AP-1200 ASPHALT PAVER 200 Hour Service Caterpillar

1. Check and service as required:

a. Engine drive belts.

b. Tension in drive chains for the ground drive and conveyor drives. (After first 200 hours only. See "400 Hour Service" for procedures.)

c. Drag conveyor chain adjustment. (After first 200 hours only. See "400 Hour Service" for procedures.)

2. Change the engine crankcase oil and filters.

3. Change the fuel water separator element.

Checking The Engine Drive Belts

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INADVERTENT STARTING OF THE ENGINE COULD CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH.

1. Check the belts for excessive wear, fraying and cracking.

When belt replacement is necessary, belts must be replaced in complete matched sets. Never replace only one belt. The new belt will carry all the load and fail rapidly.

2. Apply pressure in the center of the run between the alternator and fan pulleys and measure the belt deflection.

Proper belt deflection is 3/8 inch (10 mm). Adjust the belt tension as required.

To adjust the belts:

1. Loosen the bolt in the slotted bracket.

2. Move the alternator in or out to obtain proper adjustment.

3. Tighten the bolt after the belt is properly adjusted.

Changing The Engine Oil And Filters

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HOT OIL AND COMPONENTS CAN CAUSE PERSONAL INJURY. DO NOT ALLOW HOT OIL OR COMPONENTS TO CONTACT SKIN.

WITH THE ENGINE STOPPED AND THE OIL WARM:

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

2. Wipe the dirt from the oil filter housings.

3. Remove and discard the filters.

4. Clean the filter bases. Make sure all of the old gaskets are removed.

5. Using clean engine oil, liberally oil the top seal on each new filter.

6. Prime each filter with lubricating oil. Allow time for the oil to filter through the element.

7. Screw each filter onto its filter base until the seal just touches the base, then tighten by hand as per instruction on the filter.

If a tool is available tighten each filter to 15 lb.-ft. (20 Nm).

8. Clean the drain plug in clean nonflammable solvent and install the plug.

9. Fill the crankcase. See "Capacities (Approximate)" on page 5-1.

10. Start the engine and observe the engine oil pressure gauge for an indication of oil pressure. If oil pressure does not indicate within 15 seconds, shut the engine down and troubleshoot.

11. Shut the engine down, allow time for the oil to drain into the crankcase, then check the oil level. Maintain the level as indicated on the dipstick.

Changing The Water Separator Element

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

1. Thoroughly clean the exterior of the water separator assembly.

2. Remove the bolt in the center of the top cover.

3. Lower the bottom cover and filter element away from the top cover. Discard the filter element.

4. Clean the top and bottom covers.

5. Check that the rubber gaskets are in good condition and replace if necessary.

6. Place the new filter element and bottom cover in position and install the bolt.

7. Bleed the fuel system (see "Bleeding the Fuel System" below).

Bleeding The Fuel System

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

To bleed systems with a C.A.V. fuel pump, SHUT THE ENGINE DOWN, then:

1. Loosen the air vent screw near the top of the governor control cover (A).

2. Loosen the vent screw on the hydraulic head locking screw on the side of the fuel pump body (B).

3. Loosen the vent screw on top of the final fuel filter (D).

4. Operate the priming lever of the fuel lift pump and when fuel, free from air bubbles, issues from each venting point, tighten the screws in the following order:

a. Fuel filter venting point (D).

b. Head locking screw (B).

c. Governor vent screw (A).

NOTE: IF THE CAM ON THE ENGINE CAMSHAFT OPERATING THE FUEL LIFT PUMP IS ON MAXIMUM LIFT, IT WILL NOT BE POSSIBLE TO OPERATE THE HAND PRIMER. IF SUCH A CONDITION ARISES, THE ENGINE SHOULD BE TURNED ONE COMPLETE REVOLUTION.

5. Loosen the pipe union nut at the fuel injection pump inlet (C), operate the priming lever on the lift pump and retighten when fuel, free from air bubbles, issues from around the threads.

6. Loosen two of the fuel injection line nuts.

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WORKING NEAR THE ENGINE WHILE THE ENGINE IS RUNNING COULD RESULT IN PERSONAL INJURY. A PERSON SHOULD BE AT THE CONTROLS AT ALL TIMES SO THE ENGINE CAN BE SHUT DOWN IMMEDIATELY IF SOMETHING GOES WRONG.

7. Turn the engine until fuel, free from air bubbles, issues from both line nuts.

8. SHUT THE ENGINE DOWN and tighten the line nuts.

NOTE: IF, AFTER BLEEDING THE FUEL SYSTEM, THE ENGINE RUNS SATISFACTORILY FOR A FEW MOMENTS AND THEN THE SAME SYMPTOMS RECUR AND WHEN CHECKED THE SYSTEM IS FOUND TO BE FULL OF AIR; THEN A LEAK ON THE SUCTION SIDE OF THE FUEL SYSTEM IS INDIAVSED.

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

To bleed systems with a Bosh fuel pump, SHUT THE ENGINE DOWN, then:

1. Loosen the vent screw on top of the final fuel filter (D).

2. Loosen the inlet connection on the fuel pump (A).

3. Loosen the outlet connection on the fuel pump (B).

NOTE: IF THE CAM ON THE ENGINE CAMSHAFT OPERATING THE FUEL LIFT PUMP IS ON MAXIMUM LIFT, IT WILL NOT BE POSSIBLE TO OPERATE THE HAND PRIMER. IF SUCH A CONDITION ARISES, THE ENGINE SHOULD BE TURNED ONE COMPLETE REVOLUTION.

4. Operate the priming lever on the fuel lift pump until fuel, free from air, issues from the final fuel filter venting point (D). Tighten the vent screw.

5. Continue to operate the lift pump until fuel, free from air, issues from the inlet connection on the fuel pump (A). Tighten the inlet connection.

6. Continue to operate the lift pump until fuel, free from air, issues from the outlet connection on the fuel pump (B). Tighten the connection.

7. Thoroughly clean the top of the fuel pump around the center plug (C) in the hydraulic head.

8. Loosen the plug a MAXIMUM of half a turn - no more.

9. Operate the priming lever of the lift pump until fuel, free from air, issues from around the plug.

10. Tighten the plug.

11. Loosen two of the fuel injection line nuts.

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WORKING NEAR THE ENGINE WHILE THE ENGINE IS RUNNING COULD RESULT IN PERSONAL INJURY. A PERSON SHOULD BE AT THE CONTROLS AT ALL TIMES SO THE ENGINE CAN BE SHUT DOWN IMMEDIATELY IF SOMETHING GOES WRONG.

12. Turn the engine until fuel, free from air bubbles, issues from both line nuts.

13. SHUT THE ENGINE DOWN and tighten the line nuts.

NOTE: IF, AFTER BLEEDING THE FUEL SYSTEM, THE ENGINE RUNS SATISFACTORILY FOR A FEW MOMENTS AND THEN THE SAME SYMPTOMS RECUR AND WHEN CHECKED THE SYSTEM IS FOUND TO BE FULL OF AIR; THEN A LEAK ON THE SUCTION SIDE OF THE FUEL SYSTEM IS INDIAVSED.