AP-1200 ASPHALT PAVER 400 Hour Service Caterpillar

1. Check and service as required:

a. Tension in drive chains for the ground drive and conveyor drives.

b. Drag conveyor chain adjustment.

2. Change the engine final fuel filter element.

3. Clean the engine fuel lift pump gauze strainer.

4. Replace the engine air cleaner elements.

Adjusting The Ground Drive Chain Tension

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

1. Loosen the axle mounting bolts.

2. Turn the adjusting bolts evenly until the slack is removed from the drive chain.

3. Tighten the axle mounting bolts.

Adjusting The Conveyor Drive Chain Tension

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INADVERTENT ENGAGEMENT OF THE CONVEYOR DRIVE SYSTEM COULD CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH.

1. Loosen the mounting plate mounting bolts and the jam nut.

2. Turn the adjusting nut until the slack is removed from the chain.

3. Tighten the mounting bolts and jam nut.

4. If necessary, repeat for the other drive chain.

Adjusting The Drag Conveyor Chain Tension

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INADVERTENT ENGAGEMENT OF THE CONVEYOR DRIVE SYSTEM COULD CAUSE PERSONAL INJURY. SHUT THE ENGINE DOWN AND REMOVE THE KEY FROM THE IGNITION SWITCH.

Each drag conveyor has a take-up bearing mounted on each end of the front take-up shaft. A take-up rod, threaded into the take-up bearing, extends through a plate at the front of the hopper and has a sleeved adjusting nut threaded onto the take-up rod.

Adjust each drag conveyor separately. Turn the adjusting nuts for the drag conveyor alternately and evenly until the proper chain tension is obtained.

Changing The Engine Final Fuel Filter 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 fuel filter 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 them 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" on page 5-23).

Cleaning The Engine Fuel Lift Pump Gauze Strainer

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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.

Remove the strainer by unscrewing the bolt securing the domed cover on the top of the fuel lift pump. Wash the strainer in nonflammable solvent.

When reassembling after cleaning, ensure that a good joint is made between the cover and fuel lift pump body, as any leakage of air here will cause air locks in the fuel system.

Replacing The Engine Air Cleaner Elements

The main element should be cleaned or replaced with a new element every 400 hours. Replace the main element after six cleanings or one year of use, whichever occurs first. Change the safety element every third time the main element is cleaned or replaced. (See the Service Manual for cleaning procedueres.)

Although it is possible to clean the safety element using the procedures described for the main element, it is not recommended except in an emergency situation. Maximum engine protection is achieved by replacing the plugged safety element with a new element.

Replacing The Main Element

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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. STOP THE ENGINE, remove the cover assembly and clean it.

2. Remove the main element. DO NOT REMOVE THE SAFETY ELEMENT.

3. Immediately inspect the main element for any dust streaks on the inside. If there are any dust streaks, the element is damaged, THROW IT AWAY.

4. Inspect the main element gasket. If the element gasket is not smooth and flat or is damaged in any way that might allow dust to get by, THROW THE ELEMENT AWAY.

5. Install a new or cleaned main element.

6. Inspect the gasket washer on the wing nut and replace it if a good air seal cannot be guaranteed.

7. Tighten the wing nut securely.

8. Install the cover assembly.

Replacing The Safety Element

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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. STOP THE ENGINE, remove the cover assembly and clean it.

2. Remove the main element.

3. Remove the safety element and clean out any dust dislodged into the cleaner outlet.

4. Install a new safety element.

5. Inspect the gasket washer on the wing nut and replace it if a good air seal cannot be guaranteed.

6. Tighten the wing nut securely.

7. Install the main element and tighten the wing nut securely.

8. Install the cover assembly.