AP-800 ASPHALT PAVER Daily Or 10 Hour Service Caterpillar

1. Check and service as required:

a. Engine oil level.

b. Engine coolant level.

c. Fuel level.

d. Hydraulic oil level.

e. Hydraulic oil cooler and engine radiator.

f. Engine air cleaner.

g. Tension in drive chains for the ground drive and conveyor drives. (After first 10 hours only. See "500 Hour Service" for procedures.)

h. Drag conveyor chain adjustment. (After first 10 hours only. See "500 Hour Service" for procedures.)

i. General machine for leaks, loose bolts, loose connectors, etc.

2. Lubricate those points shown in the 10 hour column of the lubrication chart.

Checking The Engine Oil Level

Check the oil level before starting. Maintain the oil level as indicated on the dipstick.

Checking The Engine Coolant Level

Show/hide table

AT OPERATING TEMPERATURE, ENGINE COOLANT IS HOT AND UNDER PRESSURE. STEAM CAN CAUSE PERSONAL INJURY. CHECK COOLANT LEVEL ONLY WHEN ENGINE IS STOPPED AND FILLER CAP IS COOL ENOUGH TO TOUCH WITH YOUR HAND. REMOVE FILLER CAP SLOWLY TO RELIEVE PRESSURE.

1. Slowly turn the pressure cap to the first stop and release pressure.

2. Push the cap down and turn until released.

3. Maintain coolant level to within 1/2 inch (1 cm) of base of fillpipe. Never add coolant to an overheated engine; allow it to cool first.

4. Make-up coolant should be one of the following in order of preference:

a. Permanent antifreeze and water solution.

b. Drinkable water and rust inhibitor solution.

c. Drinkable water.

d. Any available water.

If the engine is to be left exposed to freezing weather, coolant "a" must be used. Coolant "b" can be used only if the coolant temperature will remain above freezing. Coolant "c" or "d" should be used only as a temporary fix. Return the system to "a" or "b" as soon as possible.

Checking The Fuel Level

The fuel tank is located at the left forward corner of the mainframe. The tank should be filled at the end of each work day to reduce the amount of water condensed out of the air as the tank cools during the night.

Checking The Hydraulic Oil Level

The hydraulic oil tank is equipped with a sight gauge for easy checking of the oil level. The tank should be kept full with new water-free hydraulic oil conforming to the specification on page 5-1. This will ensure that hydraulic oil is available and will keep condensation to a minimum. Do not overfill the tank, allow for expansion of the oil.

Checking The Hydraulic Oil Cooler and Radiator

The hydraulic oil cooler and the radiator should be checked for any obstructions to proper cooling air flow through them. Since the cooling air flows through the oil cooler and then through the radiator, any obstruction to air flow through either will also obstruct the air flow through the other. Any rags, paper, mud, bugs, etc. that may obstruct the air flow must be removed.

Checking And Replacing The Engine Air Cleaner Elements

The main element should be cleaned or replaced whenever the indicator shows a red signal after the engine is shut down. 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 procedures.)

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

Show/hide table

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

Show/hide table

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.