NorAM 65E Turbo Service Manual
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NorAM 65E Turbo Service Manual

Motor grader
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Table of Contents

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65
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TURBO
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Manual
Service Manual
June, 2005
EFF. S/N 9101
Catalog #4472

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Summary of Contents for NorAM 65E Turbo

  • Page 1 | Motor Grader Grader TURBO TURBO TURBO TURBO TURBO Opera Opera Opera Opera Manual Service Manual June, 2005 EFF. S/N 9101 Catalog #4472...
  • Page 2 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 3 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 4 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 5 65E Turbo Motor Grader Service Manual ONTENTS VERVIEW Engine ............... . Section 1 Operator’s Platform and Controls .
  • Page 6 Service Manual Section 1: Engine Service 1.00_2006.03...
  • Page 8 65E Turbo Motor Grader Section 1 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: Read the Operator's Manual carefully before using the machine.
  • Page 9 Section 1 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 10 65E Turbo Motor Grader Section 1 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 11 Section 1 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 12 65E Turbo Motor Grader Section 1 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 13 Section 1 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 14 65E Turbo Motor Grader Section 1 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 15 Section 1 65E Turbo Motor Grader Engine Service Manual This page intentionally left blank. Service 1.00_2006.03...

  • Page 16: Table Of Contents

    65E Turbo Motor Grader Section 1 Service Manual Engine ONTENTS General Information ............1-1 Engine Protection and Diagnostics .
  • Page 17 Section 1 65E Turbo Motor Grader Engine Service Manual This page intentionally left blank. 1-xii Service 1.00_2006.03...

  • Page 18: General Information

    1-800-343-7357. Engine Protection and Diagnostics The NORAM 65E grader uses amber and red warning lights to signal the operator when the engine elec- tronic control module (ECM) detects an engine fault or problem. Depending on the severity of the engine problem, the ECM may decrease engine power or shut the engine down after warning the operator with flashing warning lights.

  • Page 19: Diagnostics

    Section 1 65E Turbo Motor Grader Engine Service Manual Diagnostics Using the engine warning lights, engine fault codes may be retrieved from the engine ECM using the follow- ing procedure: Step 1: Turn the key switch to the “OFF” position.

  • Page 20: Specifications

    65E Turbo Motor Grader Section 1 Service Manual Engine PECIFICATIONS Model ..............Cummins QSB4.5 Type .

  • Page 21: Engine Electrical

    Section 1 65E Turbo Motor Grader Engine Service Manual 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 left-hand side of the flywheel area.

  • Page 22: Fuses

    65E Turbo Motor Grader Section 1 Service Manual Engine 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 Engine dies No engine lights with key “ON”...

  • Page 23: Qsb Fault Code Information

    Section 1 65E Turbo Motor Grader Engine Service Manual QSB Fault Code Information Fault PID(P) SPN(S) Reason Effect (Only when fault code is Code SID(S) active) Lamp 111* S25412 62912 ECM internal hardware error. Possible no effect or engine may run Yellow rough or not start.
  • Page 24 65E Turbo Motor Grader Section 1 Service Manual Engine Fault PID(P) SPN(S) Reason Effect (Only when fault code is Code SID(S) active) Lamp P105 4 105 4 Low voltage detected at intake Default value used for intake manifold Yellow manifold temperature signal pin 34 of temperature.
  • Page 25 Section 1 65E Turbo Motor Grader Engine Service Manual Fault PID(P) SPN(S) Reason Effect (Only when fault code is Code SID(S) active) Lamp P251 2 251 2 Power to the real time clock has been Time stamp in ECM powerdown data will Maint.
  • Page 26 65E Turbo Motor Grader Section 1 Service Manual Engine Fault PID(P) SPN(S) Reason Effect (Only when fault code is Code SID(S) active) Lamp S233 7 10777 VP44 fuel pump controller is not Equipment batteries may be drained low Yellow powering down when key switch power is during long shutdown periods.
  • Page 27 Section 1 65E Turbo Motor Grader Engine Service Manual Fault PID(P) SPN(S) Reason Effect (Only when fault code is Code SID(S) active) Lamp P091 13 Idle validation signal at pin 26 of the Engine will only idle. Yellow OEM harness indicates the throttle is at...
  • Page 28 65E Turbo Motor Grader Section 1 Service Manual Engine Fault PID(P) SPN(S) Reason Effect (Only when fault code is Code SID(S) active) Lamp S251 12 1076 12 A mechanically stuck fuel control valve Engine may shut down. Yellow has been detected by the VP44 fuel pump controller.
  • Page 29 Section 1 65E Turbo Motor Grader Engine Service Manual This page intentionally left blank. 1-12 Service 1.00_2006.03...
  • Page 30 Service Manual Section 2: Operator’s Platform and Controls Service 1.00_2006.03...
  • Page 32 65E Turbo Motor Grader Section 2 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: Read the Operator's Manual carefully before using the machine.
  • Page 33 Section 2 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 34 65E Turbo Motor Grader Section 2 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 35 Section 2 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 36 65E Turbo Motor Grader Section 2 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 37 Section 2 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 38 65E Turbo Motor Grader Section 2 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 39 Section 2 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual This page intentionally left blank. Service 1.00_2006.03...
  • Page 40 65E Turbo Motor Grader Section 2 Service Manual Operator’s Platform and Controls ONTENTS General ..............2-1 ROPS / FOPS / Cab and Environment Controls .
  • Page 41 Section 2 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual Throttle Linkage / Engine Speed Adjustment ......... . . 2-30 Low Idle Setting .

  • Page 42: General

    65E Turbo Motor Grader Section 2 Service Manual Operator’s Platform and Controls Section 2: 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 43: Rops / Fops

    Section 2 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 44: Installation

    65E Turbo Motor Grader Section 2 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 45: Cab

    Section 2 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual Service 1.00_2006.03...

  • Page 46: Removal

    65E Turbo Motor Grader Section 2 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 47 Section 2 65E Turbo Motor Grader Operator’s Platform and Controls Service Manual Service 1.00_2006.03...

  • Page 48: Installation

    65E Turbo Motor Grader Section 2 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 49: Console Controls

    Section 2 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 50: Installation

    65E Turbo Motor Grader Section 2 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 51: Scarifier Control (Standard), Ripper Control (Optional), Dozer Lift Control (Optional) And Other Left-Hand Controls

    Section 2 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 52 65E Turbo Motor Grader Section 2 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 53: Installation

    Section 2 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 54: Steering Wheel

    65E Turbo Motor Grader Section 2 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 55: Side View Mirror

    Section 2 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 56: Rear View Mirror

    65E Turbo Motor Grader Section 2 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 57: Console Tilt Mechanism

    Section 2 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 58: Installation

    65E Turbo Motor Grader Section 2 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 59: Control Lock

    Section 2 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 60: Installation

    65E Turbo Motor Grader Section 2 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 61 Section 2 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 62: Service Brakes

    65E Turbo Motor Grader Section 2 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 63 Section 2 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 64 65E Turbo Motor Grader Section 2 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 65: Installation

    Section 2 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 66 65E Turbo Motor Grader Section 2 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 67 Section 2 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 68: Brake Adjustment

    65E Turbo Motor Grader Section 2 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 69: Brake Valve Plunger Clearance Adjustment

    Section 2 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 70: Lever Assembly Clearance Adjustment

    65E Turbo Motor Grader Section 2 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 71: Throttle Linkage / Engine Speed Adjustment

    Section 2 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 72: High Idle Setting

    65E Turbo Motor Grader Section 2 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 73: Throttle Lever Adjustment

    Section 2 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 74: Throttle Pedal Adjustment

    65E Turbo Motor Grader Section 2 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 75: Door Latch Adjustment

    Section 2 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 76 Service Manual Section 3: Transmission Service 1.00_2006.03...
  • Page 78 65E Turbo Motor Grader Section 3 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: Read the Operator's Manual carefully before using the machine.
  • Page 79 Section 3 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 80 65E Turbo Motor Grader Section 3 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 81 Section 3 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 82 65E Turbo Motor Grader Section 3 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 83 Section 3 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 84 65E Turbo Motor Grader Section 3 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 85 Section 3 65E Turbo Motor Grader Transmission Service Manual This page intentionally left blank. Service 1.00_2006.03...
  • Page 86 65E Turbo Motor Grader Section 3 Service Manual Transmission ONTENTS Mounting Transmission onto Engine ..........3-2...
  • Page 87 Section 3 65E Turbo Motor Grader Transmission Service Manual This page intentionally left blank. 3-xii Service 1.00_2006.03...
  • Page 88 Transmission Section 3: 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 above the mating surfaces of the engine flywheel housing and transmission housing. (Refer to the Electrical section for con- verter information.) The transmission and converter can be viewed by removing the vent covers on each side...
  • Page 89 Section 3 65E Turbo Motor Grader Transmission Service Manual 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 90 65E Turbo Motor Grader Section 3 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 91 Section 3 65E Turbo Motor Grader Transmission Service Manual Step 7: Turn engine crankshaft, 1, until one of four flywheel bolt holes, 2, is aligned with access hole, 3. Service 1.00_2006.03...
  • Page 92 65E Turbo Motor Grader Section 3 Service Manual Transmission Step 8: Looking through access hole, 2, align flywheel bolt hole, 1, with transmission flex plate threaded hole, 3. Step 9: Apply Loctite 242 (blue) to threads of bolt (not shown). Secure flywheel to transmission flex plate using bolt.
  • Page 93 Section 3 65E Turbo Motor Grader Transmission Service Manual Step 11: Install cover plate, 1, onto engine using two mounting bolts. Step 12: Install electronic control module (ECM), 1, onto engine using two mounting bolts. Service 1.00_2006.03...
  • Page 94 ZF FRIEDRICHSHAFEN Aktiengesellschaft Benennung: fault codes Nr.: Seite 1 Zusatzbenennung: description of fault codes for Ergo von 30 Diese technische Unterlage darf weder kopiert 03-05-13 Schwarz noch dritten Personen ohne unsere Erlaubnis mitgeteilt werden. Index Datum Name Film K3 ZFN 904 Ä...
  • Page 95 ZF Friedrichshafen AG 05-04-05 Faultcodes ERGO-Control EST37A Index of changes: date index comment software version Seite 2 von 30...
  • Page 96 ZF Friedrichshafen AG 05-04-05 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 97 ZF Friedrichshafen AG 05-04-05 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 98 ZF Friedrichshafen AG 05-04-05 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. _ and Kx wait for start, initialization of clutch Kx, x: 1, 2, 3, 4, V, R ≡...
  • Page 99 ZF Friedrichshafen AG 05-04-05 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 100 ZF Friedrichshafen AG 05-04-05 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 178 Order No.: 5871 146 002 ZF – ERGOPOWER 6 WG-115 ZF Passau GmbH Donaustr. 25 - 71 D- 94 034 Passau...
  • Page 179 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 180 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 181 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 182 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 183 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 184 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 185 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 186 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 187 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 188 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 189 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 190 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 191 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 192 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 193 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 194 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 195 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 196 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 197 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 198 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 199 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 200 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 201 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 202 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 203 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 204 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 205 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 206 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 207 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 208 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 209 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 210 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 211 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 212 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 213 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 214 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 215 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 216 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 217 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 218 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 219 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 220 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 221 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 222 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 223 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 224 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 225 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 226 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 227 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 228 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 229 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 230 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 231 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 232 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 233: 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 234: 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 235 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 236 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 237 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 238 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 239 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 240 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 241 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 242 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 243 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 244 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 245 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 246: 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 247 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 248: 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 249: 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 250 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 251 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 252 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 253 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 254 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 255 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 256 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 257 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 258 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 259 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 260 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 261 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 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) 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 263 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 264 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 265 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 266 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 267 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 268 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 269 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 270 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 271 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 272: 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 273 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 274 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 275 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 276 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 277 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 278: 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 279 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 280: 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 281: 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 282: 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 283 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 284: 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 285: 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 286 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 287 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 288: 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 289 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 290 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 291 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 292: 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 293 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 294: 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 295 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 296 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 297 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 298 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 299 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 300 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 301 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 302 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 303 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 304 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 305 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 306 Service Manual Section 4: Front Axle Service 1.00_2006.03...
  • Page 308 65E Turbo Motor Grader Section 4 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: Read the Operator's Manual carefully before using the machine.
  • Page 309 Section 4 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 310 65E Turbo Motor Grader Section 4 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 311 Section 4 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 312 65E Turbo Motor Grader Section 4 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 313 Section 4 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 314 65E Turbo Motor Grader Section 4 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 315 Section 4 65E Turbo Motor Grader Front Axle Service Manual This page intentionally left blank. Service 1.00_2006.03...
  • Page 316 65E Turbo Motor Grader Section 4 Service Manual Front Axle ONTENTS Front Axle, Steering And Articulation ......... . . 4-1 General .
  • Page 317 Section 4 65E Turbo Motor Grader Front Axle Service Manual This page intentionally left blank. 4-xii Service 1.00_2006.03...

  • Page 318: Front Axle, Steering And Articulation

    65E Turbo Motor Grader Section 4 Service Manual Front Axle Section 4: 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 319: Wheel Lean

    Section 4 65E Turbo Motor Grader Front Axle Service Manual 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. Input is received by operating the control lever on the front console.

  • Page 320: Troubleshooting

    65E Turbo Motor Grader Section 4 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 321 Section 4 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 322: Troubleshooting Chart

    65E Turbo Motor Grader Section 4 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 323: Front Axle Adjustments

    Section 4 65E Turbo Motor Grader Front Axle Service Manual RONT DJUSTMENTS Front Axle Toe-In Step 1: 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 324: Steering Cylinder

    65E Turbo Motor Grader Section 4 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 325: Front Wheel Bearings

    Section 4 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 326: Front Axle Disassembly And Repair

    65E Turbo Motor Grader Section 4 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 327 Section 4 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 328 65E Turbo Motor Grader Section 4 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 329: Rh Steering Knuckle And King Pin Removal

    Section 4 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 330: Lh Steering Knuckle And King Pin Installation

    65E Turbo Motor Grader Section 4 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 331 Section 4 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 332 65E Turbo Motor Grader Section 4 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 333 Section 4 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 334 65E Turbo Motor Grader Section 4 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 335: Rh Steering Knuckle And King Pin Installation

    Section 4 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 336: Lh Wheel Lean Pivot Pin Removal

    65E Turbo Motor Grader Section 4 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 337 Section 4 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 338: Lh Wheel Lean Pivot Pin Installation

    65E Turbo Motor Grader Section 4 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 339: Rh Wheel Lean Pivot Pin Removal

    Section 4 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 340: Axle Oscillation Pin Removal

    65E Turbo Motor Grader Section 4 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 341 Section 4 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 342: Axle Oscillation Pin Installation

    65E Turbo Motor Grader Section 4 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 343 Section 4 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 344 65E Turbo Motor Grader Section 4 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 345: Steering Valve Disassembly And Repair

    Section 4 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 346: Steering Valve Installation

    65E Turbo Motor Grader Section 4 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 347 Section 4 65E Turbo Motor Grader Front Axle Service Manual This page intentionally left blank. 4-30 Service 1.00_2006.03...
  • Page 348 Please reference “Eaton Publication #C-STCU-TS002.pdf” on this CD for further information on the Steering Control Unit...
  • Page 349 Service Manual Section 5: Rear Axle and Tandem Service 1.00_2006.03...
  • Page 351 65E Turbo Motor Grader Section 5 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: Read the Operator's Manual carefully before using the machine.
  • Page 352 Section 5 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 353 65E Turbo Motor Grader Section 5 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 354 Section 5 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 355 65E Turbo Motor Grader Section 5 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 356 Section 5 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 357 65E Turbo Motor Grader Section 5 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 358 Section 5 65E Turbo Motor Grader Rear Axle and Tandem Service Manual This page intentionally left blank. Service 1.00_2006.03...
  • Page 359 65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandem ONTENTS Rear Axle And Tandems ............5-1 General .
  • Page 360 Section 5 65E Turbo Motor Grader Rear Axle and Tandem Service Manual Friction Discs And Piston ............5-23 Removal .

  • Page 361: Rear Axle And Tandems

    65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems Section 5: Rear Axle and Tandems 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 362: Tandem Box

    Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual Tandem Box Construction ............Welded Steel Box Mount.

  • Page 363: Tandem Drive Assembly

    65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems Step 3: Disconnect the two brake fluid lines, 1, then remove the fittings, 2, and o-rings, 3, from the top of the rear axle, 4. Be sure wheels are on the...

  • Page 364: Removal

    Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 365: Installation

    65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 366 Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 367: Driveshaft

    65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 368: Rear Axle And Tandem Drive Assembly

    Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 369: Brakes - Maintenance And Adjustment

    65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 370: Specifications

    Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual The service brake hydraulic system is divided into sepa- rate circuits for the right and left brakes, with two separate reservoirs supplying the master cylinder. The circuits are connected when at rest to vent pressure from the system.

  • Page 371: Parking Brake

    65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems Actuation ............Hydraulic with Booster Fluid Supply Pressure @ 700 N (317 Ib) Pedal Force .

  • Page 372: Bleeding The Brakes

    Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 inter- mittent and ineffective.

  • Page 373: Parking Brake Cable Adjustment

    65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 374: Lever End Adjustment

    Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 375: Parking Brake Switch

    65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 376: Brake Pedal

    Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 377 65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 378: Pedal Height

    Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 379: Pedal Return Spring

    65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 380 Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 381 65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 382 Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 383: Friction Discs And Piston

    65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 384: Parking Brake Friction Pad Replacement

    Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 385: Replacing Lube Oil

    65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 386: Assembling Leak Proof Components

    Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 387 65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 388 Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 389 65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 390 Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 391: Assembly

    65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 392 Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 393: Center Section Unit

    65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 394 Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 395 65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 396 Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 397 65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 398 Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 399 65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 400 Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 401 65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 402 Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 403 65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 404 Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 405 65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 406 Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 407 65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 408: Disassembly

    Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 409 65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 410 Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual Step 11: Remove plug, 2, with fitting then remove plugs, 1, 3, 4, and 5. 5-50 Service 1.00_2006.03...
  • Page 411 65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 412: Assembly

    Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 413 65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 414 Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 415 65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 416 Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 CM-183 grease and install cone, 3, with wide side towards seal, 6, using bearing driver.
  • Page 417 65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 418 Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 419 65E Turbo Motor Grader Section 5 Service Manual Rear Axle and Tandems 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 420 Section 5 65E Turbo Motor Grader Rear Axle and Tandems Service Manual 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 421 Service Manual Section 6: Electrical Service 1.00_2006.03...
  • Page 423 65E Turbo Motor Grader Section 6 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: Read the Operator's Manual carefully before using the machine.
  • Page 424 Section 6 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 425 65E Turbo Motor Grader Section 6 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 426 Section 6 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 427 65E Turbo Motor Grader Section 6 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 428 Section 6 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 429 65E Turbo Motor Grader Section 6 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 430 Section 6 65E Turbo Motor Grader Electrical Service Manual This page intentionally left blank. Service 1.00_2006.03...
  • Page 431 65E Turbo Motor Grader Section 6 Service Manual Electrical ONTENTS General ..............6-1 Electrical Schematics .
  • Page 432 Section 6 65E Turbo Motor Grader Electrical Service Manual This page intentionally left blank. 6-xii Service 1.00_2006.03...

  • Page 433: General

    65E Turbo Motor Grader Section 6 Service Manual Electrical Section 6: 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 434 Section 6 65E Turbo Motor Grader Electrical Service Manual LECTRICAL CHEMATICS GROUND BATTERY 1-RD BLOWER THERMISTOR 0-BK TO CONVERTER PIN #9 BLOWER SWITCH START/ON/OFF/ACC 61L-OR FUSE 13-OR 61-OR 61M-OR 61H-OR AIR RIDE SEAT ADJUSTMENT COMPRESSER ADJUSTMENT MOTOR SWITCH FUSE 58-PK...
  • Page 435 65E Turbo Motor Grader Section 6 Service Manual Electrical BATTERY 1-RD START/ON/OFF/ACC GROUND 43-OR TURN SIGNAL SWITCH MAIN POWER RELAY 1-RD 13-OR 0-BK 12-OR HOURMETER PRESSURE SWITCH FUSE 30-YL 31HM-YL 0-BK ENGINE DIAGNOSTIC 10 PSI PLUGS ENGINE WARNING FUSE 36-YL w/BK...
  • Page 436 Section 6 65E Turbo Motor Grader Electrical Service Manual GROUND 0-BK 0-BK 67-BK 88A-LT BU 68-LT BU OUTPUT SPEED SENSOR 94-LT BU 69A-LT BU TO BACK UP ALARM RELAY 70-LT BU 71-LT BU CONTROL VALVE 72-LT BU 74-LT BU 75-LT BU...
  • Page 437 65E Turbo Motor Grader Section 6 Service Manual Electrical BATTERY 1-RD START/ON/OFF/ACC GROUND BEACON SWITCH BEACON FUSE 1-RD 18-PK 46-PK 0-BK 0-BK HAZARD LIGHT SWITCH LEFT REAR TURN SIGNAL FLASHER 47-YL 0-BK FUSE 1-RD 46-BR 46A-PK RIGHT REAR TURN SIGNAL...

  • Page 438: Engine

    Section 6 65E Turbo Motor Grader Electrical Service Manual VOLTMETER 0-BK ENGINE OIL PRESSURE GAUGE PRESSURE SENDER 31GP-YL 0-BK ENGINE TEMPERATURE GAUGE TEMPERATURE SENDER FUSE 37-PU 31GT-YL 7.5A 0-BK FUEL LEVEL GAUGE FUEL LEVEL SENDER 36G-YL 0-BK 0-BK TRANSMISSION TEMPERATURE GAUGE...

  • Page 439: Definition Of Terms

    65E Turbo Motor Grader Section 6 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 440: Starting And Charging

    Section 6 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 441: Specifications

    65E Turbo Motor Grader Section 6 Service Manual Electrical PECIFICATIONS Voltage ..............12 Volt System Transmission .

  • Page 442: Standard Lighting

    Section 6 65E Turbo Motor Grader Electrical Service Manual Standard Lighting Headlights ............2, Sealed Beam Halogen Front Work Lights.

  • Page 443: Special Tools

    65E Turbo Motor Grader Section 6 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 444: Troubleshooting

    Section 6 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 445: Preliminary Troubleshooting

    65E Turbo Motor Grader Section 6 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 446 Section 6 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, 1, are located at left-hand rear side of engine near flywheel housing.
  • Page 447 65E Turbo Motor Grader Section 6 Service Manual Electrical Step 5: Fuses are identified by a tag, 1, located below right-hand side instrument panel. IMPORTANT: Turn "OFF" master switch before replacing fuses. Isolate cause of blown fuse before replacing fuse.

  • Page 448: Troubleshooting Chart

    Section 6 65E Turbo Motor Grader Electrical Service Manual 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 449: Batteries

    65E Turbo Motor Grader Section 6 Service Manual Electrical ATTERIES Battery Removal Never make or break any charging system connections, including battery, when engine is running. Step 1: Ensure engine is turned "OFF".I Turn "OFF" master switch before working around batteries.

  • Page 450: Battery Installation

    Section 6 65E Turbo Motor Grader Electrical Service Manual 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 451: Component Locations

    65E Turbo Motor Grader Section 6 Service Manual Electrical OMPONENT OCATIONS Front Console The front console houses the implement control switches, hazard switch, hourmeter, warning lights, turn sig- nal switch with in-line 20 amp fuse, flasher, and harness. Removable access panels provide for component repair and replacement.
  • Page 452 Section 6 65E Turbo Motor Grader Electrical Service Manual Flasher Relay Hourmeter (Behind Hourmeter) Multifunction Switch (Turn Signals, Taillights, Headlights, High and Low Beam Selection, Horn) 6-20 Service 1.00_2006.03...

  • Page 453: Instrument Panel Group

    65E Turbo Motor Grader Section 6 Service Manual Electrical Instrument Panel Group Service 1.00_2006.03 6-21...

  • Page 454: Below Instrument Panel

    Section 6 65E Turbo Motor Grader Electrical Service Manual Below Instrument Panel Transmission Control Unit (TCU) Main Power Relay Back-up Alarm Relay Throttle Position Sensor (TPS) 6-22 Service 1.00_2006.03...

  • Page 455: Right-Hand Side Of Grader

    65E Turbo Motor Grader Section 6 Service Manual Electrical Right-Hand Side of Grader Oil Pressure Sensor 12/24 Volt Converter Battery Disconnect Starter Alternator Fuses for 12/24 Volt Converter Service 1.00_2006.03 6-23...
  • Page 456 Section 6 65E Turbo Motor Grader Electrical Service Manual Neutral Start Relay Starter Relay 6-24 Service 1.00_2006.03...
  • Page 457 65E Turbo Motor Grader Section 6 Service Manual Electrical Brake Differential Pressure Switch Service 1.00_2006.03 6-25...

  • Page 458: Left-Hand Side Of Grader

    Section 6 65E Turbo Motor Grader Electrical Service Manual Left-Hand Side of Grader Engine Temperature Sender Engine ECM Power Fuses Oil Pressure Switch Engine Electronic Control Module (ECM) 6-26 Service 1.00_2006.03...
  • Page 459 65E Turbo Motor Grader Section 6 Service Manual Electrical Engine Diagnostic Connectors Engine Diagnostic Connectors Connected for Flashing Out Engine Codes Service 1.00_2006.03 6-27...
  • Page 460 Section 6 65E Turbo Motor Grader Electrical Service Manual Injection Pump Relay 6-28 Service 1.00_2006.03...
  • Page 461 65E Turbo Motor Grader Section 6 Service Manual Electrical Park Brake Switch Service 1.00_2006.03 6-29...

  • Page 462: Bottom Of Grader

    Section 6 65E Turbo Motor Grader Electrical Service Manual Bottom of Grader Transmission Inching Pressure Switch Accessed through Bottom Cover of Grader (Below Operator Platform) Brake Lights Pressure Switch (Below Operator Platform) 6-30 Service 1.00_2006.03...
  • Page 463 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 464 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 465 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 466 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 467 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 468 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 469 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...
  • Page 471 Service Manual Section 7: Hydraulics Service 1.00_2006.03...
  • Page 473 65E Turbo Motor Grader Section 7 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: Read the Operator's Manual carefully before using the machine.
  • Page 474 Section 7 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 475 65E Turbo Motor Grader Section 7 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 476 Section 7 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 477 65E Turbo Motor Grader Section 7 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 478 Section 7 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 479 65E Turbo Motor Grader Section 7 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.
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  • Page 481 65E Turbo Motor Grader Section 7 Service Manual Hydraulics ONTENTS General ..............7-1 Hydraulic Schematic .
  • Page 482 Section 7 65E Turbo Motor Grader Hydraulics Service Manual Cartridge Replacement ............7-48 Pitch/Side Shift and Front/Rear Implement Selector Valve Removal .

  • Page 483: General

    65E Turbo Motor Grader Section 7 Service Manual Hydraulics Section 7: 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 484 Section 7 65E Turbo Motor Grader Hydraulics Service Manual This page intentionally left blank. Service 1.00_2006.03...

  • Page 485: Hydraulic Schematic

    65E Turbo Motor Grader Section 7 Service Manual Hydraulics YDRAULIC CHEMATIC Service 1.00_2006.03...

  • Page 486: Specifications

    65E Turbo Motor Grader Section 7 Service Manual Hydraulics PECIFICATIONS Pump Manufacturer ..............Eaton Type .

  • Page 487: Cylinders

    Section 7 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 488: Troubleshooting

    65E Turbo Motor Grader Section 7 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 489: Troubleshooting Chart

    Section 7 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 490: Pressure Settings

    65E Turbo Motor Grader Section 7 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 491 Section 7 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 492: Steering Valve Pressure Check

    65E Turbo Motor Grader Section 7 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 493 Section 7 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 494: Fan Motor

    65E Turbo Motor Grader Section 7 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. Turn off the engine.

  • Page 495: Adjustments

    Section 7 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 496: Adjustments

    65E Turbo Motor Grader Section 7 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 497 Section 7 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 498 65E Turbo Motor Grader Section 7 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 Nm (35-39 Ib-ft).

  • Page 499: Disassembly And Repair

    Section 7 65E Turbo Motor Grader Hydraulics Service Manual ISASSEMBLY EPAIR Pump The pump, 2, is attached to the back of the transmission, 1. A direct drive shaft through the transmission drives the pump. 7-18 Service 1.00_2006.03...

  • Page 500: Removal

    65E Turbo Motor Grader Section 7 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 501 Section 7 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 502 65E Turbo Motor Grader Section 7 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 503: Installation

    Section 7 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 504 65E Turbo Motor Grader Section 7 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 505 Section 7 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 506: Control Valve

    65E Turbo Motor Grader Section 7 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 507 Section 7 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 508 65E Turbo Motor Grader Section 7 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 509: Valve Disassembly

    Section 7 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 510: Valve Assembly

    65E Turbo Motor Grader Section 7 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 511: Valve Installation

    Section 7 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 512 65E Turbo Motor Grader Section 7 Service Manual Hydraulics Step 5: Attach inlet hose, 1, to control valve inlet fitting. Torque bolts attaching control valve to mounting plate to 47-53 Nm (35-39 Ib-ft). Torque mounting plate bolts to 47-53 Nm (35-39 Ib-ft).
  • Page 513 Section 7 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 514: Valve Sections

    65E Turbo Motor Grader Section 7 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 515: Standard Section Disassembly

    Section 7 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 516: Float Section Disassembly

    65E Turbo Motor Grader Section 7 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 517: Inspection

    Section 7 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 518: Standard Section Assembly

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

  • Page 519: Float Section Assembly

    Section 7 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 520 65E Turbo Motor Grader Section 7 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 521 Section 7 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 522: Anti-Cavitation Cartridge

    65E Turbo Motor Grader Section 7 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 523 Section 7 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 524: Back Pressure Valve

    65E Turbo Motor Grader Section 7 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 525 Section 7 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 526: Selector Valves

    65E Turbo Motor Grader Section 7 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 527: Solenoids

    Section 7 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 528 65E Turbo Motor Grader Section 7 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 529: Cartridge Replacement

    Section 7 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 530 65E Turbo Motor Grader Section 7 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 531: Pitch/Side Shift And Front/Rear Implement Selector Valve Removal

    Section 7 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 532: Pitch/Side Shift And Front/Rear Implement Selector Valve Installation

    65E Turbo Motor Grader Section 7 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 533: Circle Shift/Saddle Pin Selector Valve Removal

    Section 7 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 534: Circle Shift/Saddle Pin Selector Valve Installation

    65E Turbo Motor Grader Section 7 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 535 Section 7 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 536: Hydraulic Swivel

    65E Turbo Motor Grader Section 7 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 537: Disassembly

    Section 7 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 538: Inspection

    65E Turbo Motor Grader Section 7 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 539: Installation

    Section 7 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 540 65E Turbo Motor Grader Section 7 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 541: Circle Turn Hydraulic Motor

    Section 7 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 542 65E Turbo Motor Grader Section 7 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 543: Installation

    Section 7 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 544: Circle Turn Gearbox

    65E Turbo Motor Grader Section 7 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 instal- lation.

  • Page 545: Disassembly

    Section 7 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 546: Assembly

    65E Turbo Motor Grader Section 7 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 547: Installation

    Section 7 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 548 65E Turbo Motor Grader Section 7 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 549: Cylinders

    Section 7 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 550: Lift Cylinder Installation

    65E Turbo Motor Grader Section 7 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 551 Section 7 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 552: Circle Shift Cylinder Removal

    65E Turbo Motor Grader Section 7 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 553: Circle Shift Cylinder Installation

    Section 7 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 554: Moldboard Side Shift Cylinder Removal

    65E Turbo Motor Grader Section 7 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 555: Moldboard Pitch Cylinder Removal

    Section 7 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 556: Moldboard Pitch Cylinder Installation

    65E Turbo Motor Grader Section 7 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 557 Section 7 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 558: Articulation Cylinder Installation

    65E Turbo Motor Grader Section 7 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 559: Wheel Lean Cylinder Removal

    Section 7 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 560: Wheel Lean Cylinder Installation

    65E Turbo Motor Grader Section 7 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 561: Steering Cylinder Removal

    Section 7 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 562: Steering Cylinder Installation

    65E Turbo Motor Grader Section 7 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 563: Steering Cylinder Adjustment

    Section 7 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 564 65E Turbo Motor Grader Section 7 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 565: Front End Attachment Cylinder Removal

    Section 7 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 566: Front End Attachment Cylinder Installation

    65E Turbo Motor Grader Section 7 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 567: Rear Ripper Cylinder Removal

    Section 7 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 568: Bank Slope Cylinder Removal

    65E Turbo Motor Grader Section 7 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 569: Bank Slope Cylinder Installation

    Section 7 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 570: Cylinder Disassembly

    65E Turbo Motor Grader Section 7 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 571: Cylinder Inspection And Assembly

    Section 7 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 572 65E Turbo Motor Grader Section 7 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 573 Section 7 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 574: Hydraulic Oil Filter And Strainers

    65E Turbo Motor Grader Section 7 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 575: Hydraulic Strainers

    Section 7 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 576 Please reference “Eaton Publication #06-623.pdf” on this CD for further information on the L2 Series Gear Pump...
  • Page 577 Please reference “Eaton Publication #07-145.pdf” on this CD for further information on the T Series Geroler Motor...
  • Page 578 Service Manual Section 8: Moldboard and Implement Service 1.00_2006.03...
  • Page 580 65E Turbo Motor Grader Section 8 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: Read the Operator's Manual carefully before using the machine.
  • Page 581 Section 8 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 582 65E Turbo Motor Grader Section 8 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 583 Section 8 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 584 65E Turbo Motor Grader Section 8 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 585 Section 8 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 586 65E Turbo Motor Grader Section 8 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 587 Section 8 65E Turbo Motor Grader Moldboard and Implement Service Manual This page intentionally left blank. Service 1.00_2006.03...
  • Page 588 65E Turbo Motor Grader Section 8 Service Manual Moldboard and Implement GENERAL ..............8-1 Specifications .
  • Page 589 Section 8 65E Turbo Motor Grader Moldboard and Implement Service Manual This page intentionally left blank. 8-xii Service 1.00_2006.03...
  • Page 590 65E Turbo Motor Grader Section 8 Service Manual Moldboard and Implement Section 8: 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 591 Section 8 65E Turbo Motor Grader Moldboard and Implement Service Manual PECIFICATIONS Drawbar Type ....... . A-Frame Welded Steel with Center Mounted Circle Turn Motor Connection.
  • Page 592 65E Turbo Motor Grader Section 8 Service Manual Moldboard and Implement Standard Moldboard Reach* (Including Circle Shift, Outside Rear Wheels, Frame Straight): Left..............994 mm (39.1 in.) Right .
  • Page 593 Section 8 65E Turbo Motor Grader Moldboard and Implement Service Manual Front Dozer Blade Attachment............... . Front Weight .
  • Page 594 65E Turbo Motor Grader Section 8 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 595 Section 8 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 596 65E Turbo Motor Grader Section 8 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 597 Section 8 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 598 65E Turbo Motor Grader Section 8 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 599 Section 8 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 Nm (19 +/- 1 Ib-ft.). Step 6: Using two bolts and washers, secure two moldboard hoses, 1, with two hose clamps, 2.
  • Page 600 65E Turbo Motor Grader Section 8 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 601 Section 8 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 602 65E Turbo Motor Grader Section 8 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 603 Section 8 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 604 65E Turbo Motor Grader Section 8 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 605 Section 8 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 606 65E Turbo Motor Grader Section 8 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 607 Section 8 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 608 65E Turbo Motor Grader Section 8 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 609 Section 8 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 610 65E Turbo Motor Grader Section 8 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 611 Section 8 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 612 65E Turbo Motor Grader Section 8 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 613 Section 8 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.

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