecting The Air Compressor

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

Remove the discharge head fittings and inspect the compressor discharge line for excessive carbon deposits. If excessive buildup is noted in either, the discharge line must be cleaned or replaced and the compressor checked more thoroughly, paying special attention to the air induction system, oil supply and return system, and proper cooling. If necessary, repair or replace the compressor. Check for noisy compressor operation, which could indicate a worn drive gear coupling, and replace and/or adjust as necessary. Check all compressor mounting bolts and retighten evenly if necessary. Check for leakage and proper unloader mechanism operation. Replace if defective in any way.