NorAM 65E Turbo Motor Grader Service Manual
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NorAM 65E Turbo Motor Grader Service Manual

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65E Turbo Motor Grader
Service Manual
65
E
TURBO
Service Manual
Service 2.00_2013.02
Motor Grader
Part # 22145
Serial #
Tier III 65ET9500 - 65ET9899
Tier IVi 65ET9900 - UP
I

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Table of Contents
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Summary of Contents for NorAM 65E Turbo Motor Grader

  • Page 1 65E Turbo Motor Grader Service Manual Motor Grader TURBO Service Manual Part # 22145 Serial # Tier III 65ET9500 - 65ET9899 Tier IVi 65ET9900 - UP Service 2.00_2013.02...
  • Page 2 This page intentionally left blank.
  • Page 3 65E Turbo Motor Grader Service Manual ROPRIETARY OTICE The contents of this manual are proprietary data of the manufacturer. Reproduction or use of any part for other than the operation and maintenance of this equipment is permissible only if expressly authorized in writing by the manufacturer.
  • Page 4 65E Turbo Motor Grader Service Manual WNER The machine was designed to power and propel itself. It is intended to move material in the normal and customary applications. Do not modify or alter or permit anyone else to modify or alter this machine or any of its components mechanical function without first consulting your dealer.
  • Page 5 65E Turbo Motor Grader Service Manual The symbol above is used throughout this book whenever personal safety is involved. Take time to read and follow the instructions. Be careful! Pictures in this manual may show protective shielding open or removed to better illustrate a particular feature or adjustment.
  • Page 6 65E Turbo Motor Grader Service Manual ONTENTS VERVIEW Electronic Display............Section 1 Engine .
  • Page 7 Service Manual Section 1: Electronic Display Service 2.00_2013.03...
  • Page 8 Section 1 65E Turbo Motor Grader Electronic Display Service Manual SAFETY PRECAUTION INFORMATION UNSAFE OPERATING PRACTICES AND IMPROPER USE OF THE MACHINE AND ITS ATTACHMENTS ON THE PART OF THE OPERATOR OR SERVICE TECHNICIAN CAN RESULT IN INJURIES. OBSERVE THE FOLLOWING SAFETY PRECAUTIONS AT ALL TIMES: 1.
  • Page 9 65E Turbo Motor Grader Section 1 Service Manual Electronic Display 15. Install all shields before starting or operating machine. 16. Do not operate an unsafe machine. If items are found during inspection that render a machine unsafe, be sure any malfunctions are remedied before accepting responsibility for operation.
  • Page 10 Section 1 65E Turbo Motor Grader Electronic Display Service Manual 33. Remember that the vehicle, if abused or incorrectly used, can be dangerous and become a hazard to the operator and bystanders. 34. Noise levels can exceed recommended levels when working between buildings or in confined areas on canopy equipped machines or cab equipped machines with doors and windows open.
  • Page 11 65E Turbo Motor Grader Section 1 Service Manual Electronic Display 50. After operating the engine, never touch the muffler, exhaust pipe, engine or radiator until they have had time to cool. 51. Dress appropriately - wear relatively tight-fitting clothing when operating or servicing the machine.
  • Page 12 Section 1 65E Turbo Motor Grader Electronic Display Service Manual 65. Do not attempt to service air conditioning system, if equipped. It is possible to be severely frostbitten or injured by escaping refrigerant. Special equipment and instruments are required to service air conditioning system. See an authorized dealer for service.
  • Page 13 65E Turbo Motor Grader Section 1 Service Manual Electronic Display 81. If welding is required on an attachment, remove the attachment from the machine. 82. Give complete and undivided attention to the job at hand so that complete control of the machine is maintained at all times.
  • Page 14 Section 1 65E Turbo Motor Grader Electronic Display Service Manual OSHA REQUIREMENTS NOW MAKE IT THE EMPLOYER'S RESPONSIBILITY TO FULLY INSTRUCT EACH OPERATOR IN THE PROPER AND SAFE OPERATION OF ALL OPERATIVE EQUIPMENT. BOTH EMPLOYER AND EMPLOYEE SHOULD THOROUGHLY FAMILIARIZE THEMSELVES WITH THE MACHINE OPERATION.

  • Page 15: Table Of Contents

    65E Turbo Motor Grader Section 1 Service Manual Electronic Display ONTENTS ..........1-1...
  • Page 16 Section 1 65E Turbo Motor Grader Electronic Display Service Manual This page intentionally left blank. 1-II Service 2.00_2013.03...

  • Page 17: Electronic Display

    65E Turbo Motor Grader Section 1 Service Manual Electronic Display Section 1: Electronic Display CREEN ESCRIPTIONS The system incorporates gauges and diagnostics with a LCD (Liquid Crystal Display) of current readings through which the operator may scroll. Start-Up Screen This screen appears for 2 seconds after engine is started.
  • Page 18 Section 1 65E Turbo Motor Grader Electronic Display Service Manual High exhaust temperatures during a regeneration cycle. 9. Regeneration In-Progress - Displays icon when a regeneration in-progress cycle is active. NOTE: Regeneration In-Progress is only available on the CAT C3.4 Tier IVi engine.

  • Page 19: Menu Screen

    65E Turbo Motor Grader Section 1 Service Manual Electronic Display Menu Screen Down arrow, 1, moves selection box down. Up arrow, 2, moves selection box up. Right arrow, 3, enters selected screen. ESC, 4, exits to previous screen. Highlight screen name and select with the right arrow key.

  • Page 20: View Engine Diagnostics 2 Screen

    Section 1 65E Turbo Motor Grader Electronic Display Service Manual View Engine Diagnostics 2 Screen View Engine Diagnostics 2 Screen displays the following: – Battery – Manifold Temperature – Fuel Temperature – Hest Lamp – DPF Inhibit Lamp (Only available on the CAT C3.4 TIVi engine option) –...

  • Page 21: View Can Screen

    65E Turbo Motor Grader Section 1 Service Manual Electronic Display View CAN Screen View CAN Screen displays the following: – CAN Conditions – Power in Volts – Current Software Revision If a problem is present in the CAN system, TCU, ECM or display and an entity is not connected to the CAN system, the line, 1, above the entity will not be present.

  • Page 22: Contrast Adjustment

    Section 1 65E Turbo Motor Grader Electronic Display Service Manual – Contrast Adjustment The Contrast Adjustment Option allows the user to change the contrast of the display screen. To activate, press the control keys associated with the up or down arrows, followed by the right arrow to select desired setting.

  • Page 23: Aeb Mode Request

    65E Turbo Motor Grader Section 1 Service Manual Electronic Display – AEB Mode Request The AEB serves to compensate tolerances (plate clearance and pressure level), which are influencing the filling procedure of the transmission clutches. Before activating AEB Mode it is necessary to: •...

  • Page 24: Top Left

    Section 1 65E Turbo Motor Grader Electronic Display Service Manual The “Top Left”, “Top Right”, “Bottom Left”, and “Bottom Right” system settings screens allow the user to customize the Main Operating Screen, 1. – Top Left – Top Right – Bottom Left –...
  • Page 25 65E Turbo Motor Grader Section 1 Service Manual Electronic Display The following monitored engine and transmission parameters are available. Battery Voltage Fuel Pressure Hours Transmission Oil Temperature Engine RPM Coolant Temperature (Metric) Percent Load (Engine) Oil Pressure (Metric) Coolant Temperature...

  • Page 26: View Errors Screen

    Section 1 65E Turbo Motor Grader Electronic Display Service Manual View Errors Screen View Errors Screen displays: – Active Error Count – Active Error Occurrences – Display Voltage High – SPN Error Code – FMI Error Code – OC (Number of Occurrences)

  • Page 27: Electronic Display Navigation

    65E Turbo Motor Grader Section 1 Service Manual Electronic Display LECTRONIC ISPLAY AVIGATION Service 2.00_2013.03 1-11...
  • Page 28 Section 1 65E Turbo Motor Grader Electronic Display Service Manual 1-12 Service 2.00_2013.03...
  • Page 29 65E Turbo Motor Grader Section 1 Service Manual Electronic Display Service 2.00_2013.03 1-13...
  • Page 30 Section 1 65E Turbo Motor Grader Electronic Display Service Manual 1-14 Service 2.00_2013.03...
  • Page 31 65E Turbo Motor Grader Section 1 Service Manual Electronic Display Service 2.00_2013.03 1-15...
  • Page 32 Section 1 65E Turbo Motor Grader Electronic Display Service Manual This page intentionally left blank. 1-16 Service 2.00_2013.03...
  • Page 33 Service Manual Section 2: Engine Service 2.00_2013.03...
  • Page 35 65E Turbo Motor Grader Section 2 Service Manual Engine SAFETY PRECAUTION INFORMATION UNSAFE OPERATING PRACTICES AND IMPROPER USE OF THE MACHINE AND ITS ATTACHMENTS ON THE PART OF THE OPERATOR OR SERVICE TECHNICIAN CAN RESULT IN INJURIES. OBSERVE THE FOLLOWING SAFETY PRECAUTIONS AT ALL TIMES: 1.
  • Page 36 Section 2 65E Turbo Motor Grader Engine Service Manual 15. Install all shields before starting or operating machine. 16. Do not operate an unsafe machine. If items are found during inspection that render a machine unsafe, be sure any malfunctions are remedied before accepting responsibility for operation.
  • Page 37 65E Turbo Motor Grader Section 2 Service Manual Engine 33. Remember that the vehicle, if abused or incorrectly used, can be dangerous and become a hazard to the operator and bystanders. 34. Noise levels can exceed recommended levels when working between buildings or in confined areas on canopy equipped machines or cab equipped machines with doors and windows open.
  • Page 38 Section 2 65E Turbo Motor Grader Engine Service Manual 50. After operating the engine, never touch the muffler, exhaust pipe, engine or radiator until they have had time to cool. 51. Dress appropriately - wear relatively tight-fitting clothing when operating or servicing the machine.
  • Page 39 65E Turbo Motor Grader Section 2 Service Manual Engine 65. Do not attempt to service air conditioning system, if equipped. It is possible to be severely frostbitten or injured by escaping refrigerant. Special equipment and instruments are required to service air conditioning system. See an authorized dealer for service.
  • Page 40 Section 2 65E Turbo Motor Grader Engine Service Manual 81. If welding is required on an attachment, remove the attachment from the machine. 82. Give complete and undivided attention to the job at hand so that complete control of the machine is maintained at all times.
  • Page 41 65E Turbo Motor Grader Section 2 Service Manual Engine OSHA REQUIREMENTS NOW MAKE IT THE EMPLOYER'S RESPONSIBILITY TO FULLY INSTRUCT EACH OPERATOR IN THE PROPER AND SAFE OPERATION OF ALL OPERATIVE EQUIPMENT. BOTH EMPLOYER AND EMPLOYEE SHOULD THOROUGHLY FAMILIARIZE THEMSELVES WITH THE MACHINE OPERATION.
  • Page 42 Section 2 65E Turbo Motor Grader Electronic Display Service Manual This page intentionally left blank. Service 2.00_2013.03...
  • Page 43 65E Turbo Motor Grader Section 2 Service Manual Engine ONTENTS ............2-1 NGINE ENGINE: General Information .
  • Page 44 Section 2 65E Turbo Motor Grader Engine Service Manual CAT Tier IVi - Engine Component Locations ........2-24 CAT Tier IVi Fuse Designations .

  • Page 45: Engine

    ENERAL NFORMATION The NORAM 65ET Grader is equipped with one of four engine options. 1. Cummins™ QSB4.5 Tier III engine. Detailed operation and maintenance information for the engine is located in the Cummins™ Operation and Maintenance Manual. Refer to the Cummins™ manual for engine troubleshooting and diagnostic help.

  • Page 46: Engine Protection And Diagnostics

    Engine Protection and Diagnostics The NORAM 65ET grader uses the digital display screen to signal the operator when it detects an engine fault or problem. If there are system issues, an error message will automatically display on the main screen.

  • Page 47: Diagnostics

    65E Turbo Motor Grader Section 2 Service Manual Engine Diagnostics From the menu screen, press the button below the right arrow to enter Engine Diagnostics 1. The Engine Diagnostics Screen 1 displays the following: - Engine Speed - Percent Load...

  • Page 48: Cummins Tier Iii - Specifications

    Section 2 65E Turbo Motor Grader Engine Service Manual III - S UMMINS PECIFICATIONS Model ............Cummins QSB4.5 Tier III Type.

  • Page 49: Cummins Tier Iii - Engine Electrical

    65E Turbo Motor Grader Section 2 Service Manual Engine III - E UMMINS NGINE LECTRICAL Electronic Control Module (ECM) The engine electronic control module, 1, is supplied power through a fuse located in a sealed connector, 2, near the right- hand side of the flywheel area.

  • Page 50: Cummins Tier Iii - Engine Component Locations

    Section 2 65E Turbo Motor Grader Engine Service Manual III - E UMMINS NGINE OMPONENT OCATIONS 1. A/C Compressor 2. Washer Fluid Tank 3. Fuel Filler Neck 4. Fuel Filter 5. Water Separator 6. Fuel Primer 7. Fuel Pump 8. Engine Oil Fill 9.
  • Page 51 65E Turbo Motor Grader Section 2 Service Manual Engine III - E UMMINS NGINE OMPONENT OCATIONS 13. Hydraulic Tank 14. Hydraulic Tank Fill 15. Hydraulic Tank Sight Gauge 16. Master Switch 17. Starter 18. Engine Oil Filter 19. Alternator Service 2.00_2013.03...

  • Page 52: Cummins Tier Iii Fuses

    Section 2 65E Turbo Motor Grader Engine Service Manual Cummins Tier III Fuses Located under right-side console. Service 2.00_2013.03...
  • Page 53 65E Turbo Motor Grader Section 2 Service Manual Engine Cummins Tier III - Fuses Wire schematic detail above is shown to explain fuse failure symptoms below. Refer to wiring schematic in Electrical section for further wiring details. Symptom Engine Characteristics...

  • Page 54: Cummins Tier Ivi - Specifications

    Section 2 65E Turbo Motor Grader Engine Service Manual UMMINS PECIFICATIONS Model ............Cummins QSB3.3 Tier IVi Type.

  • Page 55: Cummins Tier Ivi - Engine Component Locations

    65E Turbo Motor Grader Section 2 Service Manual Engine UMMINS NGINE OMPONENT OCATIONS 1. A/C Compressor 2. Muffler 3. Air Cleaner 4. Fuel Filter 5. Water Separator 6. Fuel Primer 7. Fuel Pump 8. Fuel Filler Neck 9. Crankcase Coalescence Filter 10.
  • Page 56 Section 2 65E Turbo Motor Grader Engine Service Manual UMMINS NGINE OMPONENT OCATIONS 14. Heater Shutoff Valve 15. Master Switch 16. Hydraulic Tank 17. Hydraulic Tank Fill 18. Hydraulic Tank Sight Gauge 19. Alternator 20. Washer Fluid Tank 21. Air Intake Temperature Sensor 22.

  • Page 57: Cummins Tier Ivi Fuse Designations

    65E Turbo Motor Grader Section 2 Service Manual Engine Cummins Tier IVi Fuse Designations 1. SEAT - 10A 14. FUEL SENDER - 5A 2. DISPLAY - 7.5A 15. DOME / DASH 3. BLADE PITCH - 30A LIGHTS - 7.5A 4. DEFOG FANS - 30A 16.

  • Page 58: Cummins Tier Ivi Fuses

    Section 2 65E Turbo Motor Grader Engine Service Manual Cummins Tier IVi Fuses Wire schematic detail above is shown to explain fuse failure symptoms below. Refer to wiring schematic in Electrical section for further wiring details. Symptom Engine Characteristics Possible Cause...

  • Page 59: Cat Tier Iii - Specifications

    65E Turbo Motor Grader Section 2 Service Manual Engine CAT T III - S PECIFICATIONS Model ..............CAT C4.4 Tier III Type.

  • Page 60: Electronic Control Module (Ecm)

    Section 2 65E Turbo Motor Grader Engine Service Manual CAT T III- E NGINE LECTRICAL Electronic Control Module (ECM) The engine electronic control module, 1, is supplied power through six fuses located in sealed connectors, 2, near the right-hand side of the flywheel area.

  • Page 61: Cat Tier Iii - Engine Component Locations

    65E Turbo Motor Grader Section 2 Service Manual Engine CAT T III - E NGINE OMPONENT OCATIONS 1. A/C Compressor 2. Engine Oil Fill 3. Fuel Filter 4. Water Separator 5. Fuel Primer 6. A/C Dryer 7. Injector Pump 8. Engine Oil Filter 9.
  • Page 62 Section 2 65E Turbo Motor Grader Engine Service Manual CAT T III - E NGINE OMPONENT OCATIONS 12. Washer Fluid Tank 13. Air Cleaner 14. Air Filter Indicator 15. Muffler 16. Brake Fluid Reservoirs 17. Hydraulic Tank 18. Hydraulic Tank Fill 19.

  • Page 63: Cat Tier Iii Fuses

    65E Turbo Motor Grader Section 2 Service Manual Engine CAT Tier III Fuses 1. SEAT - 10A 14. FUEL SENDER - 5A 2. DISPLAY - 7.5A 15. DOME / DASH 3. BLADE PITCH - 30A LIGHTS - 7.5A 4. DEFOG FANS - 30A 16.
  • Page 64 Section 2 65E Turbo Motor Grader Engine Service Manual CAT Tier III Fuses Wire schematic detail above is shown to explain fuse failure symptoms below. Refer to wiring schematic in Electrical section for further wiring details. Symptom Engine Characteristics Possible Cause...

  • Page 65: Cat Tier Ivi - Specifications

    65E Turbo Motor Grader Section 2 Service Manual Engine CAT T PECIFICATIONS Model ..............CAT C3.4 Tier IVi Type.
  • Page 66 Section 2 65E Turbo Motor Grader Engine Service Manual CAT T NGINE OMPONENT OCATIONS 1. Engine Electronic Control Module (ECM), 1, is supplied power through fuses located in sealed connectors. 2. Glow Plug Control Unit (GPCU) 3. ECM Diagnostic Port 4.

  • Page 67: Cat Tier Ivi - Engine Component Locations

    65E Turbo Motor Grader Section 2 Service Manual Engine CAT T NGINE OMPONENT OCATIONS 10. Engine Oil Filter 11. Fuel Fill 12. Master Switch 13. Starter 14. Fuel Pump 15. Washer Fluid Tank 16. Air Filter 17. Air Filter Indicator 18.

  • Page 68: Cat Tier Ivi - Engine Component Locations

    Section 2 65E Turbo Motor Grader Engine Service Manual CAT T NGINE OMPONENT OCATIONS 19. Brake Fluid Reservoirs 20. Hydraulic Tank 21. Hydraulic Tank Fill 22. Hydraulic Tank Gauge 23. Turbocharger 24. Alternator 25. Air Temperature Sensor 26. Lambda O2 Sensor 27.

  • Page 69: Cat Tier Ivi Fuse Designations

    65E Turbo Motor Grader Section 2 Service Manual Engine CAT Tier IVi Fuse Designations 1. SEAT - 10A 14. FUEL SENDER - 5A 2. DISPLAY - 7.5A 15. DOME / DASH 3. BLADE PITCH - 30A LIGHTS - 7.5A 4. DEFOG FANS - 30A 16.

  • Page 70: Cat Tier Ivi Fuses

    Section 2 65E Turbo Motor Grader Engine Service Manual CAT Tier IVi Fuses 2-26 Service 2.00_2013.03...
  • Page 71 65E Turbo Motor Grader Section 2 Service Manual Engine Wire schematic detail above is shown to explain fuse failure symptoms below. Refer to wiring schematic in Electrical section for further wiring details. Symptom Engine Characteristics Possible Cause Engine dies Engine cranks, Will not start, No smoke 7.5A Fuse blown (6-RD wire) Refer...

  • Page 72: Diesel Particulate Filter Regeneration

    Section 2 65E Turbo Motor Grader Engine Service Manual Diesel Particulate Filter Regeneration NOTE: Diesel Particulate Filter Regeneration Option is only available on CAT C3.4 Tier IVi engine. Regeneration is the process of removing the accumulated soot from the diesel particulate filter (DPF). This is done by actively introducing very high heat into the exhaust system.
  • Page 73 65E Turbo Motor Grader Section 2 Service Manual Engine When the DPF reaches 90% soot-load, the automatic regeneration cycle is activated. It is possible to inhibit the automatic regeneration cycle by placing the Regeneration Inhibit Switch in the “ON” position.
  • Page 74 Section 2 65E Turbo Motor Grader Engine Service Manual This page intentionally left blank. 2-30 Service 2.00_2013.03...
  • Page 75 Service Manual Section 3: Operator’s Platform and Controls Service 2.00_2013.03...
  • Page 77 65E Turbo Motor Grader Section 3 Service Manual Operator’s Platform and Controls SAFETY PRECAUTION INFORMATION UNSAFE OPERATING PRACTICES AND IMPROPER USE OF THE MACHINE AND ITS ATTACHMENTS ON THE PART OF THE OPERATOR OR SERVICE TECHNICIAN CAN RESULT IN INJURIES. OBSERVE THE FOLLOWING SAFETY PRECAUTIONS AT ALL TIMES: 1.
  • Page 78 Section 3 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual 15. Install all shields before starting or operating machine. 16. Do not operate an unsafe machine. If items are found during inspection that render a machine unsafe, be sure any malfunctions are remedied before accepting responsibility for operation.
  • Page 79 65E Turbo Motor Grader Section 3 Service Manual Operator’s Platform and Controls 33. Remember that the vehicle, if abused or incorrectly used, can be dangerous and become a hazard to the operator and bystanders. 34. Noise levels can exceed recommended levels when working between buildings or in confined areas on canopy equipped machines or cab equipped machines with doors and windows open.
  • Page 80 Section 3 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual 50. After operating the engine, never touch the muffler, exhaust pipe, engine or radiator until they have had time to cool. 51. Dress appropriately - wear relatively tight-fitting clothing when operating or servicing the machine.
  • Page 81 65E Turbo Motor Grader Section 3 Service Manual Operator’s Platform and Controls 65. Do not attempt to service air conditioning system, if equipped. It is possible to be severely frostbitten or injured by escaping refrigerant. Special equipment and instruments are required to service air conditioning system. See an authorized dealer for service.
  • Page 82 Section 3 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual 81. If welding is required on an attachment, remove the attachment from the machine. 82. Give complete and undivided attention to the job at hand so that complete control of the machine is maintained at all times.
  • Page 83 65E Turbo Motor Grader Section 3 Service Manual Operator’s Platform and Controls OSHA REQUIREMENTS NOW MAKE IT THE EMPLOYER'S RESPONSIBILITY TO FULLY INSTRUCT EACH OPERATOR IN THE PROPER AND SAFE OPERATION OF ALL OPERATIVE EQUIPMENT. BOTH EMPLOYER AND EMPLOYEE SHOULD THOROUGHLY FAMILIARIZE THEMSELVES WITH THE MACHINE OPERATION.
  • Page 84 Section 3 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual This page intentionally left blank. Service 2.00_2013.03...
  • Page 85 65E Turbo Motor Grader Section 3 Service Manual Operator’s Platform and Controls ONTENTS General ..............3-1 ROPS / FOPS / Cab and Environment Controls .
  • Page 86 Section 3 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual Throttle Linkage / Engine Speed Adjustment ......... . . 3-30 Low Idle Setting .

  • Page 87: General

    65E Turbo Motor Grader Section 3 Service Manual Operator’s Platform and Controls Section 3: Operator’s Platform and Controls ENERAL The operator's platform can be accessed from either side of the machine. A ROPS/FOPS structure is stan- dard on all units. Lockable storage area and instrument panel deters vandalism.

  • Page 88: Rops / Fops

    Section 3 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual ROPS / FOPS / C AB AND NVIRONMENT ONTROLS ROPS / FOPS Removal Step 1: Remove floodlights, if installed. Step 2: Remove rear view mirror and external mirrors, if installed.

  • Page 89: Installation

    65E Turbo Motor Grader Section 3 Service Manual Operator’s Platform and Controls Installation Step 1: Connect a hoist to the two cap screws, 5, on the top surface of the ROPS/FOPS unit, 3. Use a hoist of sufficient lifting capacity for the weight of the ROPS/FOPS unit.

  • Page 90: Cab

    Section 3 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual Service 2.00_2013.03...

  • Page 91: Removal

    65E Turbo Motor Grader Section 3 Service Manual Operator’s Platform and Controls Removal Step 1: Remove floodlights, if installed. Step 2: Remove rear view mirror and external mirrors, if installed. Step 3: Remove defrost fan, if installed. Step 4: Remove rear windshield wiper assembly, if installed.
  • Page 92 Section 3 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual Service 2.00_2013.03...

  • Page 93: Installation

    65E Turbo Motor Grader Section 3 Service Manual Operator’s Platform and Controls Installation Step 1: Connect a hoist to two cap screws, 22, on the top surface of the cab, 21. Step 2: Connect any required ground straps. Step 3: Install mirrors, if applicable.

  • Page 94: Console Controls

    Section 3 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual ONSOLE ONTROLS Right-Hand Controls The right-hand controls are as follows: Callouts Console Controls Articulation Control Wheel Lean Control Left-Hand Blade Lift Control Right-Hand Blade Lift Control Removal Step 1: Loosen nut, 1, and remove knob, 2.

  • Page 95: Installation

    65E Turbo Motor Grader Section 3 Service Manual Operator’s Platform and Controls Installation Step 1: Slide control lever, 5, onto shaft. Step 2: Attach rod end, 4, to control lever with screw, 1, washer, 2, and nut, 3. Step 3: Install screw, 3, and flat washers, 4, 5, and 6.

  • Page 96: Scarifier Control (Standard), Ripper Control (Optional), Dozer Lift Control (Optional) And Other Left-Hand Controls

    Section 3 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual Scarifier Control (Standard), Ripper Control (Optional), Dozer Lift Control (Optional) and Other Left-Hand Controls The left-hand controls are as follows: Callouts Console Controls Circle Shift Control Circle Turn Control...
  • Page 97 65E Turbo Motor Grader Section 3 Service Manual Operator’s Platform and Controls Step 3: Remove screw, 1, washer, 2, and nut, 3, securing rod end, 4, to scarifier control lever, 5. Step 4: Slide scarifier control lever off of shaft.

  • Page 98: Installation

    Section 3 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual Installation Step 1: Slide scarifier control lever, 5, onto shaft. Step 2: Attach rod end, 4, to control lever, 5, with screw, 1, washer, 2, and nut, 3.

  • Page 99: Steering Wheel

    65E Turbo Motor Grader Section 3 Service Manual Operator’s Platform and Controls Steering Wheel Removal Step 1: Remove cover guard, 1. Step 2: Remove steering wheel cover, 2. Step 3: Remove nut, 3. Step 4: Pull steering wheel, 4, off shaft, 5.

  • Page 100: Side View Mirror

    Section 3 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual Side View Mirror Mirror Removal Step 1: Remove screw, 3, washer, 5, nut, 6, securing mirror, 7. Remove mirror, 7, from clamp, 4. Step 2: Remove cap screw, 1, and washer, 2, securing clamp, 4.

  • Page 101: Rear View Mirror

    65E Turbo Motor Grader Section 3 Service Manual Operator’s Platform and Controls Rear View Mirror Removal Step 1: Remove cap screws, 1, attaching mirror, 2, to ceiling of cab. Step 2: Remove mirror. Installation Step 1: Align mirror support mounting holes with mirror mounting holes at ceiling of cab.

  • Page 102: Console Tilt Mechanism

    Section 3 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual Console Tilt Mechanism Removal Step 1: Remove screws, 1, and remove front access cover, 2, from front console. Step 2: Remove knob, 1, jam nut, 2, rod, 3, and jam nut, 4, from adjustable end yoke, 5.

  • Page 103: Installation

    65E Turbo Motor Grader Section 3 Service Manual Operator’s Platform and Controls Installation Step 1: Attach rack, 17, with screws, 18, and washers, 19. Step 2: Torque screws, 18, to 48-52 Nm (35-39 Ib-ft). Step 3: Insert shaft, 9, through upper block on guide, 14, then through upper washer, 15, spring, 16, lower washer, 15 and lower block on guide, 14.

  • Page 104: Control Lock

    Section 3 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual Control Lock The control lock is used to lock the control levers. The controls can be locked in all tilt positions of the front con- sole except when pulled fully back toward the seat.

  • Page 105: Installation

    65E Turbo Motor Grader Section 3 Service Manual Operator’s Platform and Controls Installation Step 1: Install jam nut, 2, on screw, 3, until it engages the screw head. Step 2: Fasten screw, 3, to shaft, 1, so that screw is almost flush with the shaft.
  • Page 106 Section 3 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual NOTE: If properly installed, screw, 1, should be directly over rod, 2. Step 10: Adjust screw, 1, so that the gap between the screw head and rod, 2, is 0.06 inches.

  • Page 107: Service Brakes

    65E Turbo Motor Grader Section 3 Service Manual Operator’s Platform and Controls Service Brakes Removal Step 1: Remove screws, 1, and remove front access cover, 2, from front console. Step 2: Loosen jam nuts, 1, on all control levers on the right side of front console.
  • Page 108 Section 3 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual Step 6: Remove roll pin, 1, and remove left brake pedal, 2. Step 7: Remove bearings, 3, and check for wear. Step 8: Remove roll pin, 4, and remove right brake pedal, 5.
  • Page 109 65E Turbo Motor Grader Section 3 Service Manual Operator’s Platform and Controls Step 13: Remove roll pin, 1, from shaft, 2. Step 14: Slide shaft out to release lever assembly, 4, from bracket, 3. Step 15: Check bearings, 5, for wear.

  • Page 110: Installation

    Section 3 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual Step 24: Remove screws, 1, washers, 2, and pin, 3, then remove bracket, 4. Step 25: To replace brake hydraulic valve or other components of the brake system refer to the Rear Axle Section.
  • Page 111 65E Turbo Motor Grader Section 3 Service Manual Operator’s Platform and Controls Step 2: Attach yoke, 19, to bracket, 23, with clevis pin, 22, and cotter pin, 21. Step 3: Screw jam nut, 20, onto rod, 8, then screw yoke, 19, onto rod, 8.
  • Page 112 Section 3 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual Step 10: Attach rod, 13, to lever assembly, 16, with clevis pin, 15, and cotter pin, 14. Step 11: Fasten jam nut, 12, on rod, 13. Step 12: Screw link, 11, onto rod, 13.

  • Page 113: Brake Adjustment

    65E Turbo Motor Grader Section 3 Service Manual Operator’s Platform and Controls Brake Adjustment Pedal Height Adjustment Step 1: To adjust pedal height, remove cotter pin, 7, and remove clevis pin, 8, to allow link, 11, to be removed from lever, 9, and adjusted on rod, 13.

  • Page 114: Brake Valve Plunger Clearance Adjustment

    Section 3 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual Brake Valve Plunger Clearance Adjustment Step 1: Adjust set screw, 7, to provide a clearance of 0.02 inch between plunger of brake valve, 5, and bracket, 4. Step 2: Lock set screw, 7, in place with jam nut, 8.

  • Page 115: Lever Assembly Clearance Adjustment

    65E Turbo Motor Grader Section 3 Service Manual Operator’s Platform and Controls Lever Assembly Clearance Adjustment Step 1: Remove cotter pin, 21, and remove clevis pin, 22, to allow yoke, 19, to be disengaged from bracket, 23, and be adjusted on rod, 8.

  • Page 116: Throttle Linkage / Engine Speed Adjustment

    Section 3 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual Throttle Linkage / Engine Speed Adjustment Low Idle Setting Step 1: Remove link, 1, by removing nut, 2, and bolt, 3. Step 2: Start engine. Step 3: To set low idle speed, rotate lever, 4, counter-clockwise, holding it against stop bolt, 5.

  • Page 117: High Idle Setting

    65E Turbo Motor Grader Section 3 Service Manual Operator’s Platform and Controls High Idle Setting Step 1: Remove link, 1, by removing nut, 2, and bolt, 3. Step 2: Start engine. Step 3: With engine running, rotate lever, 4, clockwise against stop bolt, 6.

  • Page 118: Throttle Lever Adjustment

    Section 3 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual Throttle Lever Adjustment Step 1: Move throttle lever, 1, to low idle position (rear of slot). Step 2: Remove pedal stop bolts, 8. Step 3: Confirm throttle positioning sensor (TPS) lever, 2, is against stop bolt, 3. If not, spring-loaded override link, 4, will need a length adjustment.

  • Page 119: Throttle Pedal Adjustment

    65E Turbo Motor Grader Section 3 Service Manual Operator’s Platform and Controls Throttle Pedal Adjustment Step 1: The throttle pedal angle can be adjusted to enable full range of engine speeds. The stop bolts should be adjusted to hit the pedal at the same time as the TPS lever, 4, hits the travel stop bolts. This adjustment is necessary to keep the linkage from being overloaded and bending the linkage rod, 2.

  • Page 120: Door Latch Adjustment

    Section 3 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual Door Latch Adjustment The door latch can be adjusted for correct engagement of the hook. Once the hook is properly adjusted, the door levers can be adjusted. To access the latch, remove screws and washers, 1.
  • Page 121 Service Manual Section 4: Transmission Service 2.00_2013.03...
  • Page 123 65E Turbo Motor Grader Section 4 Service Manual Transmission SAFETY PRECAUTION INFORMATION UNSAFE OPERATING PRACTICES AND IMPROPER USE OF THE MACHINE AND ITS ATTACHMENTS ON THE PART OF THE OPERATOR OR SERVICE TECHNICIAN CAN RESULT IN INJURIES. OBSERVE THE FOLLOWING SAFETY PRECAUTIONS AT ALL TIMES: 1.
  • Page 124 Section 4 65E Turbo Motor Grader Transmission Service Manual 15. Install all shields before starting or operating machine. 16. Do not operate an unsafe machine. If items are found during inspection that render a machine unsafe, be sure any malfunctions are remedied before accepting responsibility for operation.
  • Page 125 65E Turbo Motor Grader Section 4 Service Manual Transmission 33. Remember that the vehicle, if abused or incorrectly used, can be dangerous and become a hazard to the operator and bystanders. 34. Noise levels can exceed recommended levels when working between buildings or in confined areas on canopy equipped machines or cab equipped machines with doors and windows open.
  • Page 126 Section 4 65E Turbo Motor Grader Transmission Service Manual 50. After operating the engine, never touch the muffler, exhaust pipe, engine or radiator until they have had time to cool. 51. Dress appropriately - wear relatively tight-fitting clothing when operating or servicing the machine.
  • Page 127 65E Turbo Motor Grader Section 4 Service Manual Transmission 65. Do not attempt to service air conditioning system, if equipped. It is possible to be severely frostbitten or injured by escaping refrigerant. Special equipment and instruments are required to service air conditioning system. See an authorized dealer for service.
  • Page 128 Section 4 65E Turbo Motor Grader Transmission Service Manual 81. If welding is required on an attachment, remove the attachment from the machine. 82. Give complete and undivided attention to the job at hand so that complete control of the machine is maintained at all times.
  • Page 129 65E Turbo Motor Grader Section 4 Service Manual Transmission OSHA REQUIREMENTS NOW MAKE IT THE EMPLOYER'S RESPONSIBILITY TO FULLY INSTRUCT EACH OPERATOR IN THE PROPER AND SAFE OPERATION OF ALL OPERATIVE EQUIPMENT. BOTH EMPLOYER AND EMPLOYEE SHOULD THOROUGHLY FAMILIARIZE THEMSELVES WITH THE MACHINE OPERATION.
  • Page 130 Section 4 65E Turbo Motor Grader Transmission Service Manual This page intentionally left blank. Service 2.00_2013.03...
  • Page 131 65E Turbo Motor Grader Section 4 Service Manual Transmission ONTENTS ........... . 4-1 RANSMISSION Cummins Tier III - Mounting Transmission onto Engine .
  • Page 132 Section 4 65E Turbo Motor Grader Transmission Service Manual This page intentionally left blank. 4-xii Service 2.00_2013.03...

  • Page 133: Transmission

    65E Turbo Motor Grader Section 4 Service Manual Transmission Section 4: Transmission The ZF-ERGOPOWER 6WG-115 transmission is used on 65E Turbo Motor Graders with serial numbers 65E-9100 and above. The transmission runs on 24 volts. A 12/24 volt converter is located below the operator’s station.

  • Page 134: Cummins Tier Iii - Mounting Transmission Onto Engine

    Section 4 65E Turbo Motor Grader Transmission Service Manual III - M UMMINS OUNTING RANSMISSION ONTO NGINE Step 1: Remove two mounting bolts from cover plate, 1. Remove plate from engine, 2, to access flywheel bolt holes and transmission flex plate threaded holes.
  • Page 135 65E Turbo Motor Grader Section 4 Service Manual Transmission Step 3: Using a suitable lifting device, position transmission, 3, onto engine flywheel housing, 4, as follows: a) Align flywheel slots, 5, with bolt heads, 6. b) Align turbine spud shaft, 7, with engine pilot diameter, 8.
  • Page 136 Section 4 65E Turbo Motor Grader Transmission Service Manual Step 4: Apply Loctite 242 (blue) to threads on 12 bolts, Step 5: Secure transmission housing to engine flywheel housing using 12 bolts. Torque bolts to 47 Nm (35 Ib- ft).
  • Page 137 65E Turbo Motor Grader Section 4 Service Manual Transmission Step 7: Looking through access hole, 13, align flywheel bolt hole, 10, with transmission flex plate threaded hole, 9. Step 8: Apply Loctite 242 (blue) to threads of bolt (not shown). Secure flywheel to transmission flex plate using bolt.

  • Page 138: Cummins Tier Ivi - Mounting Transmission Onto Engine

    Section 4 65E Turbo Motor Grader Transmission Service Manual UMMINS OUNTING RANSMISSION ONTO NGINE Step 1: Remove mounting bolts from starter, 1. Remove starter from engine, 2, to access flywheel bolt holes and transmission flex plate threaded holes. Step 2: Clean mating surfaces between transmission housing and engine flywheel housing.
  • Page 139 65E Turbo Motor Grader Section 4 Service Manual Transmission Step 3: Using a suitable lifting device, position transmission, 3, onto engine flywheel housing, 4, as follows: a) Align turbine spud shaft, 5, with engine pilot diameter, 6. b) Align a transmission flex plate threaded hole, 7, with a flywheel bolt hole, 8.
  • Page 140 Section 4 65E Turbo Motor Grader Transmission Service Manual Step 4: Apply Loctite 242 (blue) to threads on 12 bolts, Step 5: Secure transmission housing to engine flywheel housing using 12 bolts. Torque bolts to 47 Nm (35 Ib- ft).
  • Page 141 65E Turbo Motor Grader Section 4 Service Manual Transmission Step 7: Looking through access hole, 11, align flywheel bolt hole, 8, with transmission flex plate threaded hole, 7. Step 8: Apply Loctite 242 (blue) to threads of bolt (not shown). Secure flywheel to transmission flex plate using bolt.

  • Page 142: Cat Tier Iii - Mounting Transmission Onto Engine

    Section 4 65E Turbo Motor Grader Transmission Service Manual CAT T III - M OUNTING RANSMISSION ONTO NGINE Step 1: Clean mating surfaces between transmission housing and engine flywheel housing. No gasket or sealant is used between surfaces. Step 2: Using a suitable lifting device, position...
  • Page 143 65E Turbo Motor Grader Section 4 Service Manual Transmission Step 3: Apply Loctite 242 (blue) to threads on 12 bolts, Step 4: Secure transmission housing to engine flywheel housing using 12 bolts. Torque bolts to 47 Nm (35 Ib- ft).
  • Page 144 Section 4 65E Turbo Motor Grader Transmission Service Manual Step 6: Looking through access hole, 11, align flywheel bolt hole, 8, with transmission flex plate threaded hole, 12. Step 7: Apply Loctite 242 (blue) to threads of bolt (not shown). Secure flywheel to transmission flex plate using bolt.

  • Page 145: Cat Tier Ivi - Mounting Transmission Onto Engine

    65E Turbo Motor Grader Section 4 Service Manual Transmission CAT T OUNTING RANSMISSION ONTO NGINE Step 1: Clean mating surfaces between transmission housing and engine flywheel housing. No gasket or sealant is used between surfaces. Step 2: Using a suitable lifting device, position...
  • Page 146 Section 4 65E Turbo Motor Grader Transmission Service Manual Step 3: Apply Loctite 242 (blue) to threads on 12 bolts, Step 4: Secure transmission housing to engine flywheel housing using 12 bolts. Torque bolts to 47 Nm (35 Ib- ft).
  • Page 147 65E Turbo Motor Grader Section 4 Service Manual Transmission Step 6: Looking through access hole, 9, align flywheel bolt hole, 6, with transmission flex plate threaded hole, 5. Step 7: Apply Loctite 242 (blue) to threads of bolt (not shown). Secure flywheel to transmission flex plate using bolt.
  • Page 148 Order-No.: 5872 154 002 ZF – ERGOPOWER TRANSMISSION 6 WG-115 TECHNICAL DATA DESCRIPTION OPERATION MAINTENANCE DIAGNOSTIC SYSTEMS ZF Passau GmbH Donaustr. 25 - 71 D - 94034 Passau Edition: 2003/03 Subject to changes w/o notice...
  • Page 149 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme 1. Edition...
  • Page 150 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme Preface The present Documentation has been developped for skilled personnel which has been trained by the ZF for the Maintenance and Repair operations on ZF-units. However, because of technical development of the product, the Maintenance and Repair of the unit in your hands may require differing steps as well as also different setting and test data.
  • Page 151 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme TABLE OF CONTENTS Page: Summary of the TECHNICAL DATA 6 - 7 Indentification Plate IMPORTANT INSTRUCTIONS 9 - 10 DESCRIPTION Function of the Converter Powershift transmission Transmission control Speed range selector 1.5.1 General 1.5.2 Speed range selector DW-3 1.5.3 Speed range selector VTS-3 1.5.4...
  • Page 152 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme ANNEX, comprising: Tables: Design 6 WG-115 Installation survey 6 WG-115 - Front view Installation survey 6 WG-115 -Rear view Measure plan and connections 6 WG-115 Oil scheme 6 WG-115 -Forward 1st gear - Wheel scheme 6 WG-115 Power flow 6 WG-115 -Forward gears- Power flow 6 WG-115 -Reverse gears - Electro- hydraulic gear shifting with proportional valve...
  • Page 153 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme TECHNICAL DATA Engine power: max. KW ---------------------------- Turbine moment: max. Nm ---------------------------- 750* Engine speed: max. min ---------------------------- 2 600* Starting torque multiplication: ---------------------------- 1,7 to 3,0 Engine-dependent Power take-offs: Torque: ---------------------------- Speed: ---------------------------- 1 x n Engine Mass (without oil): kg about...
  • Page 154 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme Transmission accessories: Upon request, the transmissions can be additionally equipped with the following components: - Emergency steering pump with a feed rate off 16 cm /rev. or 32 cm /rev. - Electronic speedometer signal for: - Construction site vehicles here, the Electronic unit EST-37 offers a speedometer signal.
  • Page 155 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme INSCRIPTIONS ON A ZF-MODEL INDENTIFICATION PLATE FOR ZF-HYDROMEDIA-REVERSING -TRANSMISSION Gearbox type Gearbox Serial-No. ZF-Parts List-No. Total ratio of the Gearbox Oil (Oil specification) List of lubricants Oil capacity Customer no. NOTES REGARDING THE SPARE PARTS ORDERS: When ordering genuine ZF-Spare Parts, please indicate: 1.
  • Page 156 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme IMPORTANT INSTRUCTIONS Oil level check (see 4.2): In the cold start phase, the engine must be running about 2 – 3 minutes at idling speed and the marking on the oil dipstick must then be lying above the cold start mark.
  • Page 157 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme At stopped engine, there is on the Controller, despite a preselected gear, no po- wer flow between transmission and engine, i.e. the transmission is in the idling position. The parking brake must therefore be completely actuated ! When leaving the vehicle, secure it additionally by brake blocks ! The towing speed must in no case be higher than 10 km/h, the towing distance not longer than 10 km.
  • Page 158 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme DESCRIPTION Function of the Converter: Function of a hydrodynamic Torque converter (Schematic view) = Torque of the wheel Turbine Impeller Impeller = Torque of the Turbine wheel = Torque of the Reaction member (Stator) from the Engine to the Transmission...
  • Page 159 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme The stator (reaction member) following the turbine, has the task to reverse the oil, which is streaming out of the turbine once more and to deliver it under the suitable discharge direction to the impeller. Due to the reversion, the stator is receiving a reaction torque.
  • Page 160 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme At closed WK, the slip between impeller and turbine wheel, and with it the hydraulic loss in the converter is equal to „Zero“ (see Figure-No. 1.2 B1). The WK will be automatically shifted dependent on the turbine speed. The pressure oil (15 + 1 bar) for the closing of the WK, is directed via a solenoid shift valve (see Figure-No.
  • Page 161 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme ZF-Fine filter: Filtration ratio according to ISO 4572: ß > 75 ß = 25 ß = 5.0 Filter surface at least: 6700 cm Dust capacity according to ISO 4572 at least: 17 g The six clutches of the transmission are selected via the 6 proportional valves P1 to P6. The proportional valve (pressure regulator unit) is composed of pressure regulator (e.g.
  • Page 162 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme Speed range selector 1.5.1 General: In view of the great variety of available speed range selectors, the precise technical data must be taken from the respective installation drawing. 1.5.2 Speed range selector DW-3 see table-11 The selector is designed for being mounted left to the steering column.
  • Page 163 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme Automatic shifting forward gears 1 to 6. Automatic shifting reverse gears 1. For reversing to manual operation, there are two options: Activating the function pushbutton (remaining in the actual gear). Selecting a lower or higher gear by touching the gear selector lever to the left (-) or the right (+).
  • Page 164 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme Pushbutton switch D7 Figure-No.: 1.5.4 The individual pushbuttons are lettered as follows: = 1. Gear - Forward = Automatic = 2. Gear – Forward = Neutral = 3. Gear – Forward = Reverse Display 1.6.1 General: Because the Display can be used with all Controller types, as e.g.
  • Page 165 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme DISPLAY left central right Side Side Side Figure-No.: 1.6.2 Display of the Driving direction: V or F: Vorwärts / Forward (right Side Neutral Reverse Display 1, 2, ... 6 Display of the engaged gear: (central Side) Waiting for Controller-Neutral: Indication on the Display: NN (central and right Side).
  • Page 166 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme Error display: If the system is recognizing an error, the spanner (Spe- cial symbol „g“) is flashing. If Neutral is preselected on the Controller, a two-digit error number appears on the two alphanumeric display positions (central and right Side). If more than one error is pending, the different error numbers will be indicated one after the other on the Display in cycles (about 1 second).
  • Page 167 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme Since there are different Software versions for the Customers, the listing of the error codes must be taken from the Documentation of the Vehicle Manufacturer. First Number Meaning of the Number 1 hex Digital input signal 2 hex Analog input signal 3 hex...
  • Page 168 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme Due to the great number of the available TCU, the exact Technical Data must be taken from the respective installation drawing. Installation position of the TCU 90° 90° 90° 90° Figure-No.: 1.7 B1 The installation position of the TCU can be at random. As an advantage, the ZF re- commends the Version illustrated in the Figure-No.
  • Page 169 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme Installation dimensions of the TCU ZF-Typ plate Minimum Distance to disengage the plut Figure-No.: 1.7 B2 Elektronic Control for ZF-Powershift transmissions: 1.8.1 General: Because of the different configurations of the electronic transmission controls at the various vehicles, the corresponding documentation must be taken from the operating Instructions of the Vehicle Manufacturer or from the Data sheets of the respective Parts List Versions.
  • Page 170 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme 1.8.2 Description of the Basic functions: The Powershift transmission of the Ergopower-Series 6 WG-115 is equipped with the Elect- ronic control EST-37, developped for it. For Dumpers, Graders and Crane vehicles, the ZF has developped with the Controllers VST-3, DW-3 and D7 a special Controller configuration.
  • Page 172 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme Afer a replacement of the transmission, the electrohydraulic control or the TCU in the vehicle, the Aeb-Cycle must be as well carried out again. The AEB-Cycle continues for about 3 to 4 minutes. The determined filling parameters are stored in the EEProm of the Electronics.
  • Page 173 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme Axle disconnection: The output is realised via an integrated transfer gearbox. Here, on the converter side, the out- put can be equipped with an axle disconnection device so that, depending on the application, the axle (front or rear axle) can be connected or disconnected. Fig.-No. 1.9 B1 shows the dis- connection of the front axle.
  • Page 174 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme Legend to Fig.-No. : 1.9 B1: VA = Output front axle (converter side) HA = Output rear axle = Output shaft for front axle = K3-Spur gear – Input = Output shaft for rear axle = Shift fork = Pneumatic or hydraulic connection and disconnection of the front axle = Connection for pneumatic or hydraulic operation of the axle disconnection...
  • Page 175 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme II. INSTALLATION SPECIFICATION This Specification for the installation of hydrodynamic Powershift transmissions of the Ergo- power-Series is the basis for the technically faultless installation of these transmissions in the vehicle. The Installation Specification is part of the Transmission Documentation and must be absolutely respected.
  • Page 176 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme III. OPERATION Driving preparation and Maintenance: Prior to the commissioning of the transmission, take care that the prescribed oil grade will be filled in with the correct quantity. At the initial filling of the transmission has to be considered that the oil cooler, the pressure filter as well as the pipes must get filled with oil.
  • Page 177 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme At the start off, the converter takes over the function of a master clutch. On a level road it is possible to start off also in higher gears. - Upshifting under load. Upshifting under load will be then realized if the vehicle can continue to accelerate by it. - Downshifting under load.
  • Page 178 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme Transmission control in the Driving mode Automatic: Precise informations about the design of the Controllers as well as the speeds shifted in the single driving ranges, must be taken from the Operating Instructions belon- ging to the vehicle. A manual intervention into the automatic shifting sequence is only then practical if the road condition or the form of the terrain is suitable.
  • Page 179 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme MAINTENANCE 4.1. Oil grade: Permitted for the Powershift transmissions 6 WG-115 are oils according to ZF-List of lubricants TE-ML 03. This List of lubricants will be updated every two years and can be requested, resp. inspected as follows: - At all ZF-Plants - At all ZF-Service Stations...
  • Page 180 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme Figure-No.: 4.2 B1 Legend: 1 = Oil filler tube with oil dipstick 2 = Oil drain plug M38x1,5 3 = Exchange filter (ZF-Fine filter) 4 = Possible installation position for oil-dipstick – and tube (pipe) Ölmeßstab COLD MIEASURED AT LOW...
  • Page 181 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme - Fill in oil (about 21 liters) according to ZF-List of lubricants TE-ML 03 . (Sump capacity, external oil capacities e.g. in the cooler, in the lines etc. are dependent on the vehicle. The indicated value is a guide value. It is imperative to pay attention to absolute cleanliness of oil and filter ! Binding is in any case the marking on the oil dipstick ! - Start the engine –...
  • Page 182 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme ZF-DIAGNOSTIC SYSTEMS General: The Control electronics EST-37 for the Transmission Series Ergopower is equipped with a diagnostic package, which makes the Trouble shouting and the elimination of Repairs easier for the Service. The Electronics is able to monitor the states of certain inputs and outputs. If the Electronics recognizes during it an error, it stores an error code in the fault storage (EEPROM) and is transmitting the error code also to the vehicle controller of the Vehicle Ma- nufacturer.
  • Page 183 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme Laptop Version: Specialized Dealers Pentium Latop min. 90 MHz Windows 95/98 or NT Basic-Software Testman WIN 95/98 or NT 6008 308 901 RS-232 Connecting cable Laptop ⇔ DPA-04I Diagnostic set 5870 221 179 6008 308 601 WIN 95/98 Programming adapter DPA-04I...
  • Page 184 Geschäftsbereich ERGOPOWER Arbeitsmaschinen-Antriebe und Achssysteme ZF-Multi-System 5000: Multi- System 5000 Measuring box with corresponding sensor sys- tem for pressure, temperature and speed without printer. 5870 221 280 Multi- System 5000 Measuring box with corresponding sensor sys- tem for pressure, temperature and speed with printer.
  • Page 185 0 7 3 0 7 4 9 1 8 4 ( O Z ) E . I . 1 3 1 3 3 0 4 0 4 3 0 7 3 0 7 4 9 1 8 4 ( O Z ) E .
  • Page 202 Order No.: 5871 146 002 ZF – ERGOPOWER 6 WG-115 ZF Passau GmbH Donaustr. 25 - 71 D- 94 034 Passau...

  • Page 203: Zf Repair Manual

    REPAIR MANUAL ZF - ERGOPOWER 6 WG-115 I M P O R T A N T I N F O R M A T I O N : Due to the great variety of ZF units it is necessary to limit disassembly and reassembly manuals to a current ZF production unit.
  • Page 204 T A B L E O F C O N T E N T S Chapt./Page Preface 0/2 ... 3 General Denomination of standard dimensions Conversion table Tightening torques for screws Labeling of identification plate and notes on spare parts ordering 0/8 ...
  • Page 205 T A B L E O F C O N T E N T S Chapt./Page DISASSEMBLY - Clutches KV/KR/K1/K2/K3/K4 input and 8.1/1 ... 8.8/1 output shaft KV clutch 8.1/1 … 3 KR clutch 8.2/1 … 3 K1 clutch 8.3/1 … 2 K2 clutch 8.4/1 …...
  • Page 206 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems PREFACE This documentation has been developed for specialized staff trained by ZF Passau for repair and maintenance work to be made on ZF units. This documentation describes a ZF series product with a design level valid at the date of edition.
  • Page 207 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems GENERAL The Service Manual covers all work required for disassembly and the relating reassembly. When repairing the unit, ensure utmost cleanliness and that the work is done in a professional manner. Dismantle the unit only if any damaged parts must be replaced.
  • Page 208 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Structure of Service Manual The structure of this manual reflects the sequence of the work steps for completely disassembling the dismantled unit.
  • Page 209 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems BEZEICHNUNG DER GESETZLICHEN EINHEITEN DENOMINATION OF STANDARD DIMENSIONS DÉNOMINATION DES DIMENSIONS STANDARDISÉES Hinweis : längenbezogene Masse in kg/m; flächenbezogene Masse in t/m Note : linear density in kg/m;...
  • Page 210 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems VERGLEICHSTABELLE FÜR MASSEINHEITEN CONVERSION TABLE TABLEAU DE CONVERSION 25.40 mm 1 in ( inch) 1 kg ( kilogram ) 2.205 lb ( pounds ) 9.81 Nm ( 1 kpm ) 7.233 lbf x ft ( pound force foot) 1.356 Nm ( 0.138 kpm )
  • Page 211 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems TIGHTENING TORQUES FOR SCREWS (in Nm) ACC. TO ZF STANDARD 148 Friction coefficient: µ tot.= 0.12 for plugs and nuts without rework, as well as phosphated nuts. Tighten manually! Take tightening torques from the following chart, unless otherwise specified: Metric ISO standard thread DIN 13, page 13 Dimension...
  • Page 212 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems LABELING OF IDENTIFICATION PLATE FOR ZF POWERSHIFT TRANSMISSION Transmission type Transmission number ZF parts list number Overall transmission ratio Oil filling (oil specification) ZF List of Lubricants Oil fill quantity Customer number...
  • Page 213 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems CONFIGURATION 6 WG-115 1 = Input flange - drive via prop shaft 2 = Converter 3 = Inductive sensor for engine speed 4 = Transmission pump 5 = Clutch shaft „KR“...
  • Page 214 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Legend: KV = Forward clutch KR = Reverse clutch K1 = 1st gear clutch K2 = 2nd gear clutch K3 = 3rd gear clutch K4 = 4th gear clutch AN = Input AB = Output...
  • Page 215 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems MEASURING POINTS AND CONNECTIONS 6 WG-115 Carry out measurements when the transmission has reached operating temperature (approx. 80° - 90° C) ! DENOMINATION OF ITEM CONNECTION DESIGNATION AT...
  • Page 216 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems NOTES ON THE REQUIRED OIL GRADE: Approved oils for 6 WG-115 powershift transmissions see ZF List of Lubricants TE-ML 03. The list of lubricants is being continuously updated and can be obtained or viewed as follows: - at all ZF plants...
  • Page 217 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems LIST OF SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY ERGOPOWER 6 WG -115 4656 006 012 Disassembly Reassembly Designation and application Part Number Chapter/Figure Chapter/Fig.
  • Page 218 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems LIST OF SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY ERGOPOWER 6 WG -115 4656 006 012 Disassembly Reassembly Designation and application Part Number Chapter/Figure Chapter/Fig.
  • Page 219 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems LIST OF SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY ERGOPOWER 6 WG -115 4656 006 012 Disassembly Reassembly Designation and application Part Number Chapter/Figure Chapter/Fig.
  • Page 220 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems LIST OF SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY ERGOPOWER 6 WG -115 4656 006 012 Disassembly Reassembly Designation and application Part Number Chapter/Figure Chapter/Fig.
  • Page 221 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems LIST OF SPECIAL TOOLS FOR DISASSEMBLY AND REASSEMBLY ERGOPOWER 6 WG -115 4656 006 012 Disassembly Reassembly Designation and application Part Number Chapter/Figure Chapter/Fig.
  • Page 222 5870 970 004 5870 900 013 ZF - ERGOPOWER 6 WG/115 MOTORANSCHLUSS ENGINE CONNECTION Spezial 4656 006 012 230V 115V 5870 221 500 5870 221 501 5870 057 010 5870 260 002 5870 204 002 5870 281 047 ZF Passau GmbH Donaustraße 25-71 94034 Passau Ausgabe:/Edition: 09/2005...
  • Page 223 5873 011 014 5873 001 058 5873 001 000 5870 900 015 ZF - ERGOPOWER 6 WG/115 ANTRIEB / INPUT 4656 006 012 Spezial ODER / OR ODER / OR 5870 204 002 5870 281 047 5870 204 007 5873 011 014 5873 001 058 5870 026 100 ZF Passau GmbH Donaustraße 25-71 94034 Passau...
  • Page 224 5870 280 004 ZF - ERGOPOWER 6 WG/115 GETR. GEHAEUSE GEARBOX HOUSING Spezial 4656 006 012 5870 204 011 0636 804 003 0664 462 774 5870 281 047 5870 350 000 5870 350 062 5870 350 090 ZF Passau GmbH Donaustraße 25-71 94034 Passau Ausgabe:/Edition: 09/2005...
  • Page 225 5870 260 010 5873 001 057 5873 011 011 5870 026 100 ZF - ERGOPOWER 6 WG/115 KUPPLUNG K1 COUPLING K1 Spezial 4656 006 012 ODER / OR ODER / OR 230V 115V 5873 001 057 5873 011 011 5870 026 100 5870 221 500 5870 221 501 5870 970 004...
  • Page 226 5870 260 010 5870 026 100 5873 001 057 5873 011 011 ZF - ERGOPOWER 6 WG/115 KUPPLUNG K2 COUPLING K2 Spezial 4656 006 012 ODER / OR ODER / OR 230V 115V 5873 001 057 5873 011 011 5870 026 100 5870 221 500 5870 221 501 5870 970 004...
  • Page 227 5873 011 014 5873 001 058 5870 026 100 ZF - ERGOPOWER 6 WG/115 KUPPLUNG K3 COUPLING K3 Spezial 4656 006 012 ODER/OR ODER / OR 230V 115V 5873 001 057 5873 011 011 5870 026 100 5870 221 500 5870 221 501 5870 970 004 5870 260 010...
  • Page 228 5870 260 010 5870 900 015 5870 026 100 5873 001 057 5873 011 011 ZF - ERGOPOWER 6 WG/115 KUPPLUNG K4 COUPLING K4 Spezial 4656 006 012 ODER / OR ODER / OR 230V 115V 5873 001 057 5873 011 011 5870 026 100 5870 221 500 5870 221 501...
  • Page 229 5870 345 089 5870 280 007 ZF - ERGOPOWER 5873 011 011 5873 001 057 5870 026 100 6 WG/115 KUPPLUNG KV COUPLING KV Spezial 4656 006 012 ODER/OR ODER / OR ODER / OR 230V 115V 5870 260 010 5873 001 057 5873 011 011 5870 026 100...
  • Page 230 5870 950 101 5870 287 007 ZF - ERGOPOWER 6 WG/115 FESTSTELLBREMSE PARKING BRAKE Spezial M12x1,5 4656 006 012 ZF Passau GmbH Donaustraße 25-71 94034 Passau Ausgabe:/Edition: 09/2005...
  • Page 231 5870 260 010 ZF - ERGOPOWER 5873 011 011 5873 001 057 5870 026 100 6 WG/115 KUPPLUNG KR COUPLING KR Spezial 4656 006 012 ODER/OR ODER / OR ODER / OR 230V 115V 5873 001 057 5873 011 011 5870 026 100 5870 300 028 5870 900 015...
  • Page 232 5870 048 057 5870 260 002 5870 057 011 ZF - ERGOPOWER 6 WG/115 ABTRIEB / OUTPUT 4656 006 012 Spezial ODER/OR 5870 260 002 5870 057 011 5873 011 014 5873 001 058 5873 001 000 ZF Passau GmbH Donaustraße 25-71 94034 Passau Ausgabe:/Edition: 09/2005...
  • Page 233 5870 204 063 ZF - ERGOPOWER 6 WG/115 SCHALTUNG / GEARSHIFT SYS. 4656 006 012 Spezial 10 - 90 Nm 1/2” 1/2”-1/4” 1 - 12 Nm 5870 042 004 5870 203 034 5870 656 056 5870 203 031 5873 042 002 ZF Passau GmbH Donaustraße 25-71 94034 Passau Ausgabe:/Edition: 09/2005...
  • Page 234 ZF - ERGOPOWER 6 WG/115 SCHALTUNG / GEARSHIFT SYS. 4656 006 012 Spezial 5,5Nm 5,5Nm 5,5Nm 1/2” 1/2”-1/4” 1 - 12 Nm 5873 042 002 5870 656 056 5870 203 031 5870 204 036 5870 204 063 ZF Passau GmbH Donaustraße 25-71 94034 Passau Ausgabe:/Edition: 09/2005...
  • Page 235 5870 345 107 ZF - ERGOPOWER 6 WG/115 DRUCKREGLER / PRESSURE REGULATOR Spezial 4656 006 012 ZF Passau GmbH Donaustraße 25-71 94034 Passau Ausgabe:/Edition: 09/2005...
  • Page 236 ZF - ERGOPOWER 6 WG/115 DRUCKOELPUMPE PRESS. OEL PUMP Spezial 4656 006 012 5870 055 070 5870 260 002 5870 280 004 ZF Passau GmbH Donaustraße 25-71 94034 Passau Ausgabe:/Edition: 09/2005...
  • Page 237 ZF - ERGOPOWER 6 WG/115 NOTLENKPUMPE EMERGENCY STEERING PUMP Spezial 4656 006 012 5870 048 080 ZF Passau GmbH Donaustraße 25-71 94034 Passau Ausgabe:/Edition: 09/2005...
  • Page 238 ZF - ERGOPOWER 6 WG/115 FILTER Spezial 4656 006 012 23Nm 10-90Nm 5873 042 004 5870 203 034 5870 105 005 ZF Passau GmbH Donaustraße 25-71 94034 Passau Ausgabe:/Edition: 09/2005...
  • Page 239 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems DISASSEMBLY: Electro-hydraulic control ZF fine filter (replaceable filter) Attach transmission to assembly truck. (S) Assembly truck 5870 350 000 (S) Holding fixtures 5870 350 063 (S) Clamping angles 5870 350 090...
  • Page 240 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Removal of electric gear-shift control Remove gear-shift control (1). Loosen Torx screws (2) and separate gear-shift control housing from intermediate plate. (S) Socket wrench TX-27 5873 042 002 (S) Adjusting screws M6...
  • Page 241 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Pull converter safety valve (1) out of housing hole. Figure 8 Mark installation position of wiring harness (1) towards valve block (2).
  • Page 242 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Remove retaining clamp (1). Figure 12 Loosen Torx screws (1) and remove cover (2). Remove opposite cover (3) in the same way. (S) Socket wrenchTX-27 5873 042 002 Figure 13...
  • Page 243 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Loosen two Torx screws (1) and preliminarily fix housing by means adjusting screws (S). (Housing is spring-loaded.) Then loosen remaining Torx screws. (S) Adjusting screws 5870 204 036 Figure 16...
  • Page 244 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems DISASSEMBLY: Inductive sensor, Hall sensor, breather, oil filler and oil drain plug Attach transmission to assembly truck. (S) Assembly truck 5870 350 000 (S) Holding fixtures 5870 350 063...
  • Page 245 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems DISASSEMBLY: Engine connection, oil pressure pump, converter back-pressure valve and temperature sensor (measuring point “63“ after the converter). Engine connection (direct mount) Loosen hexagon screw (2) and separate flexplate (1) from converter (3).
  • Page 246 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Separate cover from converter bellhousing by means of lifting device. (S) Eye bolts assortment 5870 204 002 (S) Lifting chain 5870 281 047 Figure 4 Pull off output flange.
  • Page 247 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Loosen hexagon screws (1) and remove flexplate (2) from converter. Figure 8 Loosen hexagon screws (1) and remove flexplate (2) from input shaft (3).
  • Page 248 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Separate oil pressure pump (1) from oil feed housing (2). (S) Hammer 5870 280 004 Figure 12 Loosen both cylindrical screws (1) and remove control disk. In case of wear marks in the pump housing or on the control disk, the oil pressure pump assy must be replaced.
  • Page 249 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Remove individual parts of converter safety valve which are getting released. 1 = Pressure plate 2 = Compression spring 3 = Piston Figure 16 Remove temperature sensor (1).
  • Page 250 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems DISASSEMBLY - Emergency steering pump Version without emergency steering pump Loosen bolted connection (1) cover/housing front part and remove cover (2) and seal. Figure 1 Version with emergency steering pump Loosen cylindrical screws (1) and separate emergency steering...
  • Page 251 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems DISASSEMBLY - Outputs Output flange on converter side Remove locking plate (1), loosen hexagon screws, remove washer and O-ring. Figure 1 Pull off output flange (1) and remove shaft seal (2).
  • Page 252 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Output flange on output side with parking brake Connect HP pump at port (1) and apply approx. 80 bar pressure to the hydraulically actuated parking brake (2) until the brake disc (3) can be rotated by hand.
  • Page 253 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems DISASSEMBLY - PTO Loosen hexagon screws (1) and remove cover (2). Figure 1 Take O-ring (1) out of cover and loosen cylindrical screws (2). Figure 2 Remove flange (1) and O-ring (2).
  • Page 254 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Press ball bearing (1) off the pump shaft. Figure 5 5871 146 002...
  • Page 255 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Removal of input shaft, output shaft and clutches Force out both cylindrical pins (1). Loosen bolted connection (2) between housing front and rear part and separate housing rear part by means of lifting device.
  • Page 256 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Use lifting device to bring housing rear part (1) into contact position with housing front part (2) again. (S) Lifting chain 5870 281 047 (S) Eye bolt M20 0636 804 003...

  • Page 257: Kr Clutch 8.2/1

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Remove bearing outer rings (arrows) from the housing front part. If, contrary to the ZF recommendation, the tapered roller bearings of clutches, input and output are not replaced, it is imperative to ensure the previous pairing (bearing outer ring/ bearing inner ring).

  • Page 258: Kr Clutch

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems DISASSEMBLY: Clutches KV / KR / K1 / K2 /K3, input and output shaft See opposite picture. K1 = clutch K2 = clutch K3 = clutch K4 = clutch...
  • Page 259 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Snap out retaining ring (1) . (S) Set of external pliers 5870 900 015 Figure 5 Fix idler gear (1) by means of cut-off device (S) and press it off the clutch shaft (2) .
  • Page 260 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Turn shaft (2) by 180° and snap out piston ring (1). Figure 9 Pull tapered roller bearing (inner ring) off the shaft. (S) Forcing device 5870 026 100 (S) Grab sleeve...
  • Page 261 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems KR clutch Remove stud bolt (1) and snap out piston ring (2). Figure 1 Pull tapered roller bearing (inner ring) off the shaft. (S) Forcing device 5870 026 100 (S) Grab sleeve...
  • Page 262 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Fix idler gear (1) by means of cut-off device (S) and press it off the clutch shaft (2). (S) Cut-off device 5870 300 028 Figure 5 Snap retaining ring (2) out of the idler gear (1) and remove ball...
  • Page 263 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Pull tapered roller bearing (inner ring) off the shaft. (S) Forcing device 5870 026 100 (S) Grab sleeve 5873 001 057 (S) Rapid grip 5873 011 011 Figure 9...
  • Page 264 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems K1 clutch Remove stud bolt (1) and snap out piston ring (2). Figure 1 Pull tapered roller bearing (inner ring) off the shaft. (S) Forcing device 5870 026 100 (S) Grab sleeve...
  • Page 265 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Take off idler gear (1), remove needle cage (2) and axial bearing assy (3). Figure 5 Pull clutch (1) off the shaft. (S) Two-armed puller 5870 970 004 Figure 6...

  • Page 266: K2 Clutch

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems K2 clutch Remove stud bolt (1) and snap out piston ring (2). Figure 1 Pull tapered roller bearing (inner ring) off the shaft. (S) Forcing device 5870 026 100 (S) Grab sleeve...
  • Page 267 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Take off idler gear (1), remove needle cage (2) and axial bearing assy (3). Figure 5 Pull clutch (1) off the shaft. (S) Two-armed puller 5870 970 004 Figure 6...
  • Page 268 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems K3 clutch Remove stud bolt (1) and snap out piston ring (2). Figure 1 Pull tapered roller bearing (inner ring) off the shaft. (S) Forcing device 5870 026 100 (S) Grab sleeve...
  • Page 269 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Pull clutch (1) off the shaft. (S) Two-armed puller 5870 970 004 Figure 5 Turn shaft (2) by 180° and snap out piston ring (1). Figure 6 Pull tapered roller bearing (inner ring) off the shaft.

  • Page 270: K4 Clutch

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems K4 clutch Remove stud bolt (1) and snap out piston ring (2). Figure 1 Pull tapered roller bearing (inner ring) off the shaft. (S) Forcing device 5870 026 100 (S) Grab sleeve...
  • Page 271 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Remove axial bearing assy (1) and idler gear (2). Figure 5 Remove needle cage (1) and axial bearing assy (2). The gear (3) cannot be removed (shrink fit)! Figure 6 Turn shaft (2) by 180°...

  • Page 272: Input Shaft

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Input shaft Snap out piston ring (1). Turbine wheel shaft (2) and drive gear (3) are fixed by a snap ring.

  • Page 273: Output Shaft

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Output shaft Pull tapered roller bearing (inner ring) off the output shaft and remove oil screen sheet (1). (S) Basic tool 5873 001 000 (S) Grab sleeve 5873 001 058...
  • Page 274 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems REASSEMBLY - Clutches KV / KR / K1 / K2 / K3 / K4 input and output shaft: General: In the EST-37A (electronic transmission control), the shifting operations (filling times and pressure level) are controlled via the driving program of the transmission electronics.
  • Page 275 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems KV clutch Press tapered roller bearing (inner ring) (1) onto the shaft (2) until contact is obtained. Figure 1 Install piston ring (1). Figure 2 Mount needle bearing (1) onto the shaft.
  • Page 276 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Press in preassembled idler gear (1) until contact is obtained. Figure 5 Fix idler gear (1) by means of retaining ring (2). (S) Set of external pliers 5870 900 015 Figure 6...
  • Page 277 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Press tapered roller bearing (inner ring) (1) until contact is obtained. Figure 9 Mount stud bolt (1). Tightening torque (M10 /8.8 x15)....= 17 Nm Check closing and opening of the clutch by means of compressed air at the hole (2).
  • Page 278 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems KR clutch Press tapered roller bearing (inner ring) (1) onto the shaft (2) until contact is obtained. Figure 1 Install piston ring (1). Figure 2 Mount needle bearing (1) onto the shaft.
  • Page 279 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Press in preassembled idler gear (1) until contact is obtained. Figure 5 Fix idler gear (1) by means of retaining ring (2). (S) Set of external pliers 5870 900 015 Figure 6...
  • Page 280 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Press tapered roller bearing (inner ring) (1) until contact is obtained. Figure 9 Mount stud bolt (1). Tightening torque (M10 /8.8 x15)....M = 17 Nm Check closing and opening of the clutch by means of compressed air at the hole (2).
  • Page 281 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems K1 clutch Press tapered roller bearing (inner ring) (1) onto the shaft until contact is obtained. Figure 1 Install piston ring (1). Figure 2 Heat up clutch inner diameter (approx.
  • Page 282 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Mount running disk (1), axial cage (2) and axial washer (3). Chamfer Install chamfer (see arrow) of running disk (1) showing towards the axial cage! Figure 5 Mount needle cage (1).
  • Page 283 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Fix idler gear (1) and single parts by means of retaining ring (2). (S) Set of external pliers 5870 900 015 Figure 9 Press tapered roller bearing (inner ring) (1) until contact is obtained.
  • Page 284 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems K2 clutch Press tapered roller bearing (inner ring) (1) onto the shaft until contact is obtained. Figure 1 Install piston ring (1). Figure 2 Heat up clutch inner diameter (approx.
  • Page 285 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Mount running disk (1), axial cage (2) and axial washer (3). Chamfer Install chamfer (see arrow) of running disk (1) showing towards the axial cage! Figure 5 Mount needle cage (1).
  • Page 286 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Fix idler gear (1) and single parts by means of retaining ring (2). (S) Set of external pliers 5870 900 015 Figure 9 Press tapered roller bearing (inner ring) (1) until contact is obtained.
  • Page 287 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems K3 clutch Press tapered roller bearing (inner ring) (1) onto the shaft until contact is obtained. Figure 1 Install piston ring (1). Figure 2 Mount stud bolt (1).
  • Page 288 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Mount clutch (1) until contact is obtained. Wear protective gloves! Figure 5 Mount running disk (1), axial cage (2) and axial washer (3). Chamfer Install chamfer (see arrow) of running disk (1) showing towards the axial cage!
  • Page 289 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Press tapered roller bearing (inner ring) (1) until contact is obtained. Figure 9 Check closing and opening of the clutch by means of compressed air at the hole (1).
  • Page 290 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems K4 clutch Press tapered roller bearing (inner ring) (1) onto the shaft (2) until contact is obtained. Figure 1 Install piston ring (1). Figure 2 Undercool shaft (1) (approx.
  • Page 291 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Mount lower axial washer (1), axial needle cage (2) and upper axial washer (1). Upper and lower axial washer are identical (50 x 70 x 1)! Figure 5 Mount both needle bearings (1).
  • Page 292 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Heat up clutch inner diameter (approx. 120 ° C). (S) Hot-air blower 230 V 5870 221 500 (S) Hot-air blower 115 V 5870 221 501 Figure 9 Mount clutch (1) until contact is obtained and fix it by retaining...
  • Page 293 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Input shaft Undercool input shaft (1) (approx. -80°C), heat up drive gear (2) (approx. +120° C) and mount until contact is obtained. Wear protective gloves! Figure 1 Secure drive gear by means of retaining ring 90x3 (1).
  • Page 294 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Install snap ring SB 38 (1) into the annular groove (2) of the turbine shaft. Figure 5 Mount turbine shaft (1) until the snap ring engages into the input shaft groove.
  • Page 295 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Output shaft Press tapered roller bearing (inner ring) (1) onto the output shaft until contact is obtained. Figure 1 Mount screen sheet (2) and press tapered roller bearing (inner ring) (1) onto the output shaft until contact is obtained.

  • Page 296: Installation Of Input Shaft, Output Shaft And Clutches

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Installation of input shaft, output shaft and clutches If the suction tube (1) in the housing front part is to be replaced, it is imperative to use the ZF special tool (rolling tool) for assembly.
  • Page 297 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Insert all bearing outer rings into the bearing holes of both housing parts. Housing front part AN = Input AB = Output KV = Forward clutch KR = Reverse clutch K1 = 1st gear clutch...
  • Page 298 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Mount K3 clutch. Figure 9 Position K2 clutch. Figure 10 Slightly lift K4 clutch and position K1 clutch. Figure 11 The figure again shows the installation position of the individual clutches in the housing rear part.
  • Page 299 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Rotate housing rear part by 180°, install eye bolts and eye nuts. (S) Lifting chain 5870 281 047 (S) Eye nuts (M12) 0664 462 774 (S) Eye bolts 2x (M20) 0636 804 003...
  • Page 300 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Fix screen sheets by means of cylindrical screws (1). Tightening torque (M8/8.8x12) ....M = 23 Nm Mount O-rings 22x3 (2) into the annular groove of the oil tubes and oil them.
  • Page 301 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Fix housing front and rear part by means of cylindrical screws (1). Tightening torque (M10/8.8x65) ....M = 46 Nm Tightening torque (M10/8.8x40) ....

  • Page 302: Reassembly - Pto

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems REASSEMBLY - PTO Press ball bearing (1) onto the pump shaft (2) until contact is obtained. Figure 1 Mount rectangular ring 50x2 (1). Grease and centrically align rectangular ring.
  • Page 303 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Place cover plate (1) onto the flange and fix it by means of hexagon screws (2). Tightening torque (M16/8.8x20)……....M = 46 Nm Figure 5 5871 146 002...

  • Page 304: Reassembly - Outputs

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems REASSEMBLY - Outputs 12.1 Output flange on output side without parking brake Use driver (S) to mount shaft seal, with the sealing lip showing to the oil sump.

  • Page 305: Output Flange On Output Side With Parking Brake 12/3

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems 12.2 Output flange on output side with parking brake Use driver to mount shaft seal, with the sealing lip showing to the oil sump.

  • Page 306: Output Flange On Converter Side

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Connect HP-pump to port (1), apply approx. 80 bar pressure to parking brake (2) and position it until contact with the bracket is obtained.
  • Page 307 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Mount output flange (1) until contact is obtained. Figure 13 Insert O-ring 38x4 into the space between output flange and shaft.

  • Page 308: Reassembly - Engine Connection, Oil Pressure Pump, Converter Back- Pressure Valve And Temperature Sensor

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems REASSEMBLY: Engine connection, oil pressure pump, converter back-pressure valve and temperature sensor (measuring point “63“ after the converter). 13.1 Converter back-pressure valve The figure shows the single parts of the converter back-pressure valve.

  • Page 309: Oil Pressure Pump

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems 13.2 Oil pressure pump Insert pressure relief valve (1) into the housing hole until contact is obtained. Mount two adjusting screws (S) and place gasket (2) and oil feed housing (3).
  • Page 310 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems With the sealing lip showing downwards, carefully insert the shaft seal (3) into the pump housing (1) until contact is obtained, and fix it by means of snap ring (2).
  • Page 311 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Mount preassembled pump (1) and, as a first step, insert it equally by means of cylindrical screws (3 pcs) until contact is obtained.

  • Page 312: Engine Connection (Direct Mount) 13/5

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems 13.3 Engine connection (direct mount) Position converter (1) by means of lifting device until contact is obtained. (S) Eye bolts assortment 5870 204 002 (S) Lifting chain 5870 281 047...
  • Page 313 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Install ball bearing (1) and fix it by means of V-ring JV 100 (2). (S) Set of internal pliers 5870 900 013 Figure 20 Put cover (1) onto the converter and press it until contact is obtained.
  • Page 314 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Mount input flange (1) until contact is obtained. Wear protective gloves! Figure 24 Fix input flange (3) by means of washer (1) and hexagon screws (2).
  • Page 315 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Bolt converter bellhousing (1) to cover (2) by means of cylindrical screws and hexagon nuts. Pay attention to radial installation position, see markings done during disassembly (arrows)! Tightening torque (M10/8.8) ....

  • Page 316: Version Without Emergency Steering Pump 14/1

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems REASSEMBLY Emergency steering pump 14.1 Version without emergency steering pump Fit adjusting screws (S) and assemble seal (1) and cover (2). Figure 1 Fix cover by means of hexagon screws (1).
  • Page 317 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Fit adjusting screws (S) and assemble seal (1) and cover (2). Figure 5 Fix cover (1) by means of Torx screws (2). Tightening torque (M8/10.9 x30) ....

  • Page 318: Reassembly - Inductive Sensor, Hall Sensor, Breather, Oil Filler And Oil Drain Plug

    Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Reassembly: Inductive sensor, Hall sensor, breather, oil filler and oil drain plug Mount inductive sensors (1, 2 and 3) with new O-rings 15x2. 1 = Inductive sensor - engine speed 2 = Inductive sensor - speed/central gear chain 3 = Inductive sensor - turbine speed...
  • Page 319 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Bring cover (1) with seal into contact position with the housing front part and fix it by means of hexagon screws (2). Tightening torque (M8/8.8x18).....M = 23 Nm Figure 4...
  • Page 320 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems REASSEMBLY: Electro-hydraulic control with proportional valves: Different versions regarding the wiring harness position are possible! Please observe the vehicle manufacturer's specifications! The following sketches show the sectional views of the electro-hydraulic control.
  • Page 321 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems 16.1 Fitting of electric control All single parts are to be checked for damage and replaced, if required! Ensure free travel of the moving parts in the valve block prior to installation! Pistons can be exchanged individually! Prior to the installation, oil single parts acc.
  • Page 322 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Bring housing (1) into contact position by means of the Torx screws. This will preload the pistons, and you can remove the cylindrical pins (assembly aid).
  • Page 323 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Install the single parts acc. to Figure 11. Preload compression springs of the follow-on slides and preliminarily fix pistons by means of cylindrical pins ∅ ∅ ∅ ∅ 5.0 mm (assembly aid), see arrows (S)! Fit two adjusting screws.
  • Page 324 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Place seal (1). With the groove showing to the cover plug nose, mount socket until contact is obtained. Fix cover by means of Torx screws. Tightening torque (M5/10.9x30)....
  • Page 325 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Put on intermediate plate (1). Screens (2) to show upwards! Figure 20 Place duct plate (1) and fix it equally by means of Torx screws (2).
  • Page 326 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Mount stud bolts (1). Wet screw-in thread with Loctite (type No. 243)! Tightening torque (M8/10.9x25) ....M = 15 Nm Place seal (2) and duct plate (3) at the housing rear part until contact is obtained.
  • Page 327 Corporate Division R e p a i r M a n u a l Off-Road Driveline Technology and Axle Systems Fix electro-hydraulic control unit (1) equally by means of Torx screws (2). Tightening torque (M6/10.9x76) ..... M = 12 Nm (S) Torque wrench 5870 203 031 (S) Reducing adapter...
  • Page 328 Functional characteristics and maintenance instructions TM 64/97 KNOTT Mechanical sliding caliper disc brake M 90 NOTE: The present Assembly Manual concerns the nonmodified Reprint of the Original Assembly of the Component Manufacturer. The ZF Passau GmbH is not liable in this connection for faulty Assembly Manuals, and is especially not responsible for the positive knowledge about a New Edition at the User of the Manual.
  • Page 329 Technical Information 64/97 Functional characteristics and maintenance instructions for mechanical sliding caliper M90 1. General 6. Assembly Prior to assembly make sure all parts are clean and serviceable. This data sheet covers important service procedures that apply to the M90A model brake. Refer to the exploded drawing as the steps are performed.
  • Page 330 Service Manual Section 5: Front Axle Service 2.00_2013.03...
  • Page 332 65E Turbo Motor Grader Section 5 Service Manual Front Axle SAFETY PRECAUTION INFORMATION UNSAFE OPERATING PRACTICES AND IMPROPER USE OF THE MACHINE AND ITS ATTACHMENTS ON THE PART OF THE OPERATOR OR SERVICE TECHNICIAN CAN RESULT IN INJURIES. OBSERVE THE FOLLOWING SAFETY PRECAUTIONS AT ALL TIMES: 1.
  • Page 333 Section 5 65E Turbo Motor Grader Front Axle Service Manual 15. Install all shields before starting or operating machine. 16. Do not operate an unsafe machine. If items are found during inspection that render a machine unsafe, be sure any malfunctions are remedied before accepting responsibility for operation.
  • Page 334 65E Turbo Motor Grader Section 5 Service Manual Front Axle 33. Remember that the vehicle, if abused or incorrectly used, can be dangerous and become a hazard to the operator and bystanders. 34. Noise levels can exceed recommended levels when working between buildings or in confined areas on canopy equipped machines or cab equipped machines with doors and windows open.
  • Page 335 Section 5 65E Turbo Motor Grader Front Axle Service Manual 50. After operating the engine, never touch the muffler, exhaust pipe, engine or radiator until they have had time to cool. 51. Dress appropriately - wear relatively tight-fitting clothing when operating or servicing the machine.
  • Page 336 65E Turbo Motor Grader Section 5 Service Manual Front Axle 65. Do not attempt to service air conditioning system, if equipped. It is possible to be severely frostbitten or injured by escaping refrigerant. Special equipment and instruments are required to service air conditioning system. See an authorized dealer for service.
  • Page 337 Section 5 65E Turbo Motor Grader Front Axle Service Manual 81. If welding is required on an attachment, remove the attachment from the machine. 82. Give complete and undivided attention to the job at hand so that complete control of the machine is maintained at all times.
  • Page 338 65E Turbo Motor Grader Section 5 Service Manual Front Axle OSHA REQUIREMENTS NOW MAKE IT THE EMPLOYER'S RESPONSIBILITY TO FULLY INSTRUCT EACH OPERATOR IN THE PROPER AND SAFE OPERATION OF ALL OPERATIVE EQUIPMENT. BOTH EMPLOYER AND EMPLOYEE SHOULD THOROUGHLY FAMILIARIZE THEMSELVES WITH THE MACHINE OPERATION.
  • Page 339 Section 5 65E Turbo Motor Grader Front Axle Service Manual This page intentionally left blank. Service 2.00_2013.03...
  • Page 340 65E Turbo Motor Grader Section 5 Service Manual Front Axle ONTENTS Front Axle, Steering And Articulation ......... . . 5-1 General .
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  • Page 342: Front Axle, Steering And Articulation

    65E Turbo Motor Grader Section 5 Service Manual Front Axle Section 5: Front Axle RONT TEERING RTICULATION General The motor grader can be turned using either the steering wheel or the articulation lever. Operated together, they provide a high degree of maneuverability. The steering wheel operates a steering valve, causing the front wheels to change angle.

  • Page 343: Wheel Lean

    Section 5 65E Turbo Motor Grader Front Axle Service Manual The frame pivots at the upper and lower articulation pins. Refer to Section 07, Hydraulics, for articulation cyl- inder replacement and overhaul procedures. Wheel Lean Wheel lean is provided to create an aggressive bite in soft terrain. Oil flow for wheel lean is controlled by a section on the main control valve.

  • Page 344: Troubleshooting

    65E Turbo Motor Grader Section 5 Service Manual Front Axle ROUBLESHOOTING Before starting the machine or its attachment for troubleshooting, check, adjust and lock the operator's seat. Ensure that no one is within the operating range of the machine. Sound the horn. Lower the attachment slowly.
  • Page 345 Section 5 65E Turbo Motor Grader Front Axle Service Manual Before disconnecting lines or fittings, make sure to turn off the engine and relieve all pressure. Before applying pressure to the system, make sure all connections are tight and that lines, pipes and hoses are not damaged.

  • Page 346: Troubleshooting Chart

    65E Turbo Motor Grader Section 5 Service Manual Front Axle Troubleshooting Chart Problem Possible Cause Correction Machine is hard to steer. Spindles will not rotate in axle Grease bushings. Low steering pressure Check steering operation. Vehicle wanders on ridged roads.

  • Page 347: Front Axle Adjustments

    Section 5 65E Turbo Motor Grader Front Axle Service Manual RONT DJUSTMENTS Front Axle Toe-In Step 6: Ensure tires are properly inflated to 172 kPa (25 psi). Block rear tires in both directions. Install wheel lean lock pin, 1. Raise the front wheels slightly off the ground using moldboard down functions.

  • Page 348: Steering Cylinder

    65E Turbo Motor Grader Section 5 Service Manual Front Axle Steering Cylinder IMPORTANT: Do not hold steering wheel against the lock. If steering relief valve goes over relief, release steering wheel slightly to prevent damage to components. Step 1: Operate engine and fully turn steering wheel to right.

  • Page 349: Front Wheel Bearings

    Section 5 65E Turbo Motor Grader Front Axle Service Manual Front Wheel Bearings Wheel bearings should be cleaned and the torque periodically checked. The external front wheel bearings, 5, can be serviced without removing the front wheel or hub. Refer to maintenance and lubrication section of Operator's Manual for time schedules.

  • Page 350: Front Axle Disassembly And Repair

    65E Turbo Motor Grader Section 5 Service Manual Front Axle RONT ISASSEMBLY AND EPAIR LH Steering Knuckle and King Pin Removal Step 1: Block rear tires in both directions. Install wheel lean lock pin. Using moldboard down function, raise front part of machine until front tires are above ground, then support front part of drawbar with suitable blocking, hoist, or lift.
  • Page 351 Section 5 65E Turbo Motor Grader Front Axle Service Manual Step 6: Remove cotter pin and crown nut, 1, securing steering cylinder socket, 2, to LH spindle, 3. Dismount socket end of steering cylinder, 4, from LH spindle, 3, and support steering cylinder.
  • Page 352 65E Turbo Motor Grader Section 5 Service Manual Front Axle KING PIN STEERING KNUCKLE FRONT AXLE NOTE: When the king pin is removed, the spindle can be separated from the steering knuckle. Step 8: Remove plugs, 1, 2, and o-ring, 3, from lower LH steering knuckle.

  • Page 353: Rh Steering Knuckle And King Pin Removal

    Section 5 65E Turbo Motor Grader Front Axle Service Manual RH Steering Knuckle and King Pin Removal Step 1: Apply previous steps 1 through 4 to RH steering knuckle and king pin. Step 2: Remove cotter pin and crown nut, 1, securing steer bar and RH socket link, 2, to RH spindle, 3.

  • Page 354: Lh Steering Knuckle And King Pin Installation

    65E Turbo Motor Grader Section 5 Service Manual Front Axle LH Steering Knuckle and King Pin Installation Step 1: Remove seals, 1, from bearings, 2, in LH wheel lean pivot pin, 3, bore. Discard seals. Step 2: Using a bearing driver and hammer, drive out bearings, 2.
  • Page 355 Section 5 65E Turbo Motor Grader Front Axle Service Manual Step 10: Start wheel lean pivot pin, 3, into axle wheel lean pivot pin bore, with set screw, 5, hole in steering knuckle in line with set screw hole in pivot pin. Align steering knuckle pivot pin bore with axle pivot pin bore, and drive pivot pin through both bores with rubber mallet, making certain that set screw holes align.
  • Page 356 65E Turbo Motor Grader Section 5 Service Manual Front Axle WHEEL LEAN PIVOT BAR Step 21: Install o-ring, 22, into LH rear of wheel lean pivot pin bore. Install inner plug, 23, with counter bore away from o-ring, 22. Install outer plug, 24, and tighten until outer plug is flush with inner plug, 23.
  • Page 357 Section 5 65E Turbo Motor Grader Front Axle Service Manual Step 24: Secure wheel lean pivot bar, 1, to LH steering knuckle, 2, with bolt, 3, washer, and nut. Torque bolt, 3, to 542.3-677.9 Nm (400-500 Ib-ft). Step 25: Install new nylon washer on steering cylinder socket, 4.
  • Page 358 65E Turbo Motor Grader Section 5 Service Manual Front Axle Step 28: Inspect inner bearing, 1, for damage. Replace, if necessary. Clean bearing, 1, bearing area, and spindle shaft, 2, of dirt and grease. Use a commercial solvent, as required. Pack bearing with wheel bearing grease NLGI2.

  • Page 359: Rh Steering Knuckle And King Pin Installation

    Section 5 65E Turbo Motor Grader Front Axle Service Manual Step 33: Install LH front wheel on hub, 3, with eight lug nuts, 10, and washers. Torque lug nuts to 440-475 Nm (325-350 Ib-ft). Step 34: Upon completion of RH Steering Knuckle and King Pin Installation procedure, perform front axle toe-in and steering cylinder adjustments in accordance with previous FRONT AXLE, ADJUSTMENTS procedures in this section.

  • Page 360: Lh Wheel Lean Pivot Pin Removal

    65E Turbo Motor Grader Section 5 Service Manual Front Axle LH Wheel Lean Pivot Pin Removal NOTE: NOTE: The steering knuckle and king pin may be removed to provide greater access, but it is not necessary. Step 1: Block rear tires in both directions. Install wheel lean lock pin, 1.
  • Page 361 Section 5 65E Turbo Motor Grader Front Axle Service Manual LH WHEEL LEAN PIVOT PIN Step 5: Remove outer plug, 1, inner plug, 2, and o-ring, 3, from LH rear of front axle. Discard o-ring, 3. Step 6: Remove lube fitting, 4, plugs, 5, 6, and o-ring, 7, from LH front of axle. Discard o-ring, 7.

  • Page 362: Lh Wheel Lean Pivot Pin Installation

    65E Turbo Motor Grader Section 5 Service Manual Front Axle LH Wheel Lean Pivot Pin Installation LH WHEEL LEAN PIVOT PIN Step 1: Using a bearing driver and hammer, install bearings, 1, in pivot pin bores 4. from outside in.

  • Page 363: Rh Wheel Lean Pivot Pin Removal

    Section 5 65E Turbo Motor Grader Front Axle Service Manual Step 8: Install new nylon washer on steering cylinder socket, 1. Align steering cylinder socket with mounting hole in LH spindle, 2. Install crown nut, 3, and torque to 135.6 Nm (100 Ib-ft). Continue tightening crown nut to align hole for cotter pin.

  • Page 364: Axle Oscillation Pin Removal

    65E Turbo Motor Grader Section 5 Service Manual Front Axle Axle Oscillation Pin Removal NOTE: To access the oscillation pin, the axle must be removed. Step 1: Block rear tires in both directions. Install wheel lean lock pin, 1. Use moldboard down function to raise both front tires off ground.
  • Page 365 Section 5 65E Turbo Motor Grader Front Axle Service Manual Step 7: Remove eight lug nuts, 1, and washers securing each wheel and tire assembly, to front hubs, then remove both wheel and tire assemblies. Step 8: Label, disconnect, and cap hydraulic hoses, 1, to steering cylinder, 2.

  • Page 366: Axle Oscillation Pin Installation

    65E Turbo Motor Grader Section 5 Service Manual Front Axle FRONT AXLE CENTER TUBE Step 10: Use a drift to tap and remove axle oscillation pin. Save washers, 1, between axle and vertical plate of front frame. Step 11: Using a suitable lift, lower front axle assembly to access oil seals, 2, and bearings, 3. Remove oil seals and bearings, if necessary.
  • Page 367 Section 5 65E Turbo Motor Grader Front Axle Service Manual Step 4: Insert axle oscillation pin, using a rubber mallet, as necessary. Take care not to damage bearings, 3, or seals, 2. Step 5: Secure axle oscillation pin to vertical plate of front frame using two bolts, 4, washers, 5, and spacers, 6.
  • Page 368 65E Turbo Motor Grader Section 5 Service Manual Front Axle Step 9: Align front end attachment cylinder lower clevis, 1, with front end attachment lower clevis, 2. Step 10: Install lower pin, 3, with two washers, and with retainer bolt holes in cylinder clevis, 1, and pin, 3, aligned.

  • Page 369: Steering Valve Disassembly And Repair

    Section 5 65E Turbo Motor Grader Front Axle Service Manual TEERING ALVE ISASSEMBLY EPAIR Steering Valve Removal Step 1: Remove steering wheel cover, 1, from steering wheel. Step 2: Remove nut, 2, securing steering wheel, 3, to steering column, 4. Remove steering wheel from steering column.

  • Page 370: Steering Valve Installation

    65E Turbo Motor Grader Section 5 Service Manual Front Axle Steering Valve Installation Step 1: Place steering column mounting plate, 1, flush against inside front of console, 2, and install four bolts, 3, through mounting holes and mounting plate. Step 2: Align mounting holes of steering valve, 4, with four bolts, 3.
  • Page 371 Section 5 65E Turbo Motor Grader Front Axle Service Manual This page intentionally left blank. 5-30 Service 2.00_2013.03...
  • Page 372 Power Steering Repair Information 5 Series Steering Control Units Square Housing with Side Ports Round Housing with Side Ports Round Housing with End Ports...
  • Page 373 Round Housing and Square Housing with Side Ports Thrust Bearing O-ring Quad Seal** *Round housing shown, Housing Seal** but applies to square housing also. Bearing Tools Required Race (2) Dust • 10 mm Socket Seal Check • 7/8 in. Socket Ball O-ring** •...
  • Page 374 Round Housing and Square Housing with Side Ports Disassembly Cleanliness is extremely 1. Remove the seven cap 3. Slide the spool and sleeve 6. Using a small blade screw- important when repairing screws and disassemble from the housing, see driver, carefully pry the hydraulic Steering Control the SCU as shown in figure 2.
  • Page 375 Round Housing and Square Housing with Side Ports Disassembly cont. Figure 3 Standard Torque Centering Springs 7. Remove the pin that holds and Spacers the spool and sleeve together, see figure 3. Sleeve 8. Carefully slide the spool out of the sleeve. The springs and retaining ring will stay with the spool as it’s removed.
  • Page 376 Round Housing and Square Housing with Side Ports Reassembly cont. 23. Lubricate and install a new 28. Install end cap and seven o-ring seal in the groove in cap screws. Tighten cap 20. Lubricate and install a new the wear plate. screws, in a crisscross o-ring seal in the groove in pattern, to 16 -18 Nm...
  • Page 377 Round Housing with End Ports Tools Required • 10 mm Socket • 7/8 in. Socket • Torque Wrench (18 Nm [160 lb-in] Thrust Capacity) Bearing • Small Blade Screwdriver Quad O-ring Seal** Seal** Housing Dust Bearing Race (2) Seal Wear Plate Drive Centering...
  • Page 378 Round Housing with End Ports Disassembly Cleanliness is extremely 1. Remove the plug and inlet 3. Slide the spool and 6. Using a small blade important when repairing relief as shown in figure 1. sleeve from the housing, screwdriver, carefully pry hydraulic Steering Control Note: The manual steering see figure 2.
  • Page 379 Round Housing with End Ports Disassembly cont. Figure 3 Standard Torque Centering Springs 7. Remove the pin that holds and Spacers the spool and sleeve together, see figure 3. Sleeve 8. Carefully slide the spool out of the sleeve. The springs and retaining ring will stay with the spool as it’s removed.
  • Page 380 Round Housing with End Ports Reassembly cont. 20. Install manual steering 23. Install the drive, be sure 27. Lubricate and install a new 30. Install the relief check ball and pin into the slot in the drive o-ring and seal ring in the valve/check if present.
  • Page 381 Section 5 65E Turbo Motor Grader Front Axle Service Manual This page intentionally left blank. 5-40 Service 2.00_2013.03...
  • Page 382 Service Manual Section 6: Rear Axle and Tandem Service 2.00_2013.03...
  • Page 384 65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem SAFETY PRECAUTION INFORMATION UNSAFE OPERATING PRACTICES AND IMPROPER USE OF THE MACHINE AND ITS ATTACHMENTS ON THE PART OF THE OPERATOR OR SERVICE TECHNICIAN CAN RESULT IN INJURIES. OBSERVE THE FOLLOWING SAFETY PRECAUTIONS AT ALL TIMES: 1.
  • Page 385 Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual 15. Install all shields before starting or operating machine. 16. Do not operate an unsafe machine. If items are found during inspection that render a machine unsafe, be sure any malfunctions are remedied before accepting responsibility for operation.
  • Page 386 65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem 33. Remember that the vehicle, if abused or incorrectly used, can be dangerous and become a hazard to the operator and bystanders. 34. Noise levels can exceed recommended levels when working between buildings or in confined areas on canopy equipped machines or cab equipped machines with doors and windows open.
  • Page 387 Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual 50. After operating the engine, never touch the muffler, exhaust pipe, engine or radiator until they have had time to cool. 51. Dress appropriately - wear relatively tight-fitting clothing when operating or servicing the machine.
  • Page 388 65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem 65. Do not attempt to service air conditioning system, if equipped. It is possible to be severely frostbitten or injured by escaping refrigerant. Special equipment and instruments are required to service air conditioning system. See an authorized dealer for service.
  • Page 389 Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual 81. If welding is required on an attachment, remove the attachment from the machine. 82. Give complete and undivided attention to the job at hand so that complete control of the machine is maintained at all times.
  • Page 390 65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem OSHA REQUIREMENTS NOW MAKE IT THE EMPLOYER'S RESPONSIBILITY TO FULLY INSTRUCT EACH OPERATOR IN THE PROPER AND SAFE OPERATION OF ALL OPERATIVE EQUIPMENT. BOTH EMPLOYER AND EMPLOYEE SHOULD THOROUGHLY FAMILIARIZE THEMSELVES WITH THE MACHINE OPERATION.
  • Page 391 Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual This page intentionally left blank. Service 2.00_2013.03...
  • Page 392 65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem ONTENTS Rear Axle And Tandems ............6-1 General .
  • Page 393 Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Brakes - Disassembly and Repair ..........6-20 Master Cylinder .

  • Page 394: Rear Axle And Tandems

    65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Section 6: Rear Axle and Tandem ANDEMS General A drive shaft, connected to the transmission output shaft, transfers power to the rear axle assembly. The rear axle assembly is a double reduction unit with three inboard planetary gears and integral, multi-disc hydraulic brakes.

  • Page 395: Drive Shaft

    Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Drive Shaft Type............Telescoping Double U-Joint Maximum Length (Center to Center) .

  • Page 396: Rear Axle And Tandem Drive Assembly

    65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem ANDEM RIVE SSEMBLY The rear axle and tandem drive can be removed as a unit for servicing off of the machine. If the rear axle does not have to be serviced the tandem drive assemblies can be serviced while mounted on the machine.

  • Page 397: Tandem Drive Assembly

    Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Be sure wheels are on the ground before removing the support hardware in the next step. Step 4: Remove nut, 5, washer, 4, bolt, 3, and bushing, 2, from all four mounting brackets on the rear axle, 1.

  • Page 398: Removal

    65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Do not lift the tandem drive assembly. Place lift under frame rails. NOTE: This procedure outlines removal of the tandem drive on one side. Repeat the process for the other side, if necessary.

  • Page 399: Installation

    Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Be sure tandem assembly is supported with a lift of sufficient capacity before detaching hub. Step 5: Support tandem assembly. Step 6: Remove the sixteen (16) screws, 1, and sixteen (16) flat washers, 2, attaching the hub, 3, to the tandem, 4.
  • Page 400 65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Step 6: Install bolts, 5, access covers, 6, and gaskets, 7, at front of tandem case. Step 7: Install the wheel assembly with tire, 4, on the tandem and secure with eight lug nuts, 2 and eight screws, 3.

  • Page 401: Driveshaft

    Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual RIVESHAFT Drive shaft removal and installation as described in this paragraph covers only the removal (disconnection) of the drive shaft from the rear axle and the reconnection (installation) of the drive shaft to the rear axle. At this point the drive shaft remains connected to the transmission.

  • Page 402: Rear Axle And Tandem Drive Assembly

    65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem NOTE: The dust cap, 1, should be loosened, by turning counterclockwise, so that the drive shaft can be compressed or extended easily. Step 1: If the cross and bearing assembly, 4, was left attached to the drive shaft, 5, proceed with sub-step "a"...

  • Page 403: Brakes - Maintenance And Adjustment

    Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Step 5: Install the four bushings, 2, into mounting brackets on the rear axle, 1. Step 6: Apply anti-seize to the four cap screws, 3. Step 7: Insert the four cap screws, 3, from the inside through the bushing, 2.

  • Page 404: Specifications

    65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem The service brake hydraulic system is divided into sepa- rate circuits for the right and left brakes, with two sepa- rate reservoirs supplying the master cylinder. The circuits are connected when at rest to vent pressure from the system.

  • Page 405: Parking Brake

    Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Piston Thickness (Nominal) ..........0.728 in. (18.5 mm) Actuation .

  • Page 406: Bleeding The Brakes

    65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Bleeding The Brakes Bleeding the brakes removes all air from the system, ensuring a constant flow of brake fluid to the brake pis- ton. Gases compress to a much greater extent than fluid. If air is in the system, brake actuation may be intermittent and ineffective.

  • Page 407: Parking Brake Cable Adjustment

    Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Step 3: Have an assistant depress the brake pedal and hold it. With the pedal depressed, loosen the bleed screw, 1, on one side of the rear axle and allow fluid and air to escape.

  • Page 408: Lever End Adjustment

    65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Lever End Adjustment Step 1: Remove plate along LH side of seat. NOTE: It is not necessary to remove the seat but greater access will be gained if it is removed.

  • Page 409: Parking Brake Switch

    Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Parking Brake Switch The parking brake switch, 1, sends a signal to the trans- mission that causes the oil to be released from the clutches, disconnecting the transmission. When the park-...

  • Page 410: Brake Pedal

    65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Brake Pedal The brake pedal has several adjustments. The brake pedal stop, the gap between the floor and pivot weld- ment, and the pedal height. The brake pedal stop should be adjusted before pedal height.
  • Page 411 Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Step 4: To adjust gap, remove floor mat. Remove bolts, 1, and floor plate, 2. Step 5: Loosen return spring, 1, at front of cab. Remove spring from yoke pin, 2. Remove cotter pin, 3, and yoke pin, 2.

  • Page 412: Pedal Height

    65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Pedal Height Measure pedal height with console assembly in the sec- ond notch (nearly vertical). Pedal height should be 9.06- 9.56 in. (230-243 mm). If incorrect, adjust pedal height.

  • Page 413: Pedal Return Spring

    Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Pedal Return Spring Adjust eyelet, 1, to provide sufficient spring tension on spring, 2, to hold pedals against pedal stop. Secure with jam nuts, 3. RAKES ISASSEMBLY AND...
  • Page 414 65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Step 1: Remove the floor mat. Remove bolts, and floor plate. Step 2: Remove bolts, 1, and washers, 2, and disconnect horizontal linkage, 3, from pivot bracket, 4. Allow horizontal linkage, 3, to drop to gain access to the master cylinder, 5.

  • Page 415: Installation

    Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Step 9: Remove bolts, nuts and washers securing steering lines to bracket. Step 10: Remove bolts, 1, and washers, 2, securing plate, 3. Remove plate, 3, and pivot assembly, 4.
  • Page 416 65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Step 2: Place pivot bracket, 3, on mounting flanges. Secure with bolts, 1, and washers, 2. Step 3: Install yoke pin, 4, through yoke, 5, and pivot plate, 6. Secure with cotter pin, 7.

  • Page 417: Friction Discs And Piston

    Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Friction Discs And Piston Follow the procedure in the section "DISASSEMBLING SIDE FINAL DRIVES". Removal Step 1: Remove the rear axle from the machine. Step 2: Remove output gears and side cases.

  • Page 418: Parking Brake Friction Pad Replacement

    65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Parking Brake Friction Pad Replacement Refer to the following information in the Transmission section to replace the friction pads: • ZF-ERGOPOWER 6WG-115 Repair Manual, pages 5/2, 12/2, and 12/3 •...

  • Page 419: Replacing Lube Oil

    Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Replacing Lube Oil Step 1: Remove oil level plug. Step 2: Remove oil drain plug and drain used oil. Step 3: Tighten drain plug. Step 4: Fill up to edge of level plug until oil overflows.

  • Page 420: Assembling Leak Proof Components

    65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem In order to heat bearings, use proper heating plates, piping or suitable ovens. never use a torch for heating parts. • An oil bath, heated by a torch, may be used to warm up components.
  • Page 421 Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Step 2: Loosen screw securing drive wheel. Remove screw, lock plate, backing plate, and drive wheels. Step 3: Loosen and remove nuts from studs securing side final drive unit to axle case and remove the complete side final drive unit.
  • Page 422 65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Step 5: Undo screws and remove reaction spring from brake piston. Step 6: Use compressed air and draw out brake piston. Step 7: Remove screw, lock plate and washer retaining side gear carrier to wheel shaft.
  • Page 423 Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Step 8: Draw out side gear carrier from wheel shaft. Remove shim for side gear carrier and play adjustment. Step 9: Remove shaft complete with drive wheel side bearing.
  • Page 424 65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Step 11: Remove lip seal. Step 12: Remove pin lock ring. During this stage, ring must be widened to free it from its seat on side gear carrier and, at the same time, displace the three pins so as to free ring from casting.

  • Page 425: Assembly

    Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual In case of replacement, fit side gears with needle rollers of the same selection class. Assembly Step 1: Press fit bearing in side gear case on axle case side.
  • Page 426 65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Step 4: Position side gear assemblies with thrust washers in relevant seat of side gear carrier. IMPORTANT: Position thrust washer of side gear carrier on wheel shaft prior to assembling the third side gear, thrust washer cannot be fitted if assembly is completed.

  • Page 427: Center Section Unit

    Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Center Section Unit Disassembly Step 1: Loosen screws retaining bevel pinion support to center case. Remove unit from center case and position on proper stand. Step 2: Loosen pinion nut, position reaction tool on drive flange for unlocking wrench.
  • Page 428 65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Step 3: Remove drive flange. Step 4: Remove bevel pinion from support. Hammer on shank end being careful not to damage threads. Step 5: Remove inner race of pinion shank bearing pre- load shims, spacer, and remove lip seal.
  • Page 429 Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Step 6: Remove outer race of pinion under head bearing with relevant positioning shims and outer race of pinion shank bearing. Step 7: Remove fixing screws, both side supports and shims (for bearing pre-load and standard clearance between pinion sides and bevel ring gear).
  • Page 430 65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Step 9: Should bevel gear seat be replaced, it is necessary to remove differential ring gear by undoing assembling screws. Step 10: Mark position of half-cases, undo and remove assembling screws, separate halves.
  • Page 431 Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Step 12: Remove sun gears from half-cases and remove clutch drive and driven disks. Step 13: Should bearings be replaced, it is necessary to remove inner races on half-cases of differential support using a proper puller.
  • Page 432 65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Assembly Step 1: Heat differential bearings at 248°F (120°C), position them on half-cases. Step 2: Assemble sun gears with disks (with inner teeth) and counter disks of clutch into half-cases. Insert disk...
  • Page 433 Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Step 4: Mount side gears with relevant bevel thrust washers on spider. Step 5: Position spider assembly in half-case. Step 6: Position the second half-case, matching reference marks and lock screws.
  • Page 434 65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Step 7: As assembly is completed, the clearance of each clutch pack must be from 0.002-0.004 in. (0.05-0.1 mm), this is required for proper operation of super MAX-TRAC differential unit. Make sure of proper gear rotation.
  • Page 435 Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual NOTE: Some dimensions should be recorded prior to assembly to determine thickness of shims for axial position of bevel pinion. Step 10: Computation of dimension from seating surface of pinion support to ring gear axis on center section case, "A".
  • Page 436 65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Step 13: Record thickness of pinion head, "H". Step 14: Fit under head bearing on pinion and measure thickness, it can be reached measuring height from pinion head face to outer edge of bearing less thickness of pinion head (dimension "H").
  • Page 437 Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Step 16: Insert pinion in support, fit spacer and adjustment shims for bearing pre-load. To simplify determination of proper preload, it is advisable to fit a number of shims so as to cause pinion play and not a pre-load.
  • Page 438 65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Step 19: As bearing pre-load has been determined, remove drive flange and fit lip seal. Refit drive flange and lock pinion nut. Step 20: Mount differential unit in axle center section case.
  • Page 439 Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Step 22: Change if required, the adjustment shims of differential supports to reach the specified pre-load, (rolling torque of 1.5-3.0 Ib-ft (0.2-0.4 daNvn). Step 23: Smear ring gear teeth with red lead and mount the complete pinion support on the center section case, without using sealing compound on matching surfaces.
  • Page 440 65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Step 25: In case inner and outer brake linings should be replaced, assure position and fitting in relevant seat. Refit brake piston being careful to align seats with relevant anti-rotation pins.
  • Page 441 Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Step 28: Using sealing compound, position spacer on studs. Mount ring gear using sealant on matching surfaces. Using sealing compound, insert side final drive assembly, apply medium thread locking compound on nuts, lock with a torque of 151-168 Ib-ft (20.5-22.7 daNm).

  • Page 442: Disassembly

    65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem ANDEM RIVE Disassembly Step 1: Using a lifting device, lift rear axle and tandem and place in a cradle. Step 2: Remove drain plug from tandem and drain oil.
  • Page 443 Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Step 7: Remove sprocket, 1, by removing cap screw, 2, lock plate, 3, and washer, 4. Step 8: Hook up lifting device to tandem to support tandem when removed from rear axle.
  • Page 444 65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Step 11: Remove plug, 2, with fitting then remove plugs, 1, 3, 4, and 5. Service 2.00_2013.03 6-51...
  • Page 445 Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Step 12: Remove both shaft and retainer assemblies from tandem case by removing fourteen (14) cap screws, 17, and washers, 18. Step 13: Remove lockwire, 15, from three (3) cap screws, 10.

  • Page 446: Assembly

    65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Step 23: Remove shim washers, 6, 7, and 8, as applicable. Step 24: Remove thrust washer, 5, from cap, 4. Step 25: Remove washers, 10, and screws, 9, and remove cap, 4.
  • Page 447 Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Step 2: If a new rear axle is being installed to a tandem, reverse the fittings on the axle. Step 3: Apply anti-seize to I.D. of bore on axle assembly, 1, and O.D.
  • Page 448 65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Step 9: Apply grease to I.D. of bore on hub, 1, and O.D. of bushing, 2. Step 10: Using a rubber mallet, install bushing, 2, evenly in hub, 1.
  • Page 449 Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Step 15: Place washers, 10, over cap screws, 9, and fasten cap, 4, in place. Step 16: Torque cap screws, 9, to 200 ± 20 Ib-ft (271.16 ± 27.11 N-rn) with a torque wrench.
  • Page 450 65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Step 19: Install cup, 5, into retainer, 4. Step 20: Install seal, 6, with small flange up. Seat large flange over spacer on shaft, 1. Step 21: Pack cone, 3, with Extreme Pressure Grease (EPG) NLGI Grade 2 grease and install cone, 3, with wide side towards seal, 6, using bearing driver.
  • Page 451 Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Step 29: Torque cap screws to 30 Ib-ft (40.67 Nm). Step 30: Rotate hub one revolution clockwise and one revolution counterclockwise. Step 31: Check to determine if 30 Ib-ft (40.67 Nm) of torque is maintained. If value has fallen below 30 Ib-ft (40.67 Nm), torque and rotate.
  • Page 452 65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Step 41: Apply pipe dope to threads of plugs, 1, 2, 3, 4, and 5. Install plug, 2, with fitting then install plugs, 1, 3, 4, and 5.
  • Page 453 Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Step 42: Install shim pack, 1, selected in step 14, and apply Loctite to outside surface. Step 43: Apply Loctite to threads of cap screws, 2, Install washers, 3, over cap screws, 2, and install through hub with cap screw threads facing out.
  • Page 454 65E Turbo Motor Grader Section 6 Service Manual Rear Axle and Tandem Step 48: Install inside chain first. Start chain, 1, through top hole, A, and line up on sprocket, 3, Turn yoke on the front of the axle to help feed the chain through.
  • Page 455 Section 6 65E Turbo Motor Grader Rear Axle and Tandem Service Manual This page intentionally left blank. 6-62 Service 2.00_2013.03...
  • Page 456 Service Manual Section 7: Electrical Service 2.00_2013.03...
  • Page 458 65E Turbo Motor Grader Section 7 Service Manual Electrical SAFETY PRECAUTION INFORMATION UNSAFE OPERATING PRACTICES AND IMPROPER USE OF THE MACHINE AND ITS ATTACHMENTS ON THE PART OF THE OPERATOR OR SERVICE TECHNICIAN CAN RESULT IN INJURIES. OBSERVE THE FOLLOWING SAFETY PRECAUTIONS AT ALL TIMES: 1.
  • Page 459 Section 7 65E Turbo Motor Grader Electrical Service Manual 15. Install all shields before starting or operating machine. 16. Do not operate an unsafe machine. If items are found during inspection that render a machine unsafe, be sure any malfunctions are remedied before accepting responsibility for operation.
  • Page 460 65E Turbo Motor Grader Section 7 Service Manual Electrical 33. Remember that the vehicle, if abused or incorrectly used, can be dangerous and become a hazard to the operator and bystanders. 34. Noise levels can exceed recommended levels when working between buildings or in confined areas on canopy equipped machines or cab equipped machines with doors and windows open.
  • Page 461 Section 7 65E Turbo Motor Grader Electrical Service Manual 50. After operating the engine, never touch the muffler, exhaust pipe, engine or radiator until they have had time to cool. 51. Dress appropriately - wear relatively tight-fitting clothing when operating or servicing the machine.
  • Page 462 65E Turbo Motor Grader Section 7 Service Manual Electrical 65. Do not attempt to service air conditioning system, if equipped. It is possible to be severely frostbitten or injured by escaping refrigerant. Special equipment and instruments are required to service air conditioning system. See an authorized dealer for service.
  • Page 463 Section 7 65E Turbo Motor Grader Electrical Service Manual 81. If welding is required on an attachment, remove the attachment from the machine. 82. Give complete and undivided attention to the job at hand so that complete control of the machine is maintained at all times.
  • Page 464 65E Turbo Motor Grader Section 7 Service Manual Electrical OSHA REQUIREMENTS NOW MAKE IT THE EMPLOYER'S RESPONSIBILITY TO FULLY INSTRUCT EACH OPERATOR IN THE PROPER AND SAFE OPERATION OF ALL OPERATIVE EQUIPMENT. BOTH EMPLOYER AND EMPLOYEE SHOULD THOROUGHLY FAMILIARIZE THEMSELVES WITH THE MACHINE OPERATION.
  • Page 465 Section 7 65E Turbo Motor Grader Electrical Service Manual This page intentionally left blank. Service 2.00_2013.03...
  • Page 466 65E Turbo Motor Grader Section 7 Service Manual Electrical ONTENTS ............7-1 LECTRICAL General .
  • Page 467 Section 7 65E Turbo Motor Grader Electrical Service Manual Left-Hand Side of Grader - CAT Tier III Engine ......... 7-37 Right-Hand Side of Grader - CAT Tier IVi Engine .

  • Page 468: Electrical

    65E Turbo Motor Grader Section 7 Service Manual Electrical Section 7: Electrical ENERAL The electrical system is a 12 volt, negative ground system which provides power to start, control and monitor the motor grader. Two 12 volt batteries, connected in parallel, provide voltage to the starting motor and power electrical sys- tems.
  • Page 469 Section 7 65E Turbo Motor Grader Electrical Service Manual The display screen on the right-side console contains a screen called the View Can. This screen contains infor- mation on the engine, transmission, battery life and soft- ware revision. The right-side console, 1, contains the ignition switch and allows control of lights, wipers and heating.

  • Page 470: Tier Iii - Electrical Schematics

    65E Turbo Motor Grader Section 7 Service Manual Electrical III - E LECTRICAL CHEMATICS Service 2.00_2013.03...
  • Page 471 Section 7 65E Turbo Motor Grader Electrical Service Manual Service 2.00_2013.03...
  • Page 472 65E Turbo Motor Grader Section 7 Service Manual Electrical Service 2.00_2013.03...
  • Page 473 Section 7 65E Turbo Motor Grader Electrical Service Manual Service 2.00_2013.03...
  • Page 474 65E Turbo Motor Grader Section 7 Service Manual Electrical Service 2.00_2013.03...
  • Page 475 Section 7 65E Turbo Motor Grader Electrical Service Manual Service 2.00_2013.03...

  • Page 476: Tier Ivi - Electrical Schematic

    65E Turbo Motor Grader Section 7 Service Manual Electrical LECTRICAL CHEMATIC Service 2.00_2013.03...
  • Page 477 Section 7 65E Turbo Motor Grader Electrical Service Manual 7-10 Service 2.00_2013.03...
  • Page 478 65E Turbo Motor Grader Section 7 Service Manual Electrical Service 2.00_2013.03 7-11...
  • Page 479 Section 7 65E Turbo Motor Grader Electrical Service Manual 7-12 Service 2.00_2013.03...
  • Page 480 65E Turbo Motor Grader Section 7 Service Manual Electrical Service 2.00_2013.03 7-13...
  • Page 481 Section 7 65E Turbo Motor Grader Electrical Service Manual 7-14 Service 2.00_2013.03...

  • Page 482: Definition Of Terms

    65E Turbo Motor Grader Section 7 Service Manual Electrical EFINITION OF ERMS ALTERNATING CURRENT (AC) - A flow of electrical current which reverses its direction of flow at regular intervals in a conductor. AMMETER - Measures flow of electrical current in amperes. Ammeters are connected in series with the cir- cuit to be tested.

  • Page 483: Starting And Charging

    Section 7 65E Turbo Motor Grader Electrical Service Manual SHORT CIRCUIT - A part of a circuit that comes in contact with part of the same circuit, or unintentionally touches a metallic object, resulting in voltage loss to another component wire or to ground. Can result in wrong component being operated, or blown circuit protection device (fuse or breaker).

  • Page 484: Specifications

    65E Turbo Motor Grader Section 7 Service Manual Electrical PECIFICATIONS Voltage..............12 Volt System Transmission .

  • Page 485: Standard Lighting

    Section 7 65E Turbo Motor Grader Electrical Service Manual 12V / 24V Voltage Doubler Make ............... Sure Power Model .

  • Page 486: Special Tools

    65E Turbo Motor Grader Section 7 Service Manual Electrical PECIAL OOLS • Voltmeter, 0-20 VDC • Ammeter, 0-500 Amps • Ohmmeter • Test Lamp • Mechanical Speed Indicator • Hand Tachometer • Torque Wrench • Carbon Pile Load Tester (Variable Load Resistor) •...

  • Page 487: Troubleshooting

    Section 7 65E Turbo Motor Grader Electrical Service Manual ROUBLESHOOTING Before starting the machine or its attachment for troubleshooting or testing, check, adjust and lock the oper- ator's seat. Ensure that no one is within the operating range of the machine. Sound the horn. Lower the attachment slowly.

  • Page 488: Preliminary Troubleshooting

    65E Turbo Motor Grader Section 7 Service Manual Electrical Always connect positive to positive and negative to negative. Never make or break any charging system connections, including battery, when engine is running. Never short any charging system components to ground.
  • Page 489 Section 7 65E Turbo Motor Grader Electrical Service Manual Step 3: Fuses are located under instrument panel, 1, on right-hand side of seat. Raise instrument panel for access. Step 4: Engine control fuses, 2, are located at right-hand side of engine near flywheel housing.
  • Page 490 65E Turbo Motor Grader Section 7 Service Manual Electrical Step 5: Fuses are identified by a tag, 1, located below right-hand side instrument panel. NOTICE: Turn "OFF" master switch before replacing fuses. Isolate cause of blown fuse before replacing fuse.
  • Page 491 Section 7 65E Turbo Motor Grader Electrical Service Manual Step 6: Ensure all connections are tight and clean, and that there are no frayed wires which may cause shorts, opens, grounds, or high resistance in the system. Turn "OFF" master switch before working around batteries.

  • Page 492: Troubleshooting Chart

    65E Turbo Motor Grader Section 7 Service Manual Electrical Troubleshooting Chart Problem Possible Cause Correction Engine does not turn over when " " " " Transmission control lever not in NEUTRAL Place lever in NEUTRAL key start is operated. "OFF"...

  • Page 493: Batteries

    Section 7 65E Turbo Motor Grader Electrical Service Manual ATTERIES Battery Removal Never make or break any charging system connections, including battery, when engine is running. Step 1: Ensure engine is turned "OFF". Turn "OFF" master switch before working around batteries.

  • Page 494: Battery Installation

    65E Turbo Motor Grader Section 7 Service Manual Electrical Explosive gas may be present. Do not allow tools or metal objects to bridge terminal poles. Sparking may result in personal injury or battery damage. Handle batteries with care. Each battery weighs approximately 50 pounds and may cause personal injury if dropped.

  • Page 495: Component Locations

    Section 7 65E Turbo Motor Grader Electrical Service Manual OMPONENT OCATIONS Front Console The front console houses the implement control switches, hazard switch, indicator lights, turn signal switch with in-line 20 amp fuse, flasher, and harness. Removable access panels provide for component repair and replacement.
  • Page 496 65E Turbo Motor Grader Section 7 Service Manual Electrical Multifunction Switch (Turn Signals, Taillights, Headlights, High and Low Beam Selection, Horn) Service 2.00_2013.03 7-29...

  • Page 497: Instrument Panel Group

    Section 7 65E Turbo Motor Grader Electrical Service Manual Instrument Panel Group Display Right Side Console Lights (2) Front Work Lights Front Wiper Rear Work Lights Blower Fan Rotating Beacon Light Ignition Switch Defog Fan Rear Wiper Switch AC Switch...
  • Page 498 65E Turbo Motor Grader Section 7 Service Manual Electrical Main Power Relay Transmission Control Unit (TCU) 12/24 Volt Converter Throttle Position Sensor (TPS) Back-up Alarm Relay Service 2.00_2013.03 7-31...

  • Page 499: Right-Hand Side Of Grader - Cummins Tier Iii Engine

    Section 7 65E Turbo Motor Grader Electrical Service Manual Right-Hand Side of Grader - Cummins Tier III Engine Oil Pressure Sensor Master Switch Starter Alternator Neutral Start Relay A/C Relay Starter Relay 7-32 Service 2.00_2013.03...

  • Page 500: Left-Hand Side Of Grader - Cummins Tier Iii Engine

    65E Turbo Motor Grader Section 7 Service Manual Electrical Left-Hand Side of Grader - Cummins Tier III Engine Engine Temperature Sender Engine Electronic Control Module (ECM) Oil Pressure Switch Service 2.00_2013.03 7-33...
  • Page 501 Section 7 65E Turbo Motor Grader Electrical Service Manual Terminal Resistor Located Under Control Panel Engine Diagnostic Connectors Connected for Flashing Out Engine Codes Engine Diagnostic Connector Located Under Control Panel 7-34 Service 2.00_2013.03...

  • Page 502: Right-Hand Side Of Grader - Cummins Tier Ivi Engine

    65E Turbo Motor Grader Section 7 Service Manual Electrical Right-Hand Side of Grader - Cummins Tier IVi Engine Air Intake Temperature Sensor Alternator Heated Grid Relay Neutral Start Relay A/C Relay Service 2.00_2013.03 7-35...

  • Page 503: Left-Hand Side Of Grader - Cummins Tier Ivi Engine

    Section 7 65E Turbo Motor Grader Electrical Service Manual Left-Hand Side of Grader - Cummins Tier IVi Engine A/C Condenser Engine Electronic Control Module (ECM) Master Switch Starter ECM Diagnostic Port Buss Fuse 7-36 Service 2.00_2013.03...
  • Page 504 65E Turbo Motor Grader Section 7 Service Manual Electrical Right-Hand Side of Grader - CAT Tier III Engine Master Switch Starter Alternator A/C Relay Neutral Start Relay Starter Relay Service 2.00_2013.03 7-37...

  • Page 505: Left-Hand Side Of Grader - Cat Tier Iii Engine

    Section 7 65E Turbo Motor Grader Electrical Service Manual Left-Hand Side of Grader - CAT Tier III Engine Glow Plug Relay 7-38 Service 2.00_2013.03...

  • Page 506: Right-Hand Side Of Grader - Cat Tier Ivi Engine

    65E Turbo Motor Grader Section 7 Service Manual Electrical Right-Hand Side of Grader - CAT Tier IVi Engine Crankcase Breather Heater Sensor Air Temperature Sensor ECM Circuit Breaker Lambda O2 Sensor Glow Plug Circuit Breaker ECM Power Relay Neutral Start Relay...

  • Page 507: Left-Hand Side Of Grader - Cat Tier Ivi Engine

    Section 7 65E Turbo Motor Grader Electrical Service Manual Left-Hand Side of Grader - CAT Tier IVi Engine A/C Condenser Battery Disconnect Engine Electronic Control Module (ECM) Starter ECM Diagnostic Port Glow Plug Control Unit (GPCU) 7-40 Service 2.00_2013.03...

  • Page 508: Bottom Of Operator Console

    65E Turbo Motor Grader Section 7 Service Manual Electrical Bottom of Operator Console Park Brake Switch Service 2.00_2013.03 7-41...
  • Page 509 Section 7 65E Turbo Motor Grader Electrical Service Manual 12/24 VOLT CONVERTER 7-42 Service 2.00_2013.03...

  • Page 510: Bottom Of Grader

    65E Turbo Motor Grader Section 7 Service Manual Electrical Bottom of Grader Transmission Inching Pressure Switch Accessed through Bottom Cover of Grader (Below Operator Platform) Brake Lights Pressure Switch (Below Operator Platform) Service 2.00_2013.03 7-43...
  • Page 511 3315 PRODUCTION RELEASE 1/16/01 BF 002 3660 UPDATE/EMC CHANGES Product Specification 41222 DC-DC Converter 12V / 24V, 10 Amp High Temperature Voltage Doubler MODEL NO: 41222 DRAWINGS IN THIS DOCUMENT ARE NOT TO SCALE 12V/24V, 10A Voltage Doubler PROPRIETARY PRODUCT SPECIFICATION PRJCT ENGR THIS DRAWING IS THE PROPERTY OF SURE POWER INC.
  • Page 512 FUNCTIONAL DESCRIPTION The Sure Power 41222 is a remote enabled, step-up DC to DC voltage converter powered from a 12 volt charging source. It is designed to provide a nominal fixed output voltage of 2 times the input voltage at an output current of 10 amps continuous when the input voltage is between 6 and 16 volts (see voltage profile in electrical characteristics).
  • Page 513 ABSOLUTE MAXIMUM RATINGS: Maximum ratings establish the maximum electrical ratings to which the unit may be subjected without damage. Symbol Value Parameter Steady State Input Voltage Input Reverse Polarity -32V Output Current 320W Max Power Output at T = 25°C Heat Sink Temperature 125°C Operating Temperature Range...
  • Page 514 ELECTRICAL CHARACTERISTICS: Unless otherwise stated, conditions apply to full operational input voltage range (6V to 16V) Characteristic Unit Notes: Input voltage range applicable only after an input voltage greater than Input Voltage (Vin) 14.7 the undervoltage lockout has enabled the equalizer. Once enabled the equalizer will Input Undervoltage operate within the full input voltage...
  • Page 515 ELECTRICAL CHARACTERISTICS: (cont.) Operational Output Voltage Profile vs. Input Voltage (Typical) Applicable only after equalizer has been enabled. Input Voltage (volts) Maximum Rated Continuous Output Current vs. Ambient Temperature Characteristic Ambient Temperature (deg C) MODEL NO: 41222 12V/24V, 10A Voltage Doubler PRODUCT SPECIFICATION SPEC 41222 NONE...
  • Page 516 Electrical Connection Diagram Input Enable en #2 en #1 Input Enable 12V = on 24V = on 41222 12V-24V Gnd = off Gnd = off Voltage Doubler Vout_s Vout 1,11,12 2,3,4 Input Batterry Load Required External 30A Fuse Connector: Deutsch DT13F-12PA Mating connector: Deutsch DT06-12SA Connections: Pin #1:...
  • Page 517 MECHANICAL SPECIFICATIONS Housing: Black anodized aluminum (.5ml) Weight: 10 lbs. MECHANICAL OUTLINE 8.00 4X .28 7.13 4.00 1.56 1.65 3.42 8.50 7.84 3.16 MODEL NO: 41222 12V/24V, 10A Voltage Doubler PRODUCT SPECIFICATION SPEC 41222 NONE SPEC 41222-002...
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  • Page 519 Service Manual Section 8: Hydraulics Service 2.00_2013.03...
  • Page 521 65E Turbo Motor Grader Section 8 Service Manual Hydraulics SAFETY PRECAUTION INFORMATION UNSAFE OPERATING PRACTICES AND IMPROPER USE OF THE MACHINE AND ITS ATTACHMENTS ON THE PART OF THE OPERATOR OR SERVICE TECHNICIAN CAN RESULT IN INJURIES. OBSERVE THE FOLLOWING SAFETY PRECAUTIONS AT ALL TIMES: 1.
  • Page 522 Section 8 65E Turbo Motor Grader Hydraulics Service Manual 15. Install all shields before starting or operating machine. 16. Do not operate an unsafe machine. If items are found during inspection that render a machine unsafe, be sure any malfunctions are remedied before accepting responsibility for operation.
  • Page 523 65E Turbo Motor Grader Section 8 Service Manual Hydraulics 33. Remember that the vehicle, if abused or incorrectly used, can be dangerous and become a hazard to the operator and bystanders. 34. Noise levels can exceed recommended levels when working between buildings or in confined areas on canopy equipped machines or cab equipped machines with doors and windows open.
  • Page 524 Section 8 65E Turbo Motor Grader Hydraulics Service Manual 50. After operating the engine, never touch the muffler, exhaust pipe, engine or radiator until they have had time to cool. 51. Dress appropriately - wear relatively tight-fitting clothing when operating or servicing the machine.
  • Page 525 65E Turbo Motor Grader Section 8 Service Manual Hydraulics 65. Do not attempt to service air conditioning system, if equipped. It is possible to be severely frostbitten or injured by escaping refrigerant. Special equipment and instruments are required to service air conditioning system. See an authorized dealer for service.
  • Page 526 Section 8 65E Turbo Motor Grader Hydraulics Service Manual 81. If welding is required on an attachment, remove the attachment from the machine. 82. Give complete and undivided attention to the job at hand so that complete control of the machine is maintained at all times.
  • Page 527 65E Turbo Motor Grader Section 8 Service Manual Hydraulics OSHA REQUIREMENTS NOW MAKE IT THE EMPLOYER'S RESPONSIBILITY TO FULLY INSTRUCT EACH OPERATOR IN THE PROPER AND SAFE OPERATION OF ALL OPERATIVE EQUIPMENT. BOTH EMPLOYER AND EMPLOYEE SHOULD THOROUGHLY FAMILIARIZE THEMSELVES WITH THE MACHINE OPERATION.
  • Page 528 Section 8 65E Turbo Motor Grader Hydraulics Service Manual This page intentionally left blank. Service 2.00_2013.03...
  • Page 529 65E Turbo Motor Grader Section 8 Service Manual Hydraulics ONTENTS General ..............8-1 Hydraulic Schematic .
  • Page 530 Section 8 65E Turbo Motor Grader Hydraulics Service Manual Back Pressure Valve ............. 8-43 Hoses And Fittings .
  • Page 531 65E Turbo Motor Grader Section 8 Service Manual Hydraulics Hydraulic Strainers ............8-94...
  • Page 532 Section 8 65E Turbo Motor Grader Hydraulics Service Manual This page intentionally left blank. 8-xiv Service 2.00_2013.03...

  • Page 533: General

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Section 8: Hydraulics ENERAL The hydraulics supply the implements, steering, and cooling systems with oil flow to create movement. A tandem pump is mounted to the auxiliary drive shaft of the transmission. One section supplies the fan motor.
  • Page 534 Section 8 65E Turbo Motor Grader Hydraulics Service Manual This page intentionally left blank. Service 2.00_2013.03...

  • Page 535: Hydraulic Schematic

    65E Turbo Motor Grader Section 8 Hydraulics Service Manual YDRAULIC CHEMATIC Service 2.00_2013.03...
  • Page 536 Section 8 65E Turbo Motor Grader Hydraulics Service Manual YDRAULIC CHEMATIC Service 2.00_2013.03...

  • Page 537: Specifications

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics PECIFICATIONS Pump Manufacturer ..............Eaton Type.

  • Page 538: Cylinders

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Cylinders Cylinder Bore Stroke Rod Diameter (in.) (in.) (in.) Moldboard Lift* (Qty. 2) 76.2 (3.00) 850.9 (33.50) 50.8 (2.00) Circle Shift* 76.2 (3.00) 403.4 (15.88) 50.8 (2.00) Saddle Lock Pin* 63.5 (2.50)

  • Page 539: Troubleshooting

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics ROUBLESHOOTING When performing a test on the hydraulic system, use the proper test procedures and test equipment. Before testing, lower attachments to the ground. If testing is to be performed with raised attachment, make sure lock pin is installed, and that attachment is resting on lock pin.

  • Page 540: Troubleshooting Chart

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Troubleshooting Chart Problem Possible Cause Correction All hydraulic functions fail to oper- Pump worn. Contact an authorized dealer. ate. Low oil level. Add oil. Faulty system relief valve. Contact an authorized dealer.

  • Page 541: Pressure Settings

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics RESSURE ETTINGS Main Relief Valve The main relief valve is located in the inlet section of the control valve. It should be set at 131-144 bar (1900-2100 psi). The pressure should be tested with the oil above 71 °C (160°F).
  • Page 542 Section 8 65E Turbo Motor Grader Hydraulics Service Manual b) The main relief valve adjustment screw, 1, is located on top of the valve inlet/outlet endcap (LH side of control valve). c) Loosen adjustment screw lock nut. d) Turn screw (1/4 in. Allen wrench) clockwise to increase pressure setting, counterclockwise to decrease.

  • Page 543: Steering Valve Pressure Check

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics TEERING ALVE RESSURE HECK Steering pressure is checked at the test point located on the forward LH side of the tandem pump, at the rear of the transmission. An adjustable inlet relief valve is located in the load sense priority steering valve, limiting pressure to 107-120 bar (1550-1750 psi).
  • Page 544 Section 8 65E Turbo Motor Grader Hydraulics Service Manual Step 5: Using all applicable safety practices, start engine. Fully rotate steering wheel in both directions to fully dead-head cylinder. Record inlet pressure at gauge. Stop engine. Pressure should be between 107- 120 bar (1550-1750 psi).

  • Page 545: Fan Motor

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Fan Motor The hydraulic fan motor is mounted in front of the fan. It has an external relief valve which should be set at 103 bar (1500 psi). Step 1: Park the machine and set the parking brake.

  • Page 546: Adjustments

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual DJUSTMENTS Control Lever Linkage The control levers may require adjustment. They must be aligned with each other to allow the lever lock to engage. There are three threaded rods which link each lever to the control valve.

  • Page 547: Adjustments

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Adjustments Step 1: The easiest adjustment is at the top, 1, of the upper vertical link rod, 2. Step 2: If insufficient adjustment is available, the horizontal link rod, 1, should be adjusted.
  • Page 548 Section 8 65E Turbo Motor Grader Hydraulics Service Manual Step 3: Turn clevis, 1, counterclockwise to lengthen link rod, 2, and clockwise to shorten link rod. NOTE: Maintain a minimum of three threads between the link rods and clevis yokes.
  • Page 549 65E Turbo Motor Grader Section 8 Service Manual Hydraulics To replace main control valve bottom cover plate: Step 6: Using a lift, position cover plate, 1, for installation. Install seven bolts, 2, through cover plate into frame under control valve. Torque bolts to 47-53 (35-39 Ib-ft).

  • Page 550: Disassembly And Repair

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual ISASSEMBLY EPAIR Pump The pump, 2, is attached to the back of the transmis- sion, 1. A direct drive shaft through the transmission drives the pump. 8-18 Service 2.00_2013.03...

  • Page 551: Removal

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Removal Step 1: Remove bolts, 1, securing side vent covers, then remove side vent covers. Step 2: Place a lift under the bottom transmission cover, 1. Remove bolts, 2, 3, on rear and front of cover, and remove cover.
  • Page 552 Section 8 65E Turbo Motor Grader Hydraulics Service Manual NOTE: Since the hydraulic reservoir is above the pump up to a gallon of oil may drain from the lowest line. Rotating the engine by hand for one revolution will remove most of the oil from the pump.
  • Page 553 65E Turbo Motor Grader Section 8 Service Manual Hydraulics Step 8: Remove two bolts, 1, securing pump to transmission. Carefully remove pump, using pry bars as necessary. Step 9: Disassemble pump as needed. Refer to Eaton publication #6-623 (March 1993), for L2 Series Gear Pumps, at the end of this section.

  • Page 554: Installation

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Installation Step 1: Clean area around transmission output shaft and mounting surface of pump. Step 2: Install fittings, 1, in ports. Leave jam nuts loose to allow adjustment after hose connection.
  • Page 555 65E Turbo Motor Grader Section 8 Service Manual Hydraulics Step 6: Connect fan supply line, 1, to pump. Tighten and torque jam nut to 88-95 Nm (65-70 Ib-ft). Step 7: Connect pressure line, 2, from pump to fan motor. Tighten and torque jam nut to 125-136 Nm (92-100 Ib-ft).
  • Page 556 Section 8 65E Turbo Motor Grader Hydraulics Service Manual Step 10: Install side vent covers. Torque bolts, 1, to 47-53 Nm (35-39 Ib-ft). Step 11: Install bottom transmission cover, 1, with rear bolts, 2, and front bolts, 3. Snug torque rear bolts.

  • Page 557: Control Valve

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Control Valve The control valve sections operate the following hydraulic cylinder functions: 1, blade lift, 2, wheel lean, 3, articula- tion, 4, circle turn, 5, circle shift, 6, blade shift, 7, scarifier.
  • Page 558 Section 8 65E Turbo Motor Grader Hydraulics Service Manual Step 2: Place a lift under the control valve bottom cover plate, 1. Remove seven bolts, 2, securing cover plate. Remove cover plate. Step 3: Remove plug in hydraulic reservoir drain, 1, and attach hoses, 2.
  • Page 559 65E Turbo Motor Grader Section 8 Service Manual Hydraulics Step 5: Mark and disconnect harnesses as necessary and move out of the way. Step 6: Mark outlet hoses according to connections and disconnect. Plug and cap hoses and ports. Step 7: Disconnect inlet line, 1.

  • Page 560: Valve Disassembly

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Step 12: Remove upper valve mounting bolts, 1. Using adequate support for the valve, remove lower mounting bolts. Lower valve assembly with vertical linkage and pivot brackets attached and remove from bottom.

  • Page 561: Valve Assembly

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Step 3: Pull each section from the tie rods, 1. Do not lose the check valve spring, 2, and check valve between each section. Keep the spring and check valve with the section which it was removed from.

  • Page 562: Valve Installation

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Valve Installation Step 1: Install fittings in each section. Install valve on mounting plate, 1. Do not tighten bolts, 2. Step 2: Install inlet fitting, 1. Install back-pressure valve, 2, if equipped with float functions. Do not tighten jam nut to allow rotation and proper positioning of valve.
  • Page 563 65E Turbo Motor Grader Section 8 Service Manual Hydraulics Step 5: Attach inlet hose, 1, to control valve inlet fitting. Torque bolts attaching control valve to mounting plate 47-53 Nm (35-39 Ib-ft). Torque mounting plate bolts to 47-53 Nm (35-39 Ib-ft).
  • Page 564 Section 8 65E Turbo Motor Grader Hydraulics Service Manual Step 14: Using a lift, position control valve bottom cover plate for installation. Install seven bolts, 1, through cover plate into frame under control valve. Torque bolts to 47-53 Nm (35-39 Ib-ft).

  • Page 565: Valve Sections

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Valve Sections The sections are identical except for the end caps which contain the centering springs and detent balls. The stan- dard section, 1, uses a centering spring which forces the spool to the center, neutral position when the control lever is released.

  • Page 566: Standard Section Disassembly

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Standard Section Disassembly Step 1: Secure section in vice. Use care to prevent damage to the machined sealing surfaces, 1, on the side of the housing. Step 2: Remove screws, 2, securing lock ring on clevis end of spool, 3.

  • Page 567: Float Section Disassembly

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Float Section Disassembly Step 1: Place section in vise, taking care not to damage machined surfaces, 1, on housing. Step 2: Remove socket head screws, 2, securing lock ring, 3, and spacers, 4, 5, on clevis end of spool.

  • Page 568: Inspection

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Step 5: Place the clevis end of the spool in a vice and remove snap ring, 1, and washer, 2. Wrap a rag around the plunger cap, 3, to catch detent balls (four small balls...

  • Page 569: Standard Section Assembly

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Standard Section Assembly (1) Housing (5) Spring Seat (2) Lock Ring (6) Cap (3) Wiper (7) Spool (4) Seal NOTICE: Do not reuse seals and wipers. Step 1: Coat all parts with oil prior to installation.

  • Page 570: Float Section Assembly

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Step 5: With ports down and check valve visible, clevis end of spool is on left Insert spool, 1, into housing, 2. Carefully seat seal, 3, and wiper, 4, in counterbore in housing.
  • Page 571 65E Turbo Motor Grader Section 8 Service Manual Hydraulics Step 1: Coat all parts with oil prior to installation. Step 2: Place clevis end of spool in vise. Slide seal, 1, and wiper, 2, onto cap end of spool, 3. Wiper should be oriented with flat surface away from housing.
  • Page 572 Section 8 65E Turbo Motor Grader Hydraulics Service Manual Step 6: Raise the cap, 1, up against the detent sleeve. Place washer, 2, on end of cap and secure with snap ring, 3. Step 7: With ports down and check valve visible, clevis end of spool is on left Insert spool into housing, 1.

  • Page 573: Anti-Cavitation Cartridge

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Anti-Cavitation Cartridge The moldboard lift, 1, and implement lift, 2, sections incorporate anti-cavitation cartridge valves. Due to their weight, the implement and moldboard cylinders can drop faster than the hydraulic circuit can flow, causing cavita- tion (air in the system).
  • Page 574 Section 8 65E Turbo Motor Grader Hydraulics Service Manual If the check valve cartridge does not seem to be function- ing properly, it is usually the result of foreign material lodged between the piston, 11, and relief valve poppets, 12, 15. It can be disassembled for cleaning.

  • Page 575: Back Pressure Valve

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Back Pressure Valve When the optional float valve is installed, a back pressure valve, 1, is mounted at the outlet of the control valve. The check valve maintains a minimum of 207 kPa (30 psi) of back pressure through the control valve.
  • Page 576 Section 8 65E Turbo Motor Grader Hydraulics Service Manual To access the front bulkhead fittings and hose ends, remove the access plate, 1, and head lamp bracket, 2, from each side. The triple clamp is located at the articulation, and holds all hoses which are routed to the front hydraulic functions (excluding articulation and rear ripper cylinders).

  • Page 577: Selector Valves

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics When installing hoses using O-ring fittings and specific torque values are not provided, use the following chart as a guide. Size Thread Size (in.) Torque lb-ft 9/16-18 14-16 10-12 11/16-16 24-27...

  • Page 578: Solenoids

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Solenoids Solenoids can be removed and checked individually for the correct resistance. If resistance is incorrect, replace the solenoid. Step 1: Clean area around valve, 1, to prevent dirt contamination. Step 2: Remove three bolts, 1, securing cover and valve to terminal.
  • Page 579 65E Turbo Motor Grader Section 8 Service Manual Hydraulics Step 5: Measure the resistance between the two spade terminals, 1. Resistance should be 9.8 ohms. If resistance is incorrect, replace the solenoid. Current draw can also be checked by placing an ammeter in the series with a power source.

  • Page 580: Cartridge Replacement

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Cartridge Replacement If the solenoid is operating properly, the cartridges can be removed and connected to a 12 volt power source to determine if the poppet operates. Step 1: Remove three bolts, 1, securing cover and valve to terminal.
  • Page 581 65E Turbo Motor Grader Section 8 Service Manual Hydraulics Step 6: Install solenoid onto cartridge with inscription (12 VDC) away from cartridge. Install nut, 1, snugly against solenoid. Connect positive lead to terminal away from cartridge. Connect ground to terminal on cartridge end.

  • Page 582: Pitch/Side Shift And Front/Rear Implement Selector Valve Removal

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Pitch/Side Shift and Front/Rear Implement Selector Valve Removal The pitch/side shift and front/rear implement selector valves are mounted in similar fashion and can be removed and installed in the same manner.

  • Page 583: Pitch/Side Shift And Front/Rear Implement Selector Valve Installation

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Pitch/Side Shift and Front/Rear Implement Selector Valve Installation Step 1: Place valve in a suitable vise and install fittings. Leave angle fittings, 1, loose. Torque straight fittings to 25.8 +/- 1.3 Nm (19 +/- 1 Ib-fl.).

  • Page 584: Circle Shift/Saddle Pin Selector Valve Removal

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Circle Shift/Saddle Pin Selector Valve Removal The circle shift/saddle pin selector valve is mounted inside the front frame module. Access to the solenoids or cartridges require removal, which is different than the other selector valves.

  • Page 585: Circle Shift/Saddle Pin Selector Valve Installation

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Step 5: Remove nuts, 1, and washers from mounting bolts and remove bolts. Step 6: Maneuver valve rearward inside frame to access wire connections to the upper solenoids, 1. Pull wire connectors, 2, from spade terminals.
  • Page 586 Section 8 65E Turbo Motor Grader Hydraulics Service Manual Step 2: Place valve assembly inside front frame module. Orient valve with four outlet ports on top and two inlet ports on left side. Step 3: Maneuver valve forward in the frame to attach wire connectors to spade terminals on rear solenoids.

  • Page 587: Hydraulic Swivel

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Step 7: Attach saddle pin pressure lines to ports on left top face of valve. Torque hose fittings, 1, to 25.8 +/- 1.3 Nm (19 +/-1 Ib-ft). Torque jam nuts, 2, on elbow fittings to 25.8 +/- 1.3 Nm (19 +/-1 Ib-ft).

  • Page 588: Disassembly

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Step 3: Remove three bolts and nuts, 1, securing rotator plate, 2, to swivel assembly. Lower rotator plate down against mold-board. Step 4: Remove top bolts, 1, securing swivel assembly to mounting plate, 2.

  • Page 589: Inspection

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Step 3: Remove seals, 1, and wipers, 2, and discard. Inspection Inspect seals and wipers for cuts, tears and flat surfaces. Inspect rotor land surfaces and internal case surface for scratches, nicks and burrs.

  • Page 590: Installation

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Step 3: Place rotor in case until it contacts the first wiper. Place a hose clamp, 1, over the first wiper and seal. Snug hose clamp sufficiently to compress wiper but do not over-tighten.
  • Page 591 65E Turbo Motor Grader Section 8 Service Manual Hydraulics Step 3: Attach rotation plate, 1, to bottom of swivel assembly, 2, with bolts, 3, nuts and washers. Two mounting holes on case should in front (opposite guide rods) and one mounting hole in rear. Torque nuts to 122-136 Nm (90-100 Ib-ft).

  • Page 592: Circle Turn Hydraulic Motor

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Circle Turn Hydraulic Motor The circle turn hydraulic motor, 1, is mounted on the drawbar in front of the circle turn gearbox, 2. An adapter, 3, contains the coupler shaft NOTE: To aid access, side shift the circle to the right side.
  • Page 593 65E Turbo Motor Grader Section 8 Service Manual Hydraulics Step 5: Remove coupler, 1. Step 6: Remove bolts, 2, attaching adapter, 3, to gear box. Remove adapter. Step 7: Disassemble motor as needed. Refer to Eaton publication #7-145 (November 1996), for T Series Geroler Motors, at the end of this section.

  • Page 594: Installation

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Installation Step 1: Clean mounting surfaces of adapter, motor and gearbox. Step 2: Place two bolts, 2, through mounting holes in adapter, 3. Place gasket over bolts and attach to gearbox. Install remaining bolts and torque to 27-34 Nm (20-25 Ib-ft).

  • Page 595: Circle Turn Gearbox

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Circle Turn Gearbox The circle turn gearbox, 1, multiplies the torque from the motor, 2, at 18:1. It drives the circle through a small pin- ion gear attached to the output shaft If the pinion gear is replaced, the backlash will require adjustment after installation.

  • Page 596: Disassembly

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Step 7: Remove gearbox from drawbar. It may be necessary to use a jack or hydraulic ram, 1, to push gearbox boss and dowel pins from drawbar circle. Disassembly Step 1: Remove bolts, 1, and washers securing cover, 2.

  • Page 597: Assembly

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Assembly Step 1: Press bushing, 1, into bottom of case, 2. Install bushing, 3, and cap, 4, for input shaft, 5. Install bushing, 6, and cap, 7, in cover, 8. Step 2: Insert seal, 9, in bottom hole.

  • Page 598: Installation

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Key, 1, will push out of worm, 2, and against opposite end of case as shaft is inserted. Pull shaft back slightly until sufficient space is available for second spacer. Use a screw driver to move key back into worm, if necessary.
  • Page 599 65E Turbo Motor Grader Section 8 Service Manual Hydraulics Step 4: Install new lockwire, 1, through two retainer plate bolts, 2. Step 5: Rotate gearbox to one side so pinion teeth, 1, and circle teeth, 2, are contacting. Loosen mounting bolts (refer to previous step 2), move gearbox forward or backward to provide 1.016-1.524 mm...

  • Page 600: Cylinders

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Cylinders The cylinders are the same design, with a threaded cap, except for the steering and mold-board pitch cylinders, which use an internal snap ring to retain the gland. The saddle pin cylinder is a special pin/cylinder design.

  • Page 601: Lift Cylinder Installation

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Step 4: Carefully rotate cylinder assembly to horizontal and place barrel end on a support to gain access to the bottom bolts. Step 5: Remove bottom bolts, 1, washers, socket cap, 2, and shims, 3.
  • Page 602 Section 8 65E Turbo Motor Grader Hydraulics Service Manual Step 5: While supporting the barrel end of the cylinder, attach the socket end of the cylinder, 1, to the ball with the correct number of shims, 2, installed. Insert bolts, 3, and washers and torque to 407-475 Nm (300-350 Ib-ft).

  • Page 603: Circle Shift Cylinder Removal

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Circle Shift Cylinder Removal The circle shift cylinder uses a ball and socket connection Drawbar at each end. Frame Ball NOTE: The circle side shift cylinder should be extended a minimum of 76 mm (3 in.) before removal.

  • Page 604: Circle Shift Cylinder Installation

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Circle Shift Cylinder Installation Step 1: Place socket cap, 1, on end of cylinder, 2, and Drawbar measure inside dimension in line with cylinder. Frame Ball Step 2: Measure diameter of ball in approximate direction of circle side shift operation.

  • Page 605: Moldboard Side Shift Cylinder Removal

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Moldboard Side Shift Cylinder Removal Step 1: Support moldboard, 1, with chain and hoist, and tilt moldboard slightly forward. Step 2: Remove four screws, 2, securing two upper moldboard guides, 3. Remove guides. Using chain and hoist, tilt moldboard, 1, forward enough on lower moldboard guides, 4, to access two hydraulic lines, 5.

  • Page 606: Moldboard Pitch Cylinder Removal

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Step 4: Apply Loctite 242 to bolts, 1. Loosely install four bolts and washers on two top moldboard guides, 2. Adjust shims, 3, to 0.000-0.127 mm (0.00-0.005 in.) clearance, then torque bolts, 1, to 1,085 +/- 136 Nm (800 +/- 100 lb-ft).

  • Page 607: Moldboard Pitch Cylinder Installation

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Moldboard Pitch Cylinder Installation Step 1: Position moldboard pitch cylinder, 1, with cylinder clevis pin holes aligned with rear clevis, 2, on circle and front clevis, 3, on moldboard support. Step 2: Install mounting pin, 4, through rear circle clevis, 2, and cylinder clevis pin hole.
  • Page 608 Section 8 65E Turbo Motor Grader Hydraulics Service Manual Step 2: Remove bolts, 1, securing step assembly to operator's area. Step 3: Disconnect and cap hoses, 1. Step 4: Remove nut and bolt, 2, through pin at each end of cylinder.

  • Page 609: Articulation Cylinder Installation

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Articulation Cylinder Installation Step 1: Press spherical bushings, 2, in each cylinder end. Secure with snap rings, 1. Step 2: Position cylinder on front and rear clevis. Step 3: Orient pin on front clevis, 1, so hole aligns with clevis hole.

  • Page 610: Wheel Lean Cylinder Removal

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Wheel Lean Cylinder Removal Step 1: Mark, disconnect and cap hoses, 1. Step 2: Remove nut, 2, bolt, and two washers securing wheel lean cylinder, 3, and linkage, 4, to RH knuckle, 5.

  • Page 611: Wheel Lean Cylinder Installation

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Wheel Lean Cylinder Installation Step 1: Align wheel lean cylinder clevises with RH knuckle clevis, 1, and front axle clevis, 2. Step 2: Linkage, 3, must be raised enough to clear installation of pin, 4, from back to front back.

  • Page 612: Steering Cylinder Removal

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Steering Cylinder Removal Step 1: Disconnect and cap hoses, 1, from steering cylinder, 2. Step 2: Remove two bolts, 1, and washers securing lock plate, 2, to front axle. Slide lock plate out from slot in cylinder pin, 3.

  • Page 613: Steering Cylinder Installation

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Steering Cylinder Installation Step 1: Position steering cylinder for installation with cylinder clevis, 1, aligned with front axle clevis, 2, and cylinder socket, 3, aligned with mounting hole in LH spindle, 4. Rotate wheels as required to fit steering cylinder.

  • Page 614: Steering Cylinder Adjustment

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Step 4: Reconnect hoses, 1, to steering cylinder, 2. Torque fittings to 25.8 +/- 1.3 Nm (19 +/- 1 Ib-ft). Steering Cylinder Adjustment Step 1: Turn left wheel until LH spindle stop, 1, touches LH axle stop surface, 2.
  • Page 615 65E Turbo Motor Grader Section 8 Service Manual Hydraulics If steering cylinder fully closed/fully extended measure- ments do not meet requirements of proceeding steps 1 and 2, steering cylinder must be adjusted as follows: Step 3: Turn left wheel until LH spindle stop, 1, touches LH axle stop surface, 2.

  • Page 616: Front End Attachment Cylinder Removal

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Front End Attachment Cylinder Removal Step 1: Raise front end attachment until lock pin holes on right side of lift linkage are aligned, then install red safety support bolt, 1, through lock pin holes.

  • Page 617: Front End Attachment Cylinder Installation

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Step 4: Remove nut from cylinder upper pin, 1, retainer bolt, 2, then remove bolt and drive out upper pin. Step 5: Remove front end attachment cylinder, 3, and four washers (two washers per pin).

  • Page 618: Rear Ripper Cylinder Removal

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Rear Ripper Cylinder Removal Step 1: Raise rear ripper until lock pin holes on right side of lift linkage are aligned, then install red safety support bolt through lock pin holes.

  • Page 619: Bank Slope Cylinder Removal

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Step 6: Install retainer bolt, 1, through holes in cylinder upper clevis, 2, and pin, 3. Install nut, 4, on retainer bolt, 1, and torque to 14.9 +/- 1.3 Nm (11 +/- 1 Ib-ft).

  • Page 620: Bank Slope Cylinder Installation

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Bank Slope Cylinder Installation Step 1: Align cylinder rod, 1, with rod holes in saddle, 2, and saddle support, 3. Step 2: Align mounting holes in cylinder, 4, with mounting holes in saddle, 2, and install four bolts, 5, and washers.

  • Page 621: Cylinder Disassembly

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Cylinder Disassembly The hydraulic cylinders are basically the same design, except that the wheel lean, moldboard shift, circle side shift, lift, articulation, front end attachment, and rear rip- per cylinders use a threaded cap to retain the gland.

  • Page 622: Cylinder Inspection And Assembly

    Section 8 65E Turbo Motor Grader Hydraulics Service Manual Cylinder Inspection and Assembly Step 1: Clean all components thoroughly. Inspect piston and rod surfaces for scratches, nicks, burrs, tears, etc. If seals are torn or deformed, they must be replaced.
  • Page 623 65E Turbo Motor Grader Section 8 Service Manual Hydraulics Step 4: The bank slope cylinder is of a different design, with a tube assembly, 1, differences in the piston, 6, and rod, 14, a retaining ring, 7, and a cylinder head, 12, that serves as a threaded cap and gland.
  • Page 624 Section 8 65E Turbo Motor Grader Hydraulics Service Manual Step 6: Install nut, 4, on end of rod,1. Torque nut, 4, to 366-406 Nm (270-300 Ib-ft). Step 7: Install nut end of rod, 1, into barrel with piston, 3, and gland, 2, (except bank slope cylinder) taking care to keep piston and gland centered in barrel.

  • Page 625: Hydraulic Oil Filter And Strainers

    65E Turbo Motor Grader Section 8 Service Manual Hydraulics Hydraulic Oil Filter And Strainers Hydraulic Filter Change hydraulic filter when oil is cool. Refer to the Operator Manual for hydraulic oil and filter service inter- vals. Fluid is under pressure. turn cap slowly to relieve pressure before removing.
  • Page 626 Section 8 65E Turbo Motor Grader Hydraulics Service Manual Hydraulic Strainers Two strainers, a fill neck strainer and suction strainer, are used in the hydraulic system. Both are located under the fill cap cover, 2. Clean strainers when filter element is changed.
  • Page 627 No. 6-623 Eaton ® Revised March, 1993 Gear Pumps Parts Information Model 25500 Gear Pumps L2 Series...
  • Page 628 Model 25500 Gear Pumps L2 Series Pump Drawing Item 2 Backplate see pages 3 and 4 Item No. 3 Item No. 13 Item No. 14 Displacement Body /r in Assembly Screw Screw 21.3 [1.30] 25500 - 263 16119 - 630 16119 - 626 25.4 [1.55] 25501 - 261...
  • Page 629 Model 25500 Gear Pumps L2 Series Backplate Drawings Plain Backplate Flow Divider Backplate Tandem Backplate – AAFlange 32A4 32A3 32A2 32A1 32A4 32A3 Tandem Backplate – AFlange 32A2 32B1...
  • Page 630 Model 25500 Gear Pumps L2 Series Backplate Parts List Item Part Number Description Qty. Plain Backplate 25500 - 49 O-ring Ports – Side 25500 - 51 O-ring Ports – Rear 25500 - 47 Split Flange Ports – Side Flow Divider Backplate 25530 - 31 O-ring Ports –...
  • Page 631 Model 25500 Gear Pumps L2 Series Pump Parts List Item Part Number Description Qty. Frontplate Assembly 25500 - 526 Left-Hand Rotation 25500 - 527 Right-Hand Rotation Backplate Assembly (see pages 3 and 4) ∆ Body Assembly ∆ Drive Gear Assembly (7/8 inch 13 Tooth Spline Shaft) ∆...
  • Page 632 Model 25500 Gear Pumps L2 Series Pump Identification – Numbers Stamped on Mounting Flange Date Code 0 0 0 0 0 0 2 5 5 0 2 - RSA Product Number Last Number Sequential Identification of Year Built Rotation Engineering R = Right-Hand Change Code L = Left-Hand...
  • Page 633 ® No. 7-145 Char-Lynn November, 1996 Hydraulic Motor Repair Information T Series ® General Purpose Geroler Motor...
  • Page 634 General Purpose Motors Output Shaft Needle Thrust Bearing Parts Drawing Bearing Race Seal Pressure Seal Back-Up Ring Mounting Flange Exclusion Seal Screw Cap Screw End Cap Seal Geroler Seal Spacer Plate Drive Seal Housing Tools Required • Torque wrench ( 34 Nm [300 lb-in] capacity) •...
  • Page 635 General Purpose Motors T Series Geroler Motors Seal End Cap Geroler Seal Cap Screw (7) Disassembly Spacer Plate Seal Drive Figure 1 Cleanliness is extremely important when repairing hydraulic 2 Remove the seven cap screws from the end cap and disas- motors.
  • Page 636 General Purpose Motors Disassembly Caution: These screws were Loctited during assembly. Do Not exceed 56 Nm [500 lb-in] of removal torque. If the Loctite is holding the screws too tightly, heat the motor housing, with a propane torch, while turning the screw. Apply heat to where the screw threads into the motor housing, see figure 3.
  • Page 637 General Purpose Motors T Series Geroler Motors Reassembly Important: The Loctite must cure completely before the motor is put into service. Loctite curing time is six hours. 11 Lubricate and install the back-up ring and pressure seal. Use of Loctite Primer reduces curing time to 15 minutes. Use seal installation tool no.
  • Page 638 General Purpose Motors Geroler Star Valley Star Point Timing Dot Spacer Plate Threaded hole for Timing Dot Reference Standard Timing Reverse Timing Speed Sensor Installation Figure 6 Reference Notch Notch Perpendicular to Centerline of Motor Speed Sensor 9/16 inch 90° Hex Head Fabricated Wrench...
  • Page 639 General Purpose Motors How to Order Replacement Parts Date Code Char-Lynn ® Each Order Must Include the Following: 00 0 Product number 1. Product Number 4. Part Number Week of Last 2. Date Code 5. Quantity of Parts Year 01 Number Eaton Corp.
  • Page 640 Section 8 65E Turbo Motor Grader Hydraulics Service Manual This page intentionally left blank. 8-108 Service 2.00_2013.03...
  • Page 641 Service Manual Section 9: Moldboard and Implement Service 2.00_2013.03...
  • Page 643 65E Turbo Motor Grader Section 9 Service Manual Moldboard and Implement SAFETY PRECAUTION INFORMATION UNSAFE OPERATING PRACTICES AND IMPROPER USE OF THE MACHINE AND ITS ATTACHMENTS ON THE PART OF THE OPERATOR OR SERVICE TECHNICIAN CAN RESULT IN INJURIES. OBSERVE THE FOLLOWING SAFETY PRECAUTIONS AT ALL TIMES: 1.
  • Page 644 Section 9 65E Turbo Motor Grader Moldboard and Implement Service Manual 15. Install all shields before starting or operating machine. 16. Do not operate an unsafe machine. If items are found during inspection that render a machine unsafe, be sure any malfunctions are remedied before accepting responsibility for operation.
  • Page 645 65E Turbo Motor Grader Section 9 Service Manual Moldboard and Implement 33. Remember that the vehicle, if abused or incorrectly used, can be dangerous and become a hazard to the operator and bystanders. 34. Noise levels can exceed recommended levels when working between buildings or in confined areas on canopy equipped machines or cab equipped machines with doors and windows open.
  • Page 646 Section 9 65E Turbo Motor Grader Moldboard and Implement Service Manual 50. After operating the engine, never touch the muffler, exhaust pipe, engine or radiator until they have had time to cool. 51. Dress appropriately - wear relatively tight-fitting clothing when operating or servicing the machine.
  • Page 647 65E Turbo Motor Grader Section 9 Service Manual Moldboard and Implement 65. Do not attempt to service air conditioning system, if equipped. It is possible to be severely frostbitten or injured by escaping refrigerant. Special equipment and instruments are required to service air conditioning system. See an authorized dealer for service.
  • Page 648 Section 9 65E Turbo Motor Grader Moldboard and Implement Service Manual 81. If welding is required on an attachment, remove the attachment from the machine. 82. Give complete and undivided attention to the job at hand so that complete control of the machine is maintained at all times.
  • Page 649 65E Turbo Motor Grader Section 9 Service Manual Moldboard and Implement OSHA REQUIREMENTS NOW MAKE IT THE EMPLOYER'S RESPONSIBILITY TO FULLY INSTRUCT EACH OPERATOR IN THE PROPER AND SAFE OPERATION OF ALL OPERATIVE EQUIPMENT. BOTH EMPLOYER AND EMPLOYEE SHOULD THOROUGHLY FAMILIARIZE THEMSELVES WITH THE MACHINE OPERATION.
  • Page 650 Section 9 65E Turbo Motor Grader Moldboard and Implement Service Manual This page intentionally left blank. Service 2.00_2013.03...
  • Page 651 65E Turbo Motor Grader Section 9 Service Manual Moldboard and Implement ONTENTS General ..............9-1 Specifications .
  • Page 652 Section 9 65E Turbo Motor Grader Moldboard and Implement Service Manual This page intentionally left blank. 9-xii Service 2.00_2013.03...

  • Page 653: General

    65E Turbo Motor Grader Section 9 Service Manual Moldboard and Implement Section 9: Moldboard and Implement GENERAL The moldboard, 1, is used to contact the ground and move material. The load on the moldboard is trans- ferred through the circle, 2, drawbar, 3, and to the frame, 4.

  • Page 654: Specifications

    Section 9 65E Turbo Motor Grader Moldboard and Implement Service Manual PECIFICATIONS Drawbar Type....... .A-Frame Welded Steel with Center Mounted Circle Turn Motor Connection.

  • Page 655: Standard Moldboard Reach

    65E Turbo Motor Grader Section 9 Service Manual Moldboard and Implement Standard Moldboard Reach* (Including Circle Shift, Outside Rear Wheels, Frame Straight): Left..............994 mm (39.1 in.) Right .

  • Page 656: Front Dozer Blade

    Section 9 65E Turbo Motor Grader Moldboard and Implement Service Manual Front Dozer Blade Attachment............... . Front Weight .

  • Page 657: Troubleshooting Chart

    65E Turbo Motor Grader Section 9 Service Manual Moldboard and Implement Before disconnecting lines or fittings, be sure to turn off the engine and relieve all pressure. Before applying pressure to the system, be sure all connections are tight and that lines, pipes and hoses are not damaged.

  • Page 658: Disassembly And Repair

    Section 9 65E Turbo Motor Grader Moldboard and Implement Service Manual ISASSEMBLY EPAIR Drawbar The drawbar is attached to the front frame through a pin. Removal Step 1: Remove access plates, 1, on both sides of front frame, then mark, disconnect and cap hydraulic lines, 2.

  • Page 659: Circle

    65E Turbo Motor Grader Section 9 Service Manual Moldboard and Implement Step 3: Attach drawbar to front frame with drawbar pin, install pin retaining bolt, 3, and torque to 14.9 +/- 1.3 Nm (11 +/- 1 ft-lb). Step 4: Connect drawbar hydraulic lines, 2, to front frame hydraulic fittings, and torque to 25.8 +/- 1.3 Nm...
  • Page 660 Section 9 65E Turbo Motor Grader Moldboard and Implement Service Manual Step 3: Loosen two horizontal set screws, 2, then remove two vertical lock screws, 1, at each of four guide clamps. Remove guide clamps. Step 4: Mark, disconnect, and cap four hydraulic lines, 1, from swivel assembly, 2, to allow separation of drawbar, 3, from circle, 4.

  • Page 661: Installation

    65E Turbo Motor Grader Section 9 Service Manual Moldboard and Implement Installation Step 1: Align drawbar, 1, with circle, 2, so that moldboard, 3, is perpendicular to drawbar. Step 2: Before lowering drawbar, 1, position drawbar so that guide bars, 2, are slightly in front of and aligned with guide bar holes in circle, 3.
  • Page 662 Section 9 65E Turbo Motor Grader Moldboard and Implement Service Manual Step 5: Connect four hydraulic lines, 1, to four lower fittings on swivel assembly, 2. Torque to 25.8 +/- 1.3 (19 +/- 1 Ib-ft.). Step 6: Using two bolts and washers, secure two moldboard hoses, 1, with two hose clamps, 2.
  • Page 663 65E Turbo Motor Grader Section 9 Service Manual Moldboard and Implement Step 8: Install shims, 4, on vertical screws between wear plates and guide clamps at four guide clamp locations. Start with guide closest to circle motor, and adjust to provide 1.52 mm (0.06 in.) vertical clearance, 3,...

  • Page 664: Swivel Yoke

    Section 9 65E Turbo Motor Grader Moldboard and Implement Service Manual Swivel Yoke Removal NOTE: Before removing swivel yoke, remove lift cylinder in accordance with Section 07, Hydraulics, Disassembly and Repair, Cylinders. Step 1: Place pipe, 1, through yoke, 2, to prevent movement.
  • Page 665 65E Turbo Motor Grader Section 9 Service Manual Moldboard and Implement Step 2: Place thrust washer, 1, in retainer end of support. Step 3: Apply grease liberally to bearings and cavity between bearings. Holes in bearings should retain as much grease as possible.

  • Page 666: Moldboard

    Section 9 65E Turbo Motor Grader Moldboard and Implement Service Manual Moldboard Removal Step 1: Support moldboard, 1, with chain and hoist. Step 2: Loosen four screws, 1, securing two upper moldboard guides, 2, then support and tilt moldboard, 3, forward enough on lower moldboard guides, 4, to access two hydraulic lines.

  • Page 667: Installation

    65E Turbo Motor Grader Section 9 Service Manual Moldboard and Implement Installation Step 1: Using chain and hoist, position and support moldboard, 1, on lower support guides, 2, and align shift cylinder LH clevis, 3, with moldboard LH clevis, 4.

  • Page 668: Saddle

    Section 9 65E Turbo Motor Grader Moldboard and Implement Service Manual Saddle NOTE: To remove lift cylinders from saddle, refer to Section 07, Hydraulics, Disassembly and Repair, Cylinders. Removal Step 1: Support saddle, 1, with chain and hoist. Step 2: Mark, disconnect, and cap two hydraulic lines, 1, from circle shift cylinder, 2.

  • Page 669: Installation

    65E Turbo Motor Grader Section 9 Service Manual Moldboard and Implement Step 5: Loosen screws, 1, on lift cylinder clamp mounts, 2, enough to remove from drawbar knuckles, 3. Step 6: Unscrew and remove eight screws, 1, securing saddle, 2, to four saddle mounts, 3 (two screws per mount).
  • Page 670 Section 9 65E Turbo Motor Grader Moldboard and Implement Service Manual Step 4: Use a micrometer, 1, to measure vertical diameter of drawbar knuckle ball, 2. Step 5: Subtract the inside socket measurement from the vertical diameter measurement. Add shims to obtain clearance between 0.00-0.13mm (0.000-0.005 in.).
  • Page 671 65E Turbo Motor Grader Section 9 Service Manual Moldboard and Implement Step 10: Place a dial indicator at the bottom of the cylinder socket cap, 1. Set to 0.000 mm (0.000 in.). Step 11: Use the grader hydraulics to raise the moldboard.

  • Page 672: Front Scarifier

    Section 9 65E Turbo Motor Grader Moldboard and Implement Service Manual Front Scarifier Removal Step 1: Raise scarifier, 1, until lock pin holes on right side of lift linkage are aligned, then install red safety support bolt, 2, through lock pin holes.

  • Page 673: Front Dozer Blade

    65E Turbo Motor Grader Section 9 Service Manual Moldboard and Implement Front Dozer Blade Removal Step 1: Raise front dozer blade until lock pin holes on right side of lift linkage are aligned, then install red safety support bolt, 1, through lock pin holes.

  • Page 674: Rear Ripper

    Section 9 65E Turbo Motor Grader Moldboard and Implement Service Manual Step 2: Align dozer blade, 1, four mounting holes with lift linkage four mounting holes, and install four mounting bolts, 2, twelve plain washers, 3, and eight shims, 4.

  • Page 675: Installation

    65E Turbo Motor Grader Section 9 Service Manual Moldboard and Implement Step 3: Remove four retaining bolts, 1, and nuts, 2, from four pins, 3, securing rear ripper, 4, to upper, 5, and lower, 6, arm weld assemblies, then remove four pins, 3, and eight shims, 7.
  • Page 676 Section 9 65E Turbo Motor Grader Moldboard and Implement Service Manual Step 4: Position two cylinder clevises, 1, in alignment with two rear ripper mounting tangs, 2, and install one pin, 3, and two shims, 4, in each clevis, 1.
  • Page 677 Service Manual Section 10: Diagnostic Fault Codes Service 2.00_2013.03...
  • Page 679 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes SAFETY PRECAUTION INFORMATION UNSAFE OPERATING PRACTICES AND IMPROPER USE OF THE MACHINE AND ITS ATTACHMENTS ON THE PART OF THE OPERATOR OR SERVICE TECHNICIAN CAN RESULT IN INJURIES. OBSERVE THE FOLLOWING SAFETY PRECAUTIONS AT ALL TIMES: 1.
  • Page 680 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual 15. Install all shields before starting or operating machine. 16. Do not operate an unsafe machine. If items are found during inspection that render a machine unsafe, be sure any malfunctions are remedied before accepting responsibility for operation.
  • Page 681 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes 33. Remember that the vehicle, if abused or incorrectly used, can be dangerous and become a hazard to the operator and bystanders. 34. Noise levels can exceed recommended levels when working between buildings or in confined areas on canopy equipped machines or cab equipped machines with doors and windows open.
  • Page 682 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual 50. After operating the engine, never touch the muffler, exhaust pipe, engine or radiator until they have had time to cool. 51. Dress appropriately - wear relatively tight-fitting clothing when operating or servicing the machine.
  • Page 683 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes 65. Do not attempt to service air conditioning system, if equipped. It is possible to be severely frostbitten or injured by escaping refrigerant. Special equipment and instruments are required to service air conditioning system. See an authorized dealer for service.
  • Page 684 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual 81. If welding is required on an attachment, remove the attachment from the machine. 82. Give complete and undivided attention to the job at hand so that complete control of the machine is maintained at all times.
  • Page 685 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes OSHA REQUIREMENTS NOW MAKE IT THE EMPLOYER'S RESPONSIBILITY TO FULLY INSTRUCT EACH OPERATOR IN THE PROPER AND SAFE OPERATION OF ALL OPERATIVE EQUIPMENT. BOTH EMPLOYER AND EMPLOYEE SHOULD THOROUGHLY FAMILIARIZE THEMSELVES WITH THE MACHINE OPERATION.
  • Page 686 Section 10 65E Turbo Motor Grader Electronic Display Service Manual This page intentionally left blank. 10-x Service 2.00_2013.03...
  • Page 687 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes ONTENTS ......... 10-1...
  • Page 688 Section 10 65E Turbo Motor Grader Electronic Display Service Manual This page intentionally left blank. 10-xii Service 2.00_2013.03...
  • Page 689 Section 10: Diagnostic Fault Codes The NORAM 65ET Grader is equipped with one of four engine options. The following tables list all the fault codes for the NORAM 65ET Grader engine options and transmission. Fault codes are listed according to type of engine followed by transmission fault codes.
  • Page 690 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual UMMINS AULT ODES Cummins Description Extended Crankcase Blow-by Pressure Circuit - Voltage Above Normal, or Shorted to High Source Extended Crankcase Blow-by Pressure Circuit - Voltage Below Normal, or Shorted...
  • Page 691 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description Engine Particulate Trap Inlet Pressure - Data Valid but Above Normal Operational Range - Moderately Severe Level Air Start Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source...
  • Page 692 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description SAE J1939 Multiplexed Accelerator Pedal or Lever Sensor System - Abnormal Update Rate. The ECM expected information from a multiplexed accelerator pedal or lever sensor but did not receive it soon enough or did not receive it at all.
  • Page 693 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description Water in Fuel Indicator Sensor Circuit - Voltage Above Normal, or Shorted to High Source Water in Fuel Indicator Sensor Circuit - Voltage Below Normal, or Shorted to Low...
  • Page 694 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description Crankcase Pressure Circuit - Voltage Above Normal, or Shorted to High Source Crankcase Pressure Circuit - Voltage Below Normal, or Shorted to Low Source Crankcase Pressure - Data Erratic, Intermittent, or Incorrect...
  • Page 695 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description Intake Manifold 1 Temperature Sensor Circuit - Voltage Below Normal, or Shorted to Low Source Intake Manifold 1 Temperature - Data Valid but Above Normal Operational Range -...
  • Page 696 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description Engine Coolant Temperature - Data Valid but Below Normal Operational Range - Least Severe Level Coolant Temperature Gauge Circuit - Root Cause Not Known Engine Coolant Temperature - Data Erratic, Intermittent, or Incorrect...
  • Page 697 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description Fuel Delivery Pressure 1 - Data Valid but Above Normal Operational Range - Most Severe Level Injector Timing Rail 1 Fuel Pressure Sensor Circuit - Voltage Above Normal, or...
  • Page 698 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description Gas Supply Pressure (Regulated) - Data Valid but Above Normal Operational Range - Most Severe Level Gas Supply Pressure (Regulated) - Data Valid but Below Normal Operational...
  • Page 699 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description Exhaust Gas Temperature - Data Valid but Above Normal Operational Range - Moderately Severe Level Exhaust Gas Temperature Sensor 1 Circuit - Voltage Above Normal, or Shorted to...
  • Page 700 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description Transmission Oil Temperature Sensor Circuit - Voltage Below Normal, or Shorted to Low Source Transmission (or Gearbox) Oil Temperature - Data Valid but Above Normal Operational Range - Most Severe Level...
  • Page 701 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description Exhaust Gas Recirculation Valve Delta Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Source Exhaust Gas Recirculation Valve Delta Pressure Sensor Circuit - Voltage Below...
  • Page 702 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description Accelerator Pedal or Lever Idle Validation Switch - Received Network Data in Error. The J1939 multiplexing controller has indicated a malfunction of the accelerator pedal or lever idle validation switch.
  • Page 703 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description Analog Input signal circuit for Load Govern kW Setpoint - Voltage Below Normal, or Shorted to Low Source Analog Input signal circuit for Load Govern kVAR Setpoint - Voltage Above Normal,...
  • Page 704 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description Unable to complete remote connection via the Modem - Condition Exists Lonworks Network Failure - Condition Exists Permission to connect to a closed bus has not been received in the required time -...
  • Page 705 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description Power Down Mode Function is Enabled, but the Automatic Main Utility Module and/ or the Lonworks board is unavailable - Condition Exists Genset in Idle Mode Too Long - Condition Exists...
  • Page 706 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description Start Enable Device 1Circuit (Ether Injection) - Voltage Below Normal, or Shorted to Low Source Injector Power Supply - Bad Intelligent Device or Component Power Supply Lost With Ignition On - Data Erratic, Intermittent, or Incorrect...
  • Page 707 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description Electronic Fuel Injection Control Valve Circuit - Voltage Below Normal, or Shorted to Low Source Electronic Fuel Injection Control Valve Circuit - Current Below Normal, or Open...
  • Page 708 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description SAE J1939 Datalink - Abnormal Update Rate Auxiliary Commanded Dual Output Shutdown - Special Instructions VGT Actuator Driver Circuit - Condition Exists VGT Actuator Driver Circuit - Abnormal Update Rate...
  • Page 709 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description Injector Solenoid Driver Cylinder 1 - Mechanical System Not Responding Properly or Out of Adjustment Injector Solenoid Driver Cylinder 1 - Data Erratic, Intermittent, or Incorrect Injector Solenoid Driver Cylinder 1 - Out of Calibration...
  • Page 710 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description Injector Solenoid Driver Cylinder 7 Circuit - Current Above Normal, or Grounded Circuit Injector Solenoid Driver Cylinder 8 Circuit - Current Below Normal, or Open Circuit Injector Solenoid Driver Cylinder 8 Circuit - Current Above Normal, or Grounded...
  • Page 711 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description Auxiliary Input 1 Active - Condition Exists Auxiliary Input/Output 2 Circuit - Voltage Above Normal, or Shorted to High Source Auxiliary Input 2 Active - Condition Exists...
  • Page 712 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description Heated Oxygen Sensor Circuit - Voltage Above Normal, or Shorted to High Source Heated Oxygen Sensor Circuit - Voltage Below Normal, or Shorted to Low Source Heated Oxygen Sensor - Data Valid but Above Normal Operational Range -...
  • Page 713 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description Remote Accelerator Pedal or Lever Position Sensor 1 Circuit - Voltage Below Normal, or Shorted to Low Source Remote Accelerator Pedal or Lever Position Sensor 1 Circuit - Voltage Above...
  • Page 714 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description 1077 Fuel Pump Control Module Self-Test - Bad Intelligent Device or Component 1077 Fuel Pump Control Module Fueling or Engine Speed Mismatch - Out of Calibration 1077...
  • Page 715 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description 1128 Intake Manifold 2 Pressure - Data Valid but Above Normal Operational Range - Moderately Severe Level 1128 Intake Manifold 2 Pressure - Data Valid but Below Normal Operational Range -...
  • Page 716 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description 1132 Intake Manifold 3 Temperature - Data Valid but Above Normal Operational Range - Most Severe Level 1132 Intake Manifold 3 Temperature - Data Erratic, Intermittent, or Incorrect...
  • Page 717 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description 1138 Exhaust Gas Temperature Cylinder 2 - Data Valid but Above Normal Operational Range - Most Severe Level 1138 Exhaust Gas Temperature Sensor Circuit Cylinder 2 - Voltage Below Normal, or...
  • Page 718 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description 1141 Exhaust Gas Temperature Cylinder 5 - Data Valid but Above Normal Operational Range - Moderately Severe Level 1141 Exhaust Gas Temperature Cylinder 5 - Data Valid but Below Normal Operational...
  • Page 719 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description 1145 Exhaust Gas Temperature Cylinder 9 - Data Valid but Above Normal Operational Range - Most Severe Level 1145 Exhaust Gas Temperature Sensor Circuit Cylinder 9 - Voltage Below Normal, or...
  • Page 720 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description 1148 Exhaust Gas Temperature Cylinder 12 - Data Valid but Above Normal Operational Range - Moderately Severe Level 1148 Exhaust Gas Temperature Cylinder 12 - Data Valid but Below Normal Operational...
  • Page 721 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description 1152 Exhaust Gas Temperature Sensor Circuit Cylinder 16 - Voltage Below Normal, or Shorted to Low Source 1152 Exhaust Gas Temperature Sensor Circuit Cylinder 16 - Voltage Above Normal, or...
  • Page 722 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description 1169 Turbocharger 2 Speed - Data Valid but Above Normal Operational Range - Moderately Severe Level 1169 Turbocharger 2 Speed - Data Valid but Below Normal Operational Range -...
  • Page 723 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description 1176 Turbocharger 1 Compressor Inlet Pressure - Data Valid but Below Normal Operational Range - Moderately Severe Level 1176 Turbocharger 1 Compressor Inlet Pressure Circuit - Voltage Above Normal, or...
  • Page 724 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description 1188 Turbocharger 1 Wastegate Control Circuit - Voltage Below Normal, or Shorted to Low Source 1188 Turbocharger 1 Wastegate Control - Mechanical System Not Responding Properly or Out of Adjustment...
  • Page 725 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description 1231 SAE J1939 Data Link 2 Engine Network - Data Erratic, Intermittent, or Incorrect 1231 SAE J1939 Data Link 2 Engine Network - Abnormal Update Rate 1237...
  • Page 726 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description 1269 Ignition Coil Internal Spark Cylinder 2 - Root Cause Not Known 1270 Ignition Coil Cylinder 3 - Voltage Below Normal, or Shorted to Low Source 1270...
  • Page 727 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description 1280 Ignition Coil Cylinder 13 - Voltage Below Normal, or Shorted to Low Source 1280 Ignition Coil Prognostic Cylinder 13 - Data Valid but Above Normal Operational...
  • Page 728 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description 1295 Engine Spark Plug #2 Voltage - Data Valid but Above Normal Operational Range - Least Severe Level 1295 Engine Spark Plug #2 Voltage - Data Valid but Below Normal Operational Range -...
  • Page 729 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description 1301 Spark Plug Prognostic Cylinder 8 - Data Valid but Above Normal Operational Range - Least Severe Level 1301 Spark Plug Flash-over Cylinder 8 - Root Cause Not Known...
  • Page 730 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description 1311 Spark Plug Prognostic Cylinder 18 - Data Valid but Above Normal Operational Range - Least Severe Level 1311 Spark Plug Flash-over Cylinder 18 - Root Cause Not Known...
  • Page 731 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description 1324 Engine Misfire Cylinder 2 - Condition Exists 1324 Engine Misfire Cylinder 2 - Condition Exists 1325 Exhaust Gas Temperature Deviation Low for Cylinder 3 - Data Valid but Below...
  • Page 732 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description 1328 Exhaust Gas Temperature Cylinder 6 - Data Valid but Below Normal Operational Range - Moderately Severe Level 1328 Engine Misfire Cylinder 6 - Condition Exists 1328...
  • Page 733 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description 1333 Exhaust Gas Temperature Deviation High for Cylinder 11 - Data Valid but Above Normal Operational Range - Moderately Severe Level 1333 Exhaust Gas Temperature Cylinder 11 - Data Valid but Below Normal Operational...
  • Page 734 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description 1340 Exhaust Gas Temperature Cylinder 18 - Data Valid but Below Normal Operational Range - Moderately Severe Level 1340 Engine Gas Temperature Deviation High for Cylinder 18 - Data Valid but Above...
  • Page 735 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description 1352 Engine Cylinder 1 Knock - Data Valid but Above Normal Operational Range - Most Severe Level 1352 Engine Cylinder 1 Knock - Voltage Below Normal, or Shorted to Low Source...
  • Page 736 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description 1356 Engine Cylinder 5 Knock - Data Valid but Above Normal Operational Range - Least Severe Level 1356 Engine Cylinder 5 Knock - Data Valid but Above Normal Operational Range -...
  • Page 737 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description 1360 Engine Cylinder 9 Knock - Data Valid but Above Normal Operational Range - Moderately Severe Level 1361 Engine Cylinder 10 Knock - Data Valid but Above Normal Operational Range - Most...
  • Page 738 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description 1364 Engine Cylinder 13 Knock - Data Valid but Above Normal Operational Range - Most Severe Level 1364 Engine Cylinder 13 Knock Sensor Circuit - Voltage Below Normal, or Shorted to Low...
  • Page 739 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description 1367 Engine Cylinder 16 Knock Sensor Circuit - Voltage Above Normal, or Shorted to High Source 1368 Engine Cylinder 17 Knock - Data Valid but Above Normal Operational Range - Least...
  • Page 740 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description 1371 Engine Cylinder 20 Knock Sensor Circuit - Voltage Below Normal, or Shorted to Low Source 1371 Engine Cylinder 20 Knock Sensor Circuit - Voltage Above Normal, or Shorted to...
  • Page 741 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description 1387 Auxiliary Pressure Sensor Input 1 Circuit - Voltage Below Normal, or Shorted to Low Source 1387 Auxiliary Pressure Sensor Input 1 - Special Instructions 1387 Auxiliary Pressure Sensor Input 1 Circuit - Voltage Below Normal, or Shorted to Low...
  • Page 742 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description 1623 Tachograph Output Shaft Speed - Abnormal Update Rate. No communication or an invalid date transfer rate has been detected on the J1939 data link between the ECM and the tachograph output shaft speed sensor.
  • Page 743 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description 1761 Catalyst Tank Level - Data Valid but Above Normal Operational Range - Moderately Severe Level 1761 Catalyst Tank Level - Data Valid but Below Normal Operational Range - Most...
  • Page 744 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description 2434 Engine Exhaust Gas Temperature - Left Manifold - Data Valid but Above Normal Operational Range - Moderately Severe Level 2434 Engine Exhaust Gas Temperature - Left Manifold - Data Valid but Above Normal...
  • Page 745 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description 2629 Turbocharger Compressor Outlet Temperature (Calculated) - Data Valid but Above Normal Operational Range - Least Severe Level 2630 Engine Charge Air Cooler Outlet Temperature - Voltage Above Normal, or Shorted...
  • Page 746 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description 2795 VGT Position Sensor Circuit - Out of Calibration 2796 Transfer Case Selector Switch - Data Erratic, Intermittent, or Incorrect 2796 Transfer Case Selector Switch Circuit - Voltage Below Normal, or Shorted to Low...
  • Page 747 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description 2980 Gas Control Valve 1 Outlet Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source 2981 Engine Coolant Pressure 2 Low Temperature Sensor - Data Valid but Below Normal...
  • Page 748 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description 3217 Aftertreatment Inlet Oxygen Concentration - Data Erratic, Intermittent, or Incorrect 3217 Aftertreatment Inlet Oxygen Concentration Sensor Circuit - Abnormal Update Rate 3226 Aftertreatment Outlet NOx Sensor Circuit - Voltage Above Normal, or Shorted to...
  • Page 749 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description 3245 Aftertreatment Exhaust Gas Temperature 3 - Data Valid but Above Normal Operational Range - Most Severe Level 3249 Aftertreatment Exhaust Gas Temperature 2 Circuit - Voltage Below Normal, or...
  • Page 750 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description 3358 EGR Inlet Pressure - Voltage Above Normal, or Shorted to High Source 3360 Catalyst Tank Multi Sensor - Bad Intelligent Device or Component 3361 Catalyst Dosing Control Unit - Bad Intelligent Device or Component...
  • Page 751 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description 3465 Engine Throttle Control Actuator 2 Circuit - Voltage Above Normal, or Shorted to High Source 3465 Engine Throttle Control Actuator 2 Circuit - Voltage Below Normal, or Shorted to...
  • Page 752 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description 3489 Air Supply Actuator - Voltage Above Normal, or Shorted to High Source 3489 Air Supply Actuator - Voltage Below Normal, or Shorted to Low Source 3509...
  • Page 753 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description 3551 Engine Oil Priming Pump Control Pre-Lubrication - Data Valid but Below Normal Operational Range - Most Severe Level 3552 Engine Oil Pre-heater Control Circuit - Voltage Above Normal, or Shorted to High...
  • Page 754 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description 3673 Throttle Position 2 Sensor Circuit - Voltage Above Normal, or Shorted to High Source 3673 Throttle Position 2 Sensor Circuit - Voltage Below Normal, or Shorted to Low Source...
  • Page 755 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description 520209 GenSet Measured Speed and AC Output Frequency Conflict - Condition Exists 520210 Electronic Control Module Watchdog has Failed - Condition Exists 520211 Software version mismatch has occurred in the ECM between base board and the...
  • Page 756 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description 520233 Generator Circuit Breaker Failed to Close - Condition Exists 520234 Generator Circuit Breaker Failed to Open - Condition Exists 520235 Generator Circuit Breaker Position Contact Failed - Condition Exists...
  • Page 757 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description 520261 Change Coolant Filter - Condition Exists 520262 Change Coolant - Condition Exists 520263 Lubricating oil filters require changing - Condition Exists 520264 Excessive Operation at Low Coolant Temperature - Data Valid but Below Normal...
  • Page 758 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Cummins Description 520292 Generator is absorbing Power from the Electric Bus (High reverse KW) - Condition Exists 520292 Generator is absorbing Power from the Electric Bus (High reverse KW) - Condition...
  • Page 759 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Cummins Description 520318 Alternator Temperature - Data Valid but Above Normal Operational Range - Moderately Severe Level 520319 Engine Speed Calculation - Bad Intelligent Device or Component 520320 Crankcase Depression Valve - Mechanical System Not Responding Properly or Out...
  • Page 760 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual CAT T III F AULT ODES Description No Diagnostic Code Detected SAE J1939 Data Link abnormal update rate SAE J1939 Data Link failure Secondary Throttle Position Sensor erratic, intermittent, or incorrect...
  • Page 761 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Description Cylinder #1 Injector current below normal Cylinder #1 Injector current above normal Cylinder #1 Injector not responding properly Cylinder #2 Injector erratic, intermittent, or incorrect Cylinder #2 Injector current below normal...
  • Page 762 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Description Secondary Engine Speed Sensor abnormal frequency, pulse width, or period 1079 5 Volt Sensor DC Power Supply voltage above normal 1079 5 Volt Sensor DC Power Supply voltage below normal...
  • Page 763 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes CAT T AULT ODES The following table lists all the J1939 diagnostic trouble codes for the C3.4B engine. The table includes a description for each code and the recommended troubleshooting procedure that must be performed.
  • Page 764 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Description Refer to Procedure Engine Air Filter 1 Differential Pressure : Switch Circuits - Test Erratic, Intermittent, or Incorrect Engine Air Filter 1 Differential Pressure : Inlet Air Is Restricted...
  • Page 765 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Description Refer to Procedure Engine Exhaust Gas Temperature : Voltage Engine Temperature Sensor Open or Above Normal Short Circuit - Test Engine Exhaust Gas Temperature : Voltage Engine Temperature Sensor Open or...
  • Page 766 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Description Refer to Procedure Engine Injector Cylinder #02 : Current Injector Solenoid Circuit - Test Below Normal Engine Injector Cylinder #02 : Current Injector Solenoid Circuit - Test Above Normal...
  • Page 767 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Description Refer to Procedure Engine Auxiliary Shutdown Switch This code indicates that the shutdown switch for the engine has been activated. The ECM will disable fuel injection until the switch has been deactivated. No troubleshooting is required.
  • Page 768 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Description Refer to Procedure 2791 Engine Exhaust Gas Recirculation (EGR) Motorized Valve - Test Valve Control : Current Above Normal 2791 Engine Exhaust Gas Recirculation (EGR) Motorized Valve - Test...
  • Page 769 65E Turbo Motor Grader Section 10 Service Manual Diagnostic Fault Codes Description Refer to Procedure 3222 Aftertreatment #1 Intake Gas Sensor Heater Oxygen Level - Test : Current Below Normal 3242 Particulate Trap Intake Gas Temperature : Engine Temperature Sensor Open or...
  • Page 770 Section 10 65E Turbo Motor Grader Diagnostic Fault Codes Service Manual Description Refer to Procedure 4765 Aftertreatment #1 Diesel Oxidation Engine Temperature Sensor Open or Catalyst Intake Gas Temperature : Voltage Short Circuit - Test Above Normal 4765 Aftertreatment #1 Diesel Oxidation...
  • Page 771 ZF FRIEDRICHSHAFEN Aktiengesellschaft Benennung: fault codes Nr.: Seite 1 Zusatzbenennung: description of fault codes for Ergo control von 58 Diese technische Unterlage darf weder kopiert 06-10-17 Schwarz noch dritten Personen ohne unsere Erlaubnis mitgeteilt werden. Index Datum Name Film K3 ZFN 904 Ä...
  • Page 772 ZF Friedrichshafen AG 07-05-24 Faultcodes ERGO-Control EST37A Index of changes: date index comment software version 97-12-12 first document based on error.doc dated 97-11-03 98-03-18 corrections 98-04-02 adjusted for document automation 98-05-04 inserted internal faultcode-numbers, completed reaction of TCU for s.c to Battery at K1..KR 98-05-15 inserted fault code F6 98-05-25...
  • Page 773 ZF Friedrichshafen AG 07-05-24 Faultcodes ERGO-Control EST37A 05-01-31 Add warning code for high velocity and high load 05-02-18 Add engine torque / power overload and output torque V916 overload faultcodes Change FMI from 15 to 0 05-06-20 Add warning code for high output torque V917 06-04-11 change description of lockup clutch failure...
  • Page 774 ZF Friedrichshafen AG 07-05-24 Faultcodes ERGO-Control EST37A 1 Introduction 1.1 Abbreviations o.c. open circuit s.c. short circuit OP-Mode operating mode transmission control unit electronic engine controller power take off 1.2 ZF - Display: If a fault is detected, the display shows a spanner symbol (g) for a fault. The display shows the fault code, if the gear selector is on neutral position.
  • Page 775 ZF Friedrichshafen AG 07-05-24 Faultcodes ERGO-Control EST37A symbol) 2 bars manual mode 2 gear 3 bars manual mode 3 gear 4 bars manual mode 4 gear and also 5 gear in 6WG 4 bars and 2 automatic mode arrows Bars flashing 6 WG: converter lockup clutch open difference of engine and turbine speed above a certain limit and lockup clutch not activated...
  • Page 776 ZF Friedrichshafen AG 07-05-24 Faultcodes ERGO-Control EST37A 1.4 Display during AEB-Mode symbol meaning remarks AEB - Starter is plugged at the diagnostic plug AEB-Starter-button is pressed calibrating clutch K1..K4, KV or KR K1..K4,KV,KR resp. wait for start, initialization of clutch Kx, _ and Kx x: 1, 2, 3, 4, V, R fast fill time determination of clutch Kx...
  • Page 777 ZF Friedrichshafen AG 07-05-24 Faultcodes ERGO-Control EST37A 1.5 Display during Inchpedal Calibration symbol meaning remarks push down the pedal slowly until IP ⇓ endposition is reached and hold this position Release the pedal slowly until IP ⇑ endposition is reached A problem occurred, release the pedal If the expected enposition could not be reached, IP ⇑...
  • Page 778 ZF Friedrichshafen AG 07-05-24 Faultcodes ERGO-Control EST37A 2 definition of operating modes NORMAL: There's no failure detected in the transmission-system or the failure has no or slight effects on transmission control. TCU will work without or in special cases with little limitations. (see following table) SUBSTITUTE CLUTCH CONTROL: TCU can't change the gears or the direction under the control of the normal clutch modulation.
  • Page 779 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 3 table of fault codes Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) 5000...
  • Page 780 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) 5040 TCU shifts transmission to fault is taken back if TCU •...
  • Page 781 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) output pin, that looks like a s.c. to battery specific function no.
  • Page 782 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) output pin, that looks like a s.c. to battery specific function no.
  • Page 783 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) output pin, that looks like a s.c. to battery •...
  • Page 784 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) • cable has no connection to TCU •...
  • Page 785 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) voltage or is broken 5110 no reaction, all,...
  • Page 786 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) 5130 TCU uses default value •...
  • Page 787 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) voltage or is broken 5135 DLM T TCU uses default value...
  • Page 788 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) • cable is defective and is contacted to battery voltage •...
  • Page 789 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) 5150 OP-Mode: substitute clutch all, •...
  • Page 790 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) TCU measures a internal speed over a control up of TCU Sisu...
  • Page 791 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) ’ not used TURBINE SPEED ZERO DOESN T FIT TO OTHER SPEED SIGNALS...
  • Page 792 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) • CAN wire/connector is defective and has contact to vehicle ground or battery voltage •...
  • Page 793 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) cluster controller downshift information •...
  • Page 794 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) 5270 SCT1 OP-Mode: normal Kalm •...
  • Page 795 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) has contact to vehicle ground or battery voltage 5290 EEC1...
  • Page 796 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) defective • check cable to cluster controller •...
  • Page 797 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) 5380 no reaction Liebh •...
  • Page 798 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) is defective •...
  • Page 799 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) is out of limit, the voltage at K1 valve is if failure at another clutch is •...
  • Page 800 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) 5490 TCU shifts to neutral see chapter 4 all, •...
  • Page 801 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) 5540 no reaction •...
  • Page 802 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) contact to battery voltage OP-Mode: TCU shutdown •...
  • Page 803 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) gearbox • cable / connector is defective and has contact to another regulator output of the TCU •...
  • Page 804 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) no contact to TCU TCU shifts to neutral •...
  • Page 805 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) 5536 DLM I output will be on until TCU see chapter 4 •...
  • Page 806 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) output pin, that looks like a s.c. to vehicle OP-Mode: normal device to TCU ground...
  • Page 807 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) ground • check the resistance of starter •...
  • Page 808 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) vehicle ground solenoid •...
  • Page 809 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) • converter clutch solenoid has an internal defect •...
  • Page 810 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) defect • connector pin is contacted to vehicle ground 5600 no reaction...
  • Page 811 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) ground 5610 no reaction see chapter 4 •...
  • Page 812 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) TCU detected a wrong voltage at the OP-mode: normal warning device output pin, that looks like a o.c.
  • Page 813 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) voltage • check the resistance of customer specific •...
  • Page 814 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) voltage • check the resistance of customer specific •...
  • Page 815 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) voltage • check the resistance of customer specific •...
  • Page 816 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) slipping clutch. TCU shifts to neutral •...
  • Page 817 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) closed clutch KV. If this calculated value if failure at another clutch is •...
  • Page 818 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) 5730 no reaction •...
  • Page 819 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) ground 5750 no reaction see chapter 4 •...
  • Page 820 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) 5760 no reaction 4WG, •...
  • Page 821 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) connection to TCU •...
  • Page 822 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) connection to TCU •...
  • Page 823 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) measured voltage at power supply is lower OP-Mode: TCU shutdown Sisu •...
  • Page 824 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) vehicle ground •...
  • Page 825 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) neutral Deere SIGNALS OF SHIFTER TCU detected a o.c signals for the OP-Mode: transmission...
  • Page 826 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) Timeout of CAN-message CL1 from status test mode •...
  • Page 827 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 Fault SPN FMI Int. reaction of the TCU possible steps to repair remarks costu MEANING OF THE FAULT CODE Code Code possible reason for fault detection (hex) (dec) no fault! indicates that another computer OP-Mode: limp home request Deere...
  • Page 828 ZF Friedrichshafen AG description of fault codes for ERGO-Control 97-09-18 4 measuring of resistance at actuator/sensors and cable 4.1 actuator: open circuit: ≈ R ≈ R ≈ ∞ ≈ R; ≈ 0, R ≈ R or R ≈ R, R ≈...
  • Page 829 65E Turbo Motor Grader Service Manual Revision History EVISION ISTORY Revision Date Pages Description 65E_s1_00 03/2006 First Edition Service Manual Released. 65E_s2_00 06/2013 All, Tier III & Tier IV Second Edition Service Manual Released. Updated to Tier III & Tier...
  • Page 830 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. When operated in California, any off-road diesel vehicle may be subject to the California Air Resources Board In-Use Off-Road Diesel Vehicle Regulation.

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