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NorAM 65E Turbo Motor Grader, Service Manual

Introducing the NorAM 65E Turbo Motor Grader, a powerful heavy-duty machine designed for precision and efficiency. Complete with advanced features and unmatched performance, this product guarantees optimal results. Enhance your experience with the comprehensive Service Manual, available for free download at manualshive.com.

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ERGOPOWER

 

 
Geschäftsbereich 
Arbeitsmaschinen-Antriebe 
und Achssysteme

 

 

 

4

TABLE 

OF 

CONTENTS 

        

 

  

Page: 

Summary of the TECHNICAL DATA

                                                        

   

6 - 7

 

 

Indentification Plate 

      8

 

 

IMPORTANT INSTRUCTIONS

 

                                                                                        

9 - 10  

 

I. DESCRIPTION 

                                                                                                        11                               

1.1

 

Function of the Converter 

1.2

 

WK 

1.3

 

Powershift transmission 

1.4

 

Transmission control 

1.5

 

Speed range selector 

1.5.1

 

General 

1.5.2

 

Speed range selector DW-3 

1.5.3

 

Speed 

range 

selector 

VTS-3 

        

1.5.4 

Pushbutton switch D-7 

1.6 Display 
1.6.1  

General 

1.6.2 

  Possible Indications on the Display   

1.6.3 

  Error code definition 

1.7 

Elektronic Control unit TCU 

1.8 

Elektronic Control for ZF-Powershift transmission 

1.8.1 General 
1.8.2 

Description of the Basic functions 

1.8.3 

Automatic calibrations of the Shifting elements (AEB) 

1.8.4 Kickdown 

function 

1.8.5 Special 

functions 

1.9 Axle 

disconnection 

 
II. INSTALLATION 

SPECIFICATION 

 

 

 

 

                29

 

 

III. 

  OPERATION 

 

 

                                                                                31 

3.1 

Driving preparation and Maintenance 

3.2 

Driving and Shifting 

3.3 Cold 

start 

 

3.4 

Transmission control in the driving mode automatic 

3.5  

Stopping and Parking 

3.6 Towing 
3.7 Oil 

temperature 

3.8 

Shifting of the various outputs 

 

IV. MAINTENANCE 

 

 

 

 

 

 

                            35 

4.1  

Oil grade 

4.2 

Oil level check 

4.3 

Oil change and filter replacement interval 

4.3.1 

Oil change and oil filling capacity 

4.3.2

 

Filter replacement

 

 

V.  

ZF-DIAGNOSTIC SYSTEM  

 

 

 

 

 

 

  39

 

5.1 General 
5.2 ZF-Mobidig 

2001 

5.3 Laptop 

Version 

5.4 ZF-Multi-System 

5000

 

Summary of Contents for 65E Turbo Motor Grader

Page 1: ...65E Turbo Motor Grader Service Manual I Service 2 00_2013 02 65E TURBO Motor Grader Service Manual Part 22145 Serial Tier III 65ET9500 65ET9899 Tier IVi 65ET9900 UP ...

Page 2: ...This page intentionally left blank ...

Page 3: ... any particular machine please consult your dealer PARTS AND ACCESSORIES Genuine parts and accessories have been specifically designed for these machines We would like to point out that non genuine parts and accessories have NOT been examined and released by Weiler The instal lation and or use of such products could have negative effects upon the design characteristics of your machine and thereby ...

Page 4: ...tory recommended 50 hour service You will be responsible for the cost of lubricants fluids filters and other items replaced as part of normal maintenance Prior to taking the machine to your selling dealer for service it is recommended that you contact them to determine any other charges for which you may be responsible IMPROVEMENTS The manufacturer is continually striving to improve its products W...

Page 5: ...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 Be certain however to close or replace all shielding before operating the machine ...

Page 6: ...IV CONTENTS OVERVIEW Electronic Display Section 1 Engine Section 2 Operator s Platform and Controls Section 3 Transmission Section 4 Front Axle Section 5 Rear Axle and Tandem Section 6 Electrical Section 7 Hydraulics Section 8 Moldboard and Implement Section 9 ...

Page 7: ...Service Manual Section 1 Electronic Display Service 2 00_2013 03 ...

Page 8: ...r site supervisor or OSHA for specific requirements 5 To prevent falls use assist rails and steps when getting on and off the machine Keep steps and platform clear of mud oil grease snow tools and debris 6 Do not use controls or hoses as hand holds when climbing on or off machine Controls may move and inadvertently cause machine travel or implement movement 7 Do not permit anyone but the operator ...

Page 9: ...rols before moving Advise maintenance personnel of malfunctions before operating Be sure malfunctions are remedied before accepting responsibility for operation 22 Avoid accidental contact with the transmission control lever while the engine is running Unexpected movement may result from such contact 23 Do not get off or on the vehicle while it is moving 24 Lower unlocked implements to the ground ...

Page 10: ...rotating beacons and licensing requirements 39 Obey flagmen safety signals and signs 40 Dim vehicle lights when meeting a vehicle at night Make sure lights are adjusted to prevent blinding oncoming drivers 41 Reduce speed before turning or applying brakes 42 Always check overhead clearance especially when transporting Be aware of low overhanging obstacles such as trees and bridges 43 Know the exac...

Page 11: ...rvice procedure Be sure operator can see mechanic 57 Always use external supports when working under any linkage or raised part of the machine Lower implements to ground whenever possible 58 Do not service the grader with the engine running unless the grader is properly and securely supported with all six wheels off the ground 59 Use caution when servicing the unit around moving parts 60 The cooli...

Page 12: ...tention immediately or gangrene may result 71 Fuel oil in the injection system is under high pressure and can penetrate the skin Unqualified persons should not remove or attempt to adjust a pump injector nozzle or any other part of the fuel injector system Failure to follow these instructions can result in serious injury 72 Continuous long term contact with used engine oil may cause skin cancer Av...

Page 13: ...e tank 88 Do not fill the fuel tank to capacity Allow room for expansion 89 Wipe up spilled fuel immediately 90 Always tighten the fuel tank cap securely 91 If the original fuel tank cap is lost replace it with a genuine replacement cap A non approved cap may not be safe 92 Keep equipment clean and properly maintained 93 Do not drive equipment near open fires 94 Never use fuel for cleaning purpose...

Page 14: ...RATOR IN THE PROPER AND SAFE OPERATION OF ALL OPERATIVE EQUIPMENT BOTH EMPLOYER AND EMPLOYEE SHOULD THOROUGHLY FAMILIARIZE THEMSELVES WITH THE MACHINE OPERATION Some pictures in this manual show safety shields removed or open to show parts being serviced or for clarity all shields should be closed or replaced prior to operating the machine Fasten seat belt before starting engine ...

Page 15: ... 3 View Engine Diagnostics 1 Screen 1 3 View Engine Diagnostics 2 Screen 1 4 View Transmission Diagnostics Screen 1 4 View CAN Screen 1 5 System Settings Screens 1 5 Inching 1 5 Contrast Adjustment 1 6 Reset All 1 6 AEB Mode Request 1 7 AEB Calibration Screen 1 7 Top Left 1 8 Top Right 1 8 Bottom Left 1 8 Bottom Right 1 8 View Errors Screen 1 10 Active Error Screen 1 10 Electronic Display Navigati...

Page 16: ...65E Turbo Motor Grader Service Manual Section 1 Electronic Display Service 2 00_2013 03 1 II This page intentionally left blank ...

Page 17: ...ng Screen 1 Active Gear Displays what gear is currently active 2 Engine RPM Displays engine rpm 3 Fuel Level Displays current fuel level 4 Menu Main Menu Control key option Press control key associated with icon to enter Menu Screen 5 Top Left Displays operator chosen system setting For example the current system setting is fuel level 6 Top Right Displays operator chosen system setting For example...

Page 18: ...ne This option is best used immediately following deactivation of the Regeneration Inhibit Option When the Regeneration Force function is active the engine will enter a regeneration cycle when the ECM recognizes a high soot load The CAT C3 4 Tier IVi engine will not regenerate on command at any soot load the ECM will control the regeneration cycle 11 Regeneration Inhibit Option Displays icon when ...

Page 19: ...o previous screen Highlight screen name and select with the right arrow key View Engine Diagnostics 1 Screen View Engine Diagnostics 1 Screen displays the following Engine Speed Percent Load Engine Coolant Temperature Fuel Level Oil Pressure Boost Pressure Throttle Command NOTE View Engine Diagnostics 1 Screen is a read only screen The up down and enter control keys do not function in View Engine ...

Page 20: ...generation Inhibit Icon Only available on the CAT C3 4 TIVi engine option To activate Regeneration Force or Regeneration Inhibit press the control keys associated with the desired arrows Press the control key associated with the ESC icon to return to the Menu Screen View Transmission Diagnostics Screen View Transmission Diagnostics Screen displays the following Transmission Oil Temperature Torque ...

Page 21: ...system settings to be adjusted To adjust a setting use up down and right enter arrows to select activate and deactivate setting of choice The following system settings are available Inching When the inching control is in the OFF 0 position the transmission is disconnected through a clutch when the brake pedal is depressed When the inching control is activated ON 1 the transmission continues to dri...

Page 22: ...o select desired setting Press the control key associated with the ESC icon to return to the Menu Screen Arrow up for darker contrast arrow down for lighter contrast Reset All The Reset All Option resets all settings to the default settings To activate press the control keys associated with the right arrow Selection box will display during the reset process once process is complete the selection b...

Page 23: ...re engine is idling Once the required conditions are met to activate press the control keys associated with the up or down arrows followed by the right arrow to select desired setting Press the control key associated with the ESC icon to return to the Menu Screen Select AEB MODE REQUEST to begin AEB cycle AEB Calibration Screen When AEB Mode Request is active AEB Calibration Screen is displayed AE...

Page 24: ...ual Service 2 00_2013 03 1 8 Section 1 Electronic Display The Top Left Top Right Bottom Left and Bottom Right system settings screens allow the user to customize the Main Operating Screen 1 Top Left Top Right Bottom Left Bottom Right 1 ...

Page 25: ...ress the control key associated with the ESC icon to return to the Menu Screen 1 Battery Voltage 12 Fuel Pressure 2 Hours 13 Transmission Oil Temperature 3 Engine RPM 14 Coolant Temperature Metric 4 Percent Load Engine 15 Oil Pressure Metric 5 Coolant Temperature 16 Manifold Temperature Metric 6 Oil Pressure 17 Boost Pressure Metric 7 Intake Manifold Temperature 18 Fuel Temperature Metric 8 Boost ...

Page 26: ...e OC Number of Occurrences Active Error Screen The Active Error Screen will be displayed at start up if an error is active and during normal operation if an error becomes active The Active Error Screen will continue to be displayed every 30 seconds until the error is resolved To exit the Active Error Screen press the control key associated with the ESC icon To view a list of fault codes refer to D...

Page 27: ...65E Turbo Motor Grader Service Manual 1 11 Service 2 00_2013 03 Section 1 Electronic Display ELECTRONIC DISPLAY NAVIGATION ENTERS MAIN MENU SCREEN HOME SCREEN DIAGNOSTICS SCREENS ...

Page 28: ...65E Turbo Motor Grader Service Manual Service 2 00_2013 03 1 12 Section 1 Electronic Display ENTERS MAIN MENU SCREEN HOME SCREEN SYSTEM SETTINGS SCREENS ...

Page 29: ...65E Turbo Motor Grader Service Manual 1 13 Service 2 00_2013 03 Section 1 Electronic Display AEB CALIBRATION SCREEN ENTERS MAIN MENU SCREEN HOME SCREEN SYSTEM SETTINGS AEB MODE REQUEST SCREEN ...

Page 30: ...65E Turbo Motor Grader Service Manual Service 2 00_2013 03 1 14 Section 1 Electronic Display HOME SCREEN VIEW ERRORS SCREEN ACTIVE ERROR SCREEN ENTERS MAIN MENU SCREEN ...

Page 31: ...Service Manual 1 15 Service 2 00_2013 03 Section 1 Electronic Display HOME SCREEN ENTERS MAIN MENU SCREEN VIEW ENGINE DIAGNOSTICS 2 SCREEN INHIBIT REGENERATION SCREEN REGENERATION IN PROGRESS SCREEN FORCE REGENERATION SCREEN ...

Page 32: ...65E Turbo Motor Grader Service Manual Section 1 Electronic Display Service 2 00_2013 03 1 16 This page intentionally left blank ...

Page 33: ...Service Manual Section 2 Engine Service 2 00_2013 03 ...

Page 34: ......

Page 35: ...e supervisor or OSHA for specific requirements 5 To prevent falls use assist rails and steps when getting on and off the machine Keep steps and platform clear of mud oil grease snow tools and debris 6 Do not use controls or hoses as hand holds when climbing on or off machine Controls may move and inadvertently cause machine travel or implement movement 7 Do not permit anyone but the operator to ri...

Page 36: ...fore moving Advise maintenance personnel of malfunctions before operating Be sure malfunctions are remedied before accepting responsibility for operation 22 Avoid accidental contact with the transmission control lever while the engine is running Unexpected movement may result from such contact 23 Do not get off or on the vehicle while it is moving 24 Lower unlocked implements to the ground apply p...

Page 37: ...ng beacons and licensing requirements 39 Obey flagmen safety signals and signs 40 Dim vehicle lights when meeting a vehicle at night Make sure lights are adjusted to prevent blinding oncoming drivers 41 Reduce speed before turning or applying brakes 42 Always check overhead clearance especially when transporting Be aware of low overhanging obstacles such as trees and bridges 43 Know the exact loca...

Page 38: ... procedure Be sure operator can see mechanic 57 Always use external supports when working under any linkage or raised part of the machine Lower implements to ground whenever possible 58 Do not service the grader with the engine running unless the grader is properly and securely supported with all six wheels off the ground 59 Use caution when servicing the unit around moving parts 60 The cooling sy...

Page 39: ...n immediately or gangrene may result 71 Fuel oil in the injection system is under high pressure and can penetrate the skin Unqualified persons should not remove or attempt to adjust a pump injector nozzle or any other part of the fuel injector system Failure to follow these instructions can result in serious injury 72 Continuous long term contact with used engine oil may cause skin cancer Avoid pr...

Page 40: ... 88 Do not fill the fuel tank to capacity Allow room for expansion 89 Wipe up spilled fuel immediately 90 Always tighten the fuel tank cap securely 91 If the original fuel tank cap is lost replace it with a genuine replacement cap A non approved cap may not be safe 92 Keep equipment clean and properly maintained 93 Do not drive equipment near open fires 94 Never use fuel for cleaning purposes 95 T...

Page 41: ...N THE PROPER AND SAFE OPERATION OF ALL OPERATIVE EQUIPMENT BOTH EMPLOYER AND EMPLOYEE SHOULD THOROUGHLY FAMILIARIZE THEMSELVES WITH THE MACHINE OPERATION Some pictures in this manual show safety shields removed or open to show parts being serviced or for clarity all shields should be closed or replaced prior to operating the machine Fasten seat belt before starting engine ...

Page 42: ...65E Turbo Motor Grader Service Manual Section 2 Electronic Display Service 2 00_2013 03 2 x This page intentionally left blank ...

Page 43: ...I Fuses 2 8 Cummins Tier III Fuses 2 9 Cummins Tier IVi Specifications 2 10 Cummins Tier IVi Engine Component Locations 2 11 Cummins Tier IVi Engine Component Locations 2 12 Cummins Tier IVi Fuse Designations 2 13 Cummins Tier IVi Fuses 2 14 CAT Tier III Specifications 2 15 CAT Tier III Engine Electrical 2 16 Electronic Control Module ECM 2 16 CAT Tier III Engine Component Locations 2 17 CAT Tier ...

Page 44: ...or Grader Service Manual Service 2 00_2013 03 xii Section 2 Engine CAT Tier IVi Engine Component Locations 2 24 CAT Tier IVi Fuse Designations 2 25 CAT Tier IVi Fuses 2 26 Diesel Particulate Filter Regeneration 2 28 ...

Page 45: ... for the engine is located in the Cummins Operation and Maintenance Manual Refer to the Cummins manual for engine troubleshooting and diagnostic help If further service is required contact the local Cummins dealer or call the Cummins Customer Assistance Center 1 800 343 7357 3 CAT C4 4 Tier III engine Detailed operation and maintenance information for the engine is located in the CAT Operation and...

Page 46: ...in screen Information can be obtained by pushing the buttons below the display screen To alert the operator the Shut Down Engine error message will flash for 30 seconds before automatically shutting down the machine Pressing the button below the Menu icon 1 enters into the menu screen to view diagnostics Menu Screen Use the buttons below the up and down arrows to move the box over the name of the ...

Page 47: ...iagnostics 2 Screen displays the following Battery Manifold Temperature Fuel Temperature Hest Lamp DPF Inhibit Lamp DPF Force Lamp Regeneration Force Icon only visible when active Regeneration Inhibit Icon only visible when active NOTE DPF Inhibit Lamp DPF Force Lamp Regeneration Force Icon and Regeneration Inhibit Icon are only available on the CAT C3 4 Tier IVi engine option The Transmission Dia...

Page 48: ... of Cylinders 4 Displacement 4 5 L 275 cu in Bore and Stroke 107 mm x 124 mm 4 21 in x 4 88 in Aspiration Turbocharged and Charge Air Cooled Cooling Water Gross Power 82 kW 110 hp Maximum Torque 488 Nm 360 lb ft 1500 RPM Rated Speed 2200RPM Low Idle Speed 900 50 RPM High Idle Speed 2200 50 RPM Fuel Pump Bosch VP30 Compression Ratio 17 2 1 Firing Order 1 3 4 2 Weight Wet 390 kg 860 Ib ...

Page 49: ...e 2 00_2013 03 Section 2 Engine CUMMINS TIER III ENGINE ELECTRICAL Electronic Control Module ECM The engine electronic control module 1 is supplied power through a fuse located in a sealed connector 2 near the right hand side of the flywheel area 1 2 ...

Page 50: ...e CUMMINS TIER III ENGINE COMPONENT LOCATIONS 1 A C Compressor 2 Washer Fluid Tank 3 Fuel Filler Neck 4 Fuel Filter 5 Water Separator 6 Fuel Primer 7 Fuel Pump 8 Engine Oil Fill 9 Air Cleaner 10 Air Filter Indicator 11 Muffler 12 Brake Fluid Reservoirs 1 2 3 4 6 5 8 7 9 10 11 12 ...

Page 51: ...2 7 Service 2 00_2013 03 Section 2 Engine CUMMINS TIER III ENGINE COMPONENT LOCATIONS 13 Hydraulic Tank 14 Hydraulic Tank Fill 15 Hydraulic Tank Sight Gauge 16 Master Switch 17 Starter 18 Engine Oil Filter 19 Alternator 15 14 13 16 19 18 17 ...

Page 52: ...65E Turbo Motor Grader Service Manual Service 2 00_2013 03 2 8 Section 2 Engine Cummins Tier III Fuses Located under right side console ...

Page 53: ...s 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 Will not start 5A Fuse blown 6 RD wire Refer to fuse 8 page 2 8 Engine dies Engine cranks Will not start No smoke 30A 5 RD w WH Refer to fuse 25 page 2 8 ...

Page 54: ...iesel Number of Cylinders 4 Displacement 3 3 L 201 cu in Bore and Stroke 95 mm x 115 mm 3 74 in x 4 53 in Aspiration Turbocharged and Charge Air Cooled Cooling Water Gross Power 82 kW 110 hp Maximum Torque 415 Nm 306 lb ft 1500 RPM Rated Speed 2200RPM Low Idle Speed 950 50 RPM High Idle Speed 2200 50 RPM Compression Ratio 17 3 1 Firing Order 1 2 4 3 Weight Wet 374 kg 825 Ib ...

Page 55: ...ENGINE COMPONENT LOCATIONS 1 A C Compressor 2 Muffler 3 Air Cleaner 4 Fuel Filter 5 Water Separator 6 Fuel Primer 7 Fuel Pump 8 Fuel Filler Neck 9 Crankcase Coalescence Filter 10 Crankcase Breather Hose 11 Electronic Control Module ECM 12 Starter 13 ECM Diagnostic Port 3 2 1 5 6 4 8 7 10 9 12 13 11 ...

Page 56: ...LOCATIONS 14 Heater Shutoff Valve 15 Master Switch 16 Hydraulic Tank 17 Hydraulic Tank Fill 18 Hydraulic Tank Sight Gauge 19 Alternator 20 Washer Fluid Tank 21 Air Intake Temperature Sensor 22 Air Filter Indicator 23 Brake Fluid Reservoirs 24 Engine Oil Fill 25 Engine Oil Dipstick 15 14 18 17 16 20 19 21 22 23 24 25 ...

Page 57: ... IGN SWITCH 7 5A 9 TAIL LIGHTS 5A 10 LED STROBE 5A 11 PWR SOCKET 10A 12 TURN SIGNAL HAZARD 10A 13 BRAKE SWITCH 5A 14 FUEL SENDER 5A 15 DOME DASH LIGHTS 7 5A 16 WORK LIGHTS 30A 17 TRANS SHIFT LEVER SENSOR 5A 18 TRANSMISSION 7 5A 19 CONVERTER 30A 20 OPEN 21 OPEN 22 WIPERS 15A 23 A C 30A 24 HEATER 30A 25 ENG ECU FUSE 30A ENG ECU FUSE IS LOCATED NEAR RH SIDE OF HYD TANK INSIDE ENG COMPARTMENT 25 7 3 4...

Page 58: ...elow Refer to wiring schematic in Electrical section for further wiring details Symptom Engine Characteristics Possible Cause Engine dies Will not start 7 5A Ign Switch Fuse blown 6 RD wire Refer to fuse 8 page 2 14 Engine dies Engine cranks Will not start No smoke 30A 5 RD w WH Refer to fuse 25 page 2 14 None Engine will not start in cold weather 250A Fuse Blown Glow Plugs ...

Page 59: ...nt 4 4 L 269 cu in Bore and Stroke 105 mm x 127 mm 4 13 in x 5 0 in Aspiration Turbocharged Charge Air Cooled or After Cooled Cooling Water Gross Power 85 kW 114 hp Maximum Torque 414 Nm 380 lb ft 1400 RPM Rated Speed 2200RPM Low Idle Speed 900 50 RPM High Idle Speed 2200 50 RPM Fuel Pump CAT Compression Ratio 16 2 1 Firing Order 1 3 4 2 Weight Net Dry approximate with standard equipment 378 Kg 83...

Page 60: ...00_2013 03 2 16 Section 2 Engine CAT TIER III ENGINE ELECTRICAL Electronic Control Module ECM The engine electronic control module 1 is supplied power through six fuses located in sealed connectors 2 near the right hand side of the flywheel area 1 2 ...

Page 61: ...ection 2 Engine CAT TIER III ENGINE COMPONENT LOCATIONS 1 A C Compressor 2 Engine Oil Fill 3 Fuel Filter 4 Water Separator 5 Fuel Primer 6 A C Dryer 7 Injector Pump 8 Engine Oil Filter 9 Engine Oil Dipstick 10 Fuel Fill 11 Heater Shutoff Valve 2 1 3 5 4 7 6 10 8 9 11 ...

Page 62: ...III ENGINE COMPONENT LOCATIONS 12 Washer Fluid Tank 13 Air Cleaner 14 Air Filter Indicator 15 Muffler 16 Brake Fluid Reservoirs 17 Hydraulic Tank 18 Hydraulic Tank Fill 19 Hydraulic Tank Sight Gauge 20 Master Switch 21 Starter 22 Turbocharger 23 Alternator 12 15 14 13 19 18 17 16 20 21 22 23 ...

Page 63: ...0A 4 DEFOG FANS 30A 5 HIGH BEAMS 10A 6 HEAD LIGHT 10A 7 HORN 5A 8 IGN SWITCH 5A 9 TAIL LIGHTS 5A 10 LED STROBE 5A 11 PWR SOCKET 10A 12 TURN SIGNAL HAZARD 10A 13 BRAKE SWITCH 5A 19 23 24 20 22 21 18 17 14 FUEL SENDER 5A 15 DOME DASH LIGHTS 7 5A 16 WORK LIGHTS 30A 17 TRANS SHIFT LEVER SENSOR 5A 18 TRANSMISSION 7 5A 19 CONVERTER 30A 20 OPEN 21 OPEN 22 WIPERS 15A 23 A C 30A 24 HEATER 30A 25 ENG ECU FU...

Page 64: ...own to explain fuse failure symptoms below Refer to wiring schematic in Electrical section for further wiring details Symptom Engine Characteristics Possible Cause Engine dies Engine Cranks Will not start No smoke 30A 5 RD w WH Refer to fuse 25 page 2 20 None Engine will not start in cold weather 50A Glow Plug Circuit Breaker tripped ...

Page 65: ...nders 4 Displacement 3 3 L 201 cu in Bore and Stroke 94 mm x 124 mm 3 7 in x 4 72 in Aspiration Turbocharged Cooling Water Gross Power 83 kW 111 hp Maximum Torque 450 Nm 332 lb ft 2200 RPM Rated Speed 2200RPM Low Idle Speed 950 50 RPM High Idle Speed 2200 50 RPM Fuel Pump CAT Compression Ratio 19 5 1 Firing Order 1 3 4 2 Weight Net Dry approximate with standard equipment 265 Kg 584 Ib ...

Page 66: ... ENGINE COMPONENT LOCATIONS 1 Engine Electronic Control Module ECM 1 is supplied power through fuses located in sealed connectors 2 Glow Plug Control Unit GPCU 3 ECM Diagnostic Port 4 A C Compressor 5 Engine Oil Fill 6 Oil Dipstick 7 Fuel Filter 8 Water Separator 9 Fuel Primer 1 2 3 6 5 4 9 8 7 ...

Page 67: ...rvice 2 00_2013 03 Section 2 Engine CAT TIER IVI ENGINE COMPONENT LOCATIONS 10 Engine Oil Filter 11 Fuel Fill 12 Master Switch 13 Starter 14 Fuel Pump 15 Washer Fluid Tank 16 Air Filter 17 Air Filter Indicator 18 Muffler 11 10 14 13 12 18 17 16 15 ...

Page 68: ...NS 19 Brake Fluid Reservoirs 20 Hydraulic Tank 21 Hydraulic Tank Fill 22 Hydraulic Tank Gauge 23 Turbocharger 24 Alternator 25 Air Temperature Sensor 26 Lambda O2 Sensor 27 Crankcase Breather Heater Sensor 28 DPF Soot Sensor 29 DOC Temperature Sensor In 30 DOC Temperature Sensor Out 22 21 20 19 23 24 27 25 26 28 29 30 ...

Page 69: ...GN SWITCH 7 5A 9 TAIL LIGHTS 5A 10 LED STROBE 5A 11 PWR SOCKET 10A 12 TURN SIGNAL HAZARD 10A 13 BRAKE SWITCH 5A 14 FUEL SENDER 5A 15 DOME DASH LIGHTS 7 5A 16 WORK LIGHTS 30A 17 TRANS SHIFT LEVER SENSOR 5A 18 TRANSMISSION 7 5A 19 CONVERTER 30A 20 OPEN 21 OPEN 22 WIPERS 15A 23 A C 30A 24 HEATER 30A 25 ENG ECU FUSE 30A ENG ECU FUSE IS LOCATED NEAR RH SIDE OF HYD TANK INSIDE ENG COMPARTMENT 25 7 3 4 8...

Page 70: ...65E Turbo Motor Grader Service Manual Service 2 00_2013 03 2 26 Section 2 Engine CAT Tier IVi Fuses ...

Page 71: ...stics Possible Cause Engine dies Engine cranks Will not start No smoke 7 5A Fuse blown 6 RD wire Refer to fuse 8 page 7 8 Engine dies Will not start 5A Fuse blown 230 OR In line Engine dies Will not start 25A Fuse Blown 96 RD In line Engine derates see active error code 5A Fuse Blown 231 YL Refer to fuse 14 page 2 26 Engine dies Will not start 30A ECM Circuit Breaker tripped None Engine will not s...

Page 72: ... allows the machine to operate as normal under circumstances where changes in these elements would be of concern To activate Regeneration Inhibit Option press control key 1 from View Engine Diagnostics 2 Screen Using this option allows the operator to ensure the engine will not raise exhaust gas temperatures for the purpose of regeneration This action will reset on ignition key cycle or once the e...

Page 73: ...s it is required to activate a regeneration cycle When the diesel particulate filter DPF reaches 250 soot load the engine will shutdown Before engine is started filter must be replaced When the preceding states are achieved the following symbols are displayed on the electronic display On Off Off High Exhaust Temperature On During Active Regeneration The lamp will switch Off 1 min after regeneratio...

Page 74: ...65E Turbo Motor Grader Service Manual Section 2 Engine Service 2 00_2013 03 2 30 This page intentionally left blank ...

Page 75: ...Service Manual Section 3 Operator s Platform and Controls Service 2 00_2013 03 ...

Page 76: ......

Page 77: ...r employer site supervisor or OSHA for specific requirements 5 To prevent falls use assist rails and steps when getting on and off the machine Keep steps and platform clear of mud oil grease snow tools and debris 6 Do not use controls or hoses as hand holds when climbing on or off machine Controls may move and inadvertently cause machine travel or implement movement 7 Do not permit anyone but the ...

Page 78: ...nt controls before moving Advise maintenance personnel of malfunctions before operating Be sure malfunctions are remedied before accepting responsibility for operation 22 Avoid accidental contact with the transmission control lever while the engine is running Unexpected movement may result from such contact 23 Do not get off or on the vehicle while it is moving 24 Lower unlocked implements to the ...

Page 79: ...lashers rotating beacons and licensing requirements 39 Obey flagmen safety signals and signs 40 Dim vehicle lights when meeting a vehicle at night Make sure lights are adjusted to prevent blinding oncoming drivers 41 Reduce speed before turning or applying brakes 42 Always check overhead clearance especially when transporting Be aware of low overhanging obstacles such as trees and bridges 43 Know ...

Page 80: ...in the service procedure Be sure operator can see mechanic 57 Always use external supports when working under any linkage or raised part of the machine Lower implements to ground whenever possible 58 Do not service the grader with the engine running unless the grader is properly and securely supported with all six wheels off the ground 59 Use caution when servicing the unit around moving parts 60 ...

Page 81: ...dical attention immediately or gangrene may result 71 Fuel oil in the injection system is under high pressure and can penetrate the skin Unqualified persons should not remove or attempt to adjust a pump injector nozzle or any other part of the fuel injector system Failure to follow these instructions can result in serious injury 72 Continuous long term contact with used engine oil may cause skin c...

Page 82: ...lling the tank 88 Do not fill the fuel tank to capacity Allow room for expansion 89 Wipe up spilled fuel immediately 90 Always tighten the fuel tank cap securely 91 If the original fuel tank cap is lost replace it with a genuine replacement cap A non approved cap may not be safe 92 Keep equipment clean and properly maintained 93 Do not drive equipment near open fires 94 Never use fuel for cleaning...

Page 83: ...ACH OPERATOR IN THE PROPER AND SAFE OPERATION OF ALL OPERATIVE EQUIPMENT BOTH EMPLOYER AND EMPLOYEE SHOULD THOROUGHLY FAMILIARIZE THEMSELVES WITH THE MACHINE OPERATION Some pictures in this manual show safety shields removed or open to show parts being serviced or for clarity all shields should be closed or replaced prior to operating the machine Fasten seat belt before starting engine ...

Page 84: ...65E Turbo Motor Grader Service Manual Section 3 Operator s Platform and Controls Service 2 00_2013 03 3 x This page intentionally left blank ...

Page 85: ...ional and Other Left Hand Controls 3 10 Removal 3 10 Installation 3 12 Steering Wheel 3 13 Removal 3 13 Installation 3 13 Side View Mirror 3 14 Mirror Removal 3 14 Mirror Support Removal 3 14 Mirror Support Installation 3 14 Mirror Installation 3 14 Rear View Mirror 3 15 Removal 3 15 Installation 3 15 Console Tilt Mechanism 3 16 Removal 3 16 Installation 3 17 Control Lock 3 18 Removal 3 18 Install...

Page 86: ...ce 2 00_2013 03 3 xii Section 3 Operator s Platform and Controls Throttle Linkage Engine Speed Adjustment 3 30 Low Idle Setting 3 30 High Idle Setting 3 31 Throttle Lever Adjustment 3 32 Throttle Pedal Adjustment 3 33 Door Latch Adjustment 3 34 ...

Page 87: ... 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 As an option the motor grader can be purchased with a fully enclosed cab that is ROPS FOPS certified The cab has locking doors on both sides and is equipped with a heater front and rear windshield washer wipers and cloth seat ...

Page 88: ...traps attached to the ROPS FOPS unit Step 4 Disconnect any wires or cables attached to the ROPS FOPS unit Step 5 Remove the eight screws 1 and washers 2 attaching ROPS FOPS unit 3 to platform 4 Step 6 Connect a hoist to the two cap screws 5 on the top surface of the ROPS FOPS unit Step 7 Carefully lift the ROPS FOPS unit off the machine platform Use a hoist of sufficient lifting capacity for the w...

Page 89: ...ure to align the eight mounting holes Step 3 Secure the ROPS FOPS unit with eight bolts 1 and washers 2 Step 4 Torque the bolts to 198 Nm 146 Ib ft Step 5 Connect all wires and cables to the ROPS FOPS unit Step 6 Connect all ground straps attached to the ROPS FOPS unit Step 7 Install mirrors if applicable Step 8 Install floodlights if applicable Use a hoist of sufficient lifting capacity for the w...

Page 90: ...65E Turbo Motor Grader Service Manual Service 2 00_2013 03 3 4 Section 3 Operator s Platform and Controls Cab ...

Page 91: ...floor mat 10 and rear floor mat 11 Step 10 On machines with rear fenders remove screw 12 securing right hand threshold cover plate 13 and remove screw 14 securing left hand threshold cover plate 15 Step 11 Remove screws 1 and washers 2 attaching right threshold 3 and remove threshold Step 12 Remove screws 4 and washers 5 attaching left threshold 6 and remove threshold Step 13 Remove rear seal 16 S...

Page 92: ...65E Turbo Motor Grader Service Manual Service 2 00_2013 03 3 6 Section 3 Operator s Platform and Controls ...

Page 93: ...p 6 Carefully lift the cab 21 and set it down on the machine platform aligning the eight mounting holes Step 7 Attach the cab with eight bolts 18 washers 19 and spacers 20 Step 8 Torque the bolts to 198 Nm 146 Ib ft Step 9 Install side seal 17 Step 10 Install rear seal 16 Step 11 Attach left threshold 6 with screws 4 and washers 5 Step 12 Attach right threshold 3 with screws 1 and washers 2 Step 1...

Page 94: ... Loosen nut 1 and remove knob 2 Step 2 Remove screw 3 and flat washers 4 5 and 6 Step 3 Remove screw 1 washer 2 and nut 3 securing rod end 4 to control lever 5 Step 4 Slide control lever 5 off of shaft Step 5 All control levers can be removed using the same method Callouts Console Controls 1 Articulation Control 2 Wheel Lean Control 3 Left Hand Blade Lift Control 4 Right Hand Blade Lift Control ...

Page 95: ... 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 Step 4 Install nut 1 and knob 2 onto control lever Tight nut against knob Step 5 Adjust linkage as described in the Hydraulic section Step 6 All control levers can be installed using the same method ...

Page 96: ...zer Lift Control Optional and Other Left Hand Controls The left hand controls are as follows Removal Step 1 Loosen nut 1 and remove knob 2 Step 2 Remove screw 3 and flat washers 4 5 and 6 Callouts Console Controls 1 Circle Shift Control 2 Circle Turn Control 3 Blade Shift Control 4 Scarifier Control Standard Ripper Control Optional Dozer Lift Control Optional ...

Page 97: ...00_2013 03 Section 3 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 Step 5 All control levers can be removed using the same method ...

Page 98: ... 5 onto shaft Step 2 Attach rod end 4 to control lever 5 with screw 1 washer 2 and nut 3 Step 3 Install screw 3 and flat washers 4 5 and 6 Step 4 Install nut 1 onto scarifier control lever and screw on knob 2 Tighten nut against knob Step 5 Adjust linkage as described in the Hydraulic section Step 6 All control levers can be installed using the same method ...

Page 99: ...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 Installation Step 1 Press steering wheel 4 onto shaft 5 Step 2 Install nut 3 and torque to 55 61 Nm 40 45 Ib ft Step 3 Install steering wheel cover 2 Step 4 Install cover guard 1 ...

Page 100: ...Removal Step 1 Remove screw 9 and washer 10 securing mirror support 8 Step 2 Remove mirror support from cab Mirror Support Installation Step 1 Align mirror support mounting holes with mirror mounting holes at front of cab Step 2 Attach mirror support 8 to cab frame with washers 10 and screws 9 Step 3 Torque screws 9 to 23 Nm 17 Ib ft Mirror Installation Step 1 Attach mirror 7 to mirror support 8 w...

Page 101: ... 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 Step 2 Attach mirror 2 to cab ceiling with cap screws 1 Step 3 Torque screws 1 to 23 Nm 17 Ib ft ...

Page 102: ... jam nut 2 rod 3 and jam nut 4 from adjustable end yoke 5 Step 3 Remove cotter pin 6 from clevis pin 7 and remove roll pin 8 disengaging the adjustable end yoke 5 from the shaft 9 and the rod eye 10 If rod eye 10 needs to be replaced remove nut 11 and washer 12 Step 4 Remove roll pin 13 Step 5 Slide shaft 9 out of guide 14 Step 6 Remove washers 15 and spring 16 Step 7 If rack 17 requires replaceme...

Page 103: ...t roll pin 13 through shaft 9 between lower block 14 and lower washer 15 Step 5 Attach rod eye 10 to guide 14 using washer 12 and nut 11 Do not tighten nut at this time Step 6 Attach adjustable yoke end 5 to rod 9 with roll pin 8 Step 7 Attach adjustable end yoke 5 to rod eye 10 with clevis pin 7 and secure with cotter pin 6 Step 8 Torque nut 11 to 48 52 Nm 35 39 Ib ft Step 9 Install jam nut 4 on ...

Page 104: ...the front con sole except when pulled fully back toward the seat Removal Step 1 Push knob 1 down to disengage lock bar from control levers Step 2 Remove knob 1 Step 3 Remove two screws 2 then remove lock 3 from right hand lock bar Step 4 Remove two screws 4 and access cover 5 Step 5 Remove two screws securing left hand lock bar to shaft 1 and remove lock bar and shaft Step 6 Loosen jam nut 2 and r...

Page 105: ...ft 1 into front console with screw 3 positioned as shown in illustration Step 4 Align right hand lock shaft 3 mounting holes with center shaft and secure with two screws 2 Step 5 Attach left hand lock shaft to center shaft with two screws Step 6 Torque screws securing both left hand and right hand locking shafts to 48 52 Nm 35 39 Ib ft Step 7 Install knob 1 onto right hand locking shaft Step 8 Til...

Page 106: ...ction 3 Operator s Platform and Controls 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 Step 11 Install access cover 5 and secure with two screws 4 2 0 0 0 0 4 0 1 ...

Page 107: ...move 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 Step 3 Disengage shafts 2 from levers 3 Step 4 Move shafts out of the way for removal of brake pedals Step 5 Repeat steps 2 through 4 for all control levers on the left side of the front console ...

Page 108: ...p 7 Remove bearings 3 and check for wear Step 8 Remove roll pin 4 and remove right brake pedal 5 Step 9 Remove bearings 6 and check for wear Step 10 Remove cotter pin 7 and clevis pin 8 then remove lever 9 and flat washers 10 Step 11 Unscrew link 11 and remove jam nut 12 from rod 13 Step 12 Remove cotter pin 14 and clevis pin 15 securing rod 13 to lever assembly 16 ...

Page 109: ... 6 and clevis pin 7 to release rod 8 from lever assembly 4 Step 17 Remove spring 9 from eyebolt 10 Step 18 Remove nut 11 and remove eyebolt 10 from plate 12 Step 19 Remove nut 13 from eyebolt 10 Step 20 If bracket 3 needs to be replaced remove screw 14 and washer 15 Step 21 If plate 12 needs to be replaced remove nut 16 washer 17 and screw 18 Step 22 Unscrew yoke 19 and remove jam nut 20 Step 23 R...

Page 110: ...orm and Controls 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 Installation Step 1 Attach bracket 4 to hydraulic valve 5 with roll pin 3 screws 1 and washers 2 ...

Page 111: ...emoved install plate 12 using nut 16 washer 17 and screw 18 Step 5 If bracket 3 was removed install bracket 3 using screw 14 and washer 15 Step 6 Fasten nut 13 onto eyebolt 10 then attach eyebolt 10 to plate 12 with nut 11 Step 7 Attach rod 8 to lever assembly 4 with clevis pin 7 and cotter pin 6 Step 8 Install bearings 5 into lever assembly 4 and attach lever assembly to bracket 3 with shaft 2 an...

Page 112: ...link 11 and secure with clevis pin 8 and cotter pin 7 Step 14 Install bearings 3 into housing and insert left pedal 2 through bearings into lever 9 Step 15 Secure right pedal 2 to lever 9 with roll pin 1 Step 16 Install bearings 6 into housing and insert right pedal 5 through bearings into lever 9 Step 17 Secure right pedal 5 to lever 9 with roll pin 4 Step 18 Connect control lever shaft to contro...

Page 113: ...al 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 Step 2 Adjust the position of the brake pedals to 8 50 inches above floor by adjusting link 11 on rod 13 Step 3 When brake height is set reattach link 11 to lever 9 with clevis pin 8 and cotter pin 7 Step 4 Lock the link 11 in place with jam nut 12 ...

Page 114: ...2013 03 3 28 Section 3 Operator s Platform and Controls Brake Valve Plunger Clearance Adjustment Step 1 Adjust set screw 7 to provide a clearance of 0 02 inch between plunger of brake valve 5 and bracket 4 Step 2 Lock set screw 7 in place with jam nut 8 ...

Page 115: ... cotter pin 21 and remove clevis pin 22 to allow yoke 19 to be disengaged from bracket 23 and be adjusted on rod 8 Step 2 Adjust rod 8 in yoke 19 for a 0 09 inch clearance between top of lever assembly 4 and the channel Step 3 When clearance is set reattach yoke 19 bracket 23 with clevis pin 22 and cotter pin 21 Step 4 Lock yoke 19 in place with jam nut 20 ...

Page 116: ... 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 Step 4 Check low idle speed using a tachometer Speed should be 900 rpm Step 5 If speed is too high turn bolt 5 into mounting tab allowing lever 4 to rotate further counterclockwise Step 6 Tighten jam nut on bolt 5 Step 7 Turn off engine and reconnect link 1 between levers 4 ...

Page 117: ... 3 Step 2 Start engine Step 3 With engine running rotate lever 4 clockwise against stop bolt 6 Step 4 Check high idle speed using a tachometer Speed should be 2300 to 2400 rpm Step 5 If speed is low turn stop bolt into mounting tab until speed is correct Step 6 Tighten jam nut on bolt 6 to lock it in place Step 7 Turn off engine and reconnect link 1 between levers 4 and 7 ...

Page 118: ...ll need a length adjustment Step 4 To lengthen spring loaded override link 4 do the following a Loosen jam nuts 5 on both ends of springs b Turn jam nuts to move springs down rod 6 The overall length of link 4 should be 17 18 in measuring from center of ball joint to center of ball joint c Tighten jam nuts 5 on both ends of springs Step 5 Move throttle lever 1 to full engine speed position front o...

Page 119: ...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 Step 2 Turn the pedal stop bolts in or out as required to get complete travel of the TPS lever 4 Step 3 The linkage rod 2 can be adjusted to get different pedal angles as required by the operator Step 4 Lock all jam nuts to ke...

Page 120: ...he latch remove screws and washers 1 Slide cover 2 off lever For vertical adjustment loosen screws 1 For forward rearward horizontal adjustment loosen screws 2 With bottom of rod 3 disconnected from bottom lever adjust actuator rod 4 so lever 5 is vertical Adjust bottom clevis 1 so bottom lever is fully rotated toward the center of the grader by the spring in the latch Ensure that sufficient lever...

Page 121: ...Service Manual Section 4 Transmission Service 2 00_2013 03 ...

Page 122: ......

Page 123: ... site supervisor or OSHA for specific requirements 5 To prevent falls use assist rails and steps when getting on and off the machine Keep steps and platform clear of mud oil grease snow tools and debris 6 Do not use controls or hoses as hand holds when climbing on or off machine Controls may move and inadvertently cause machine travel or implement movement 7 Do not permit anyone but the operator t...

Page 124: ...s before moving Advise maintenance personnel of malfunctions before operating Be sure malfunctions are remedied before accepting responsibility for operation 22 Avoid accidental contact with the transmission control lever while the engine is running Unexpected movement may result from such contact 23 Do not get off or on the vehicle while it is moving 24 Lower unlocked implements to the ground app...

Page 125: ...tating beacons and licensing requirements 39 Obey flagmen safety signals and signs 40 Dim vehicle lights when meeting a vehicle at night Make sure lights are adjusted to prevent blinding oncoming drivers 41 Reduce speed before turning or applying brakes 42 Always check overhead clearance especially when transporting Be aware of low overhanging obstacles such as trees and bridges 43 Know the exact ...

Page 126: ...vice procedure Be sure operator can see mechanic 57 Always use external supports when working under any linkage or raised part of the machine Lower implements to ground whenever possible 58 Do not service the grader with the engine running unless the grader is properly and securely supported with all six wheels off the ground 59 Use caution when servicing the unit around moving parts 60 The coolin...

Page 127: ...ntion immediately or gangrene may result 71 Fuel oil in the injection system is under high pressure and can penetrate the skin Unqualified persons should not remove or attempt to adjust a pump injector nozzle or any other part of the fuel injector system Failure to follow these instructions can result in serious injury 72 Continuous long term contact with used engine oil may cause skin cancer Avoi...

Page 128: ...tank 88 Do not fill the fuel tank to capacity Allow room for expansion 89 Wipe up spilled fuel immediately 90 Always tighten the fuel tank cap securely 91 If the original fuel tank cap is lost replace it with a genuine replacement cap A non approved cap may not be safe 92 Keep equipment clean and properly maintained 93 Do not drive equipment near open fires 94 Never use fuel for cleaning purposes ...

Page 129: ...OR IN THE PROPER AND SAFE OPERATION OF ALL OPERATIVE EQUIPMENT BOTH EMPLOYER AND EMPLOYEE SHOULD THOROUGHLY FAMILIARIZE THEMSELVES WITH THE MACHINE OPERATION Some pictures in this manual show safety shields removed or open to show parts being serviced or for clarity all shields should be closed or replaced prior to operating the machine Fasten seat belt before starting engine ...

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Page 131: ...ion onto Engine 4 2 Cummins Tier IVi Mounting Transmission onto Engine 4 6 CAT Tier III Mounting Transmission onto Engine 4 10 CAT Tier IVi Mounting Transmission onto Engine 4 13 ZF Technical Data Description Operation Maintenance Diagnostic System Manual 4 16 ZF Repair Manual 4 70 KNOTT Functional Characteristics and Maintenance Instructions 4 71 ...

Page 132: ...65E Turbo Motor Grader Service Manual Section 4 Transmission Service 2 00_2013 03 4 xii This page intentionally left blank ...

Page 133: ...r information The transmission can be viewed by opening the side panels on each side of the machine Transmission error fault codes are displayed on the electronic display located on the RH instrument panel at the operator s platform The fault code definitions are located in Section 10 In order of occurrence this section contains the following information Procedure for mounting the transmission ont...

Page 134: ... TRANSMISSION ONTO ENGINE Step 1 Remove two mounting bolts from cover plate 1 Remove plate from engine 2 to access flywheel bolt holes and transmission flex plate threaded holes Step 2 Clean mating surfaces between transmission housing and engine flywheel housing No gasket or sealant is used between surfaces 1 2 ...

Page 135: ...lywheel housing 4 as follows a Align flywheel slots 5 with bolt heads 6 b Align turbine spud shaft 7 with engine pilot diameter 8 c Align a transmission flex plate threaded hole 9 with a flywheel bolt hole 10 d Apply Loctite 242 blue to threads of bolt not shown Secure flywheel to transmission flex plate using bolt Torque bolt to 47 Nm 35 ft lb 5 8 6 7 4 3 9 10 ...

Page 136: ...ion Step 4 Apply Loctite 242 blue to threads on 12 bolts 11 Step 5 Secure transmission housing to engine flywheel housing using 12 bolts Torque bolts to 47 Nm 35 Ib ft Step 6 Turn engine crankshaft 12 until one of four flywheel bolt holes 10 is aligned with access hole 13 11 12 10 13 ...

Page 137: ...el bolt hole 10 with transmission flex plate threaded hole 9 Step 8 Apply Loctite 242 blue to threads of bolt not shown Secure flywheel to transmission flex plate using bolt Torque bolt to 47 Nm 35 Ib ft Step 9 Repeat previous three steps for other two bolts Step 10 Install cover plate 14 onto engine using two mounting bolts 10 13 9 14 ...

Page 138: ...ING TRANSMISSION ONTO ENGINE Step 1 Remove mounting bolts from starter 1 Remove starter from engine 2 to access flywheel bolt holes and transmission flex plate threaded holes Step 2 Clean mating surfaces between transmission housing and engine flywheel housing No gasket or sealant is used between surfaces 1 2 ...

Page 139: ...nsmission 3 onto engine flywheel housing 4 as follows a Align turbine spud shaft 5 with engine pilot diameter 6 b Align a transmission flex plate threaded hole 7 with a flywheel bolt hole 8 c Apply Loctite 242 blue to threads of bolt not shown Secure flywheel to transmission flex plate using bolt Torque bolt to 47 Nm 35 ft lb 7 6 5 4 3 8 ...

Page 140: ...ssion Step 4 Apply Loctite 242 blue to threads on 12 bolts 9 Step 5 Secure transmission housing to engine flywheel housing using 12 bolts Torque bolts to 47 Nm 35 Ib ft Step 6 Turn engine crankshaft 10 until one of four flywheel bolt holes 8 is aligned with access hole 11 9 10 8 11 ...

Page 141: ...lywheel bolt hole 8 with transmission flex plate threaded hole 7 Step 8 Apply Loctite 242 blue to threads of bolt not shown Secure flywheel to transmission flex plate using bolt Torque bolt to 47 Nm 35 Ib ft Step 9 Repeat previous three steps for other two bolts Step 10 Install starter 12 onto engine using mounting bolts 8 11 7 12 ...

Page 142: ...en surfaces Step 2 Using a suitable lifting device position transmission 1 onto engine flywheel housing 2 as follows a Align flywheel slots 3 with bolt heads 4 b Align turbine spud shaft 5 with engine pilot diameter 6 c Align a transmission flex plate threaded hole 7 with a flywheel bolt hole 8 d Apply Loctite 242 blue to threads of bolt not shown Secure flywheel to transmission flex plate using b...

Page 143: ...ssion Step 3 Apply Loctite 242 blue to threads on 12 bolts 9 Step 4 Secure transmission housing to engine flywheel housing using 12 bolts Torque bolts to 47 Nm 35 Ib ft Step 5 Turn engine crankshaft 10 until one of four flywheel bolt holes 8 is aligned with access hole 11 9 10 8 11 ...

Page 144: ...through access hole 11 align flywheel bolt hole 8 with transmission flex plate threaded hole 12 Step 7 Apply Loctite 242 blue to threads of bolt not shown Secure flywheel to transmission flex plate using bolt Torque bolt to 47 Nm 35 Ib ft Step 8 Repeat previous three steps for other two bolts 8 11 8 12 ...

Page 145: ... or sealant is used between surfaces Step 2 Using a suitable lifting device position transmission 1 onto engine flywheel housing 2 as follows a Align turbine spud shaft 3 with engine pilot diameter 4 b Align a transmission flex plate threaded hole 5 with a flywheel bolt hole 6 c Apply Loctite 242 blue to threads of bolt not shown Secure flywheel to transmission flex plate using bolt Torque bolt to...

Page 146: ...mission Step 3 Apply Loctite 242 blue to threads on 12 bolts 7 Step 4 Secure transmission housing to engine flywheel housing using 12 bolts Torque bolts to 47 Nm 35 Ib ft Step 5 Turn engine crankshaft 8 until one of four flywheel bolt holes 6 is aligned with access hole 9 7 8 6 9 ...

Page 147: ...g through access hole 9 align flywheel bolt hole 6 with transmission flex plate threaded hole 5 Step 7 Apply Loctite 242 blue to threads of bolt not shown Secure flywheel to transmission flex plate using bolt Torque bolt to 47 Nm 35 Ib ft Step 8 Repeat previous three steps for other two bolts 6 9 6 5 ...

Page 148: ...o 5872 154 002 ZF ERGOPOWER TRANSMISSION 6 WG 115 TECHNICAL DATA DESCRIPTION OPERATION MAINTENANCE DIAGNOSTIC SYSTEMS ZF Passau GmbH Donaustr 25 71 D 94034 Passau Edition 2003 03 Subject to changes w o notice ...

Page 149: ...ERGOPOWER Geschäftsbereich Arbeitsmaschinen Antriebe und Achssysteme 2 1 Edition ...

Page 150: ...out previous information The responsibility lies with the owner and the user to pay attention to the safety indications and to carry out the Maintenance operations according to the prescribed Specifications The ZF is not liable for faulty installation incorrect treatment insufficient Maintenance im pro perly and unskilled performed works and for the subsequential damages resulting from it It is im...

Page 151: ...ntrol for ZF Powershift transmission 1 8 1 General 1 8 2 Description of the Basic functions 1 8 3 Automatic calibrations of the Shifting elements AEB 1 8 4 Kickdown function 1 8 5 Special functions 1 9 Axle disconnection II INSTALLATION SPECIFICATION 29 III OPERATION 31 3 1 Driving preparation and Maintenance 3 2 Driving and Shifting 3 3 Cold start 3 4 Transmission control in the driving mode auto...

Page 152: ...G 115 7 Power flow 6 WG 115 Forward gears 8 Power flow 6 WG 115 Reverse gears 9 Electro hydraulic gear shifting with proportional valve 10 6 WG 115 fully automatic control EST 37 Standard Circuit diagram 6029 717 039 11 Speed range selector DW 3 12 Speed range selector VTS 3 13 Speed range selector D7 Abbreviations used in the text Abbreviation Description WK Torque converter lock up clutch EST 37...

Page 153: ...ting via diaphragm on the engine or separate installation input via uni versal shaft with DIN Mechanic or Spicer input flange The transmission can be shifted manually or fully automatically by means of the Electronic unit EST 37 Torque converter Unit size W 300 and 340 with torque multiplication according to the version and a WK Powershift transmission 6 Forward speeds and 3 Reverse speeds Output ...

Page 154: ...a speedometer signal Road vehicles the signal required for the speedometer interpretation will be picked up on the output side by a pulse generator e g is needed for trip recorders For this a frequency divider from the Customer side is necessary Separate mounting of the ZF Fine filter Transmission ratio mechanical SPEED DRIVING DIRECTION Ratio 1 Forward 5 636 2 Forward 3 728 3 Forward 2 374 4 Forw...

Page 155: ...cification 6 List of lubricants 7 Oil capacity 8 Customer no NOTES REGARDING THE SPARE PARTS ORDERS When ordering genuine ZF Spare Parts please indicate 1 Gearbox type 2 Serial No 3 ZF Parts List No 4 Mark and type of vehicle 5 Denomination of the spare part 6 Spare parts No 7 Way of transport When all of the above required indications are considered errors in the delivery of spare parts Orders ca...

Page 156: ...ntroller at the starting of the engine always to the Neutral position At running engine and transmission in Neutral the parking brake must be enga ged or the service brake be actuated to prevent the vehicle from rolling Prior to every start off loosen the parking brake The engagement of the speed out of Neutral is only possible under the program med transmission input speed turbine speed Neutral p...

Page 157: ...amages due to insufficient oil supply At a longer distance the best solution would be to transport the vehicle with a low loader Operating temperature behind the converter at least 65 and 100 C in continu ous operation a short time increase up to max 120 C is permitted Temperature in the sump 60 90 C In case of irregularities on the transmission put the vehicle out of service and ask for Specialis...

Page 158: ...st favourable operating conditions are obtained for each installation case The Torque converter is composed of 3 main components Impeller Turbine wheel Stator Reaction member These 3 impellers are arranged in such a ring shaped system that the fluid is streaming through the circuit components in the indicated order Pressure oil from the transmission pump is constantly streaming through the convert...

Page 159: ...s decreasing The adaption of the output speed to a certain required output torque will be infinitely variable and automatically achieved by the torque converter When the turbine speed is reaching about 80 of the pump speed the torque multiplication becomes 1 0 i e the turbine torque becomes equal to that of the pump torque From this point on the converter is working similar to a fluid clutch A sta...

Page 160: ...l A compression spring takes over the pushing back of the piston thus the release of the plate pack As to the layout of the transmission as well as the specifications of the closed clutches in the single speeds see Table 1 4 and 5 1 4 Transmission control Transmission control see Schedule of measuring points Oil circuit diagram and Electro hydraulic control unit Table 4 5 and 9 The transmission pu...

Page 161: ...full and part load traction overrun inclusive consideration of load cycles during the gear change The main pressure valve is limiting the max control pressure to 16 2 5 bar and releases the main flow to the converter and lubricating circuit In the inlet to the converter a converter safety valve is installed which protects the converter from high internal pressures opening pressure 11 2 bar Within ...

Page 162: ...N Speed range selector blocked in this position Position D Driving Speed range selector DW 3 D F N R N Figure No 1 5 2 1 5 3 Speed range selector VTS 3 see table 12 In the case of the console selector VTS 3 preselector pushbutton switch the driving direc tion is preselected by horizontally turning the speed range selector lever By pressing the speed range selector lever to the right or the left th...

Page 163: ...vehicle to vehi cle Below two options are described how to define gear limitations Dumper Trough in top position vehicle can only be driven in the 1st and 2nd forward gear and in the 1st reverse gear Crane All wheel drive connected vehicle can only be driven in the 1st and 2nd gear Operation reversed to upper chassis driving only possible in the 1st gear Speed range selector VTS 3 V N R Figure No ...

Page 164: ...s RoRo trucks as well as with the VTS 3 SG 6 or D7 for Cranes Dumpers Graders and Rail vehicles 1 6 2 Possible Indications on the Display Spec charact Display see Figure No 1 6 2 a f Automatic range up and downshifting b c d e Preselected gear g EST 37 has recognized an error is flashing h This special character is not used for the moment at the EST 37 Left Side For the moment without function Cen...

Page 165: ...Neutral must be shifted on the Controller before the electronics allows to engage a gear again Preselected Driving range Special characters b c d e The number of the lines indicates the driving range resp the gear preselected 1 Bar Driving range 1 2 Bars Driving range 2 3 Bars Driving range 3 4 Bars Driving range 4 5 or 6 Display Manual Automatic Special characters a f If the two Symbols a f Arrow...

Page 166: ...s the indication on the Display to the actual gear and the corresponding warning indicator If several warnings are simultaneously active only the warning with the highest priority will be indicated Warning in dicator Warning Priority WR Temp behind Retarder 1 WT Temp behind Converter 1 WS Temperature in Sump 2 WE Engine speed 3 Display EE Indication on the Display EE central and right Side In this...

Page 167: ...is available for which the following Order No has been defined 5872 993 025 GERMAN 5872 993 026 ENGLISH This Diagnostic and Trouble shooting Specification can be requested under the follo wing address ZF Passau GmbH Abt ASPL Donaustr 25 71 94034 Passau 1 7 Elektronic Control unit TCU The electrohydraulic transmission control can be automated by connection on the electronic TCU The basic functions ...

Page 168: ...f the TCU Figure No 1 7 B1 The installation position of the TCU can be at random As an advantage the ZF re commends the Version illustrated in the Figure No 1 7 B1 The installation of the TCU must be realized on a protected point in the cabin An overfloating with water must be excluded Besides the penetration of water via the plug connection must be prevented by corresponding measures on the cable...

Page 169: ...corresponding circuit diagram see Sample Table 10 and the connection diagram upon request these Informati ons can be asked for at the ZF Passau According to the type of vehicle the wiring will be performed according to the wi ring diagrams Variations such as double cabin Version e g RT Crane vehicles are possible The cabin change over is not scope of supply of the ZF The corresponding electric cir...

Page 170: ...ssure cut off possible vehicle specific only after contact with ZF Change over possibility for Auto Manual mode Gear holding function possible kickdown Legend ref Figure No 1 8 2 1 Load sensor for load registration engine torque Option 2 Position switch under accelerator pedal for kickdown function Option 3 Controller VST 3 optional also possible with the Controllers DW 3 or D7 4 Display 5 Supply ...

Page 171: ......

Page 172: ...CAN Communication between transmission and vehicle electronics is necessary Due to the operation of the transmission the paper friction linings installed in the Er gopower transmissions are settling i e the plate clearance becomes greater Because these settling appearances can interfere the shifting quality ZF recommends to repeat the AEB Cycle at the Maintenance intervals see 4 3 1 The ZF recomme...

Page 173: ...Here on the converter side the out put can be equipped with an axle disconnection device so that depending on the application the axle front or rear axle can be connected or disconnected Fig No 1 9 B1 shows the dis connection of the front axle Connection and disconnection can take place hydraulically or pneumatically Figure No 1 9 B1 1 5 3 4 2 VA HA 6 7 ...

Page 174: ...nput 4 Output shaft for rear axle 5 Shift fork 6 Pneumatic or hydraulic connection and disconnection of the front axle 7 Connection for pneumatic or hydraulic operation of the axle disconnection 8 Switch for indication acknowledgement axle disconnection Indication operating condition of the axle disconnection system Axle disconnection connected Axle disconnection disconnected Figure No 1 9 B2 7 7 ...

Page 175: ...admit any guarantee or warranty claims for damages which has been caused by a faulty installation In order to assist the Customer in case of new resp initial applications the ZF carries out by authorized personnel transmission checks On this occasion all transmission specific instal lation features are examined and the Vehicle Manufacturer resp the Equipment Manufacturer will be informed about the...

Page 176: ...lations have to be absolutely observed For example the vehicle has to be secured against rolling by blocks articulated vehicles additionally against unintended turning in 3 2 Driving and Shifting Which control lamps in the INFOCENTER dashboard are illuminated for the functional check can be different from Vehicle Manufacturer to Vehicle Manufac turer Control elements and displays can be from the Z...

Page 177: ...verter It is convenient to brake the vehicle at every stop securely in position with the parking brake At longer stops the Controller has to be shifted to the NEUTRAL POSITION At the start off the parking brake has to be released We know from experience that at a con verter transmission it might not immediately be noted to have forgotten this quite normal ope rating step because a converter due to...

Page 178: ... a trouble free unit and an adequate driving mode a higher temperature will not occour If the temperature is rising above 90 C the vehicle has to be stopped and controlled for external oil loss and the engine must run with a speed of 1200 1500 min 1 at NEUTRAL POSITION of the transmission Now the temperate must drop quickly in about 2 3 minutes to normal values If this is not the case there is a t...

Page 179: ...ngine must be running about 2 3 minutes at idling speed and the marking on the oil dipstick must then be lying above the cold start mark COLD MIN see Figure No 4 2 B2 At operating temperature of the transmission about 80 90 C With engine idling speed all measurements must be carried out with low engine idling speed Loosen oil dipstick by counterclock rotation remove and clean it Insert oil dipstic...

Page 180: ...l change after 100 operating hours in application Every further oil change after 1000 operating hours in application however at least once a year At every oil change the ZF Fine filter pressure filter has to be replaced 4 3 1 Oil change and Oil filling capacity The oil change must be carried out as follows At operating temperature of the transmission and horizontally standing vehicle open the oil ...

Page 181: ...as well as the pipes must get filled with oil According to these cavities the oil capacity to be filled in is greater than at the later oil fillings in the course of the usual Maintenance service ZF recommends to start the AEB at every oil change see 1 8 3 4 3 2 Filter replacement At the replacement of the ZF Filter in the main oil stream pay attention that no dirt or oil sludge can penetrate into...

Page 182: ...rs Read fault storage Cancel fault storage AEB Automatic calibration of the shifting elements Testing Inputs and Outputs Outputs Check inputs Check systems downtime System test drive Additionally for the Diagnosis can be used the Multi System 5000 see 5 4 with correspon ding sensor system for pressure temperature speed through flow current transformer etc 5 2 ZF MOBIDIG 2001 The ZF Diagnostic syst...

Page 183: ...NT 6008 308 901 RS 232 Connecting cable Laptop DPA 04I 6008 308 601 Programming adapter DPA 04I 6008 308 600 Adapter cable DPA 04I EST 37 6029 017 005 Diagnostic set 5870 221 179 WIN 95 98 or NT Diagnostic Software WG 115 6008 308 005 GERMAN 6008 308 105 ENGLISH 6008 308 205 FRENCH Terminal Tester 68 pin For the test of single control signals line interruptions etc 6008 304 038 Figure No 5 3 ...

Page 184: ...er 5870 221 280 Multi System 5000 Measuring box with corresponding sensor sys tem for pressure temperature and speed with printer 5870 221 281 Multi System 5000 Portable measuring instrument without accesso ries 5870 221 250 Accessories Sensor system for through flow current transformer etc Current transformer 5870 221 284 Turbine Metering tubes 15 300 l min 5870 221 133 25 600 l min 5870 221 134 ...

Page 185: ... t c h s h a f t K 3 6 O u t p u t f l a n g e r e a r s i d e A B 7 O u t p u t f l a n g e c o n v e r t e r s i d e A B 8 O u t p u t s h a f t 9 T r a n s m i s s i o n p u m p 1 0 I n p u t f l a n g e I n p u t t h r o u g h u n i v e r s a l s h a f t A N 1 1 C o n v e r t e r 1 2 I n d u c t i v e t r a n s m i t t e r f o r e n g i n e s p e e d 1 3 C l u t c h s h a f t K 4 1 4 C o n v e...

Page 186: ... a n s m i s s i o n s u s p e n s i o n h o l e s M 2 0 4 E m e r g e n c y s t e e r i n g p u m p S M 2 6 x 1 5 D M 2 2 x 1 5 5 O u t p u t f l a n g e c o n v e r t e r s i d e 6 O i l d r a i n p l u g w i t h m a g n e t M 3 8 x 1 5 7 M o d e l i d e n t i f i c a t i o n p l a t e 8 O i l f i l l e r t u b e w i t h o i l d i p s t i c k r e a r s i d e 9 C o n v e r t e r ...

Page 187: ...i c c o n t r o l 4 O i l f i l l e r t u b e w i t h o i l d i p s t i c k 5 P a r k i n g b r a k e o p e r a t e d h y d r a u l i c a l l y 6 T r a n s m i s s i o n s u s p e n s i o n h o l e s M 2 0 7 O u t p u t f l a n g e r e a r s i d e 7 C o n n e c t i o n r e t u r n l i n e f r o m p a r k i n g b r a k e 8 B r a k e d i s c 9 E x c h a n g e f i l t e r f i n e f i l t e r 1 0 F i ...

Page 188: ...s h o r t t i m e 1 2 0 C M 1 4 x 1 5 6 5 S y s t e m p r e s s u r e 1 6 2 5 b a r M 1 0 x 1 K M e a s u r i n g p o i n t s f o r d e l i v e r y r a t e s 1 5 C o n n e c t i o n t o t h e h e a t e x c h a n g e r 1 5 1 6 1 2 U N 2 B 1 6 C o n n e c t i o n f r o m t h e h e a t e x c h a n g e r 1 5 1 6 1 2 U N 2 B I N D U C T I V E T R A N S M I T T E R S S P E E D S E N S O R A N D S W I T ...

Page 189: ...e 2 from 2 Pressure regulator under voltage Engaged clutches Driving direction Speed Y1 Y2 Y3 Y4 Y5 Y6 FORWARD 1 K1 KV 2 K4 K1 3 KV K2 4 K4 K2 5 K3 KV 6 K4 K3 REVERSE 1 KR K1 2 KR K2 3 KR K3 NEUTRAL Engaged clutch K4 KR K1 K3 KV K2 Positions on the valve block F E D C B A Current no of the measuring points 60 55 56 58 53 57 ...

Page 190: ...ve K3 P5 Proportional valve KV P6 Proportional valve K2 Y1 Y6 Pressure regulators TEMP Temperature sensor UEDV Pressure relief valve 40 5 bar FDV Filter pressure differential valve Bypass valve p 5 5 bar The marked positons e g 53 correspond with the positions on the table 4 CODIERUNG Pressure regulator active Engaged clutches Driving direction Speed Y1 Y2 Y3 Y4 Y5 Y6 Forward 1 K1 KV 2 KV K2 3 K3 ...

Page 191: ...a t i o n R e t u r n i n t o t h e s u m p L e g e n d W T S c o p e o f s u p p l y c u s t o m b e r L u b r i c a t i o n M a i n o i l c i r c u i t O i l s u m p B y p a s s v a l v e D p 1 5 b a r n E n g i n e 2 0 0 0 m i n T r a n s m i s s i o n p u m p p 1 6 2 b a r Q p 8 5 l m i n b y 1 Z F f i n e f i l t e r F i l t e r g r a d e a c c o r d i n g I S O 4 5 7 2 ß 3 0 7 5 ß 1 5 2 5 ß ...

Page 192: ...d K V C l u t c h f o r w a r d K R C l u t c h r e v e r s e K 1 C l u t c h 1 s t s p e e d K 2 C l u t c h 2 s t s p e e d K 3 C l u t c h 3 s t s p e e d K 4 C l u t c h 4 s t s p e e d A N I n p u t A B O u t p u t W K A x l e d i s c o n n e c t i o n D R I V I N G S P E E D S P E E D C L U T C H F o r w a r d 1 K V K 1 2 K 4 K 1 3 K V K 2 4 K 4 K 2 5 K V K 3 6 K 4 K 3 R e v e r s e 1 K R K ...

Page 193: ... b o x d i a g r a m 6 t h S P E E D K V A N K R K 2 K 3 K 4 K 1 A B 2 n d S P E E D D r i v i n g d i r e c t i o n S p e e d C l u t c h F o r w a r d 1 K V K 1 2 K 4 K 1 3 K V K 2 4 K 4 K 2 5 K V K 3 6 K 4 K 3 V i e w d i r e c t i o n o f r o t a t i o n D i a g r a m C l u t c h e s L e g e n d K V C l u t c h f o r w a r d K R C l u t c h r e v e r s e K 1 C l u t c h 1 s t s p e e d K 2 C l...

Page 194: ...T A B L E 8 1 s t S P E E D 2 n d S P E E D 3 r d S P E E D L e g e n d P o w e r f l o w g e a r t r a i n G e a r s n o t m e s h i n g G e a r b o x d i a g r a m V i e w d i r e c t i o n o f r o t a t i o n D i a g r a m C l u t c h e s L e g e n d K V C l u t c h f o r w a r d K R C l u t c h r e v e r s e K 1 C l u t c h 1 s t s p e e d K 2 C l u t c h 2 s t s p e e d K 3 C l u t c h 3 s t ...

Page 195: ...P O R T I O N A L V A L V E S T A B L E 9 M a i n p r e s s u r e v a l v e 1 6 2 5 b a r P r e s s u r e r e d u c i n g v a l v e 9 b a r P l u g c a b l e h a r n e s s V a l v e b l o c k C o v e r A A B H o u s i n g C o v e r H o u s i n g Y 6 Y 5 Y 4 Y 3 Y 2 Y 1 B ...

Page 196: ...O C K P r e s s u r e r e g u l a t o r P r o p o r t i o n a l v a l v e P 5 P r e s s u r e r e d u c i n g v a l v e 9 b a r M a i n p r e s s u r e v a l v e 1 6 2 5 b a r P l u g c a b l e h a r n e s s S e c t i o n B B Y 5 V i b r a t i o n d a m p e r F o l l o w o n s i d e ...

Page 197: ... T I O N D I F F E R E N T I A L L O C K A 7 C A N I N T E R F A C E P L U G S 3 2 S W I T C H T R O U G H O N T O P A 9 S P E E D O M E T E R W I T H F R E Q U E N C Y D I V I D E R S 3 4 S W I T C H D I S P L A Y I L L U M I N A T I O N B 1 S P E E D S E N S O R n E N G I N E Y 7 S O L E N O I D V A L V E W K B 2 S P E E D S E N S O R n T U R B I N E Y 8 S O L E N O I D V A L V E R E T A R D E R...

Page 198: ... S M E T E R F R O M A L E N G T H O F 2 M E T E R S O N 1 1 1 2 8 7 4 1 3 1 0 9 6 2 1 3 5 1 4 1 5 1 6 K o s t a l 1 6 p i n 6 0 2 9 1 9 9 0 7 2 K o s t a l M 2 7 6 0 2 9 1 9 9 0 0 3 P o l e p a t t e r n s a r e c o r r e s p o n d i n g w i t h t h e p l u g s o n t h e w i r i n g A L L R E L A Y S W I T H P R O T E C T I V E D I O D E S 1 A 4 0 0 V A M P J P T 8 p i n 6 0 2 9 1 9 9 1 0 8 S u p...

Page 199: ... S I T I O N N E U T R A L F R N O T S H I F T A B L E C O N T R O L V N R S T U E C K L 0 5 0 1 2 1 0 1 4 8 1 2 2 4 D W 3 C O D I N G S P E E D R A N G E S E L E C T O R O U T P U T S P E E D N E U T R A L F O R W A R D 1 2 3 4 1 2 3 4 R E V E R S E A D 1 A D 2 A D 3 A D 4 A D 5 A D 6 A D 7 1 2 3 4 B 1 B 2 B 3 V R A S K 1 R E L A Y S T A R T I N G I N T E R L O C K K 2 A 1 A 2 R E L A Y R E V E R...

Page 200: ...G CONTROLLER CONTROLLER VTS 3 TABLE 12 POSITION V R N T T KD E AD1 T AD2 T AD4 V AD5 R AD6 AS N AD8 KD E FUNKTION SWITCH GEAR SHIFTING GATE S6 GE 2 GN 1 VI 4 SW 6 WS 10 RT 5 AD2 T AD1 T AD5 R AD4 V F ED1 VP X1 5 4 6 7 8 2 S5 10 AD8 KD E GR 3 S3 S2 S1 S4 AD6 AS N ...

Page 201: ...DIAGRAM CONTROLLER S A M P L E AD1 AD2 AD3 AD4 AD5 ED2 7 8 9 4 6 12 1 2 3 D N R D7 N ED1 VP 3 2 5 10 11 1 H1 AD6 AD7 AD8 VM1 K6 K8 K7 A1 PUSHBUTTON SWITCH D7 TABLE 13 CONNECTION DIAGRAM CONTROLLER D7 PUSHBUTTON SWITCH D7 A1 ELECTRONIC CONTROLLER UNIT TCU K6 STARTER INTERLOCK K7 NEUTRAL K8 REVERSING LIGHT H1 LIGHTING 1 1st SPEED FORWARD 2 2nd SPEED FORWARD 3 3rd SPEED FORWARD D AUTOMATIC N NEUTRAL ...

Page 202: ...Order No 5871 146 002 ZF ERGOPOWER 6 WG 115 ZF Passau GmbH Donaustr 25 71 D 94 034 Passau ...

Page 203: ...eration Manual ZF Order No 5872 154 002 ZF Passau GmbH reserves the right to replace this disassembly and reassembly manual by a successive edition at any time without advance notice Upon request ZF Passau GmbH will advise which edition is the latest one ATTENTION Observe the vehicle manufacturer s instructions and specifications for the installation and commissioning of the unit ZF Passau GmbH Do...

Page 204: ...rol 2 DISASSEMBLY Inductive sensor Hall sensor breather oil filler and oil drain plug 3 DISASSEMBLY Engine connection oil pressure pump converter back pressure valve and temperature sensor 3 1 Engine connection direct mount 3 2 Engine connection remote mount 3 3 Oil pressure pump 3 4 Converter back pressure valve 4 DISASSEMBLY Emergency steering pump 4 1 Version without emergency steering pump 4 2...

Page 205: ...3 1 Converter back pressure valve 13 2 Oil pressure pump 13 3 Engine connection direct mount 13 4 Engine connection remote mount 14 Reassembly Emergency steering pump 14 1 Version without emergency steering pump 14 2 Version with emergency steering pump 15 Reassembly Inductive sensor Hall sensor breather oil filler and oil drain plug 16 Reassembly Electro hydraulic control with proportional valves...

Page 206: ... on your ZF product whose practical and theoretical training is constantly updated in our training school The Service Stations established by ZF Friedrichshafen all over the world offer you 1 Permanently trained staff 2 Specified equipment e g special tools 3 State of the art genuine ZF spare parts All work is done there with utmost care and reliability In addition repair work carried out by ZF Se...

Page 207: ...arts subject to normal wear during operation such as bearings thrust washers etc will be reinstalled Parts such as seal rings locking plates split pins etc must generally be replaced Radial seal rings with worn or broken sealing lip must also be replaced In particular ensure that no chips or other foreign bodies remain in the housing Check the lube oil holes and grooves regarding unhindered passag...

Page 208: ... these regulations prior to starting any work A suitably trained and skilled staff is required for a proper repair of these ZF products The repair workshop shall be responsible for the training The following safety references are used in this manual CAUTION This symbol serves as a reference to special working procedures methods information use of auxiliaries etc indicated in this repair manual DAN...

Page 209: ...Unité Formelzeichen Symbol Symbole Neu Alt New Old Nouveau Vieux Umrechnung Conversion Conversion Bemerkungen Note Nota Masse Mass Masse m kg Kilogramm kg Kraft Force Force F N Newton kp 1 kp 9 81 N Arbeit Work Travail A J Joule kpm 0 102kpm 1J 1Nm Leistung Power Puissance P KW Kilowatt HP DIN 1 HP 0 7355 KW 1 KW 1 36 HP Drehmoment Torque Couple T Nm Newtonmeter kpm 1 kpm 9 81 Nm T Nm F N r m Kraf...

Page 210: ...1 356 Nm 0 138 kpm 1 kg cm 1 bar 1 02 kp cm2 0 070 bar 0 071 kp cm2 1 Liter 4 456 Liter 1 Liter 3 785 Liter 1609 344 m 0 C Celsius 0 C Celsius 1 in inch 2 205 lb pounds 7 233 lbf x ft pound force foot 1 lbf x ft pound force foot 5 560 lb in pound per inch 14 233 psi pound force per square inch lbf in2 1 psi lbf in2 0 264 Gallon Imp 1 Gallon Imp 0 220 Gallon US 1 Gallon US 1 Mile land mile 32 F Fah...

Page 211: ...460 M20 390 560 650 M22 530 750 880 M24 670 960 1100 M27 1000 1400 1650 M30 1350 1900 2250 M33 1850 2600 3000 M36 2350 3300 3900 M39 3000 4300 5100 Metric ISO fine thread DIN 13 page 13 Dimension 8 8 10 9 12 9 M 8 x 1 24 36 43 M 9 x 1 36 53 62 M 10 x 1 52 76 89 M 10 x 1 25 49 72 84 M 12 x 1 25 87 125 150 M 12 x 1 5 83 120 145 M 14 x 1 5 135 200 235 M 16 x 1 5 205 300 360 M 18 x 1 5 310 440 520 M 1...

Page 212: ...n 6 ZF List of Lubricants 7 Oil fill quantity 8 Customer number NOTES ON SPARE PARTS ORDERING Please indicate the following information when ordering genuine ZF spare parts 1 Transmission type 2 Unit number 3 ZF parts list number 4 Make and type of spare part 5 Denomination of spare part 6 Spare part number 7 Shipping mode Please complete the a m details to avoid any mistakes in the delivery of th...

Page 213: ...uctive sensor for engine speed 4 Transmission pump 5 Clutch shaft KR 6 PTO coaxial engine dependent 7 Clutch shaft KV 8 Clutch shaft K2 9 Clutch shaft K3 10 Output flange rear side 11 Output flange 12 Output flange converter side 13 Clutch shaft K1 14 Converter safety valve 15 Clutch shaft K4 Transmission schematics Gear schematics K4 K1 KR KV K2 K3 AB AB AN AN KR KV K2 K4 K3 K1 AB ...

Page 214: ...ion Off Road Driveline Technology and Axle Systems 5871 146 002 0 9 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 1 2 3 4 5 6 8 9 10 12 13 15 14 7 11 ...

Page 215: ...E 56 Clutch 16 2 bar K1 M10x1 D 57 Clutch 16 2 bar K2 M10x1 A 58 Clutch 16 2 bar K3 M10x1 C 60 Clutch 16 2 bar K4 M10x1 F 63 After the converter temperature 100 C short term 120 C M14x1 5 65 System pressure 16 2 5 bar M10x1 K MEASURING POINTS FOR FLOW RATES 15 Connection to heat exchanger 15 16 12 UN 2B 16 Connection from heat exchanger 15 16 12 UN 2B INDUCTIVE SENSOR IMPULSE SENSOR SPEED SENSOR A...

Page 216: ... 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 at all ZF service centers Internet http www zf com Informationen Tech Informationen Information on description operation and maintenance see relating operation manual ZF Order No 5872 154 002 51 49 60 55 56 58 53 57 65 ...

Page 217: ...niversal use To loosen and tighten the TORX screws M8 0736 101 264 0736 101 335 on the filter head and 0736 101 312 on the duct plate Also refer to torque wrench 5870 203 034 5873 042 004 1 2 4 1 2 5 1 2 10 1 2 13 16 9 16 10 16 13 16 16 16 21 16 28 Socket wrench TX 27 1 2 Universal use To loosen and tighten the TORX screws M5 0736 101 094 0736 101 257 M6 0736 101 407 0736 101 408 0736 101 259 on t...

Page 218: ...ghten the threaded joints M8 0736 101 264 0736 101 335 on the filter head and 0736 101 312 on the duct plate 5870 203 034 3 1 2 3 2 4 13 3 16 13 4 27 Eye bolts assortment Lifting chain 3 rope Universal use Disassembly and reassembly aid to remove and reinstall transmission components 5870 204 002 5870 281 047 3 2 5 8 1 4 8 2 3 8 3 6 8 4 6 8 5 5 8 6 4 Two armed puller Universal use To pull off or s...

Page 219: ... M20 2 pcs Eye nut M12 Universal use To separate and lift off the housing halves 5870 281 047 0636 804 003 0664 462 774 7 6 10 12 Handle To fix the clutch assies when moving them out of and into the transmission housing together with the housing rear part Required quantity 6 pcs 5870 260 010 8 1 3 8 1 10 8 2 2 8 2 9 8 3 2 8 3 6 8 4 2 8 4 8 8 5 7 8 6 2 8 6 8 Grab sleeve OR Rapid grip To pull the ta...

Page 220: ...1 014 5870 026 100 5873 001 000 9 1 7 9 2 7 9 3 3 9 4 3 9 5 4 9 6 9 13 4 23 Hot air blower 230 V Hot air blower 115 V Universal use To heat up housing and transmission components 5870 221 500 5870 221 501 10 1 Rolling tool Lubricant To roll the suction tube 0501 210 712 into the housing front part Repair solution only 5870 600 003 5870 451 006 10 1 Rolling tool Lubricant To roll the oil tube 0501 ...

Page 221: ...011 5870 260 002 13 2 4 Adjusting screw M8 To align and to position the gasket and the oil feed housing on the transmission housing 5870 204 011 13 2 5 Adjusting screw M10 To align and to position the stator shaft on the transmission housing 5870 204 007 13 2 8 Driver Handle To install the shaft seal 0634 311 837 into the pump housing 5870 055 070 5870 260 002 13 4 26 Driver Handle To press the lo...

Page 222: ...R V I C E S ZF Passau GmbH Donaustraße 25 71 94034 Passau Ausgabe Edition 09 2005 Spezial S ZF ERGOPOWER 6 WG 115 MOTORANSCHLUSS ENGINE CONNECTION 4656 006 012 WB 01 5870 204 002 5870 281 047 5870 970 004 5870 057 010 5870 260 002 5870 900 013 5870 221 500 5870 221 501 230V 115V ...

Page 223: ... E S ZF Passau GmbH Donaustraße 25 71 94034 Passau Ausgabe Edition 09 2005 Spezial S 5870 281 047 ZF ERGOPOWER 6 WG 115 ANTRIEB INPUT 4656 006 012 WB 02 5870 204 007 5870 204 002 5873 011 014 5870 026 100 5873 001 058 ODER OR 5873 011 014 5873 001 058 5873 001 000 ODER OR 5870 900 015 ...

Page 224: ...n S E R V I C E S ZF Passau GmbH Donaustraße 25 71 94034 Passau Ausgabe Edition 09 2005 Spezial S ZF ERGOPOWER 6 WG 115 4656 006 012 GETR GEHAEUSE GEARBOX HOUSING WB 03 5870 350 090 5870 350 062 5870 350 000 5870 281 047 0664 462 774 0636 804 003 5870 204 011 5870 280 004 ...

Page 225: ...austraße 25 71 94034 Passau Ausgabe Edition 09 2005 Spezial S 5870 970 004 ZF ERGOPOWER 6 WG 115 KUPPLUNG K1 COUPLING K1 4656 006 012 WB 04 5870 280 004 5873 011 011 5873 011 011 5870 221 501 5870 026 100 5870 221 500 115V 230V 5870 026 100 5870 900 015 5873 001 057 ODER OR 5873 001 057 ODER OR 5870 260 010 ...

Page 226: ...mbH Donaustraße 25 71 94034 Passau Ausgabe Edition 09 2005 Spezial S 5870 970 004 ZF ERGOPOWER 6 WG 115 KUPPLUNG K2 4656 006 012 COUPLING K2 WB 05 5873 011 011 5873 011 011 5870 221 501 5870 026 100 5870 221 500 115V 230V 5870 026 100 5870 900 015 5873 001 057 ODER OR 5873 001 057 ODER OR 5870 260 010 ...

Page 227: ...ssau GmbH Donaustraße 25 71 94034 Passau Ausgabe Edition 09 2005 Spezial S ZF ERGOPOWER 6 WG 115 KUPPLUNG K3 4656 006 012 COUPLING K3 WB 06 5873 011 011 5873 011 014 5870 221 501 5870 026 100 5870 221 500 115V 230V 5870 026 100 5873 001 058 ODER OR ODER OR 5873 001 057 5870 260 010 5870 970 004 ...

Page 228: ...mbH Donaustraße 25 71 94034 Passau Ausgabe Edition 09 2005 Spezial S 5870 970 004 ZF ERGOPOWER 6 WG 115 KUPPLUNG K4 4656 006 012 COUPLING K4 WB 07 5873 011 011 5873 011 011 5870 221 501 5870 026 100 5870 221 500 115V 230V 5870 026 100 5870 900 015 5873 001 057 ODER OR 5873 001 057 ODER OR 5870 260 010 ...

Page 229: ...ssau Ausgabe Edition 09 2005 Spezial S 5870 900 013 ZF ERGOPOWER 6 WG 115 KUPPLUNG KV 4656 006 012 COUPLING KV WB 08 5873 001 057 5873 011 011 5870 221 501 5873 011 011 5870 221 500 115V 230V 5870 026 100 5873 001 057 ODER OR ODER OR 5870 970 004 5870 300 028 5870 900 015 ODER OR 5870 026 100 5870 260 010 5870 345 089 5870 280 007 ...

Page 230: ...nsmissions and Axle Systems Division S E R V I C E S ZF Passau GmbH Donaustraße 25 71 94034 Passau Ausgabe Edition 09 2005 Spezial S 5870 287 007 ZF ERGOPOWER 6 WG 115 FESTSTELLBREMSE PARKING BRAKE 4656 006 012 WB 11 5870 950 101 M12x1 5 ...

Page 231: ...5 71 94034 Passau Ausgabe Edition 09 2005 Spezial S 5870 900 013 ZF ERGOPOWER 6 WG 115 KUPPLUNG KR 4656 006 012 COUPLING KR WB 09 5873 001 057 5873 011 011 5870 221 501 5873 011 011 5870 221 500 115V 230V 5870 026 100 5873 001 057 ODER OR ODER OR 5870 970 004 5870 300 028 5870 900 015 ODER OR 5870 026 100 5870 260 010 ...

Page 232: ...ision S E R V I C E S ZF Passau GmbH Donaustraße 25 71 94034 Passau Ausgabe Edition 09 2005 Spezial S 5870 260 002 5870 048 057 ZF ERGOPOWER 6 WG 115 ABTRIEB OUTPUT 4656 006 012 WB 10 5873 011 014 5873 001 000 5873 001 058 ODER OR 5870 057 011 5870 260 002 5870 057 011 ...

Page 233: ...n S E R V I C E S ZF Passau GmbH Donaustraße 25 71 94034 Passau Ausgabe Edition 09 2005 Spezial S ZF ERGOPOWER 6 WG 115 SCHALTUNG GEARSHIFT SYS 4656 006 012 WB 12 5870 204 063 5873 042 002 5870 203 031 5870 656 056 1 12 Nm 10 90 Nm 5870 203 034 5870 042 004 1 2 1 4 1 2 M6 ...

Page 234: ...on S E R V I C E S ZF Passau GmbH Donaustraße 25 71 94034 Passau Ausgabe Edition 09 2005 Spezial S ZF ERGOPOWER 6 WG 115 SCHALTUNG GEARSHIFT SYS 4656 006 012 WB 13 5870 204 036 5873 042 002 5870 204 063 5870 656 056 5870 203 031 1 2 1 2 1 4 1 12 Nm M6 5 5Nm 5 5Nm 5 5Nm M5 ...

Page 235: ...f Road Transmissions and Axle Systems Division S E R V I C E S ZF Passau GmbH Donaustraße 25 71 94034 Passau Ausgabe Edition 09 2005 Spezial S 5870 345 107 ZF ERGOPOWER 6 WG 115 DRUCKREGLER PRESSURE REGULATOR 4656 006 012 WB 14 ...

Page 236: ...missions and Axle Systems Division S E R V I C E S ZF Passau GmbH Donaustraße 25 71 94034 Passau Ausgabe Edition 09 2005 Spezial S 5870 260 002 ZF ERGOPOWER 6 WG 115 DRUCKOELPUMPE PRESS OEL PUMP 4656 006 012 WB 15 5870 055 070 5870 280 004 ...

Page 237: ...oad Transmissions and Axle Systems Division S E R V I C E S ZF Passau GmbH Donaustraße 25 71 94034 Passau Ausgabe Edition 09 2005 Spezial S 5870 048 080 ZF ERGOPOWER 6 WG 115 NOTLENKPUMPE EMERGENCY STEERING PUMP 4656 006 012 WB 16 ...

Page 238: ...Transmissions and Axle Systems Division S E R V I C E S ZF Passau GmbH Donaustraße 25 71 94034 Passau Ausgabe Edition 09 2005 Spezial S WB 17 ZF ERGOPOWER 6 WG 115 FILTER 4656 006 012 5870 105 005 5873 042 004 10 90Nm 5870 203 034 23Nm ...

Page 239: ...bly truck S Assembly truck 5870 350 000 S Holding fixtures 5870 350 063 S Clamping angles 5870 350 090 Drain oil prior to starting disassembly Figure 1 1 1 Removal of filter Separate ZF fine filter 1 from filter head by means of belt wrench S Belt wrench 5870 105 005 Figure 2 Loosen Torx screws 2 and separate filter head 1 from transmission housing Remove O rings S Socket wrench TX 40 5873 042 004...

Page 240: ...diate plate S Socket wrench TX 27 5873 042 002 S Adjusting screws M6 5870 204 063 Figure 4 Remove gear shift control assy 1 and intermediate plate 2 S Adjusting screws M6 5870 204 063 Figure 5 Remove differential pressure switch for ZF fine filter from duct plate 4 1 Switch with O ring 2 Piston 3 Compression spring Figure 6 Loosen hexagon nuts and Torx screws and separate duct plate 1 and seal 2 f...

Page 241: ...002 1 3 Pull converter safety valve 1 out of housing hole Figure 8 Mark installation position of wiring harness 1 towards valve block 2 Figure 9 Loosen Torx screws 1 S Socket wrench TX 27 5873 042 002 Figure 10 Separate duct plate 3 and intermediate plate 2 from valve block 1 Figure 11 1 2 1 1 3 2 1 ...

Page 242: ...x screws 1 and remove cover 2 Remove opposite cover 3 in the same way S Socket wrenchTX 27 5873 042 002 Figure 13 Remove wiring harness 1 Loosen cylindrical screws 3 remove fixing plates and remove pressure controllers 2 Figure 14 Loosen cylindrical screws remove fixing plates and remove pressure controllers 1 on opposite side Figure 15 1 1 1 2 3 1 3 2 ...

Page 243: ...sen remaining Torx screws S Adjusting screws 5870 204 036 Figure 16 Separate housing from valve housing by loosening the adjusting screws equally S Adjusting screws 5870 204 036 Figure 17 Remove individual parts 1 Pressure reducing valve 2 Vibration dampers 3 Follow on slide Figure 18 Remove individual parts of opposite side analogously 1 Main pressure valve 2 Vibration dampers 3 Follow on slide F...

Page 244: ...ck S Assembly truck 5870 350 000 S Holding fixtures 5870 350 063 S Clamping angles 5870 350 090 Remove positioned parts 1 Screw plug oil drain hole 2 Oil filler tube with oil dipstick 3 Breather 4 Inductive sensor n central gear chain 5 Inductive sensor n turbine 6 Inductive sensor n engine Figure 1 Loosen cylindrical screw 1 and remove speed sensor Hall sensor Remove O ring 2 Speed sensor n outpu...

Page 245: ...ct mount Loosen hexagon screw 2 and separate flexplate 1 from converter 3 Figure 1 Separate converter 1 from transmission by means of lifting device S Eye bolts assortment 5870 204 002 S Lifting chain 5870 281 047 Figure 2 3 2 Engine connection remote mount Remove locking plate 1 loosen hexagon screw and remove washer Loosen bolted connection 2 cover converter bellhousing Mark radial installation ...

Page 246: ...housing by means of lifting device S Eye bolts assortment 5870 204 002 S Lifting chain 5870 281 047 Figure 4 Pull off output flange S Two armed puller 5870 970 004 Figure 5 Press input shaft and converter out of cover ball bearing Figure 6 Snap out retaining ring 1 and remove ball bearing 2 S Set of internal pliers 5870 900 013 Figure 7 1 2 ...

Page 247: ...e 9 3 3 Oil pressure pump Loosen bolted connection 1 converter bellhousing oil feed housing and remove converter bellhousing 2 Figure 10 Loosen bolted connection 1 oil feed housing transmission housing front part with Torx screws and bolted connection 2 oil pressure pump transmission housing front part with cylindrical screws Separate oil feed housing together with oil pressure pump from transmiss...

Page 248: ...e of wear marks in the pump housing or on the control disk the oil pressure pump assy must be replaced Figure 13 Remove snap ring 1 and individual parts 1 Pump housing with rotor 2 Snap ring 3 Shaft seal ring 4 Support shim 5 Needle bearing 6 Ring Figure 14 3 4 Converter back pressure valve Preload converter safety valve 1 by means of screw driver or assembly aid S and remove locking plate 2 S Ass...

Page 249: ...ms 5871 146 002 3 5 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 Figure 17 Remove stator shaft 1 Pull pressure relief valve 2 out of the housing hole Figure 18 1 2 3 1 1 2 ...

Page 250: ...steering pump Loosen bolted connection 1 cover housing front part and remove cover 2 and seal Figure 1 4 2 Version with emergency steering pump Loosen cylindrical screws 1 and separate emergency steering pump 2 from cover Mark radial installation position see arrows Figure 2 Loosen bolted connection 1 cover housing front part and remove cover 2 and seal Figure 3 1 1 2 2 1 2 ...

Page 251: ...nverter 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 Figure 2 5 2 Output flange on output side without parking brake Remove locking plate 1 loosen hexagon screws remove washer and O ring Figure 3 Pull off output flange 1 and remove shaft seal 2 Figure 4 1 1 2 1 1 2 ...

Page 252: ... 950 101 Figure 5 Loosen hexagon screws 1 of bolted connection between parking brake and bracket Figure 6 Remove parking brake 1 Types M 90 mechanical actuation FSG 75 hydraulic actuation FSG 90 110 hydraulic actuation All further working steps for parking brake see Knott original documentation chapter 17 Remove locking plate 2 loosen hexagon screws remove washer and O ring Figure 7 Pull off outpu...

Page 253: ...n 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 Loosen hexagon nuts and remove both covers 3 with O rings Snap out retaining ring 4 and remove it Figure 3 Pull pump shaft 1 out of housing hole Snap out rectangular ring 2 Figure 4 1 2 1 2 1 1 3 3 4 2 2 ...

Page 254: ...R e p a i r M a n u a l Corporate Division Off Road Driveline Technology and Axle Systems 5871 146 002 6 2 Press ball bearing 1 off the pump shaft Figure 5 1 ...

Page 255: ...ion 2 between housing front and rear part and separate housing rear part by means of lifting device S Lifting chain 5870 281 047 S Eye bolt M20 0636 804 003 S Eye nut M12 0664 462 774 Loosen bolted connection 1 of oil screen sheets Figure 2 Remove output shaft 1 and lower oil screen sheet 2 from housing Figure 3 Remove all rectangular rings 1 from the clutches and all O rings 2 from the oil tubes ...

Page 256: ...possible Risk of injury Fix all clutches by means of handle 1 S Handle 5870 260 010 Figure 6 Separate housing rear part incl clutches from housing front part by means of the lifting device and attach it to the assembly truck Figure 7 Loosen cylindrical screws of oil tubes 1 in the housing front part and remove them The suction tube 2 and the lubrication lines 3 are rolled in and are highly difficu...

Page 257: ...ical order as described in the legend 1 K1 clutch 2 K2 clutch 3 K3 clutch 4 K4 clutch 5 KR clutch 6 KV clutch 7 input shaft Figure 10 Remove bearing outer rings arrows from the housing rear 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 Bearing ...

Page 258: ...icture K1 clutch K2 clutch K3 clutch K4 clutch KR clutch KV clutch AN input shaft 8 1 KV clutch Remove stud bolt 1 and snap out piston ring 2 Figure 2 Pull tapered roller bearing inner ring off the shaft S Forcing device 5870 026 100 S Grab sleeve 5873 001 057 or S Rapid grip 5873 011 011 Figure 3 Pull clutch 1 off the shaft S 2 armed puller 5870 970 004 Figure 4 AN K3 K1 K4 KR KV K2 1 2 S 1 ...

Page 259: ...f 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 S Cut off device 5870 300 028 Figure 6 Snap retaining ring 2 out of the idler gear 1 and remove ball bearing 3 S Set of internal pliers 5870 900 013 Figure 7 Remove needle cage 1 from the shaft 2 Figure 8 1 2 1 2 S 3 1 1 2 ...

Page 260: ...ne Technology and Axle Systems 5871 146 002 8 1 3 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 5873 001 057 or S Rapid grip 5873 011 011 Figure 10 1 2 S ...

Page 261: ...t 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 5873 001 057 or S Rapid grip 5873 011 011 Figure 2 Pull clutch 1 off the shaft S Two armed puller 5870 970 004 Figure 3 Snap out retaining ring 1 S Set of external pliers 5870 900 015 Figure 4 1 2 S 1 1 ...

Page 262: ...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 bearing 3 S Set of internal pliers 5870 900 013 Figure 6 Remove needle cage 1 from the shaft 2 Figure 7 Turn shaft 2 by 180 and snap out piston ring 1 Figure 8 1 2 S 3 1 1 2 1 2 2 ...

Page 263: ...orate Division Off Road Driveline Technology and Axle Systems 5871 146 002 8 2 3 Pull tapered roller bearing inner ring off the shaft S Forcing device 5870 026 100 S Grab sleeve 5873 001 057 or S Rapid grip 5873 011 011 Figure 9 S ...

Page 264: ... 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 5873 001 057 or S Rapid grip 5873 011 011 Figure 2 Snap out retaining ring 1 S Set of external pliers 5870 900 015 Figure 3 Remove axial bearing assy 1 Figure 4 1 2 S 1 1 ...

Page 265: ...ve 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 Turn shaft 2 by 180 and snap out piston ring 1 Figure 7 Pull tapered roller bearing inner ring off the shaft S Forcing device 5870 026 100 S Grab sleeve 5873 001 057 or S Rapid grip 5873 011 011 Figure 8 1 2 3 1 1 2 S ...

Page 266: ... 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 5873 001 057 or S Rapid grip 5873 011 011 Figure 2 Snap out retaining ring 1 S Set of external pliers 5870 900 015 Figure 3 Remove axial bearing assy 1 Figure 4 1 2 S 1 1 ...

Page 267: ...ve 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 Turn shaft 2 by 180 and snap out piston ring 1 Figure 7 Pull tapered roller bearing inner ring off the shaft S Forcing device 5870 026 100 S Grab sleeve 5873 001 057 or S Rapid grip 5873 011 011 Figure 8 1 2 3 1 1 2 S ...

Page 268: ...ove 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 5873 001 058 or S Rapid grip 5873 011 011 Figure 2 Remove axial bearing assy 1 Figure 3 Take off idler gear 1 remove needle cage 2 and axial bearing assy 3 Figure 4 1 S 2 1 1 3 2 ...

Page 269: ... 146 002 8 5 2 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 S Forcing device 5870 026 100 S Grab sleeve 5873 001 057 or S Rapid grip 5873 011 011 Figure 7 1 S 1 2 ...

Page 270: ...lt 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 5873 001 057 or S Rapid grip 5873 011 011 Figure 2 Snap out retaining ring S Set of external pliers 5870 900 015 Figure 3 Pull clutch 1 off the shaft S Two armed puller 5870 970 004 Figure 4 2 1 S 1 1 ...

Page 271: ...nd 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 and snap out piston ring 1 Figure 7 Pull tapered roller bearing inner ring off the shaft S Forcing device 5870 026 100 S Grab sleeve 5873 001 057 or S Rapid grip 5873 011 011 Figure 8 1 2 1 2 3 1 S 2 ...

Page 272: ...e fixed by a snap ring When separated the components will be destroyed Figure 1 Pull tapered roller bearing inner ring off the drive gear S Basic tool 5873 001 000 S Grab sleeve 5873 001 058 or S Rapid grip 5873 011 014 Figure 2 Pull tapered roller bearing inner ring off the drive gear S Grab sleeve 5873 001 058 S Forcing device 5870 026 100 or S Rapid grip 5873 011 011 Figure 3 1 2 3 S S ...

Page 273: ...d 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 or S Rapid grip 5873 011 014 Figure 1 Turn output shaft by 180 and pull off tapered roller bearing inner ring S Basic tool 5873 001 000 S Grab sleeve 5873 001 058 or S Rapid grip 5873 011 014 Figure 2 S S 1 ...

Page 274: ...ressure level are controlled via the driving program of the transmission electronics Furthermore the EST 37A monitors the disk clearance release clearance of the clutches If clearance is exceeded a fault message is given on the ZF display To ensure a continuous shifting quality no repairs are allowed to be made on the clutches KV KR K1 K2 K3 K4 see Figure 1 which means that only the complete clutc...

Page 275: ...ered 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 Figure 3 Install ball bearing 2 into the idler gear 1 until contact is obtained and fix it by means of retaining ring 3 S Set of internal pliers 5870 900 013 Figure 4 1 2 1 1 3 2 1 ...

Page 276: ... 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 Heat up inner diameter of clutch 1 approx 120 C S Hot air blower 230 V 5870 221 500 S Hot air blower 115 V 5870 221 501 Figure 7 Mount clutch 1 until contact is obtained Wear protective gloves Figure 8 1 1 2 1 1 ...

Page 277: ... 002 9 1 3 Press tapered roller bearing inner ring 1 until contact is obtained Figure 9 Mount stud bolt 1 Tightening torque M10 8 8 x15 MA 17 Nm Check closing and opening of the clutch by means of compressed air at the hole 2 Closing and opening of the clutch must be clearly audible Figure 10 1 2 1 ...

Page 278: ...ered 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 Figure 3 Install ball bearing 2 into the idler gear 1 until contact is obtained and fix it by means of retaining ring 3 S Set of internal pliers 5870 900 013 Figure 4 1 1 1 1 3 2 1 ...

Page 279: ... 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 Heat up inner diameter of clutch 1 approx 120 C S Hot air blower 230 V 5870 221 500 S Hot air blower 115 V 5870 221 501 Figure 7 Mount clutch 1 until contact is obtained Wear protective gloves Figure 8 1 1 2 1 1 ...

Page 280: ... 002 9 2 3 Press tapered roller bearing inner ring 1 until contact is obtained Figure 9 Mount stud bolt 1 Tightening torque M10 8 8 x15 MA 17 Nm Check closing and opening of the clutch by means of compressed air at the hole 2 Closing and opening of the clutch must be clearly audible Figure 10 1 2 1 ...

Page 281: ...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 120 C S Hot air blower 230 V 5870 221 500 S Hot air blower 115 V 5870 221 501 Figure 3 Mount clutch 1 until contact is obtained Wear protective gloves Figure 4 1 1 1 ...

Page 282: ... cage 2 and axial washer 3 Install chamfer see arrow of running disk 1 showing towards the axial cage Figure 5 Mount needle cage 1 Figure 6 Mount idler gear 1 Figure 7 Mount axial washer 1 axial cage 2 and running disk 3 Install chamfer see arrow of running disk 3 showing towards the axial cage Figure 8 3 2 1 Chamfer 1 1 Chamfer 3 2 1 ...

Page 283: ...retaining ring 2 S Set of external pliers 5870 900 015 Figure 9 Press tapered roller bearing inner ring 1 until contact is obtained Figure 10 Mount stud bolt 1 Tightening torque M10 8 8 x15 MA 17 Nm Check closing and opening of the clutch by means of compressed air at the hole 2 Closing and opening of the clutch must be clearly audible Figure 11 1 1 2 1 2 ...

Page 284: ...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 120 C S Hot air blower 230 V 5870 221 500 S Hot air blower 115 V 5870 221 501 Figure 3 Mount clutch 1 until contact is obtained Wear protective gloves Figure 4 1 1 1 ...

Page 285: ... cage 2 and axial washer 3 Install chamfer see arrow of running disk 1 showing towards the axial cage Figure 5 Mount needle cage 1 Figure 6 Mount idler gear 1 Figure 7 Mount axial washer 1 axial cage 2 and running disk 3 Install chamfer see arrow of running disk 3 showing towards the axial cage Figure 8 3 2 1 Chamfer 1 1 Chamfer 3 2 1 ...

Page 286: ...retaining ring 2 S Set of external pliers 5870 900 015 Figure 9 Press tapered roller bearing inner ring 1 until contact is obtained Figure 10 Mount stud bolt 1 Tightening torque M10 8 8 x15 MA 17 Nm Check closing and opening of the clutch by means of compressed air at the hole 2 Closing and opening of the clutch must be clearly audible Figure 11 2 1 1 2 1 ...

Page 287: ...ch 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 Tightening torque M10 8 8 x15 MA 17 Nm Figure 3 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 4 1 1 1 ...

Page 288: ...Install chamfer see arrow of running disk 1 showing towards the axial cage Figure 6 Mount needle cage 1 Figure 7 Mount idler gear 1 Mount axial washer 2 axial cage 3 and running disk 4 Install chamfer see arrow of running disk 4 showing towards the axial cage Pay attention that the running disk is flush with the shaft collar to ensure that all inner disks are mounted on the idler gear teeth Figure...

Page 289: ...logy and Axle Systems 5871 146 002 9 5 3 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 Closing and opening of the clutch must be clearly audible Figure 10 1 1 ...

Page 290: ...oller bearing inner ring 1 onto the shaft 2 until contact is obtained Figure 1 Install piston ring 1 Figure 2 Undercool shaft 1 approx 80 C heat up gear 2 approx 120 C and mount until contact is obtained Wear protective gloves Figure 3 Secure gear by means of retaining ring 80x2 5 1 S Set of external pliers 5870 900 015 Figure 4 1 1 1 1 2 ...

Page 291: ...sher 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 Figure 6 Mount idler gear 1 Figure 7 Mount axial washer 1 needle cage 2 and running disk 3 Mount running disk 3 with the chamfer showing to the needle cage Figure 8 2 1 1 1 3 1 Chamfer 2 ...

Page 292: ...21 501 Figure 9 Mount clutch 1 until contact is obtained and fix it by retaining ring 50x2 2 Wear protective gloves Figure 10 Press tapered roller bearing inner ring 1 until contact is obtained Figure 11 Mount stud bolt 1 Tightening torque M10 8 8 x15 MA 17 Nm Check closing and opening of the clutch by means of compressed air at the hole 2 Closing and opening of the clutch must be clearly audible ...

Page 293: ...pprox 120 C and mount until contact is obtained Wear protective gloves Figure 1 Secure drive gear by means of retaining ring 90x3 1 S Set of external pliers 5870 900 015 Figure 2 Press tapered roller bearing inner ring 1 onto the input shaft until contact is obtained Figure 3 Press tapered roller bearing inner ring 1 onto the input shaft until contact is obtained Figure 4 2 1 1 1 1 ...

Page 294: ...e Systems 5871 146 002 9 7 2 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 Turbine shaft is axially fixed Snap in and interlock rectangular ring 60x3 2 Figure 6 1 1 2 2 ...

Page 295: ... Axle Systems 5871 146 002 9 8 1 9 8 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 Figure 2 1 2 1 ...

Page 296: ...cant 5870 451 006 Mount O rings 22x3 into the annular groove of the oil tubes 1 and 2 and oil them Then insert tubes into the housing front part and fix them by means of cylindrical screws 3 Tightening torque M8 8 8x12 MA 23 Nm Figure 2 Mount screw plug 1 with new O ring Screw plug M38x1 5 O ring 35x2 Tightening torque MA 140 Nm Figure 3 The spare parts service supplies the lubricating oil tubes 1...

Page 297: ... grease 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 inner ring bearing outer ring see Chapter 7 Figures 9 and 11 Figure 7 Due to the installation conditions the installation of single clutches without using the special tool is not possible Risk of injury Install clutches by me...

Page 298: ...tch 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 Check grease and centrically align rectangular rings arrows Fix all clutches by means of handles S S Handle 6 pcs required 5870 260 010 Figure 12 K3 K1 KR K2 KV K3 K4 S K1 K4 K2 ...

Page 299: ...ting chain 5870 281 047 S Eye nuts M12 0664 462 774 S Eye bolts 2x M20 0636 804 003 Figure 13 Use the lifting device to bring the housing rear part into contact position with the housing front part by cautiously assembling the clutches Then remove handles Figure 14 Remove housing rear part again Figure 15 Put on screen sheet 1 Install preassembled output shaft 2 Figure 16 1 2 ...

Page 300: ...sition with the housing rear part by using the lifting device Pay attention that both oil tubes are aligned with the holes in the housing rear part S Lifting chain 5870 281 047 S Eye bolts 2x M20 0636 804 003 S Eye nuts M12 0664 462 774 Figure 18 Fit both cylindrical pins 1 centrically to the mounting face Figure 19 Checking of clearance of the gear drive train Position driving element S and rotat...

Page 301: ...al screws 1 Tightening torque M10 8 8x65 MA 46 Nm Tightening torque M10 8 8x40 MA 46 Nm Mount stud bolts 2 Wet screw in thread with Loctite type No 243 Tightening torque M8 10 9x25 MA 15 Nm Figure 21 Place O ring 76x3 1 into the annular groove of the cover 2 Figure 22 Fix cover 1 by means of hexagon nuts 2 Tightening torque M8 10 MA 25 Nm Figure 23 2 1 1 2 1 2 ...

Page 302: ...ally align rectangular ring Mount pump shaft 2 until contact is obtained Figure 2 Fix pump shaft by means of retaining ring 85x3 1 Mount O ring 104x3 2 onto the flange 3 grease it and bring it into contact position with the housing rear part S Set of internal pliers 5870 900 013 Figure 3 Fix flange by means of cylindrical screws 1 Place O ring 130x3 2 into the flange hole and grease it Tightening ...

Page 303: ...n u a l Corporate Division Off Road Driveline Technology and Axle Systems 5871 146 002 11 2 Place cover plate 1 onto the flange and fix it by means of hexagon screws 2 Tightening torque M16 8 8x20 MA 46 Nm Figure 5 2 1 ...

Page 304: ... of the specified driver S ensures the exact installation position Fill space between sealing lip and dust lip with grease Wet outer diameter rubber coated with spirit Mount output flange 1 until contact is obtained Figure 2 Insert O ring 38x4 into the space between output flange and shaft Fix output flange by means of washer 1 and hexagon screws 2 Tightening torque M8 10 9x25 MA 34 Nm Figure 3 Fi...

Page 305: ... with spirit Fix brake disk 1 at output flange 2 by means of hexagon screws 3 and washers Tightening torque M10 10 9x25 MA 68 Nm Bring bracket 4 into contact position with the transmission housing rear part and fix it by means of cylindrical screws 5 Tightening torque M14 10 9x45 MA 200 Nm Mount output flange 1 until contact is obtained Figure 6 Insert O ring 38x4 into the space between output fla...

Page 306: ...tenance instructions functional characteristics and setting specifications for the parking brake see original Knott documentation chapter 17 Types M 90 mechanical actuation FSG 75 hydraulic actuation FSG 90 110 hydraulic actuation FSG 75 90 Release clearance 0 5 1 5 mm Nom release clearance 1 0 mm FSG 110 Release clearance 1 5 2 0 mm Nom release clearance 1 7 mm 12 3 Output flange on converter sid...

Page 307: ...t flange 1 until contact is obtained Figure 13 Insert O ring 38x4 into the space between output flange and shaft Fix output flange by means of washer 1 and hexagon screws 2 Tightening torque M8 10 9x25 MA 34 Nm Figure 14 Fix locking plate by means of driver S S Driver 5870 057 011 S Handle 5870 260 002 Figure 15 1 1 2 S ...

Page 308: ...rter back pressure valve 1 oil feed housing 2 piston 3 compression spring 4 pressure plate 5 locking plate Figure 1 Install pressure plate 4 with the pin 6 mm showing to the locking plate 5 Assemble single parts preload them with assembly aid S and fix them by means of locking plate 1 S Assembly aid 5870 345 107 Figure 2 Mount temperature sensor 1 with new O ring 11x2 Tightening torque MA 25 Nm Ve...

Page 309: ...ws S and mount stator shaft 1 Pay attention to radial installation position S Adjusting screws M10 5870 204 007 Figure 5 In case of wear marks in the pump housing or on the control disk the pump assy must be replaced Items 1 6 may be exchanged 1 pump housing with rotor 2 snap ring 3 shaft seal 75x90x10 4 support shim 95x76x84x3 5 needle bearing assy bearing outer ring and needle bearing 6 ring 75x...

Page 310: ...ver 5870 055 070 S Handle 5870 260 002 Figure 8 Install outer rotor Chamfer arrow to show downwards Figure 9 Install inner rotor Teeth arrow to show upwards Figure 10 Place control disk and fix it radially by means of two cylindrical screws 1 Do not tighten the cylindrical screws just turn them in until contact is obtained and then turn them back by approx rotation Pay attention to the installatio...

Page 311: ...ase O rings Fix transmission pump 2 by means of cylindrical screws 1 Tightening torque 10 8 8x75 MA 46 Nm Figure 13 Fix oil feed housing 1 equally by means of Torx screws 2 Tightening torque M8 10 9x30 MA 23 Nm Tightening torque M8 10 9x45 MA 23 Nm Tightening torque M8 10 9x60 MA 23 Nm Fasten fixing plate 3 by means of cylindrical screws 4 Tightening torque M8 8 8x40 MA 46 Nm Pay attention to the ...

Page 312: ...exagon screws 2 Fit washers between converter 3 and flexplate 1 and under the hexagon screws Secure hexagon screws with Loctite type No 262 Tightening torque M12 10 9x18 MA 115 Nm Figure 17 13 4 Engine connection remote mount Bolt input shaft 1 to flexplate 2 by means of hexagon screws 3 Tightening torque M12 10 9x18 MA 115 Nm Figure 18 Fix flexplate 1 to converter 3 by means of hexagon screws 2 W...

Page 313: ...Set of internal pliers 5870 900 013 Figure 20 Put cover 1 onto the converter and press it until contact is obtained Support the pressure sleeve S on the bearing inner ring Figure 21 Press screen sheet 1 onto the input flange 2 Figure 22 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 23 2 1 S 1 1 2 ...

Page 314: ... 25 Figure 26 Fix input flange 3 by means of washer 1 and hexagon screws 2 Tightening torque M8 10 9x50 MA 34 Nm Fix locking plate by means of driver S S Driver 5870 057 010 S Handle 5870 260 002 Position converter by means of lifting device until the cover 1 is in contact with the converter bellhousing 2 S Eye bolts assortment 5870 204 002 S Lifting chain 5870 281 047 Figure 27 1 2 1 2 1 3 S ...

Page 315: ...nology and Axle Systems 5871 146 002 13 8 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 MA 46 Nm Figure 28 2 1 ...

Page 316: ...adjusting screws S and assemble seal 1 and cover 2 Figure 1 Fix cover by means of hexagon screws 1 Tightening torque M8 8 8x18 MA 23 Nm Figure 2 14 2 Version without emergency steering pump Press sliding bearing into the cover 1 in alignment with the plane face S Driver 5870 048 080 Figure 3 Place O ring 100x3 1 into the annular groove of the piston pump 2 and grease it Figure 4 2 1 1 1 S S 1 2 ...

Page 317: ...ssemble seal 1 and cover 2 Figure 5 Fix cover 1 by means of Torx screws 2 Tightening torque M8 10 9 x30 MA 34 Nm Mount emergency steering pump 3 and fix it by means of cylindrical screws 4 Tightening torque M8 8x135 MA 23 Nm Pay attention to radial installation position see markings done during disassembly arrows Figure 6 S 1 2 2 4 3 1 ...

Page 318: ...to secure it by Loctite type No 262 For the relating parts lists please refer to the spare parts list subassembly inductive sensor Parts list number see identification plate Figure 3 Mount speed sensor 1 with new O ring 15 54x2 62 and fix it by means of cylindrical screw 2 1 speed sensor Hall sensor output speed Tightening torque M8 8 8x16 MA 23 Nm Figure 2 Mount oil drain plug 1 with new O ring 3...

Page 319: ...ivision Off Road Driveline Technology and Axle Systems 5871 146 002 15 2 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 MA 23 Nm Figure 4 1 2 ...

Page 320: ...ase observe the vehicle manufacturer s specifications The following sketches show the sectional views of the electro hydraulic control Figure 1 Proportional valve P5 Figure 2 Figure 3 Pressure reducing valve 9 bar Wiring harness Cover Main pressure valve16 2 bar Housing Cover Housing A A B B Follow on slide Pressure controller Vibration damper Main press valve16 2 bar Press reducing valve 9 bar Wi...

Page 321: ...til contact is obtained Figure 4 See arrows for installation position The opposite figure shows the following single parts 1 pressure reducing valve 1x piston and compr spring 2 vibration damper 3x piston and compr spring 3 follow on slide 3x piston and compr spring Figure 5 Install the single parts acc to Figure 5 Preload compression springs of the follow on slides and preliminarily fix pistons b...

Page 322: ...2 Figure 9 Figure 10 Mount pressure controllers 1 and fasten them by means of fixing plates 2 and cylindrical screws 3 Install fixing plate with the claw showing downwards Pay attention to the radial installation position of pressure controllers see figure Tightening torque M5 8 8x12 MA 5 5 Nm S Torque wrench 5870 203 031 S Reducing adapter 5870 656 056 S Socket wrench TX 27 5873 042 002 Preassemb...

Page 323: ...e the cylindrical pins assembly aid Then fix housing by means of the Torx screws 1 Tightening torque M5 10 9x30 MA 5 5 Nm S Adjusting screws 5870 204 036 S Torque wrench 5870 203 031 S Reducing adapter 5870 656 056 S Socket wrench TX 27 5873 042 002 Figure 13 Mount pressure controllers 1 and fasten them by means of fixing plates and cylindrical screws Install fixing plate with the claw showing dow...

Page 324: ... M5 10 9x30 MA 5 5 Nm S Torque wrench 5870 203 031 S Socket wrench TX 27 5873 042 002 S Reducing adapter 5870 656 056 Figure 16 Fix wiring harness by means of retaining clamp 1 Fit the opposite cover Figure 17 Fit two adjusting screws S Adjusting screws 5870 204 063 Figure 18 Flush mount screens 1 into the holes of the intermediate plate see arrows Pay attention to the installation position screen...

Page 325: ...Figure 20 Place duct plate 1 and fix it equally by means of Torx screws 2 Tightening torque M6 10 9x23 MA 10 5 Nm S Socket wrench TX 27 5873 042 002 Figure 21 Provide screw plugs 1 with new O rings 8x1 5 and install them Tightening torque M10x1 MA 6 Nm Figure 22 Insert converter safety valve 1 into the housing hole until contact is obtained Figure 23 1 2 2 1 1 1 ...

Page 326: ...ue M8 MA 23 Nm Mount screw plug 4 with new O ring 13x2 Tightening torque M16x1 5 MA 30 Nm S Torque wrench 5870 203 034 S Socket wrench TX 40 5873 042 004 Mount compression spring 4 piston 3 and switch 2 with new O ring 13x2 1 Filter differential pressure valve 2 Switch with O ring 3 Piston 4 Compression spring Tightening torque MA 30 Nm Versions without filter differential pressure valve Mount scr...

Page 327: ...ter pressure filter Fix filter head 1 with new O rings 34 2x3 to the housing rear part by means of Torx screws 2 Tightening torque M8 10 9x60 MA 34 Nm S Torque wrench 5870 203 034 S Socket wrench TX 40 5870 042 004 Figure 29 The filter is to be installed as follows Slightly oil the seal Turn in the filter until contact with the sealing surface is obtained and then tighten it by hand with approx 1 ...

Page 328: ...sembly 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 ZF Passau GmbH Donaustr 25 71 D 94 034 Passau ...

Page 329: ...ssively worn or cracked If replacement is necessary press out the plastic shaft seal from inside the casting using a steel spacer block 1 078 27 38mm diameter by 2 5 63 5mm long and an arbor press Note A popular brand name 3 8 drive 13 16 hex deep socket works weH as a spacer block 4 7 After the shaft seal is pressed out remove the sliver of plastic that may be left in the groove in the casting Th...

Page 330: ...Service Manual Section 5 Front Axle Service 2 00_2013 03 ...

Page 331: ......

Page 332: ...site supervisor or OSHA for specific requirements 5 To prevent falls use assist rails and steps when getting on and off the machine Keep steps and platform clear of mud oil grease snow tools and debris 6 Do not use controls or hoses as hand holds when climbing on or off machine Controls may move and inadvertently cause machine travel or implement movement 7 Do not permit anyone but the operator to...

Page 333: ... before moving Advise maintenance personnel of malfunctions before operating Be sure malfunctions are remedied before accepting responsibility for operation 22 Avoid accidental contact with the transmission control lever while the engine is running Unexpected movement may result from such contact 23 Do not get off or on the vehicle while it is moving 24 Lower unlocked implements to the ground appl...

Page 334: ...ating beacons and licensing requirements 39 Obey flagmen safety signals and signs 40 Dim vehicle lights when meeting a vehicle at night Make sure lights are adjusted to prevent blinding oncoming drivers 41 Reduce speed before turning or applying brakes 42 Always check overhead clearance especially when transporting Be aware of low overhanging obstacles such as trees and bridges 43 Know the exact l...

Page 335: ...ice procedure Be sure operator can see mechanic 57 Always use external supports when working under any linkage or raised part of the machine Lower implements to ground whenever possible 58 Do not service the grader with the engine running unless the grader is properly and securely supported with all six wheels off the ground 59 Use caution when servicing the unit around moving parts 60 The cooling...

Page 336: ...tion immediately or gangrene may result 71 Fuel oil in the injection system is under high pressure and can penetrate the skin Unqualified persons should not remove or attempt to adjust a pump injector nozzle or any other part of the fuel injector system Failure to follow these instructions can result in serious injury 72 Continuous long term contact with used engine oil may cause skin cancer Avoid...

Page 337: ...ank 88 Do not fill the fuel tank to capacity Allow room for expansion 89 Wipe up spilled fuel immediately 90 Always tighten the fuel tank cap securely 91 If the original fuel tank cap is lost replace it with a genuine replacement cap A non approved cap may not be safe 92 Keep equipment clean and properly maintained 93 Do not drive equipment near open fires 94 Never use fuel for cleaning purposes 9...

Page 338: ...R IN THE PROPER AND SAFE OPERATION OF ALL OPERATIVE EQUIPMENT BOTH EMPLOYER AND EMPLOYEE SHOULD THOROUGHLY FAMILIARIZE THEMSELVES WITH THE MACHINE OPERATION Some pictures in this manual show safety shields removed or open to show parts being serviced or for clarity all shields should be closed or replaced prior to operating the machine Fasten seat belt before starting engine ...

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Page 340: ...t Axle Disassembly and Repair 5 9 LH Steering Knuckle and King Pin Removal 5 9 RH Steering Knuckle and King Pin Removal 5 12 LH Steering Knuckle and King Pin Installation 5 13 RH Steering Knuckle and King Pin Installation 5 18 LH Wheel Lean Pivot Pin Removal 5 19 LH Wheel Lean Pivot Pin Installation 5 21 RH Wheel Lean Pivot Pin Removal 5 22 RH Wheel Lean Pivot Pin Installation 5 22 Axle Oscillatio...

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Page 342: ...tandem pump steering priority valve and steering and wheel lean cylinder replacement and overhaul procedures The steering system receives oil from the steering load sense priority valve which ensures the steering sys tem receives oil before other hydraulic functions Oil from the steering priority valve enters the steering valve The steering valve receives input from the steering wheel If no input ...

Page 343: ...nkages allow for adjustment of toe in and camber SPECIFICATIONS Steering Control Unit Make and Model Eaton Type Orbitrol Turns Lock to Lock 5 to Left 6 to Right Displacement 120 cu cm rev 7 33 cu in rev Maximum Turn Angle 40deg from Center Pressure Relief 107 120 bar 1550 1750 psi Cylinders Steering 1 63 5 x 198 0 mm 2 50 x 7 80 in Articulation 2 76 0 x 276 0 mm 3 00 x 10 88 in Wheel Lean 1 76 2 x...

Page 344: ...king and or jack stands to securely support the implement Move with extreme care when working under the machine its attachments and even on or near them Always wear protective safety equipment as required such as hard hat goggles and safety shoes Know your jacking equipment and its capacity Jacking points should be appropriate for the load applied Be sure support area of jack at the machine and on...

Page 345: ...us infection or reaction can develop if medical treatment is not administered immediately Ensure all lifting blocking and jacking devices are appropriately rated for the weight being raised and or supported If using mold board down function to raise front part of machine lift machine until tires are raised above ground then use adequate blocking devices under drawbar and front axle Operate control...

Page 346: ... replace Slow steering hard steering or loss of power assist Worn or malfunctioning steering pump forward sec tion of tandem pump Rebuild or replace Malfunctioning pressure relief valve allowing system pressure to be less than specified Replace pressure relief valve Damaged steering valve spool Rebuild or replace Jammed steering valve spool Clean thoroughly Install new steering valve if necessary ...

Page 347: ...g hoist or lift Step 7 Spin a front tire and mark the centerline using a scribe Repeat for the other tire Step 8 Measure the distance between the centerlines at the front of the tires and the rear of the tires Subtract rear measurement from front measurement Difference should be 6 4 7 9 mm 0 25 0 31 in Step 9 If toe in is incorrect loosen tie rod clamp bolts 2 3 Adjust length of tie rod by turning...

Page 348: ... Turn off engine and check steering stop 1 It should be contacting stop surface 2 Step 3 Measure exposed portion of steering cylinder rod 1 It should be between 3 0 and 5 0 mm 0 12 and 0 20 in Step 4 If incorrect measurement is obtained loosen jam nut 1 on cylinder rod clevis Turn hex head 2 in the desired direction to obtain correct amount of exposed cylinder If requirement of step 3 is not met p...

Page 349: ...6 of dirt and grease Use a commercial solvent if necessary Step 4 If bearing 5 has been removed pack bearing with wheel bearing grease NLGI 2 Fill hub 7 cavity approximately 1 3 full with wheel bearing grease NLGI 2 Using a hammer and driver install bearing 5 narrow side in Step 5 Install washer and nut 4 Torque nut to 81 122 Nm 60 90 Ib ft Rotate hub 7 several times to distribute grease and seat ...

Page 350: ...und then support front part of drawbar with suitable blocking hoist or lift Step 2 Remove eight lug nuts 8 and washers securing LH front wheel to hub 7 then remove wheel Step 3 Remove four bolts 1 with washers bearing cover 2 cotter pin 3 nut 4 and washer from spindle shaft 6 Step 4 Using hoist remove hub 7 with outer bearing 5 inner bearing 9 and seal 10 Step 5 Remove cotter pin and crown nut 1 s...

Page 351: ...Axle 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 Step 7 Remove nut 1 bolt and washer securing LH end of wheel lean bar 2 to steering knuckle 3 ...

Page 352: ...from knuckle by driving out king pin Step 12 Remove rubber seals 10 by hand from each end of spindle Step 13 Remove flat washer 11 and thrust washer 12 from top of spindle Step 14 Remove outer plug 13 inner plug 14 and o ring 15 from LH rear of front axle Step 15 Remove lube fitting 16 plugs 17 18 and o ring 19 from LH front of axle Step 16 Loosen jam nut 20 and remove set screw 21 on RH side of L...

Page 353: ...n Step 2 Remove cotter pin and crown nut 1 securing steer bar and RH socket link 2 to RH spindle 3 Dismount RH end of steer bar 4 from RH spindle 3 and remove steer bar Step 3 Support wheel lean cylinder 1 Remove nut 2 bolt and two washers securing wheel lean cylinder and RH end of wheel lean bar 3 to RH steering knuckle 4 Step 4 Apply previous steps 8 through 18 to RH steering knuckle and king pi...

Page 354: ...t and grease from pivot pin bore and machined surfaces Step 5 Using a bearing driver and hammer install bearings 2 in pivot pin bores from outside in Step 6 Using a seal driver and hammer install new seals 1 on inner side of bearings 2 making sure groove on seals faces inside of bore Step 7 With steering knuckle secured in bench vice use a putty knife and air drill with wire brush to remove all gr...

Page 355: ...tart king pin into steering knuckle with set screw 10 hole in king pin in line with set screw hole in spindle 7 Use a rubber mallet if necessary to drive king pin through knuckle and spindle making certain that set screw holes align Step 15 Install set screw 10 with jam nut through set screw holes in spindle 7 and king pin Torque set screw to 51 5 2 7 Nm 38 2 Ib ft Snug jam nut tight against spind...

Page 356: ...Step 22 Inspect bearings 25 in wheel lean pivot bar for wear nicks and burrs To replace bearings remove wheel lean pivot bar and secure in vice Use a bearing driver and hammer to remove bearings Remove grease and paint from inside of bores with putty knife and air drill with wire brush Install new bearings with a bearing driver and hammer Step 23 Inspect lube fittings 26 on wheel lean pivot bar Re...

Page 357: ...wn nut 6 and torque to 135 6 Nm 100 Ib ft Step 26 Continue tightening crown nut 1 to align hole for cotter pin Install cotter pin 2 and bend two ends across threaded end of steering cylinder socket 3 and crown nut 1 Step 27 Install new nylon washer on threaded end of steer bar socket link 1 Align steer bar socket link with mounting hole in LH spindle arm 2 and install crown nut 3 Torque crown nut ...

Page 358: ...all with seal driver and hammer Step 30 Using hoist install hub 3 on spindle and fill hub cavity approximately 1 3 with wheel bearing grease NLGI 2 Install outer bearing 5 narrow side in with hammer and driver Step 31 Install washer and nut 6 Torque nut to 81 122 Nm 60 90 Ib ft Rotate hub 3 several times to distribute grease and seat bearing Back off nut and torque to 14 27 Nm 10 20 Ib ft Install ...

Page 359: ...g knuckle and king pin Step 2 Install new nylon washer on threaded end of steer bar RH socket link 1 Secure steer bar RH socket link to RH spindle 2 with crown nut 3 Torque crown nut to 135 6 Nm 100 Ib ft Continue tightening crown nut to align hole for cotter pin Install cotter pin and bend two ends across threaded end of socket link and crown nut Step 3 Insure bushings are seated in wheel lean cy...

Page 360: ...or lift Step 2 Use a suitable lift to support the front axle Remove eight lug nuts 1 and washers securing wheel and tire assembly to hub Remove wheel and tire assembly Step 3 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 and support steering cylinder allowing clearance for access to LH wheel lean piv...

Page 361: ...osen jam nut 8 and remove set screw 9 on RH side of LH knuckle Step 8 Drive out wheel lean pivot pin Step 9 Remove seals 10 from bearings 11 in wheel lean pivot pin bore Discard seals Step 10 Use a hammer and bearing driver to drive out bearings 11 Step 11 Inspect bearings 11 for wear nicks and burrs Replace as necessary Step 12 Using a putty knife and air drill with wire brush remove grease and p...

Page 362: ...pivot pin Use rubber mallet to drive pivot pin through bores making certain set screw holes align Step 4 Install set screw 3 with jam nut 4 through set screw holes in steering knuckle and pivot pin Torque set screw 3 to 51 5 2 7 Nm 38 2 Ib ft Snug jam nut tight against steering knuckle Step 5 Install new o ring 5 into LH front of wheel lean pivot pin bore Install plug 6 with chamfer toward o ring ...

Page 363: ...own nut 3 Step 9 Install LH front wheel on LH hub with eight washers and lug nuts 1 Torque lug nuts 1 to 440 475 Nm 325 350 Ib ft Step 10 Upon completion of RH Wheel Lean Pivot Pin Removal and Installation procedures perform steering cylinder adjustments in accordance with previous FRONT AXLE ADJUSTMENTS procedures in this section RH Wheel Lean Pivot Pin Removal Step 1 Apply previous LH Wheel Lean...

Page 364: ...led lower front implement using machine hydraulics Front implement parallel linkage must be below horizontal Set implement on suitable support Turn off engine Operate control lever to relieve any pressure in hydraulic lines before disconnecting Step 3 Label disconnect and cap hydraulic hoses 1 on each side of implement lift cylinder 2 Step 4 Remove retainer bolt 3 and nut from cylinder upper pin 4...

Page 365: ... 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 Step 9 Label disconnect and cap hydraulic hoses 1 to wheel lean cylinder 2 ...

Page 366: ... bearing area of front axle center tube Step 12 Inspect axle oscillation pin and bearings 3 for wear nicks and burrs Replace as necessary Axle Oscillation Pin Installation Step 1 Use bearing driver to install bearings 3 in each end of center tube on front axle Step 2 Use seal driver to install seals 2 into bearings 3 Step 3 Raise front axle in position for inserting axle oscillation pin through ve...

Page 367: ...t frame using two bolts 4 washers 5 and spacers 6 Torque bolts 4 to 149 1 183 Nm 110 135 Ib ft Step 6 Reconnect hydraulic hoses 1 to wheel lean cylinder 2 Torque fittings to 25 8 1 3Nm 19 1 Ib ft Step 7 Reconnect hydraulic hoses 1 to steering cylinder 2 Torque fittings to 25 8 1 3 Nm 19 1 Ib ft Step 8 Position wheel and tire assemblies for mounting on front hubs Install eight lug nuts 1 and washer...

Page 368: ... holes in cylinder clevis 1 and pin 3 Install nut on retainer bolt and torque to 14 9 1 3 Mm 11 1 Ib ft Step 12 Align front end attachment cylinder upper clevis 1 with front end attachment upper clevis 2 Step 13 Install upper pin 3 with two washers and with retainer bolt holes in cylinder clevis 1 and pin aligned Step 14 Install retainer bolt 4 through holes in cylinder clevis 1 and pin 3 Install ...

Page 369: ... securing steering valve access cover beneath steering column Remove access cover Step 4 Label disconnect and cap four hydraulic lines 1 at bottom of steering valve Step 5 Remove four screws 1 securing top access cover and remove access cover Step 6 Remove four screws 2 securing steering valve 3 to steering column mounting plate 4 and console 5 Remove steering valve and secure in bench vise Step 7...

Page 370: ...valve 4 with four bolts 3 Install bolts in steering valve Torque bolts to 47 53 Nm 35 39Ib ft Step 3 Reconnect four hydraulic lines 1 to bottom of steering valve Torque fittings to 25 8 1 3 Nm 19 1 Ib ft Step 4 Using two screws install valve access cover beneath steering column Hand tighten screws Step 5 Install steering wheel 1 on steering column 2 with nut 3 Torque nut to 55 61 Nm 40 45 Ib ft St...

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Page 372: ...Power Steering Repair Information Square Housing with Side Ports 5 Series Steering Control Units 001 Round Housing with Side Ports Round Housing with End Ports ...

Page 373: ...rust Bearing Check Ball Bearing Race 2 O ring Plug Manual Steering Relief Valve O ring Plug Centering Springs O ring Drive Spacer Sleeve Wear Plate Spool Pin Gerotor Cap Screw 7 Spring Retaining Ring O ring Seal Ring O ring Seal End Cap REPLACEMENT PART NO DESCRIPTION 64456 00 Centering Spring Kit contains parts with 64455 00 Seal Kit contains parts with 2 EATON Char Lynn Power Steering Steering C...

Page 374: ...l steering check may be a check ball 3 Slide the spool and sleeve from the housing see figure 2 4 Remove the thrust bearing and bearing races 5 Remove the quad seal 6 Using a small blade screw driver carefully pry the dust seal from the housing Important Do not damage the dust seal seat Cap During repairs always protect machined surfaces or a check relief valve End Cap Screw 7 Gerotor Sea l Ring F...

Page 375: ...ch the quad seal will be installed Hold the bearing race tightly against the input end of the housing by pushing on the gerotor end of the sleeve Fit the quad seal into its seat through the input end of the housing Be sure the seal is not twisted Remove the sleeve and bearing race 11 Lubricate and install the dust seal see Figure 4 for correct seal orientation 12 Install the centering springs in t...

Page 376: ...ove in the wear plate 24 Install the gerotor and align the screw holes 25 Lubricate and install a new o ring seal in the groove in the gerotor ring 26 Lubricate and install a new o ring and seal ring in the groove in the gerotor star 27 Install the spacer 28 Install end cap and seven cap screws Tighten cap screws in a crisscross pattern to 16 18 Nm 140 160 lb in 29 Remove the SCU from the vise 30 ...

Page 377: ...ear Plate Drive Centering Springs Sleeve Spacer O ring Seal Spool Spring Retaining Ring Gerotor Pin Seal Ring Cap Screw O ring O ring O ring End Cap Manual Steering Check Relief Valve Plug REPLACEMENT PART NO DESCRIPTION 64456 000 Centering Spring Kit contains parts with 64455 000 Seal Kit contains parts with 6 EATON Char Lynn Power Steering Steering Control Units 001 5 Series C STCU TS002 E Augus...

Page 378: ...resent the manual steering check is located in the housing 2 Remove the four cap screws and disassemble the SCU as shown in figure 1 3 Slide the spool and sleeve from the housing see figure 2 4 Remove the thrust bearing and bearing races 5 Remove the seal 6 Using a small blade screwdriver carefully pry the dust seal from the housing Important Do not damage the dust seal seat End Cap Figure 1 Gerot...

Page 379: ... seal will be installed Hold the bearing race tightly against the input end of the housing by pushing on the gerotor end of the sleeve Fit the quad seal into its seat through the input end of the housing Be sure the seal is not twisted Remove the sleeve and bearing race 11 Lubricate and install the dust seal see Figure 4 for correct seal orientation 12 Install the centering springs in the spool It...

Page 380: ...oove with the timing groove in the wear plate 26 Lubricate and install a new o ring seal in the groove in the gerotor ring 27 Lubricate and install a new o ring and seal ring in the groove in the gerotor star 28 Install the spacer 29 Install end cap and four cap screws Align timing groove on endcap with timing groove on gerotor Tighten cap screws in a crisscross pattern to 16 18 Nm 250 lb in 30 In...

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Page 382: ...Service Manual Section 6 Rear Axle and Tandem Service 2 00_2013 03 ...

Page 383: ......

Page 384: ...oyer site supervisor or OSHA for specific requirements 5 To prevent falls use assist rails and steps when getting on and off the machine Keep steps and platform clear of mud oil grease snow tools and debris 6 Do not use controls or hoses as hand holds when climbing on or off machine Controls may move and inadvertently cause machine travel or implement movement 7 Do not permit anyone but the operat...

Page 385: ...trols before moving Advise maintenance personnel of malfunctions before operating Be sure malfunctions are remedied before accepting responsibility for operation 22 Avoid accidental contact with the transmission control lever while the engine is running Unexpected movement may result from such contact 23 Do not get off or on the vehicle while it is moving 24 Lower unlocked implements to the ground...

Page 386: ...s rotating beacons and licensing requirements 39 Obey flagmen safety signals and signs 40 Dim vehicle lights when meeting a vehicle at night Make sure lights are adjusted to prevent blinding oncoming drivers 41 Reduce speed before turning or applying brakes 42 Always check overhead clearance especially when transporting Be aware of low overhanging obstacles such as trees and bridges 43 Know the ex...

Page 387: ... service procedure Be sure operator can see mechanic 57 Always use external supports when working under any linkage or raised part of the machine Lower implements to ground whenever possible 58 Do not service the grader with the engine running unless the grader is properly and securely supported with all six wheels off the ground 59 Use caution when servicing the unit around moving parts 60 The co...

Page 388: ...attention immediately or gangrene may result 71 Fuel oil in the injection system is under high pressure and can penetrate the skin Unqualified persons should not remove or attempt to adjust a pump injector nozzle or any other part of the fuel injector system Failure to follow these instructions can result in serious injury 72 Continuous long term contact with used engine oil may cause skin cancer ...

Page 389: ...the tank 88 Do not fill the fuel tank to capacity Allow room for expansion 89 Wipe up spilled fuel immediately 90 Always tighten the fuel tank cap securely 91 If the original fuel tank cap is lost replace it with a genuine replacement cap A non approved cap may not be safe 92 Keep equipment clean and properly maintained 93 Do not drive equipment near open fires 94 Never use fuel for cleaning purpo...

Page 390: ...ERATOR IN THE PROPER AND SAFE OPERATION OF ALL OPERATIVE EQUIPMENT BOTH EMPLOYER AND EMPLOYEE SHOULD THOROUGHLY FAMILIARIZE THEMSELVES WITH THE MACHINE OPERATION Some pictures in this manual show safety shields removed or open to show parts being serviced or for clarity all shields should be closed or replaced prior to operating the machine Fasten seat belt before starting engine ...

Page 391: ...65E Turbo Motor Grader Service Manual Section 6 Rear Axle and Tandem Service 2 00_2013 03 6 x This page intentionally left blank ...

Page 392: ...Assembly 6 4 Removal 6 5 Installation 6 6 Driveshaft 6 8 Removal 6 8 Installation 6 8 Rear Axle And Tandem Drive Assembly 6 9 Installation 6 9 Brakes Maintenance and Adjustment 6 10 General 6 10 Specifications 6 11 Service Brake 6 11 Parking Brake 6 12 Troubleshooting 6 12 Bleeding The Brakes 6 13 Parking Brake Cable Adjustment 6 14 Transmission End Adjustment 6 14 Lever End Adjustment 6 15 Parkin...

Page 393: ...ion Discs And Piston 6 24 Removal 6 24 Inspection 6 24 Installation 6 24 Parking Brake Friction Pad Replacement 6 25 Rear Axle 6 25 Programmed Maintenance Schedule 6 25 Replacing Lube Oil 6 26 Assembling Leak Proof Components 6 27 Side Final Drives 6 27 Disassembly 6 27 Assembly 6 32 Center Section Unit 6 34 Disassembly 6 34 Assembly 6 39 Tandem Drive 6 49 Disassembly 6 49 Assembly 6 53 ...

Page 394: ...tandem drive The axle extends into the tandem drive and a double sprocket is attached to the end of each axle A double chain is driven by the axle sprocket with each side of the chain driving one wheel The tandem drive is sealed to allow the chain to operate in an oil bath Each tandem drive is allowed to rotate freely around the axle limited by frame stops The tandem drives are the same on each si...

Page 395: ...Pitch Slip Fit Connecting Link Chain Length 42 Pitch Oil Capacity 3 0 gal 11 4 L TROUBLESHOOTING Troubleshooting Chart Problem Possible Cause Tools Required Test Solution Wheel will not pull Drive chain broken Flashlight Open chain cover and do visual inspection Replace and repair chain Rear axle broken Lift axle and rotate wheel If wheel rotates replace axle Rattle in tandem case Drive chain loos...

Page 396: ...e rails to support machine while detaching the rear axle and tandem drive assembly Removal Step 1 Use a suitable jack to raise the rear of the grader slightly in order to remove the weight from the rear wheel assemblies Place supports under the rear chassis rails Do not place the supports under the tandems Step 2 Disconnect Drive shaft as described in the section DRIVE SHAFT page 5 7 NOTE When dis...

Page 397: ...oll the axle and tandem assembly out from under the machine Step 7 Using a chain and hoist place the rear axle and tandem assembly on supports in preparation for further disassembly TANDEM DRIVE ASSEMBLY The tandem drive assemblies can be serviced while mounted on the machine however the following proce dures assume the axle and tandem assembly have been removed and placed in a suitable support Ch...

Page 398: ...ve the drain plug 1 and drain oil from tandem case into a suitable container NOTE Tilt box assembly toward drain hole so oil drains completely Step 2 Remove the eight 8 lug nuts 2 and eight 8 bolts 3 attaching each wheel assembly with tire 4 and remove the two 2 wheel assemblies from the tandem being serviced Step 3 Remove bolts 5 access covers 6 and gaskets 7 at front of tandem case Step 4 Rotate...

Page 399: ...ndem assembly and place on supports for disassembly Installation Step 1 Using a proper hoist align the tandem assembly 4 with the hub of the rear axle 3 Step 2 Coat the threads of the sixteen 16 cap screws 1 used to attach the hub 3 to the tandem assembly 4 with part Loctite 252 Step 3 Attach the hub 3 to the tandem assembly 4 with the sixteen 16 flat washers 2 and the sixteen 16 cap screws 1 Step...

Page 400: ... 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 Step 8 Torque lug nuts 2 to 325 350 Ib ft 440 64 474 54 Nm Step 9 Install the drain plug 1 Step 10 Fill tandem with oil ...

Page 401: ... transmission Removal Step 1 Loosen dust cap 1 by turning counterclockwise Step 2 Remove bolts in universal joint To remove cross and bearing assembly 4 with shaft 5 remove bolts 3 To remove drive shaft 5 and leave cross and bearing assembly 4 attached to rear axle 6 remove bolts 2 Take care not to have endcaps come off of cross and bearing assembly 4 Step 3 Compress drive shaft 5 and remove drive...

Page 402: ...h the cross and bearing assembly 4 attached to the rear axle 6 g Align the mounting holes in the drive shaft 5 with the mounting holes in the cross and bearing assembly 4 attached to the rear axle 6 h Apply Loctite to four cap screws 2 i Attach drive shaft with the four cap screws 2 j Torque screws 3 to 25 32 Ib ft 33 90 43 39 Nm Step 2 Tighten dust cap 1 by turning clockwise REAR AXLE AND TANDEM ...

Page 403: ...hoses 1 to fittings 2 Step 12 Bleed brake system and add additional brake fluid to reservoir as described in the section BRAKES Step 13 Reconnect drive shaft to rear axle as described in the section DRIVE SHAFT BRAKES MAINTENANCE AND ADJUSTMENT General The service brakes are an integral part of the rear axle Two pedals in the cab linked together operate a master cylinder under the cab floor The ma...

Page 404: ...ure is not equal in the brake circuits The parking brake is a cable operated disk type brake located on the rear output shaft of the transmission The disk is splined to the output shaft Brake pads on the brake caliper expand when the ratcheting lever in the cab is pulled preventing rotation of the output shaft and machine The transmission is equipped with a disconnect feature which dumps oil to th...

Page 405: ... or kickback Air in system Bleed brakes Leakage in brake valve Repair valve Brake piston seal leaking Replace seal Brake bleeder not sealing Replace bleeder Leak at line connections or bleed screw Inspect for leaks Brake piston seal rings leaking Apply oil pressure to brake piston and observe loss of pressure Brake pedals feel spongy Air in system Bleed brakes Leak at line connections or bleed scr...

Page 406: ...neffective Block wheels front and back before bleeding or disconnecting any brake system lines and cylinders Wear safety glasses with side shields or goggles when using compressed air for cleaning to reduce the danger of personal injury from flying particles Limit pressure to 207 kPa 30 psi according to local or national requirements IMPORTANT Clean areas around all bleed screw and drain plugs to ...

Page 407: ... level if necessary Parking Brake Cable Adjustment The parking brake lever should move three notches before engaging Adjust the cable if the lever travel is greater than three notches The cable can be adjusted at the lever end or the transmission end Transmission End Adjustment Step 1 Loosen two rear bolts on transmission guard 1 Remove bolts on front of transmission guard and allow guard to hang ...

Page 408: ...ut greater access will be gained if it is removed Step 2 Remove cotter pin 1 and clevis pin 2 Step 3 Loosen jam nut 3 and turn link 4 counterclockwise to loosen cable and clockwise to tighten cable If further adjustment is required loosen jam nuts 5 securing cable to the floor and adjust to provide more or less lever movement Step 4 Tighten jam nuts 3 and 5 Step 5 6 Install plate along LH side of ...

Page 409: ...ed and adjusted as necessary Step 1 Open storage area to the left of the seat Loosen retaining bolts 1 on switch mounting plate 2 Step 2 Pull brake lever 3 up to the third notch Step 3 With the ignition switch in RUN slide parking brake switch mounting plate 2 up or down until parking brake lamp on the front console illuminates Tighten retaining bolts 1 on the switch mounting plate 2 Step 4 Releas...

Page 410: ...brake pedal should move 1 4 1 2 in 6 35 12 7 mm If not adjust the pedal stop screw and linkage The pedal height will also need adjustment Step 1 Remove bottom cover from under grader Step 2 Loosen jam nut 1 on set screw 2 Turn set screw to provide proper clearance between plunger and brake piston Step 3 Tighten jam nut Pivot Gap When the pedal stop is adjusted the pivot weldment gap should be chec...

Page 411: ...yoke pin 2 Step 6 Loosen jam nut 4 and turn clevis 5 to provide 1 16 1 8 in 1 59 3 18 mm clearance between top of lever 6 and bottom of floor Step 7 Tighten jam nut 4 Step 8 Install yoke pin 2 and secure with cotter pin 3 Attach spring 1 and tighten adjustment until spring is strong enough to hold pedal up against stop Step 9 Slide boot down linkage rod Attach boot to floor with two screws Step 10...

Page 412: ...ut slightly Step 4 Loosen jam nut 1 on bottom of yoke 2 Step 5 Remove cotter pin 3 yoke clevis pin 4 and spacers 5 to free yoke 2 from lever weldment 6 Step 6 6 Turn yoke 2 counterclockwise to increase brake pedal height Turn yoke clockwise to decrease brake pedal height Place console assembly in second notch to verify pedal height NOTE NOTE Be sure a minimum of three yoke threads remain on the li...

Page 413: ...ISASSEMBLY AND REPAIR Always park machine on level surface and chock tires to prevent movement when working on brake system Master Cylinder The master cylinder can be removed from the pivot bracket for assembly replacement Remove the pivot bracket after the master cylinder is removed Removal The master cylinder is removed as two parts the valve 1 and the pivot linkage 2 If the valve is leaking it ...

Page 414: ...valent size plug in the hose and tighten the hose clamp Repeat for the other supply line Step 4 Disconnect pressure lines from master cylinder Step 5 Remove socket head bolts 6 and washers 7 securing master cylinder 5 to pivot bracket 4 and remove master cylinder Hold master cylinder as last bolt is removed to prevent from falling NOTE Socket head bolts can be accessed through floor Step 6 6 Pull ...

Page 415: ...r Axle and Tandem 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 Installation Step 1 Install fittings 1 through 4 on master cylinder 5 if assembly has been replaced ...

Page 416: ...aster cylinder 12 to pivot bracket 3 with bolts 8 and washers 9 Be sure plunger is seated properly against piston Secure with socket head bolts 10 and washers 11 Step 6 Attach pressure lines to master cylinder Step 7 Remove plugs bolts from supply hoses and attach to nipple fittings on master cylinder Secure supply hoses with hose clamps Step 8 Fill reservoirs with 10W hydraulic oil Step 9 Bleed b...

Page 417: ... Remove bolts and reaction spring of brake piston Step 7 Use compressed air to push the brake piston out of the center section Limit air pressure to 207 kPa 30 psi Inspection Clean all components thoroughly Check the brake piston and spacer surfaces for scratches gouges or evi dence of seizing Check piston for warping Ensure that the following minimum dimensions are met Installation Install the se...

Page 418: ...replace the friction pads ZF ERGOPOWER 6WG 115 Repair Manual pages 5 2 12 2 and 12 3 Knott TM 64 97 Functional Characteristics and Maintenance Instructions for Mechanical Sliding Caliper Disc Brake M90 REAR AXLE Programmed Maintenance Schedule Every 150 working hours check oil level with axle horizontal Refill if required After first 200 working hours replace oil Every 1500 working hours replace o...

Page 419: ...2013 03 6 26 Section 6 Rear Axle and Tandem 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 Tighten filling and level plug ...

Page 420: ...ts to prevent kinking during assembly such a position would impair proper sealing Assembling Leak Proof Components Use of proper sealing compounds is recommended when assembling matched parts to be sealed against fluid leakage oil or water and no sealing gasket is used Best results are reached with said compounds if matching surfaces are duly cleaned and degreased prior a uniform coat is spread al...

Page 421: ...n 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 Remove ring gear Remove spacer from studs on axle case Step 4 Remove axle shaft and brake disk ...

Page 422: ...ice 2 00_2013 03 Section 6 Rear Axle and Tandem Step 5 Undo screws and remove reaction spring from brake piston Step 6 Use compressed air and draw out brake piston Step 7 Remove screw lock plate and washer retaining side gear carrier to wheel shaft ...

Page 423: ...03 6 30 Section 6 Rear Axle and Tandem 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 Remove bearing Step 10 Remove bearing on axle case side ...

Page 424: ...s 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 Remove pins Step 13 Remove side gears with needle rollers and relevant thrust washers Visually check and measure wear of components Keep matched side gears with relevant pin and the full row of needle rollers ...

Page 425: ... with needle rollers of the same selection class Assembly Step 1 Press fit bearing in side gear case on axle case side Step 2 Press fit lip seal and bearing fill the space between dust shield and sealing diameter with grease fit in shaft Step 3 Insert the rows of needle rollers inside of side gear use grease to keep them in position ...

Page 426: ... securing side gear assemblies into side gear carrier Insert pin lock ring in relevant seat of pins and at the same time widen fit ring and press fit pins up to match relevant seats on side gear carrier Step 6 Insert end play adjustment shim on wheel shaft Mount the complete side gear carrier on wheel shaft Mount thrust washer lock plate and tighten screw Position a dial gauge and check end play o...

Page 427: ...tion 6 Rear Axle and Tandem Center Section Unit Disassembly Step 1 Loosen screws retaining bevel pinion support to center case Remove unit from center case and position on proper stand Step 2 Loosen pinion nut position reaction tool on drive flange for unlocking wrench ...

Page 428: ...00_2013 03 Section 6 Rear Axle and Tandem Step 3 Remove drive flange Step 4 Remove bevel pinion from support Hammer on shank end being careful not to damage threads Step 5 Remove inner race of pinion shank bearing pre load shims spacer and remove lip seal ...

Page 429: ...e 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 Step 8 Remove differential unit from center unit case ...

Page 430: ...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 Step 11 Remove spider unit complete with side gears and relevant bevel thrust washers 05 41 ...

Page 431: ...Axle and Tandem 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 Step 14 Hammer out outer races from both supports ...

Page 432: ...th inner teeth and counter disks of clutch into half cases Insert disk pack being careful to mount a counter disk facing the half case and then proceed to mount alternatively disks and counter disks The disk lined on a single face must be fitted with plain surface facing the sun gear Same assembling procedure should be followed for the second half case Step 3 Check wear and replace axle shaft thru...

Page 433: ...ice 2 00_2013 03 6 40 Section 6 Rear Axle and Tandem Step 4 Mount side gears with relevant bevel thrust washers on spider Step 5 Position spider assembly in half case Step 6 Position the second half case matching reference marks and lock screws ...

Page 434: ...al unit Make sure of proper gear rotation Should clutch pack clearance value differ from specified one the differential unit should be disassembled to change clutch pack composition selecting counter disks with proper thickness Reassemble and check Step 8 Mount bevel ring gear and lock relevant fixing screws with a torque of 89 105 Ib ft 12 0 14 2 daNm Step 9 Check that screws assembling different...

Page 435: ...face of pinion B A B D DIFFERENTIAL SEAT RADIUS Step 11 Measure depth of under pinion bearing seat on pinion support with respect to seating surface of support on center section case C Now we are able to determine the distance from ring gear axis to seating surface of pinion under head bearing on support E E A C Step 12 A number with a sign is printed on the front face of each bevel pinion head Su...

Page 436: ...n head face to outer edge of bearing less thickness of pinion head dimension H Identify thickness of bearing as M Step 15 Compute adjustment shim thickness S for proper axial position of bevel pinion S E F M Reduce by 0 002 in 0 05 mm thickness computed to compensate lengthening of bearings after press fitting Position adjustment shim in relevant seat then press fit on pinion support outer races o...

Page 437: ...hims so as to cause pinion play and not a pre load Then press fit inner race of pinion shank bearing Step 17 Mount drive flange on pinion with washer and nut Step 18 Position reaction tool and lock with a torque of 420 465 Ib ft 57 63 daNm Check pinion end play with a dial gauge then disassemble and change shim to eliminate all play to reach a pre load Remount and check the proper bearing pre load...

Page 438: ...ndem 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 Step 21 Remount differential supports with outer bearing races and adjustment shims lock fixing screws ...

Page 439: ...bling screws with a torque of 55 61 Ib ft 7 5 8 3 daNm Step 24 Fit fixture to differential case to bring to the outside the middle diameter of bevel ring gear Position a dial gauge to record specified backlash on pinion and ring gear 0 008 0 011 in 0 20 0 28 mm ring gear must be moved closer to the pinion if backlash is higher or moved away if it is low This adjustment must not vary value of shims...

Page 440: ...fitting in relevant seat Refit brake piston being careful to align seats with relevant anti rotation pins Step 26 Position piston reaction springs and lock screws with a torque of 126 139 Ib ft 17 1 18 9 daNm Step 27 Refit brake disc and mount axle shafts Right hand shaft length differs from left The longer shaft must be fitted on the side opposite to differential bevel ring gear ...

Page 441: ...ompound 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 Follow same assembling operations to assemble final drive assembly on opposite side ...

Page 442: ...cradle Step 2 Remove drain plug from tandem and drain oil Step 3 Remove cover 11 with gasket 12 by removing screws 10 Step 4 Remove three covers 7 with gaskets 8 by removing screws 9 Step 5 Remove three covers 4 with gaskets 5 by removing screws 6 Step 6 Rotate wheels to align chain master link in slot on tandem Remove link and hardware and remove both outer and inner chains from sprockets ...

Page 443: ...ar Axle and Tandem 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 Step 9 Remove cap screws 2 and washers 3 to free tandem from rear axle Step 10 Remove shim pack 1 ...

Page 444: ...65E Turbo Motor Grader Service Manual 6 51 Service 2 00_2013 03 Section 6 Rear Axle and Tandem Step 11 Remove plug 2 with fitting then remove plugs 1 3 4 and 5 ...

Page 445: ...urteen 14 cap screws 17 and washers 18 Step 13 Remove lockwire 15 from three 3 cap screws 10 Step 14 Remove washer 14 and cap screws 10 Step 15 Remove plate 9 Step 16 Remove shims 11 12 and 13 Step 17 Remove sprocket 19 Step 18 Remove seal 8 from sprocket 19 Step 19 Remove cone 7 and cup 2 Step 20 Remove retainer 4 Step 21 Remove seal 6 Step 22 Remove cup 5 and bearing cone 3 ...

Page 446: ...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 Step 26 Remove thrust washer 3 Step 27 Remove hub 1 and bushing 2 Step 28 Remove bushing 2 from hub 1 Assembly Step 1 Using a lifting device lift rear axle and place in a cradle ...

Page 447: ...bore on axle assembly 1 and O D of bushing 2 Step 4 Using a porta power install bushing 2 in axle assembly 1 Step 5 Repeat for additional three mounting brackets on rear axle Step 6 Remove bolt 1 then remove washer 2 lock plate 3 and sprocket 4 Step 7 Remove rust if any from machine surfaces of axle assembly with wire brush and clean surfaces with 1026 solvent Step 8 Repeat steps 6 and 7 for other...

Page 448: ... 11 Repeat for other side of rear axle Step 12 Place hub 1 into jig and install thrust washer 2 on top of hub Step 13 Place cap 3 and last thrust washer 4 on assembly Step 14 Place the jig top plate on and through the measuring holes provided in place measure depth to hub Average readings and subtract thickness of plate to determine gap Shim total made up of shims 6 7 and 8 must equal this gap plu...

Page 449: ...r Axle and Tandem 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 Step 17 Set shaft 1 in fixture Step 18 Install bolts 2 into shaft 1 using fixture to press bolts in place 10 ...

Page 450: ...EPG NLGI Grade 2 grease Step 23 Pack cone 7 with EPG NLGI Grade 2 grease and install cone 7 with wide side towards splines using a bearing driver and hammer Step 24 Install cup 2 Step 25 Install seal 8 into sprocket 19 with large flange seated on sprocket Step 26 Install sprocket 19 over splines of shaft 1 Sprocket teeth away from splines for high side Sprocket teeth towards splines for low side H...

Page 451: ...ft 130 16 Nm and rotate hub three more times Step 34 Through measuring hole provided in plate 9 measure depth to axle Average readings and subtract thickness of plate to determine gap Select shims from 11 12 and 13 to equal gap plus 0 007 0 001 in 0 18 0 03 mm Step 35 Install selected shims with plate 9 Shims should be free of grease and dirt Step 36 Install three 3 washers 14 and cap screws 10 To...

Page 452: ...urbo Motor Grader Service Manual 6 59 Service 2 00_2013 03 Section 6 Rear Axle and Tandem Step 41 Apply pipe dope to threads of plugs 1 2 3 4 and 5 Install plug 2 with fitting then install plugs 1 3 4 and 5 ...

Page 453: ...nd lift tandem into position at rear axle Step 45 Start cap screws 2 and then torque cap screws to 95 5 Ib ft 128 8 6 7 Nm Step 46 Check tandem oscillation at this time by attaching the oscillation jig 2 part number 73161824 with two bolts part number 70923484 to the tandem 1 Set adjustable torque wrench to 150 Ib ft 203 34 Nm and check to make sure tandem does not oscillate Set adjustable torque ...

Page 454: ...tening link Install link with hardware provided Repeat this process for outside chain Step 50 Apply Loctite to screws 6 Step 51 Install three covers 4 with gaskets 5 and secure with screws 6 Step 52 Apply Loctite to screws 9 Step 53 Install three covers 7 with gaskets 8 and secure with screws 9 Step 54 Apply Loctite to screws 10 Step 55 Apply sealer to bottom half of gasket 12 Step 56 Install cove...

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Page 457: ......

Page 458: ...site supervisor or OSHA for specific requirements 5 To prevent falls use assist rails and steps when getting on and off the machine Keep steps and platform clear of mud oil grease snow tools and debris 6 Do not use controls or hoses as hand holds when climbing on or off machine Controls may move and inadvertently cause machine travel or implement movement 7 Do not permit anyone but the operator to...

Page 459: ... before moving Advise maintenance personnel of malfunctions before operating Be sure malfunctions are remedied before accepting responsibility for operation 22 Avoid accidental contact with the transmission control lever while the engine is running Unexpected movement may result from such contact 23 Do not get off or on the vehicle while it is moving 24 Lower unlocked implements to the ground appl...

Page 460: ...ating beacons and licensing requirements 39 Obey flagmen safety signals and signs 40 Dim vehicle lights when meeting a vehicle at night Make sure lights are adjusted to prevent blinding oncoming drivers 41 Reduce speed before turning or applying brakes 42 Always check overhead clearance especially when transporting Be aware of low overhanging obstacles such as trees and bridges 43 Know the exact l...

Page 461: ...ice procedure Be sure operator can see mechanic 57 Always use external supports when working under any linkage or raised part of the machine Lower implements to ground whenever possible 58 Do not service the grader with the engine running unless the grader is properly and securely supported with all six wheels off the ground 59 Use caution when servicing the unit around moving parts 60 The cooling...

Page 462: ...tion immediately or gangrene may result 71 Fuel oil in the injection system is under high pressure and can penetrate the skin Unqualified persons should not remove or attempt to adjust a pump injector nozzle or any other part of the fuel injector system Failure to follow these instructions can result in serious injury 72 Continuous long term contact with used engine oil may cause skin cancer Avoid...

Page 463: ...ank 88 Do not fill the fuel tank to capacity Allow room for expansion 89 Wipe up spilled fuel immediately 90 Always tighten the fuel tank cap securely 91 If the original fuel tank cap is lost replace it with a genuine replacement cap A non approved cap may not be safe 92 Keep equipment clean and properly maintained 93 Do not drive equipment near open fires 94 Never use fuel for cleaning purposes 9...

Page 464: ...R IN THE PROPER AND SAFE OPERATION OF ALL OPERATIVE EQUIPMENT BOTH EMPLOYER AND EMPLOYEE SHOULD THOROUGHLY FAMILIARIZE THEMSELVES WITH THE MACHINE OPERATION Some pictures in this manual show safety shields removed or open to show parts being serviced or for clarity all shields should be closed or replaced prior to operating the machine Fasten seat belt before starting engine ...

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Page 466: ...ard Lighting 7 17 Horn 7 17 Reverse Alarm 7 17 Special Equipment 7 17 Front and Rear Wiper Motors 7 17 Special Tools 7 18 Troubleshooting 7 19 Preliminary Troubleshooting 7 20 Troubleshooting Chart 7 24 Batteries 7 25 Battery Removal 7 25 Battery Installation 7 26 Component Locations 7 27 Front Console 7 27 Instrument Panel Group 7 29 Right Hand Side of Grader Cummins Tier III Engine 7 31 Left Han...

Page 467: ...ectrical Left Hand Side of Grader CAT Tier III Engine 7 37 Right Hand Side of Grader CAT Tier IVi Engine 7 38 Left Hand Side of Grader CAT Tier IVi Engine 7 39 Bottom of Operator Console 7 40 Bottom of Grader 7 42 Sure Power Industries 12V 24V Voltage Doubler Product Information ...

Page 468: ... disconnects all cir cuits for long storage periods or for electrical system maintenance The electrical system is active when the key is in the ON position and is disabled when the key is in the OFF position to break the electrical continuity Cummins QSB4 5 Tier III Cummins QSB3 3 Tier IVi and CAT C3 4 Tier IVi A key operated master switch in the positive electrical circuit disconnects the main po...

Page 469: ... life and soft ware revision The right side console 1 contains the ignition switch and allows control of lights wipers and heating Operating conditions for the engine and transmission are displayed on the electronic display screen An optional implement control circuit is comprised of the ripper saddle lock pin pull and moldboard pitch systems These functions are controlled from a control panel 2 l...

Page 470: ...65E Turbo Motor Grader Service Manual 7 3 Service 2 00_2013 03 Section 7 Electrical TIER III ELECTRICAL SCHEMATICS ...

Page 471: ...65E Turbo Motor Grader Service Manual Service 2 00_2013 03 7 4 Section 7 Electrical ...

Page 472: ...65E Turbo Motor Grader Service Manual 7 5 Service 2 00_2013 03 Section 7 Electrical ...

Page 473: ...65E Turbo Motor Grader Service Manual Service 2 00_2013 03 7 6 Section 7 Electrical ...

Page 474: ...65E Turbo Motor Grader Service Manual 7 7 Service 2 00_2013 03 Section 7 Electrical ...

Page 475: ...65E Turbo Motor Grader Service Manual Service 2 00_2013 03 7 8 Section 7 Electrical ...

Page 476: ...65E Turbo Motor Grader Service Manual 7 9 Service 2 00_2013 03 Section 7 Electrical TIER IVI ELECTRICAL SCHEMATIC ...

Page 477: ...65E Turbo Motor Grader Service Manual Service 2 00_2013 03 7 10 Section 7 Electrical ...

Page 478: ...65E Turbo Motor Grader Service Manual 7 11 Service 2 00_2013 03 Section 7 Electrical ...

Page 479: ...65E Turbo Motor Grader Service Manual Service 2 00_2013 03 7 12 Section 7 Electrical ...

Page 480: ...65E Turbo Motor Grader Service Manual 7 13 Service 2 00_2013 03 Section 7 Electrical ...

Page 481: ...65E Turbo Motor Grader Service Manual Service 2 00_2013 03 7 14 Section 7 Electrical ...

Page 482: ... TYPE Like a diode except also adds resistance to passing of current and reduces amperes DIRECT CURRENT DC A flow of electrons moving in the same direction along a conductor from a point of high potential to one of lower potential FUSE A device to protect an electrical circuit from overloads that needs to be replaced when blown GROUNDED CIRCUIT Voltage is going directly to ground usually resulting...

Page 483: ...where voltage is to be measured STARTING AND CHARGING The starting and charging components of the cranking circuit include the master switch ignition switch transmission neutral switch batteries start relay starter motor alternator and the optional cold start system with its associated switch and ether injector When the key switch is turned to the start position 12 volts DC power is routed to the ...

Page 484: ...ht 19 1 kg 42 Ib with Electrolyte Terminals Post Type Alternator Tier III Make Model Delco II SI 12 V 95A Type Brush Type with Integral Voltage Regulator Rating 95 Amps Mounting Drive Engine Mounting with Belt Drive Alternator Tier IVi Make Model Delco II SI 12 V 120A Type Brush Type with Integral Voltage Regulator Rating 120 Amps Mounting Drive Engine Mounting with Belt Drive Starting Motor Tier ...

Page 485: ...n Signals Flashers 4 Horn Type EEC Approved 12 Volt Sound Power High Tone 130 Db Reverse Alarm Type Electronic Solid State Sealed Polarity Protected Voltage 10 36 Volts Draw 0 8 Amps 28 VDC Peak Sound Volume Single Level per SAE J994 Type A 112 DB A 28 VDC 180 Degree Dispersion Frequency 1200 Hz Typical 80 Pulses Min Special Equipment Floodlights Front 2 Floodlights Rear 2 Strobe Light 1 Front and...

Page 486: ...00_2013 03 Section 7 Electrical SPECIAL TOOLS 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 Dial Indicator Soldering Iron Belt Tension Gauge ...

Page 487: ... is filled with acid and may cause chemical burns if the battery is cracked or spillage occurs Battery posts terminals and related accessories contain lead and lead compounds wash hands after handling 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 Never use gasoline solvent or other flammable fluids...

Page 488: ...rve correct polarity when installing the battery or when using a booster battery to start the engine Preliminary Troubleshooting Before testing or disassembling components Step 1 If an electrical circuit does not work check to ensure master switch 1 right rear of engine is in ON position NOTICE Turn OFF master switch before replacing fuses Isolate cause of blown fuse before replacing fuse Always r...

Page 489: ...uses are located under instrument panel 1 on right hand side of seat Raise instrument panel for access Step 4 Engine control fuses 2 are located at right hand side of engine near flywheel housing 1 CUMMINS TIER III ENGINE CAT TIER III ENGINE CUMMINS TIER IVi ENGINE CAT TIER IVi ENGINE AND 2 AND ...

Page 490: ... 7 5A 16 WORK LIGHTS 30A 17 TRANS SHIFT LEVER SENSOR 5A 18 TRANSMISSION 7 5A 19 CONVERTER 30A 20 OPEN 21 OPEN 22 WIPERS 15A 23 A C 30A 24 HEATER 30A 25 ENG ECU FUSE 30A 1 2 4 3 11 15 7 25 16 12 8 14 13 10 9 6 5 Tier III Fuse Locations 1 1 SEAT 10A 2 DISPLAY 7 5A 3 BLADE PITCH 30A 4 DEFOG FANS 30A 5 HIGH BEAMS 10A 6 HEAD LIGHT 10A 7 HORN 5A 8 IGN SWITCH 7 5A 9 TAIL LIGHTS 5A 10 LED STROBE 5A 11 PWR...

Page 491: ...hich may cause shorts opens grounds or high resistance in the system Step 7 Ensure that batteries are fully charged Clean connection posts 1 before charging Batteries are accessed by removing the lower rear engine compartment panel 2 NOTE Batteries are maintenance free and do not require electrolyte level checks Turn OFF master switch before working around batteries 1 2 ...

Page 492: ...eces sary Solenoid does not move pinion into engagement with flywheel Open in starter activation circuit Disconnect wire at starter solenoid Check wire terminal for 12 volts with key in START position Check neutral start relay Replace as necessary Defective starter Replace or repair starter Pinion engages flywheel and starter turns but engine does not Defective drive assembly Replace drive assembl...

Page 493: ... is running Step 1 Ensure engine is turned OFF Step 2 Open right side engine compartment access door and place master switch 1 in OFF key position vertical Step 3 Remove six bolts 2 securing lower rear engine compartment panel then remove panel Step 4 Remove four clamp bolts 3 securing upper radiator grill cover then remove cover Turn OFF master switch before working around batteries 1 1 2 3 ...

Page 494: ...batteries 2 Step 6 Disconnect black negative battery cable 3 for battery to be removed Step 7 Disconnect red positive battery cable 4 for battery to be removed Battery Installation Step 1 Ensure battery hold down bracket 1 is clear of battery installation position Step 2 Lift battery 2 and place evenly on mounting pad with positive pole to the left Step 3 Install second battery if required with po...

Page 495: ...ts turn signal switch with in line 20 amp fuse flasher and harness Removable access panels provide for component repair and replacement Component electrical connections are plug in Bezels have retaining tabs The green indicator lights are head light and high beam Front Console Blade Pitch Switch Front Console Hazard Light Switch Indicator Lights Optional Saddle Pin Puller Switch Optional Ripper Sw...

Page 496: ...65E Turbo Motor Grader Service Manual 7 29 Service 2 00_2013 03 Section 7 Electrical Multifunction Switch Turn Signals Taillights Headlights High and Low Beam Selection Horn ...

Page 497: ... Display 8 Right Side Console Lights 2 2 Front Work Lights 9 Front Wiper 3 Rear Work Lights 10 Blower Fan 4 Rotating Beacon Light 11 Ignition Switch 5 Defog Fan 12 Rear Wiper Switch 6 AC Switch 13 Speed Range Selector 7 Dash Light Switch 14 Fuse Box found under control panel 2 3 4 5 6 7 1 8 9 11 10 12 8 13 14 ...

Page 498: ...65E Turbo Motor Grader Service Manual 7 31 Service 2 00_2013 03 Section 7 Electrical Main Power Relay Transmission Control Unit TCU Throttle Position Sensor TPS Back up Alarm Relay 12 24 Volt Converter ...

Page 499: ... Grader Service Manual Service 2 00_2013 03 7 32 Section 7 Electrical Right Hand Side of Grader Cummins Tier III Engine Starter Oil Pressure Sensor Alternator Starter Relay Neutral Start Relay Master Switch A C Relay ...

Page 500: ...bo Motor Grader Service Manual 7 33 Service 2 00_2013 03 Section 7 Electrical Left Hand Side of Grader Cummins Tier III Engine Engine Temperature Sender Engine Electronic Control Module ECM Oil Pressure Switch ...

Page 501: ...ice Manual Service 2 00_2013 03 7 34 Section 7 Electrical Engine Diagnostic Connector Engine Diagnostic Connectors Connected for Flashing Out Engine Codes Located Under Control Panel Terminal Resistor Located Under Control Panel ...

Page 502: ...otor Grader Service Manual 7 35 Service 2 00_2013 03 Section 7 Electrical Right Hand Side of Grader Cummins Tier IVi Engine Air Intake Temperature Sensor Alternator Heated Grid Relay Neutral Start Relay A C Relay ...

Page 503: ...rader Service Manual Service 2 00_2013 03 7 36 Section 7 Electrical Left Hand Side of Grader Cummins Tier IVi Engine ECM Diagnostic Port Starter Engine Electronic Control Module ECM Master Switch Buss Fuse A C Condenser ...

Page 504: ... Turbo Motor Grader Service Manual 7 37 Service 2 00_2013 03 Section 7 Electrical Right Hand Side of Grader CAT Tier III Engine Starter Alternator Master Switch Starter Relay Neutral Start Relay A C Relay ...

Page 505: ...65E Turbo Motor Grader Service Manual Service 2 00_2013 03 7 38 Section 7 Electrical Left Hand Side of Grader CAT Tier III Engine Glow Plug Relay ...

Page 506: ...0_2013 03 Section 7 Electrical Right Hand Side of Grader CAT Tier IVi Engine Starter Relay A C Relay Neutral Start Relay ECM Power Relay ECM Circuit Breaker Glow Plug Circuit Breaker Air Temperature Sensor Crankcase Breather Heater Sensor Lambda O2 Sensor ...

Page 507: ...ice Manual Service 2 00_2013 03 7 40 Section 7 Electrical Left Hand Side of Grader CAT Tier IVi Engine Starter Engine Electronic Control Module ECM Battery Disconnect ECM Diagnostic Port Glow Plug Control Unit GPCU A C Condenser ...

Page 508: ...65E Turbo Motor Grader Service Manual 7 41 Service 2 00_2013 03 Section 7 Electrical Bottom of Operator Console Park Brake Switch ...

Page 509: ...65E Turbo Motor Grader Service Manual Service 2 00_2013 03 7 42 Section 7 Electrical 12 24 VOLT CONVERTER ...

Page 510: ...ice Manual 7 43 Service 2 00_2013 03 Section 7 Electrical Bottom of Grader Brake Lights Pressure Switch Transmission Inching Pressure Switch Accessed through Bottom Cover of Grader Below Operator Platform Below Operator Platform ...

Page 511: ...ed of nor used for any purpose other than that for which it is specifically provided without the written permission of SURE POWER INC A 3315 PRODUCTION RELEASE 1 16 01 BF MODEL NO 41222 12V 24V 10A Voltage Doubler PRODUCT SPECIFICATION SPEC 41222 1 7 SPEC 41222 002 NONE 002 002 3660 UPDATE EMC CHANGES Product Specification 41222 DC DC Converter 12V 24V 10 Amp High Temperature Voltage Doubler ...

Page 512: ...amps the converter operates in a constant power mode in which the output voltage is folded back as the load current increases Protection for short circuits and extreme overloads is provided via an externally connected fuse on the converters input see electrical connection diagram The converter is designed to survive short circuit currents required to open a 30A ATO style fuse Reverse polarity prot...

Page 513: ...TA 40 C to 105 C Storage Temperature Range TST 55 C to 125 C ENVIRONMENTAL SPECIFICATIONS Parameter Test Level Conditions Notes Thermal Shock Humidity 95 RH Dust Bombardment 0 88 g m3 SAE J1455 REV AUG94 Salt Spray 96Hrs SAE J1455 REV AUG94 Reference ASTM B 117 Mechanical Vibration 1 0 060 in double amp Swept Sine F 10 to 55 to 10 Hz 2 0 0635 G2 Hz 5 100Hz 3dB per octave roll off to 500Hz 4 0 G s ...

Page 514: ...input voltage range Enable Low VIL 3 5 V T 25ºC Enable High VIH 5 0 V T 25ºC Overvoltage Shutdown 16 17 5 T 25 C Input Current 24 27 A Iout 10A Quiescent Current 5 6 mA Vin 12 4V and equalizer not enabled Output Voltage Vinput x2 V Line Regulation 3 5 6V Vin 16V Load Regulation 3 5 100mA Iout 10A Dynamic Regulation 20 for 20A peak loads Dynamic Load Current 20 A dt 50ms Current Slope di dt 3 A ms ...

Page 515: ...t Voltage Profile vs Input Voltage Typical Applicable only after equalizer has been enabled Maximum Rated Continuous Output Current vs Ambient Temperature Characteristic 0 2 4 6 8 10 12 40 20 0 20 40 60 80 100 120 Ambient Temperature deg C Output Current Amps 0 5 10 15 20 25 30 35 40 6 8 10 12 14 16 18 20 22 24 26 Input Voltage volts Output Voltage volts ...

Page 516: ...12SA Connections Pin 1 Vin 7 Vout_SW 2 GND 8 Vout 3 GND 9 12V Enable enable 1 4 GND 10 24V Enable enable 2 5 Vout 11 Vin 6 Vout_SW 12 Vin Note Wiring for parallel pins required for proper unit operation 41222 12V 24V Voltage Doubler Vout Gnd Vin en 1 Input Enable 12V on Gnd off Input Batterry _ Load Input Enable 24V on Gnd off en 2 1 11 12 2 3 4 5 8 9 10 Required External 30A Fuse Vout_s w 6 7 ...

Page 517: ...Voltage Doubler PRODUCT SPECIFICATION SPEC 41222 002 7 7 NONE SPEC 41222 002 MECHANICAL SPECIFICATIONS Housing Black anodized aluminum 5ml Weight 10 lbs MECHANICAL OUTLINE 62 88 3 42 1 65 25 8 00 1 56 4 00 4X 28 7 13 8 50 3 16 7 84 ...

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Page 521: ...site supervisor or OSHA for specific requirements 5 To prevent falls use assist rails and steps when getting on and off the machine Keep steps and platform clear of mud oil grease snow tools and debris 6 Do not use controls or hoses as hand holds when climbing on or off machine Controls may move and inadvertently cause machine travel or implement movement 7 Do not permit anyone but the operator to...

Page 522: ... before moving Advise maintenance personnel of malfunctions before operating Be sure malfunctions are remedied before accepting responsibility for operation 22 Avoid accidental contact with the transmission control lever while the engine is running Unexpected movement may result from such contact 23 Do not get off or on the vehicle while it is moving 24 Lower unlocked implements to the ground appl...

Page 523: ...ating beacons and licensing requirements 39 Obey flagmen safety signals and signs 40 Dim vehicle lights when meeting a vehicle at night Make sure lights are adjusted to prevent blinding oncoming drivers 41 Reduce speed before turning or applying brakes 42 Always check overhead clearance especially when transporting Be aware of low overhanging obstacles such as trees and bridges 43 Know the exact l...

Page 524: ...ice procedure Be sure operator can see mechanic 57 Always use external supports when working under any linkage or raised part of the machine Lower implements to ground whenever possible 58 Do not service the grader with the engine running unless the grader is properly and securely supported with all six wheels off the ground 59 Use caution when servicing the unit around moving parts 60 The cooling...

Page 525: ...tion immediately or gangrene may result 71 Fuel oil in the injection system is under high pressure and can penetrate the skin Unqualified persons should not remove or attempt to adjust a pump injector nozzle or any other part of the fuel injector system Failure to follow these instructions can result in serious injury 72 Continuous long term contact with used engine oil may cause skin cancer Avoid...

Page 526: ...ank 88 Do not fill the fuel tank to capacity Allow room for expansion 89 Wipe up spilled fuel immediately 90 Always tighten the fuel tank cap securely 91 If the original fuel tank cap is lost replace it with a genuine replacement cap A non approved cap may not be safe 92 Keep equipment clean and properly maintained 93 Do not drive equipment near open fires 94 Never use fuel for cleaning purposes 9...

Page 527: ...R IN THE PROPER AND SAFE OPERATION OF ALL OPERATIVE EQUIPMENT BOTH EMPLOYER AND EMPLOYEE SHOULD THOROUGHLY FAMILIARIZE THEMSELVES WITH THE MACHINE OPERATION Some pictures in this manual show safety shields removed or open to show parts being serviced or for clarity all shields should be closed or replaced prior to operating the machine Fasten seat belt before starting engine ...

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Page 529: ... 9 Steering Valve Pressure Check 8 11 Fan Motor 8 13 Adjustments 8 14 Control Lever Linkage 8 14 Adjustments 8 15 Disassembly And Repair 8 18 Pump 8 18 Removal 8 19 Installation 8 22 Control Valve 8 25 Valve Removal 8 25 Valve Disassembly 8 28 Valve Assembly 8 29 Valve Installation 8 30 Valve Sections 8 33 Standard Section Disassembly 8 34 Float Section Disassembly 8 35 Inspection 8 36 Standard Se...

Page 530: ...68 Lift Cylinder Removal 8 68 Lift Cylinder Installation 8 69 Circle Shift Cylinder Removal 8 71 Circle Shift Cylinder Installation 8 72 Moldboard Side Shift Cylinder Removal 8 73 Moldboard Side Shift Cylinder Installation 8 73 Moldboard Pitch Cylinder Removal 8 74 Moldboard Pitch Cylinder Installation 8 75 Articulation Cylinder Removal 8 75 Articulation Cylinder Installation 8 77 Wheel Lean Cylin...

Page 531: ...urbo Motor Grader Service Manual 8 xiii Service 2 00_2013 03 Section 8 Hydraulics Hydraulic Strainers 8 94 Eaton Publication 6 623 for L2 Series Gear Pumps Eaton Publication 7 145 for T Series Geroler Motors ...

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Page 533: ... and returns to the reservoir Because of the parallel passage multiple spools can be operated together if sufficient oil is available Ori fices in the port fittings limit oil flow to all but the circle shift and side shift functions to ensure multiple func tion operation An anti cavitation valve is in circuits with vertical movement The inlet section incorporates a pressure relief cartridge set to...

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Page 535: ...65E Turbo Motor Grader Service Manual 8 3 Service 2 00_2013 03 Section 8 Hydraulics TIER 3 HYDRAULIC SCHEMATIC ...

Page 536: ...65E Turbo Motor Grader Service Manual Service 2 00_2013 03 8 3 Section 8 Hydraulics TIER 4I HYDRAULIC SCHEMATIC ...

Page 537: ...ief Valve Cooling Fan 103 bar 1500 psi Relief Valve Location Cooling Fan In Line with Fan Motor Mounting 2 Bolt SAE A Drive Transmission Auxiliary Shaft Connection Splined Shaft Control Valve Manufacturer Model Husco 5000 Type 8 Section Open Center 4 Way 3 Position Parallel Features Single O Ring Between Sections Load Drop Check in Each Section Spring Return to Neutral Anti Void Valve in Lift and ...

Page 538: ...board 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 57 2 2 25 31 8 1 25 Steering 63 5 2 50 198 1 7 80 25 4 1 00 Wheel Lean 76 2 3 00 138 4 5 45 38 1 1 50 Blade Shift 76 2 3 00 939 8 37 00 50 8 2 00 Blade Pitch 63 5 2 50 203 2 8 00 25 4 1 00 Articulation Qty 2 76 2 3 00 276 3 10 88 38 1 1 50 Optional Scarifier or Dozer 76 2 3 00 28...

Page 539: ...ulic control valve circuits to relieve pressure Turn ignition switch to off position Use adequate lifting blocking and or jack stands to make sure that grader is safely supported Gauges gauge fittings and hoses must have operating pressure ratings of at least 25 higher than the highest pressures of the system Never adjust or replace the relief valves to get higher pressures than those specified by...

Page 540: ...ll circuits Pump worn Contact an authorized dealer Faulty system relief valve Contact an authorized dealer Restricted pump suction line Clean suction strainer Hydraulic oil overheats Oil level low or high Adjust oil level Blocked filter element Replace filter element Function does not change when option switch is activated Dirty or defective solenoid Clean or replace solenoid Low hydraulic power I...

Page 541: ... Remove cap from main relief valve test point 1 located on forward LH side of tandem pump at rear of transmission Step 4 Using correct fittings female 73163493 connect a pressure gauge to the test point 1 Step 5 Using all applicable safety practices start the engine Operate a function until system goes into relief mode Record inlet pressure at gauge NOTE If equipped the saddle lock pin is the pref...

Page 542: ...e pressure setting counterclockwise to decrease e Tighten lock nut and recheck pressure at gauge with machine over relief If pressure is incorrect repeat process until pressure setting is correct Step 7 Turn engine off Remove pressure gauge and fittings Recap test point Step 8 Using a lift position cover plate 1 for installation Install seven bolts 2 through cover plate into frame under control va...

Page 543: ... valve is located in the load sense priority steering valve limiting pressure to 107 120 bar 1550 1750 psi The pressure should be tested with the oil above 71 degrees C 160 degrees F Step 1 Park machine and set parking brake Turn off engine Step 2 Open right hand side engine panel access door Step 3 Remove cap from test point 1 on front half of tandem pump at rear of transmission Step 4 Using corr...

Page 544: ...ng valve 1 as follows a Remove hose and fitting 2 from valve b Relief valve adjustment is made through valve hole Using a 7 32 in Allen wrench turn adjustment screw in to increase or out to decrease pressure c Install fitting and hose d Start engine verify pressure e Repeat process until pressure is correct NOTE Load sense priority steering valve port designations are as follows A Pressure B Contr...

Page 545: ...orrect fittings female 73163493 connect a pressure gauge to the test point 1 Step 5 Disconnect T fitting 2 from motor 1 Plug T fitting and cap motor fitting Step 6 Using all applicable safety practices start the engine Record inlet pressure at gauge If pressure is not between 97 103 bar 1400 1500 psi adjust relief valve 3 a Loosen jam nut 4 b Turn adjuster screw 5 clockwise to increase pressure an...

Page 546: ...o the control valve Accessing the control levers for adjustment may require removal of the floor panel and main control valve bot tom cover plate To remove the cab floor panel Step 1 Remove floor mat and seven bolts 1 securing access panel 2 to floor of operator s platform Step 2 Remove access panel To remove the main control valve bottom cover plate Step 1 Place a lift under the control valve cov...

Page 547: ...adjustment is available the horizontal link rod 1 should be adjusted Step 3 The final location for adjustment is at the lower vertical link rod 1 Each link rod has a threaded end with a clevis attached The horizontal and upper vertical link rods have adjust ment at both ends Step 1 Turn jam nut 1 counterclockwise and separate from clevis yoke 2 Step 2 Remove bolt 3 and lock nut 4 from clevis yoke ...

Page 548: ... clockwise to shorten link rod NOTE Maintain a minimum of three threads between the link rods and clevis yokes To move the lever forward a Shorten upper vertical link 1 b Shorten horizontal link 1 c Lengthen lower vertical link 1 Step 4 Attach clevis yoke 2 to bracket 3 with bolt 4 and lock nut Step 5 Tighten jam nut 5 clockwise against clevis yoke ...

Page 549: ...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 To replace cab floor panel Step 7 Using seven bolts 1 install access panel 2 to floor of operator s platform Torque bolts to 47 53 Nm 35 39 Ib ft 1 2 1 2 ...

Page 550: ...rader Service Manual Service 2 00_2013 03 8 18 Section 8 Hydraulics DISASSEMBLY AND REPAIR Pump The pump 2 is attached to the back of the transmis sion 1 A direct drive shaft through the transmission drives the pump 1 2 ...

Page 551: ...and remove cover Step 3 Remove plug in hydraulic reservoir drain 1 and attach hose 2 Using a suitable container open valve 3 and drain hydraulic reservoir When reservoir is drained close valve 3 remove hoses 2 and install plug in reservoir drain 1 Step 4 Disconnect pressure line 1 to priority flow valve at tube 2 inside left frame rail Allow oil in lines to drain into a suitable container When lin...

Page 552: ... oil may drain from the lowest line Rotating the engine by hand for one revolution will remove most of the oil from the pump Step 5 Loosen two upper 1 and two lower 3 hose clamps on hose 2 between reservoir and pump Remove hose Step 6 Disconnect pressure line 1 to priority flow valve at pump Step 7 Disconnect pressure line 2 to fan motor at pump 3 1 2 2 1 ...

Page 553: ... 03 Section 8 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 1 ...

Page 554: ...s loose to allow adjustment after hose connection Step 3 Install connector hose 1 on inlet fitting Tighten two hose clamps 2 Step 4 Install new O ring on pump mounting flange 1 Step 5 Place pump behind transmission Align shaft and insert into transmission drive gear Press into mounting by hand until two bolts 2 can be started Carefully draw pump in evenly using mounting bolts Torque bolts to 47 53...

Page 555: ...ect pressure line 2 from pump to fan motor Tighten and torque jam nut to 125 136 Nm 92 100 Ib ft Torque hose fittings to 88 95 Nm 65 70 Ib ft Step 8 Connect supply hose 1 to pump inlet fitting 2 and reservoir fitting 3 Secure hose with double hose clamps on each end and tighten hose clamps Step 9 Connect fan motor return hose 4 to fan motor outlet fitting Tighten hose clamp 2 1 2 1 3 1 4 ...

Page 556: ...8 Nm 180 220 Ib ft Step 12 Add oil to reservoir until level with center 1 of sight gauge Check for leaks Step 13 Start engine and allow engine to run at idle for three minutes Do not operate any hydraulic functions Check for leaks Step 14 Operate one side of the moldboard raising and then lowering intermittently for three minutes Do not lower against the ground or raise up against stop do not go o...

Page 557: ...s have ports for an anti cavitation car tridge The optional valve uses five of the standard three position sections 1 Three sections 2 are four position valves which incorporate detent caps and an anti cavitation cartridge NOTE The anti cavitation cartridge is not included with the section when purchased as a part replacement The following procedure is basic removal disassembly assembly and instal...

Page 558: ...raulic reservoir When reservoir is drained close valve 3 remove hoses 2 and install plug in reservoir drain 1 Step 4 Disconnect pressure line 1 to load sense priority flow valve at tube 2 inside left frame rail Allow oil in lines to drain into a suitable container When lines are drained reconnect pressure line 1 to priority flow valve 2 NOTE Since the hydraulic reservoir is above the pump up to ga...

Page 559: ... Disconnect inlet line 1 Step 8 Loosen hose clamps securing connector hose to outlet fitting NOTE If valve is equipped with float remove back pressure valve with control valve Step 9 Remove floor mat and seven bolts 1 securing access panel to floor of operator s platform Remove access panel Step 10 Remove nut and bolt 1 from each horizontal linkage 2 and disconnect from pivot bracket 3 Step 11 Rem...

Page 560: ...ts 3 aside Step 14 Remove back pressure valve 4 from outlet port if valve is equipped with float sections Step 15 Remove mounting plate 1 Remove fittings as necessary Valve Disassembly When disassembled if the spool or section housing is damaged replace the entire section as a unit Spools and section housings are assembled as select fit items meaning that they are not interchangeable or replace ab...

Page 561: ...ch tie rod 2 Step 2 Insert each tie rod through the outlet section 3 with the nuts on the outside Place the valve on a bench with the tie rods up Step 3 Place O ring 4 in groove on outlet section Step 4 Slide first section 5 onto tie rods Step 5 Place O ring 1 in groove on section Place check valve 2 and spring 3 in hole Step 6 Repeat steps 4 and 5 until all sections are installed including inlet ...

Page 562: ...ioning of valve Step 3 Place valve assembly on a suitable lift Attach mounting plate to front of fuel tank with four bolts As valve assembly is raised insert back pressure valve outlet 1 in connector hose Secure mounting plate to fuel tank with bolts and washers Leave bolts loose to allow adjustment Step 4 Tighten hose clamps 1 on outlet hose Tighten jam nut 2 on bulkhead fitting between back pres...

Page 563: ...pin Step 8 Connect horizontal links 1 to pivot brackets 2 with bolt 3 and lock nut Torque nuts to 26 28 Nm 19 21 Ib ft Step 9 Adjust linkages so levers are all vertical and control lever lock engages Follow procedures in ADJUSTMENTS CONTROL LEVER LINKAGE Step 10 Add oil to reservoir until level with center 1 of sight gauge Check for leaks Step 11 Start engine and allow engine to run at idle for th...

Page 564: ... installation Install seven bolts 1 through cover plate into frame under control valve Torque bolts to 47 53 Nm 35 39 Ib ft Step 15 Using seven bolts 1 install access panel to floor of operator s platform Torque bolts to 47 53 Nm 35 39 Ib ft Replace floor mat Step 16 Using four bolts 1 install engine access cover Torque bolts to 47 53 Nm 35 39 Ib ft 1 ...

Page 565: ...position When the spool is moved far enough into the end cap the detent balls fall into grooves and overcome the force of centering spring The operator is required to move the control lever to neutral to move the spool out of the detent position The float section also utilizes an anti void cartridge which is threaded into each float section The anti void cartridge bleeds oil into the high pressure...

Page 566: ... of spool 3 Remove lock ring Step 3 Remove screws 4 securing end cap 5 and lock ring 6 to the other end of the section housing Remove cap and lock ring Step 4 Carefully pull spool 1 from the section housing Wiper 2 and seal 3 will stay on spool as it is pulled from housing Step 5 Carefully place clevis end of spool in a vise Remove screw 1 from end of spool Remove spring seats 2 and centering spri...

Page 567: ...using Step 2 Remove socket head screws 2 securing lock ring 3 and spacers 4 5 on clevis end of spool Remove lock ring and spacers Step 3 Remove socket head screws 1 securing cap 2 and lock ring 3 to end of housing Step 4 Carefully pull spool and cap from the section housing as an assembly Wiper and seal will come off spool at clevis end as spool is pulled into housing Discard wiper and seal ...

Page 568: ...ill remain in the cap Remove the detent spring from inside the detent pin Step 6 Insert a small rod socket head wrench 1 through the cross holes in the detent pin 2 turn counterclockwise and remove Press down on the detent spring as the detent pin disengages the threads Step 7 Remove spring seat 3 and centering spring 4 Remove lock ring 5 seal and wiper Discard seal and wiper Inspection Thoroughly...

Page 569: ...allation Step 2 Place clevis end of spool in vise Slide seal 1 and wiper 2 onto spool 3 Wiper should be oriented with flat surface away from housing Step 3 Slide lock ring 1 onto spool against flat surface of wiper Step 4 Place spring seats 2 and centering spring 3 on spool Secure with screw 4 Torque screw to 8 11 Nm 6 8 Ib ft 1 Housing 5 Spring Seat 2 Lock Ring 6 Cap 3 Wiper 7 Spool 4 Seal ...

Page 570: ...e cap 1 over spool and secure to housing with socket head screws 2 Torque socket head screws 2 to 8 11 Nm 6 8 Ib ft Step 7 Slide seal and wiper onto spool at clevis end 3 Install lock ring 4 and secure with screws 5 Torque screws 5 to 8 11 Nm 6 8 Ib ft Float Section Assembly 1 Housing 5 Cap 9 Detent Spring 13 Spring Seat 2 Lock Ring 6 Spacer 10 Ball Small 14 Wiper 3 Spacer 7 Retaining Ring 11 Dete...

Page 571: ...e spring seat 2 spring 3 and washer 4 onto spool Secure with detent pin 5 Torque detent pin to 8 11 Nm 6 8 Ib ft Step 5 Grease the detent spring and large ball and place into detent pin Place the detent sleeve over a long nose punch 1 and grasp punch and sleeve in hand Using the punch press the large ball down into the detent pin 2 and collapse the spring While holding the ball down place the four...

Page 572: ...housing 1 Carefully seat seal and wiper in counterbore in housing Secure cap 2 to housing with socket head screws 3 Torque socket head screws to 8 11 Nm 6 8 Ib ft Step 8 Slide spacer 1 onto spool 2 with O ring against housing 3 Slide O ring and wiper onto spool against spacer Install lock ring 4 and screw spacers 5 and secure with socket head screws 6 to 8 11 Nm 6 8 Ib ft NOTE To reassemble the st...

Page 573: ...s this by blocking the circuit when the pressure in the cylin der side is greater than the pressure on the valve side The anti cavitation cartridge can be removed from the individual sections and cleaned The wiper 1 and seals 2 3 are replaceable When installing cartridge in section housings torque to 40 50 Nm 30 37 Ib ft Pressure Relief Valve Cartridge The pressure relief valve cartridge 1 limits ...

Page 574: ...shers for damage All seats and seating surfaces should be smooth and free of nicks scratches or grooves After inspecting and cleaning immerse all parts in hydraulic oil and assemble If operating difficulties indicate a problem in the pilot pop pet 5 it can be removed and cleaned If the pilot poppet is removed the pressure will require adjustment when reassembled To adjust refer to section on PRESS...

Page 575: ...ol valve are routed through a bulk head left or right and single clamp center to a front tri ple clamp From the clamp the hoses are routed through the front frame until an access hole or selector valve is reached Fittings allow the disconnection and removal of any damaged hose sections with a minimal the front of the frame Hoses connecting to drawbar mounted functions such as the circle turn motor...

Page 576: ...t necessary to disassemble the entire clamp to remove a hose Most hose fittings are O Ring Face Seal ORFS Adapt ers are used to connect to valves All ORFS fittings use a seal installed in the groove on the face of the fitting Triple Clamp Holes Hoses A Open B Steering RT C Lift Cylinder RT Lower D Circle Shift LT E Steering LT F Lift Cylinder LT Lower G Circle Shift RT H Circle Turn CCW I Lift Cyl...

Page 577: ...le pin circle shift selector valve 1 is located inside the front frame module The rear ripper front implement selector valve is located under the right hand operator s area NOTE The rear ripper is a field installed option which requires installation of the selector valve Solenoid cartridges can be removed for cleaning without removing the valve assembly except the saddle pin cir cle selector valve...

Page 578: ...ect 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 Replace at least two bolts and secure with nuts to prevent valve assembly movement during further disassembly Step 3 Pull wire connectors 1 from spade terminals on solenoid s to be tested Step 4 Remove nut 2 on end of solenoid Remove solenoid 3 ...

Page 579: ...st be visible after installation Tighten solenoid nut 1 to a maximum of 6 8 Nm 5 Ib ft NOTE Over tightening of the solenoid nut will bind the armature causing improper operation Step 7 Install wire connectors on spade terminals Ground wire is attached to the inner terminal 2 The power supply is connected to the outer terminal 3 Step 8 Slide cover over valve assembly and drawbar Insert bolts 1 thro...

Page 580: ...wire connectors 1 from terminal spades Step 3 Remove nut 2 on end of solenoid and remove solenoid Step 4 Remove cartridge assembly by turning counterclockwise Step 5 Inspect cartridge for burrs or scratches Inspect seal rings 1 for cuts tears or deformation Check screen 2 for damage or clogging Use compressed air to clean the screen and poppet 3 If necessary replace cartridge NOTE Two different ty...

Page 581: ...all amount of oil is placed on the poppet oil will splash from the end of the cartridge If the cartridge is not working properly replace the cartridge Step 7 Remove the solenoid nut 1 and solenoid Step 8 Install cartridge 1 in port Torque cartridge to a maximum of 27 Nm 20 Ib ft Step 9 Install solenoid 1 on cartridge Tighten nut 2 on end of solenoid to not more than 6 8 Nm 5 Ib ft Do not overtight...

Page 582: ...he same manner Step 1 Remove three bolts 1 and nuts securing cover and valve to drawbar Remove cover Step 2 Replace two bolts 1 and secure with nuts to prevent valve assembly movement Step 3 Mark hoses according to location and disconnect the hoses Collect oil drainage from hoses into a suitable container Step 4 Pull off all wire connectors from spade terminals Step 5 Remove two bolts 1 and nuts h...

Page 583: ...3 Attach wire connectors to appropriate spade terminals Ground attaches to inner terminal 1 Power attaches to outer terminal 2 Step 4 Attach hoses as marked Torque jam nuts 3 on fittings to 25 8 1 3 Nm 19 1 Ib ft Torque hose fittings 4 to 25 8 1 3Nm 19 1 Ib ft Step 5 Remove two bolts 5 nuts and washers Step 6 Slide cover over valve assembly and drawbar Insert bolts 1 through cover drawbar and valv...

Page 584: ...d in the same manner as the other valves NOTE References to left and right are from the operator s seat Step 1 Remove bolts 1 securing access panel on each side of the front frame module Step 2 Remove supply lines 1 from the left side NOTE Collect oil drainage from hoses in a suitable container Step 3 3 Remove pressure lines 2 to the saddle pin cylinder from the top of the valve Step 4 Remove pres...

Page 585: ... from spade terminals Step 8 Remove valve assembly from frame module Place valve assembly in vise to remove fittings solenoids and cartridges as necessary Refer to previous sections concerning solenoid and cartridge testing Circle Shift Saddle Pin Selector Valve Installation Step 1 Attach fittings cartridges and solenoids as described in previous sections Leave 90 bulkhead fittings 1 slightly loos...

Page 586: ...uter terminals 2 Step 4 Maneuver valve rearward in the frame to attach wire connectors to spade terminals on front solenoids Ground wires connect to inner terminals 1 Power wires connect to outer terminals 2 Step 5 Place mounting bolts through frame and valve from right side Place ring terminal for ground on lower bolt 1 before installing washer and nut Leave nuts loose until hoses are installed S...

Page 587: ...4 to 45 53 Nm 35 39 Ib ft Step 10 Install access cover on each side of the front frame module Torque bolts 1 to 45 53 Nm 35 39 Ib ft Hydraulic Swivel A hydraulic swivel is used to allow 360 rotation of the cir cle and prevent twisting of hoses The side shift and hydraulic blade pitch hydraulic circuits pass through the swivel The swivel assembly is mounted in the center of the circle The swivel ca...

Page 588: ...ove top bolts 1 securing swivel assembly to mounting plate 2 Support swivel as last bolt is removed and remove swivel assembly Step 5 Secure swivel assembly in a vise Clamp swivel assembly on case away from rotor to prevent deformation Step 6 Remove all fittings from case and rotor Disassembly Step 1 Remove internal snap ring 1 Step 2 Carefully pry case from rotor Do not damage lands on rotor or i...

Page 589: ...nd flat surfaces Inspect rotor land surfaces and internal case surface for scratches nicks and burrs If damaged replace Assembly Step 1 Carefully install new seals in appropriate rotor grooves After installation inspect to ensure no tears or cuts occurred Ensure that the seals 1 and wipers 2 are in the correct order and not twisted Step 2 Coat rotor seals and wipers with petrol jelly ...

Page 590: ...ainst case NOTE There is insufficient room for the last seal and wiper Lightly tap rotor with soft mallet and wooden block to install over last seal and wiper Step 4 Install internal snap ring 1 in rotor groove Installation Step 1 Apply a bead of pipe sealant around the top surface of the swivel assembly Attach swivel assembly 1 to mounting plate 2 with bolts 3 Orient case so upper port boss 4 is ...

Page 591: ...site guide rods and one mounting hole in rear Torque nuts to 122 136 Nm 90 100 Ib ft Step 4 Install fittings on rotor Torque straight fittings 1 to 25 8 1 3 Nm 19 1 Ib ft Attach hoses 2 to cylinders Torque hoses to 25 8 1 3 Nm 19 1 Ib ft Step 5 Install fittings on case Torque jam nuts 3 on bulkhead fittings to 25 8 1 3 Nm 19 1 Ib ft Step 6 Attach hoses to fittings 1 as marked Torque hose fittings ...

Page 592: ...n 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 Removal Step 1 Disconnect hoses 4 from motor Step 2 Remove elbow fittings 5 from motor Step 3 Remove two bolts and nuts 1 attaching motor 2 to shaft on adapter 3 Step 4 Slide motor 1 straight out from adapter 2 until shaft clears coupler 3 ...

Page 593: ...2013 03 Section 8 Hydraulics Step 5 Remove coupler 1 Step 6 Remove bolts 2 attaching adapter 3 to gear box Remove adapter Step 7 Disassemble motor as needed Refer to Eaton publication 7 145 November 1996 for T Series Geroler Motors at the end of this section ...

Page 594: ...ing bolts and torque to 27 34 Nm 20 25 Ib ft Step 3 Install coupler 1 on shaft Step 4 Insert two bolts through mounting holes on adapter 3 Place gasket over bolts Step 5 Install motor 2 on adapter 3 Ensure that coupler and motor shaft engage properly Install nuts 1 on mounting bolts and torque to 122 136 Nm 90 100 Ib ft Step 6 Install elbow fittings 5 to motor 1 Torque jam nuts to 25 8 1 3 Nm 19 1...

Page 595: ...to Section 19 Moldboard and Imple ments NOTE To aid access side shift the circle to the right side Removal Step 1 Remove hydraulic motor and adapter shaft Refer to previous instructions Step 2 Remove plug 1 drain lubricant from gearbox then reinstall plug Step 3 Cut safety wire 2 from bolts on output shaft Remove bolts 3 washers retainer plate 4 and shims Step 4 Slide pinion gear 5 and washer from...

Page 596: ...ove worm 6 spacers 7 and key 8 Step 4 Remove snap ring 9 from input shaft 4 Remove washers 10 and bushing 11 Step 5 Use a press and remove output shaft 3 from worm gear 12 The key 13 will push the bushing 14 and seal 15 from the case 5 Step 6 Remove caps 16 17 and bushings 18 19 from cover 2 and case 5 as necessary Step 7 Clean and inspect worm 6 and worm gear 12 for damage Inspect shafts 3 4 for ...

Page 597: ... in gear Gear should be against shoulder on output shaft Step 5 Install bushing 13 washers 14 and snap ring 15 on input shaft 5 Step 6 Set case on end Slide input shaft 5 into case 2 far enough to hold first spacer 16 Orient shaft with keyway down Step 7 Place key 17 inside keyway in worm 18 Retain with grease Step 8 While holding worm 1 in position slide input shaft 2 into worm Rotate input shaft...

Page 598: ...o 47 53 Nm 35 39 Ib ft Installation Step 1 Apply anti seize compound to the pilot hole in the drawbar Place gearbox in position on drawbar Be sure dowel pins are in holes in drawbar Step 2 Install mounting bolts 1 and washers through drawbar into gearbox Torque bolts to 203 216 Nm 150 160 Ib ft NOTE It may be necessary to draw the gearbox against the drawbar with the mounting bolts Step 3 Install ...

Page 599: ...ard to provide 1 016 1 524 mm 0 040 0 060 in clearance between teeth 3 Torque mounting bolts to 203 215 Nm 150 160 Ib ft NOTE If the motor is not installed the gearbox will rotate easily by turning the input shaft If the motor is installed use the machine hydraulics to rotate the moldboard Step 6 Remove side fluid level plug 1 Remove top filler vent plug 2 Add 0 57 liter 0 6 quart of SAE 80 90W EP...

Page 600: ... ring to retain the gland The saddle pin cylinder is a special pin cylinder design Lift Cylinder Removal NOTE To aid access to the inner pivot pin position circle so lift cylinder is vertical or tilted slightly out Step 1 Mark and disconnect two lift cylinder hydraulic lines 1 and cap hoses and ports Step 2 Remove bolts 1 washers and retainer link 2 from each upper pivot pin 3 Step 3 Use a slide h...

Page 601: ...ce bushings in upper pivot assembly if necessary Lift Cylinder Installation Step 1 Place cap on cylinder with the number of shims removed at disassembly and tighten bolts Use a telescoping gauge 1 and micrometer to measure the inside dimension of the socket Step 2 Use a micrometer 1 to measure the vertical diameter of ball 2 Step 3 Subtract the inside socket measurement from the vertical diameter ...

Page 602: ...ainer links 4 Install fine thread bolt 5 in pin and coarse thread bolts 6 in yoke Torque bolts to 407 475 Nm 300 350 Ib ft Step 8 Attach hydraulic lines 1 to cylinder Torque fittings to 25 8 1 3 Nm 19 1 Ib ft Step 9 Start the machine and operate lift cylinders to remove any air Lower and apply downward force on the moldboard Step 10 Place a dial indicator at the bottom of the cylinder socket cap S...

Page 603: ...draulic hoses 1 Step 2 Remove bolts 2 and washers retaining lower cylinder socket cap 3 Remove cap and shims 4 Step 3 Using a suitable container to collect fluid remove adapter 5 on barrel end 6 of cylinder Compress cylinder using a prybar until cylinder is free from ball Step 4 With the cylinder adequately supported remove bolts 7 and washers retaining socket cap 8 on barrel end 6 Remove cap and ...

Page 604: ...3 for the other end of the cylinder 2 Step 5 Remove socket caps 1 from cylinder 2 Step 6 Using adequate support for the opposite end of the cylinder 2 place one end of the cylinder on the ball Insert a bolt 4 through the socket cap 1 and shims 3 and attach to the cylinder Step 7 Repeat step 6 for opposite end of cylinder 2 Step 8 Torque all socket cap bolts 4 to 407 475 Nm 300 350 Ib ft Step 9 App...

Page 605: ...t RH pin 11 then remove shift cylinder 6 Moldboard Side Shift Cylinder Installation Step 1 Align RH clevis of moldboard shift cylinder 1 with RH mounting point on mold board support 2 Install pin 3 then install retainer bolt 4 through pin and secure bolt with nut and washer Torque retainer bolt to 14 9 1 3 Nm 11 1 Ib ft Step 2 Using chain and hoist position and support moldboard 5 on lower support...

Page 606: ...Step 1 Fully lower moldboard support 1 to ground Step 2 Disconnect and cap two hydraulic lines 2 from moldboard pitch cylinder 3 Step 3 Remove nut and washers from mold board pitch cylinder front pin retainer bolt 4 then remove bolt from front pin 5 Step 4 Drive out front pin 5 through clevis on moldboard support 1 Step 5 Remove nut and washers from mold board pitch cylinder rear pin retainer bolt...

Page 607: ... clevis 2 and rear mounting pin 4 Install nut and washer on retainer bolt and torque to 14 9 1 3 Nm 11 1 Ib ft Step 4 Install mounting pin 1 through front moldboard support clevis 2 and cylinder clevis pin hole Step 5 Install retainer bolt 3 and washer through front moldboard support clevis 2 and front mounting pin 1 Install nut and washer on retainer bolt and torque to 14 9 7 1 3 Mm 11 1 Ib ft St...

Page 608: ... through pin at each end of cylinder Step 5 Using a drift or punch drive front pin from cylinder clevis To access the rear pin use a large C clamp 1 and socket to press or drive the pin The lower socket will allow the pin to drop below the top clevis Once the top of the pin is in the clevis a punch can be used Step 6 Remove snap rings 1 on each end of cylinder Press spherical bushings 2 from each ...

Page 609: ...evis hole Drive pin through clevis and cylinder Align bolt hole in lower clevis with pin hole Install bolt 2 and secure with nut Torque bolt to 14 9 1 3 Mm 11 1 Ib ft Step 4 Orient pin on rear clevis 3 so hole aligns with clevis hole Pin must be driven from the bottom up to clear the cab Drive pin through clevis and cylinder Align bolt hole in lower clevis with pin hole Install bolt 4 and secure w...

Page 610: ...ove nut 2 bolt and two washers securing wheel lean cylinder 3 and linkage 4 to RH knuckle 5 Step 3 Loosen nut 1 and bolt securing linkage 2 to LH knuckle 3 Step 4 Remove bolt 1 and nut securing pin 2 to cylinder clevis and front axle clevis 3 Step 5 Raise RH end of linkage 4 enough to clear pin 2 Drive out pin from back to front Step 6 Remove wheel lean cylinder ...

Page 611: ...Align pin hole and cylinder clevis hole and install bolt 5 with nut Torque bolt to 14 9 7 1 3 Mm 11 1 Ib ft Step 4 Lower linkage 3 and align RH linkage clevis with RH knuckle clevis 1 Insure that bushings are seated in RH linkage and cylinder clevises Step 5 Install bolt 6 and two washers from front to back through linkage and cylinder clevises Torque bolt to 542 3 677 9 Nm 400 500 Ib ft Step 6 Re...

Page 612: ...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 Step 3 Drive out pin 3 securing cylinder clevis to front axle Step 4 Remove cotter pin 1 securing crown nut 2 to cylinder socket 3 Remove crown nut securing socket to LH spindle 4 then remove steering cylinder ...

Page 613: ...ng cylinder Step 2 Secure cylinder socket 1 to LH spindle with crown nut 3 Torque crown nut to 135 6 Nm 100 Ib ft then continue tightening crown nut to align hole for cotter pin 4 Install cotter pin 4 and bend two ends across socket 1 and crown nut 3 Step 3 Align cylinder clevis 1 with front axle clevis 2 Install pin 3 with slot in pin facing forward to align with lock plate 4 Align lock plate wit...

Page 614: ... 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 Steering cylinder must be 0 305 0 508 cm 0 12 0 20 in from being fully closed Step 2 Turn right wheel until RH spindle stop 1 touches RH axle stop surface 2 Steering cylinder must be 0 305 0 508 cm 0 12 0 20 in from being fully extended ...

Page 615: ...ate socket 5 clockwise until mark on threading aligns with top of rod 7 Secure rod hexagon 7 and torque jam nut 6 to 122 149 Nm 90 110 Ib ft Step 5 To install cylinder socket see previous Steering Cylinder Installation step 2 Step 6 Turn right wheel until RH spindle stop 1 touches RH axle stop surface 2 Steering cylinder must be 0 305 0 508 cm 0 12 0 20 in from being fully extended Step 7 If requi...

Page 616: ... 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 Step 2 Mark disconnect and cap cylinder hoses 1 Step 3 Remove nut from cylinder lower pin 1 retainer bolt 2 then remove bolt and drive out lower pin ...

Page 617: ...is 1 with front end attachment lower clevis 2 Step 3 Install lower pin 3 with two washers and with retainer bolt holes in cylinder clevis 1 and pin aligned Step 4 Install retainer bolt 4 through holes in cylinder clevis 1 and pin 3 Install nut on retainer bolt and torque to 14 9 1 3 Mm 11 1 Ib ft Step 5 Align cylinder upper clevis 1 with front end attachment upper clevis 2 Step 6 Install upper pin...

Page 618: ...r 1 and four washers 8 two per pin Rear Ripper Cylinder Installation Step 1 Inspect bearings 1 one per rear ripper attachment mounting clevis for scoring and excessive wear Replace if required and install in attachment clevis Step 2 Align cylinder lower clevis 2 with rear ripper attachment lower clevis 3 Step 3 Install lower pin 4 with two washers 5 and with retainer bolt holes in cylinder clevis ...

Page 619: ... Cylinder Removal The hydraulically operated saddle lock pin 1 when retracted allows the saddle 2 to rotate pivoting the cir cle and moldboard for grading banks sloping up to 90 degrees Step 1 Engage the saddle lock pin 1 to lock the saddle 2 to the saddle support 3 and retain pin hole alignment for bank slope cylinder removal and installation Step 2 Disconnect and cap hydraulic lines 1 to bank sl...

Page 620: ...tion 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 Torque bolts 5 to 88 Nm 64 Ib ft Step 3 Reconnect hydraulic lines 6 to cylinder 4 Torque fittings to 25 8 1 3 Nm 19 1 Ib ft ...

Page 621: ...d a snap ring to retain the piston Cylinder seal kits provide parts seals o rings etc most likely to need replacement when rebuilding the cylinders Refer to the Parts Catalog for hydraulic cylin der Seal Kit Part Numbers Before disassembly remove cylinders in accordance with previous Cylinder Removal procedures NOTE The cap can be loosened before cylinder is removed Step 1 Turn cap 1 clockwise usi...

Page 622: ...aling components The lift cylinder and circle side shift cylinder o ring 3 is located between the piston 4 and seal 6 All other threaded cap cylinders are as shown Step 3 Cylinders with retaining snap rings 11 steering and moldboard pitch are of similar design with differences in the rod 12 and barrel 1 Parts arrangement for both cylinders is as shown Part of Seal Kit 1 Barrel 7 Gland 2 Nut 8 O Ri...

Page 623: ...d 14 a retaining ring 7 and a cylinder head 12 that serves as a threaded cap and gland Step 5 Following replacement of defective components assemble gland 2 except bank slope cylinder and piston 3 onto rod 1 Part of Seal Kit 1 Tube Assembly 8 Rod Bushing 2 Nut 9 Rod Seal 3 Wear Ring 10 O Ring 4 Outer Ring 11 Backup Ring 5 Inner Ring 12 Cylinder Head 6 Piston 13 Scraper Seal 7 Retaining Ring 14 Rod...

Page 624: ...barrel Step 8 Apply Loctite 242 to threads on cylinder cap cylinder head for bank slope cylinder and install onto barrel To install turn cap counter clockwise Hand tighten with pipe wrench NOTE For the Moldboard pitch cylinder and the Steering cylinder that uses snap ring instead of the threaded cap use a snap ring pliers to install the internal retaining ring Step 9 After assembly install cylinde...

Page 625: ... attaching filter cover 3 to hydraulic reservoir cover Carefully remove filter cover Step 3 Remove filter bypass valve 1 and cup 2 from hydraulic reservoir Inspect parts for damage and wear Replace them if necessary Step 4 Remove element 3 and discard according to federal state and local regulations Step 5 Install new element Install cup and filter bypass valve Step 6 Install filter cover Torque c...

Page 626: ...Carefully remove fill cap cover and O ring from top of reservoir Discard O ring NOTICE Clean hands before and after inserting in hydraulic oil reservoir Step 3 Reach into hydraulic reservoir with clean hand Pull suction strainer 1 and O ring from reservoir Discard O ring Step 4 Clean both strainers using a commercial non flammable non toxic solvent Use compressed air limited to 207 kPa 30 psi to b...

Page 627: ...OUT IN Eaton Gear Pumps No 6 623 Revised March 1993 PartsInformation Model 25500 Gear Pumps L2 Series ...

Page 628: ... in3 r Assembly Screw Screw 21 3 1 30 25500 263 16119 630 16119 626 25 4 1 55 25501 261 16119 630 16119 626 29 2 1 78 25502 261 16119 632 16119 630 33 6 2 05 25503 261 16119 634 16119 630 38 2 2 33 25504 263 16119 634 16119 632 42 8 2 61 25505 265 16119 636 16119 632 46 7 2 85 25506 260 16119 636 16119 634 51 1 3 12 25507 258 16119 640 16119 636 55 2 3 37 25508 268 16119 640 16119 636 2 ...

Page 629: ...Series OUT IN Backplate Drawings PlainBackplate Flow Divider Backplate 31A 31 31B 30 2A 29 TandemBackplate AAFlange 2B 32A4 32A3 32A 2C TandemBackplate AFlange 31B 31 31A 23 27 28 24 25 26 32A4 32A3 32A2 32B1 32B 32A2 32A1 2D 3 ...

Page 630: ...ew 1 26 16024 4 Nut 1 27 16003 4 90 O ring 1 28 16133 6 O ring 1 29 17066 38 Spring 1 30 25530 648 Flow Divider Spool 1 31 16103 312 Plug Assembly 2 31A NSS Plug 2 31B 16133 12 O ring 2 32A Relief Valve Assembly 1 32A1 NSS Relief Valve 1 32A2 16015 17 O ring 1 32A3 16235 111 Backup Ring 1 32A4 16003 11 O ring 1 32B 33100 301 Plug Assembly 1 32B1 NSS Plug 1 Seetable below for specific part number N...

Page 631: ...500 710 Backup Gasket 1 13 Cap Screw 4 14 Cap Screw 4 16 24500 619 Key for Straight Shaft 1 25500 901 Seal Kit for Plain Pump 25530 908 Seal Kit for Flow Divider Pump Seetable below or on page2 for specific part number NSS Not Sold Separately ItemNo 4A ItemNo 4B ItemNo 4C ItemNo 5 Displacement 7 8 in 13 Tooth 7 8 in Keyed 7 8 in 41 Tooth Idler cm3 r in3 r Spline Shaft Shaft Spline Shaft Gear 21 3 ...

Page 632: ...ek of Year 0 thru 52 Tester s Initials 25502 RSA Product Number Sequential Identification Rotation R Right Hand L Left Hand Displacement cm3 r in3 r 0 21 3 1 30 1 25 4 1 55 2 29 2 1 78 3 33 6 2 05 4 38 2 2 33 5 42 8 2 61 6 46 7 2 85 7 51 1 3 12 8 55 2 3 37 BackplateConfiguration 0 Plain 3 Flow Divider 4 Tandem 8 Multiple Pump Product Type 255 L2 Gear Pump 6 ...

Page 633: ...Char Lynn No 7 145 November 1996 Hydraulic Motor Repair Information TSeries General Purpose Geroler Motor 001 ...

Page 634: ...cer Plate Seal Housing ToolsRequired Torquewrench 34 Nm 300 lb in capacity 300 400 mm 12 16 in breaker bar 5 16 in 6 point E10 Drive socket no 64489 000 Heavy Duty 56 Nm 500 lb in capacity Small bladescrewdriver 3 16 in hex key Shaft seal installation tool P N600523 Shaft sleeveor bullet P N600304 for 1 inch dia shaft P N600466 for 7 8 inch dia shaft Tools available through Eaton order entry depar...

Page 635: ...Clamp themotor in aviseso theshaft is vertical and theend cap is on top Clamp on themounting flangeusing just enough clamping forceto hold themotor securely Protect themount ing flangewith soft visejaws 2 Removetheseven cap screws from theend cap and disas semble the motor as shown in Figure 1 Do not disassemble theGeroler 3 Un clamp themotor and removetheoutput shaft thrust needlebearing and thru...

Page 636: ...flangeto themotor housing Seal Removal Tool Figure 4 Exclusion Seal Reassembly Check all mating surfaces Replaceany parts with scratches or burrs that could causeleakage Wash all metal parts in clean solvent Blow them dry with pressurized air Do not wipeparts dry with paper towels or cloth as lint in ahydraulic system will causedamage Check thekey way and chamfered areaof the output shaft removean...

Page 637: ... capscrews If the spacer plate isflippedthe motor will not operate 21 Lightly stretch lubricateand install thesecond of three largediameter seals in thegroovein theGeroler 22 Install theGeroler Important Be sure the exclusionseal andpressure seal are undamagedandproperlyseated 12 Apply threeor four drops of Loctite277 to the threads of thefour holes in themotor housing wherethemounting flange will...

Page 638: ...ce Notch 90 Speed Sensor 9 16 inch Hex Head Fabricated Wrench Jam Nut 11 16 inch Hex Turn Speed Sensor in to bottom making surejam nut is backed off sufficiently back off 1 4 turn CCW and if referencenotch s is not positioned as shown above continue turning CC W to align reference notch 90 off of centerlineof motor or perpendicular to motor shaft Hold speed sensor in this position and tighten jam ...

Page 639: ...1 in Straight 1 2 NPTF 158 1540 1026 1027 1541 1028 1029 1030 1031 1032 2 Bolt w Woodruff Key Manifold 158 1543 1042 1043 1544 1044 1045 1046 1047 1048 Flange 1 in SAE6B 7 8 14 O ring 1 2 NPTF 158 158 1552 1082 1083 1553 1084 1085 1086 1555 1074 1075 1556 1076 1077 1078 1087 1079 1088 1080 Splined 1 in Straight 1 2 NPTF 158 1573 1002 1003 1574 1004 1005 1006 1007 1008 4 Bolt w Woodruff Key Manifol...

Page 640: ...65E Turbo Motor Grader Service Manual Section 8 Hydraulics Service 2 00_2013 03 8 108 This page intentionally left blank ...

Page 641: ...Service Manual Section 9 Moldboard and Implement Service 2 00_2013 03 ...

Page 642: ......

Page 643: ...loyer site supervisor or OSHA for specific requirements 5 To prevent falls use assist rails and steps when getting on and off the machine Keep steps and platform clear of mud oil grease snow tools and debris 6 Do not use controls or hoses as hand holds when climbing on or off machine Controls may move and inadvertently cause machine travel or implement movement 7 Do not permit anyone but the opera...

Page 644: ...ontrols before moving Advise maintenance personnel of malfunctions before operating Be sure malfunctions are remedied before accepting responsibility for operation 22 Avoid accidental contact with the transmission control lever while the engine is running Unexpected movement may result from such contact 23 Do not get off or on the vehicle while it is moving 24 Lower unlocked implements to the grou...

Page 645: ...rs rotating beacons and licensing requirements 39 Obey flagmen safety signals and signs 40 Dim vehicle lights when meeting a vehicle at night Make sure lights are adjusted to prevent blinding oncoming drivers 41 Reduce speed before turning or applying brakes 42 Always check overhead clearance especially when transporting Be aware of low overhanging obstacles such as trees and bridges 43 Know the e...

Page 646: ...e service procedure Be sure operator can see mechanic 57 Always use external supports when working under any linkage or raised part of the machine Lower implements to ground whenever possible 58 Do not service the grader with the engine running unless the grader is properly and securely supported with all six wheels off the ground 59 Use caution when servicing the unit around moving parts 60 The c...

Page 647: ... attention immediately or gangrene may result 71 Fuel oil in the injection system is under high pressure and can penetrate the skin Unqualified persons should not remove or attempt to adjust a pump injector nozzle or any other part of the fuel injector system Failure to follow these instructions can result in serious injury 72 Continuous long term contact with used engine oil may cause skin cancer...

Page 648: ...g the tank 88 Do not fill the fuel tank to capacity Allow room for expansion 89 Wipe up spilled fuel immediately 90 Always tighten the fuel tank cap securely 91 If the original fuel tank cap is lost replace it with a genuine replacement cap A non approved cap may not be safe 92 Keep equipment clean and properly maintained 93 Do not drive equipment near open fires 94 Never use fuel for cleaning pur...

Page 649: ...PERATOR IN THE PROPER AND SAFE OPERATION OF ALL OPERATIVE EQUIPMENT BOTH EMPLOYER AND EMPLOYEE SHOULD THOROUGHLY FAMILIARIZE THEMSELVES WITH THE MACHINE OPERATION Some pictures in this manual show safety shields removed or open to show parts being serviced or for clarity all shields should be closed or replaced prior to operating the machine Fasten seat belt before starting engine ...

Page 650: ...65E Turbo Motor Grader Service Manual Section 9 Moldboard and Implement Service 2 00_2013 03 9 x This page intentionally left blank ...

Page 651: ...Front Dozer Blade 9 4 Rear Ripper 9 4 Troubleshooting 9 4 Troubleshooting Chart 9 5 Disassembly And Repair 9 6 Drawbar 9 6 Removal 9 6 Installation 9 6 Circle 9 7 Removal 9 7 Installation 9 9 Swivel Yoke 9 12 Removal 9 12 Installation 9 12 Moldboard 9 14 Removal 9 14 Installation 9 15 Saddle 9 16 Removal 9 16 Installation 9 17 Front Scarifier 9 20 Removal 9 20 Installation 9 20 Front Dozer Blade 9...

Page 652: ...65E Turbo Motor Grader Service Manual Section 9 Moldboard and Implement Service 2 00_2013 03 9 xii This page intentionally left blank ...

Page 653: ...rame 4 The circle is suspended from the front frame by a saddle 5 and the lift cylinders 6 These components pro vide vertical lift and placement but pulling load is transferred through the drawbar The moldboard attaches to the circle The circle is supported by circle guides attached to the drawbar To provide free rotation of the circle and side shifting of the moldboard clearance must be maintaine...

Page 654: ... Eaton T Series Motor Type Roller Gerolor Motor Displacement 203 cu cm 11 9 cu in per Revolution Gearbox Worm Gear Ratio 18 1 Rated Hydraulic Flow 75 7 LPM 20 0 GPM Moldboard Type Roll Away Involute Curve with Replaceable Cutting Edges and End Bits Actuation Hydraulic Driven Side Shift and Mechanical Pitch Standard Moldboard Dimensions 3 050 mx416mmx 16 mm 10ft x 16 38 in x 0 63 in Optional Moldbo...

Page 655: ...t Outside Rear Wheels Frame Articulated Left 1814 mm 71 4 in Right 1900mm 74 8 in Including Circle Shift Outside Rear Wheels Frame Articulated with Hydraulic Actuated Pin Locks and Mov able Saddle Left 2096 mm 82 5 in Right 2240 mm 88 2 in Scarifier Type Front Mounted V Block Parallelogram Linkage Weight 262 kg 578 Ib Width of Scarification 1048 mm 41 25 in Over Teeth Number of Teeth 9 Tooth Spaci...

Page 656: ...at no one is within the operating range of the machine Sound the horn Lower the attachment slowly DO NOT USE float position to lower hydraulic equipment When working on raised implements make sure lock pin is installed and that implement is resting on lock pin When changing out implements use adequate lifting blocking and or jack stands to securely support the implement Move with extreme care when...

Page 657: ...tered immediately Troubleshooting Chart Problem Possible Cause Correction Moldboard does not hold grade Circle guides out of adjustment Adjust guides Lift cylinder leaks Rebuild or replace cylinder Drawbar pin worn Replace pin Cutting edges worn Reverse or replace edges Moldboard angle changes under load or does not rotate Excessive pinion tooth backlash Adjust circle guides Worn or broken circle ...

Page 658: ... lift cylinder ball joint clamps 1 to separate lift cylinders from drawbar knuckles 2 keep shims with joint Step 5 Loosen bolts on shift cylinder ball joint clamp 3 to separate shift cylinder from drawbar knuckle 4 keep shims with joint Drawbar with circle and moldboard is now separated from frame Installation Step 1 Apply Loctite 242 to two bolts install through shift cylinder ball joint clamp 3 ...

Page 659: ...39 Ib ft Circle The circle 1 attaches to the drawbar 2 with four draw bar mounted guide clamps each with two horizontal set screws and two vertical lock screws Vertical clearance 3 between circle and drawbar is maintained by shims 4 secured to the drawbar at each guide with the two vertical lock screws providing for controlled fric tion and leveling points between drawbar and circle as circle rota...

Page 660: ...amps 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 Step 5 Unscrew two bolts and washers securing two hose clamps 1 to rotator plate 2 Move hoses back and away from rotator plate 2 Step 6 Move drawbar 3 slightly forward to separate guide bars 4 from circle 5 Step 7 Raise drawbar 3 to separate from circ...

Page 661: ... 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 Step 3 Slowly lower drawbar 1 Step 4 Move drawbar slowly backward while ensuring circle teeth 1 align with gear teeth 2 on rotation gearbox ...

Page 662: ...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 Torque bolts to 47 53 Nm 35 39 Ib ft Step 7 Clean wear surfaces of circle Using vertical lock screws 1 and horizontal set screws 2 loosely mount four guide clamps in their mounting positions Leave horizontal clearance 3 between inner circle guide and curved circle guide wear plates ...

Page 663: ...circle tooth measure clearance between two teeth on opposite side using feeler gauge Clearance should be between 0 76 1 52mm 0 03 0 06 in If clearance is incorrect turn horizontal adjusting screws 3 of front guide to provide 0 76 mm 0 03 in clearance Step 12 Secure horizontal screws 3 on front guide while torquing lock nuts to 271 305 Nm 200 225 ft lb Step 13 Adjust horizontal screws 2 at rear and...

Page 664: ...ly and Repair Cylinders Step 1 Place pipe 1 through yoke 2 to prevent movement Step 2 Remove bolts 1 washers and retainer plate 2 from swivel yoke Step 3 Remove shims 1 and thrust washer 2 from retainer side Step 4 Pull swivel yoke from support 3 Remove spacer and thrust washer from yoke side Step 5 Remove split bearings 1 from inside housing Installation Step 1 Clean bore and install bearings 1 u...

Page 665: ...y seated in support Step 5 Use a depth gauge to measure the distance from the end of the shaft to the top of the thrust bearing Step 6 Install sufficient shims 1 on the end of the shaft to allow 0 025 to 0 076 mm 0 001 to 0 003 in clearance between end of shaft and retainer plate 2 Step 7 Place retainer plate 1 over shims Apply Loctite 242 to bolt threads and secure retainer plate with bolts 2 and...

Page 666: ...oosen 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 Mark disconnect and cap lines Step 3 Remove moldboard shift cylinder LH pin retainer bolt 1 drive out pin 2 through cutout in moldboard and remove mold board 3 RH pin attaches to circle and need not be removed ...

Page 667: ...ift cylinder pin 1 through cutout in moldboard Install pin retainer bolt 2 and torque to 14 9 1 3 Nm 11 1 Ib ft Step 3 Tilt and support moldboard 1 forward enough on lower support guides 2 to access two hydraulic lines and connect lines Torque fittings to 25 8 1 3 Nm 19 1 Ib ft Step 4 Apply Loctite 242 to four bolts 3 and loosely install on two upper moldboard guides 4 Adjust upper guide shims to ...

Page 668: ...ulics 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 Step 3 Support cylinder and remove two bolts 3 securing cylinder clamp 4 to saddle knuckle 5 Rest shift cylinder on circle 6 Step 4 Mark disconnect and cap hydraulic lines 1 from both lift cylinder 2 ...

Page 669: ...t remove saddle with lift cylinders from frame 4 Installation Step 1 Support saddle 2 with chain and hoist and lower saddle with lift cylinders onto saddle mounts 3 with mounting holes aligned Step 2 Install eight saddle mounting screws 1 Torque to 1 085 136 Nm 800 100lb ft Step 3 Check shim adjustment for lift cylinder clamp mounts before attachment Place cap 1 on mount with number of shims 2 rem...

Page 670: ...een 0 00 0 13mm 0 000 0 005 in Step 6 Remove cap from cylinder Step 7 Clean ball and socket surfaces Using correct number of shims and two bolts 1 and washers attach each lift cylinder clamp mount 2 to drawbar knuckle ball 3 Torque bolts to 407 475 Nm 300 350 Ib ft Step 8 Connect hydraulic lines 1 to each lift cylinder 2 two per cylinder Torque fittings to 25 8 1 3 Nm 19 1 Ib ft Step 9 Start the m...

Page 671: ... on barrel end 2 of circle shift cylinder Using a telescoping gauge and micrometer measure inside socket dimension that is in line with cylinder Step 14 Using a micrometer measure diameter of saddle frame ball in approximate direction of circle side shift operation Step 15 Subtract inside socket measurement step 13 from saddle frame ball measurement step 14 This is the amount of shims 3 required S...

Page 672: ...ter pins 3 from four scarifier mounting bolts 4 then remove four nuts mounting bolts 4 and eight plain washers Step 4 Remove red safety support bolt 2 then remove scarifier 1 Installation Step 1 Support scarifier 1 in position with chain and hoist align lock pin holes and install red safety support bolt 2 Step 2 Align four mounting holes on lift linkage and install four mounting bolts 3 and eight ...

Page 673: ...olt 1 through lock pin holes Step 2 Support front dozer blade 1 with chain and hoist Step 3 Remove four cotter pins 2 from four front dozer blade mounting bolts 3 then remove four nuts 4 four mounting bolts 3 12 plain washers 5 and eight shims 6 Step 4 Remove red safety support bolt then remove front dozer blade 1 Installation Step 1 Support front dozer blade in position with chain and hoist align...

Page 674: ...mounting bolts 2 twelve plain washers 3 and eight shims 4 Step 3 Install four nuts 5 torque to 1 085 136 Nm 800 100 ft lb then apply four cotter pins 6 through six mounting bolts 2 Rear Ripper Removal Step 1 Support rear ripper 1 with chain and hoist Step 2 Remove two retaining bolts 1 and nuts 2 from two pins 3 securing two cylinder clevises to rear ripper 4 then remove two pins 3 and four shims ...

Page 675: ... assemblies then remove four pins 3 and eight shims 7 Installation Step 1 Support rear ripper 1 in mounting position with chain and hoist align rear ripper and upper 2 and lower 3 arm weld assembly pin mounting holes and install four pins 4 with eight shims 5 Step 2 Install four retaining bolts 6 through four through four pins 4 Step 3 Install four nuts 7 on four bolts 6 Torque four bolts 6 to 14 ...

Page 676: ...Moldboard and Implement 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 Step 5 Secure clevises 1 to pins 3 with one bolt 5 and nut 6 each Torque bolts 5 to 14 9 1 3 Nm 11 1 ft lb ...

Page 677: ...Service Manual Section 10 Diagnostic Fault Codes Service 2 00_2013 03 ...

Page 678: ......

Page 679: ...oyer site supervisor or OSHA for specific requirements 5 To prevent falls use assist rails and steps when getting on and off the machine Keep steps and platform clear of mud oil grease snow tools and debris 6 Do not use controls or hoses as hand holds when climbing on or off machine Controls may move and inadvertently cause machine travel or implement movement 7 Do not permit anyone but the operat...

Page 680: ...ntrols before moving Advise maintenance personnel of malfunctions before operating Be sure malfunctions are remedied before accepting responsibility for operation 22 Avoid accidental contact with the transmission control lever while the engine is running Unexpected movement may result from such contact 23 Do not get off or on the vehicle while it is moving 24 Lower unlocked implements to the groun...

Page 681: ...s rotating beacons and licensing requirements 39 Obey flagmen safety signals and signs 40 Dim vehicle lights when meeting a vehicle at night Make sure lights are adjusted to prevent blinding oncoming drivers 41 Reduce speed before turning or applying brakes 42 Always check overhead clearance especially when transporting Be aware of low overhanging obstacles such as trees and bridges 43 Know the ex...

Page 682: ... service procedure Be sure operator can see mechanic 57 Always use external supports when working under any linkage or raised part of the machine Lower implements to ground whenever possible 58 Do not service the grader with the engine running unless the grader is properly and securely supported with all six wheels off the ground 59 Use caution when servicing the unit around moving parts 60 The co...

Page 683: ... attention immediately or gangrene may result 71 Fuel oil in the injection system is under high pressure and can penetrate the skin Unqualified persons should not remove or attempt to adjust a pump injector nozzle or any other part of the fuel injector system Failure to follow these instructions can result in serious injury 72 Continuous long term contact with used engine oil may cause skin cancer...

Page 684: ... the tank 88 Do not fill the fuel tank to capacity Allow room for expansion 89 Wipe up spilled fuel immediately 90 Always tighten the fuel tank cap securely 91 If the original fuel tank cap is lost replace it with a genuine replacement cap A non approved cap may not be safe 92 Keep equipment clean and properly maintained 93 Do not drive equipment near open fires 94 Never use fuel for cleaning purp...

Page 685: ...ERATOR IN THE PROPER AND SAFE OPERATION OF ALL OPERATIVE EQUIPMENT BOTH EMPLOYER AND EMPLOYEE SHOULD THOROUGHLY FAMILIARIZE THEMSELVES WITH THE MACHINE OPERATION Some pictures in this manual show safety shields removed or open to show parts being serviced or for clarity all shields should be closed or replaced prior to operating the machine Fasten seat belt before starting engine ...

Page 686: ...65E Turbo Motor Grader Service Manual Section 10 Electronic Display Service 2 00_2013 03 10 x This page intentionally left blank ...

Page 687: ... Service 2 00_2013 03 Section 10 Diagnostic Fault Codes CONTENTS DIAGNOSTIC FAULT CODES 10 1 Cummins Tier III and Tier IVi Fault Codes 10 2 CAT Tier III Fault Codes 10 72 CAT Tier IVi Fault Codes 10 75 ZF ERGO Control EST37 Fault Codes 10 83 ...

Page 688: ...65E Turbo Motor Grader Service Manual Section 10 Electronic Display Service 2 00_2013 03 10 xii This page intentionally left blank ...

Page 689: ...he NORAM 65ET Grader is equipped with one of four engine options The following tables list all the fault codes for the NORAM 65ET Grader engine options and transmission Fault codes are listed according to type of engine followed by transmission fault codes When searching for an active fault first search by engine then by transmission ...

Page 690: ...low Normal or Shorted to Low Source 46 2 Vehicle Wet Tank Supply Pressure Data Erratic Intermittent or Incorrect 46 5 Vehicle Wet Tank Supply Pressure Circuit Current Below Normal or Open Circuit 46 17 Vehicle Wet Tank Supply Pressure Data Valid but Below Normal Operational Range Least Severe Level 46 18 Vehicle Wet Tank Supply Pressure Data Valid but Below Normal Operational Range Moderately Seve...

Page 691: ...sition Sensor 1 Circuit Voltage Above Normal or Shorted to High Source 91 4 Accelerator Pedal or Lever Position Sensor 1 Circuit Voltage Below Normal or Shorted to Low Source 91 1 Accelerator Pedal or Lever Position 1 Sensor Circuit Frequency Data Valid but Below Normal Operational Range Most Severe Level 91 0 Accelerator Pedal or Lever Position Sensor 1 Data Valid but Above Normal Operational Ran...

Page 692: ...evel 94 13 Fuel Pump Delivery Pressure Out of Calibration 94 15 Fuel Pump Delivery Pressure Data Valid but Above Normal Operational Range Least Severe Level 94 17 Fuel Pump Delivery Pressure Data Valid but Below Normal Operational Range Least Severe Level 94 14 High Fuel Rail Pressure Detected After Shutdown Special Instructions 95 15 Fuel Filter Differential Pressure Data Valid but Above Normal O...

Page 693: ... Oil Level Data Valid but Below Normal Operational Range Moderately Severe Level 99 16 Oil Filter Restriction High Data Valid but Above Normal Operational Range Moderately Severe Level 99 1 Engine Oil Filter Differential Pressure Data Valid but Below Normal Operational Range Most Severe Level 99 16 Engine Oil Filter Differential Pressure Data Valid but Above Normal Operational Range Moderately Sev...

Page 694: ... Manifold 1 Pressure Sensor Circuit Voltage Below Normal or Shorted to Low Source 102 31 Intake Manifold Absolute Pressure Sensor disagrees with the Compressor Outlet Pressure Sensor Condition Exists 102 2 Intake Manifold 1 Pressure Data Erratic Intermittent or Incorrect 103 3 Turbocharger Speed Sensor Circuit Voltage Above Normal or Shorted to High Source 103 4 Turbocharger Speed Sensor Circuit V...

Page 695: ...uit Voltage Above Normal or Shorted to High Source 108 4 Barometric Pressure Sensor Circuit Voltage Below Normal or Shorted to Low Source 108 2 Barometric Pressure Data Erratic Intermittent or Incorrect 108 18 Barometric Air Pressure Data Valid but Below Normal Operational Range Moderately Severe Level 108 1 Barometric Air Pressure Data Valid but Below Normal Operational Range Most Severe Level 10...

Page 696: ...ant Level Data Valid but Below Normal Operational Range Least Severe Level 113 2 Auxiliary Alternate Droop Switch Validation Data Erratic Intermittent or Incorrect 115 2 Alternator Current Data Erratic Intermittent or Incorrect 127 4 Transmission Oil Pressure Circuit Voltage Below Normal or Shorted to Low Source 127 3 Transmission Oil Pressure Circuit Voltage Above Normal or Shorted to High Source...

Page 697: ... Above Normal Operational Range Moderately Severe Level 157 2 Injector Metering Rail 1 Pressure Data Erratic Intermittent or Incorrect 157 18 Injector Metering Rail 1 Pressure Data Valid but Below Normal Operational Range Moderately Severe Level 157 7 Injector Metering Rail 1 Pressure Mechanical System Not Responding Properly or Out of Adjustment 157 31 Fuel Rail Diagnostic has detected an error C...

Page 698: ...id but Below Normal Operational Range Moderately Severe Level 168 16 Battery 1 Voltage Data Valid but Above Normal Operational Range Moderately Severe Level 168 17 Battery 1 Voltage Data Valid but Below Normal Operational Range Least Severe Level 168 1 Battery 1 Voltage Data Valid but Below Normal Operational Range Most Severe Level 168 17 Battery 1 Voltage Data Valid But Below Normal Operating Ra...

Page 699: ...Range Most Severe Level 174 2 Engine Fuel Temperature Data Erratic Intermittent or Incorrect 175 3 Engine Oil Temperature Sensor 1 Circuit Voltage Above Normal or Shorted to High Source 175 4 Engine Oil Temperature Sensor 1 Circuit Voltage Below Normal or Shorted to Low Source 175 0 Engine Oil Temperature Data Valid but Above Normal Operational Range Most Severe Level 175 1 Engine Oil Temperature ...

Page 700: ...n Engine is Supposed to be Running Root Cause Not Known 190 16 Engine Crankshaft Speed Position Data Valid but Above Normal Operational Range Moderately Severe Level 190 10 Engine Speed Crank sync Abnormal Rate of Change 190 2 Engine Crankshaft Speed Position Data Erratic Intermittent or Incorrect 190 16 Engine Crankshaft Speed Position Data Valid but Above Normal Operational Range Moderately Seve...

Page 701: ...pecial Instructions 441 3 Auxiliary Temperature Sensor Input 1 Circuit Voltage Above Normal or Shorted to High Source 441 4 Auxiliary Temperature Sensor Input 1 Circuit Voltage Below Normal or Shorted to Low Source 441 3 Auxiliary Temperature Sensor Input 1 Circuit Voltage Above Normal or Shorted to High Source 441 14 Auxiliary Temperature Sensor Input 1 Special Instructions 441 4 Auxiliary Temper...

Page 702: ...ilter Bypass Valve Mechanical System Not Responding Properly or Out of Adjustment 611 31 GSP Communication Failure Condition Exists 611 31 RPC number not Supported Condition Exists 611 31 RPC Argument Mismatch Condition Exists 611 2 Auxiliary Intermediate PTO Speed Switch Validation Data Erratic Intermittent or Incorrect 611 7 Top 2 Auxiliary System Diagnostic Autoshift Mechanical System Not Respo...

Page 703: ...as not been installed correctly Condition Exists 611 31 LonWorks Board Slot 4 is missing and or has not been installed correctly Condition Exists 611 31 Slot 5 Board is missing and or has not been installed correctly Condition Exists 611 31 Slot 6 Board is missing and or has not been installed correctly Condition Exists 611 31 Slot 7 Board is missing and or has not been installed correctly Conditi...

Page 704: ...611 31 Load Dump Output Relay Driver Diagnostic has detected an error Condition Exists 611 31 Operator Interface Panel Power Relay Driver Diagnostic has detected an error Condition Exists 611 31 Modem Power Relay Driver Diagnostic has detected an error Condition Exists 611 31 Run B Output Relay Driver Diagnostic has detected an error Condition Exists 611 31 Manual Run Stop LED Driver Diagnostic ha...

Page 705: ...ply Voltage Above Normal or Shorted to High Source 622 3 SAEJ1922 Datalink Voltage Above Normal or Shorted to High Source 622 9 SAEJ1922 Datalink Abnormal Update Rate 623 4 Red Stop Lamp Driver Circuit Voltage Below Normal or Shorted to Low Source 623 3 Red Stop Lamp Driver Circuit Voltage Above Normal or Shorted to High Source 624 3 Amber Warning Lamp Driver Circuit Voltage Above Normal or Shorte...

Page 706: ...ts 629 31 At Least One Unacknowledged Moderately Severe Fault Condition Exists 630 13 Electronic Calibration Code Incompatibility Out of Calibration 630 12 Engine Control Module Calibration Memory Software Bad Intelligent Device or Component 630 31 Engine Control Module Calibration Program Memory RAM Corruption Condition Exists 630 13 Electronic Calibration Memory Code Out of Calibration 632 4 Eng...

Page 707: ...justment 635 3 Engine Timing Actuator Driver Circuit Voltage Above Normal or Shorted to High Source 635 4 Engine Timing Actuator Driver Circuit Voltage Below Normal or Shorted to Low Source 635 5 Engine Timing Actuator Driver Circuit Current Below Normal or Open Circuit 635 6 Engine Timing Actuator Driver Circuit Current Above Normal or Grounded Circuit 635 2 Engine Timing Actuator Driver Data Err...

Page 708: ...f Adjustment 641 13 VGT Actuator Controller Out of Calibration 641 12 VGT Actuator Controller Bad Intelligent Device or Component 641 31 VGT Actuator Driver Circuit Condition Exists 641 9 VGT Actuator Driver Circuit Abnormal Update Rate 641 15 VGT Actuator Driver Over Temperature Calculated Data Valid but Above Normal Operational Range Least Severe Level 644 2 External Speed Command Input Multiple...

Page 709: ...ion 654 6 Injector Solenoid Driver Cylinder 4 Circuit Current Above Normal or Grounded Circuit 654 5 Injector Solenoid Driver Cylinder 4 Circuit Current Below Normal or Open Circuit 654 7 Injector Solenoid Driver Cylinder 4 Mechanical System Not Responding Properly or Out of Adjustment 654 2 Injector Solenoid Driver Cylinder 4 Data Erratic Intermittent or Incorrect 654 13 Injector Solenoid Driver ...

Page 710: ...ove Normal or Grounded Circuit 664 5 Injector Solenoid Driver Cylinder 14 Circuit Current Below Normal or Open Circuit 664 6 Injector Solenoid Driver Cylinder 14 Circuit Current Above Normal or Grounded Circuit 665 5 Injector Solenoid Driver Cylinder 15 Circuit Current Below Normal or Open Circuit 665 6 Injector Solenoid Driver Cylinder 15 Circuit Current Above Normal or Grounded Circuit 666 5 Inj...

Page 711: ...igh Gear Actuator Driver Circuit Voltage Below Normal or Shorted to Low Source 717 11 Autoshift High Gear Actuator Driver Root Cause Not Known 718 3 Autoshift Low Gear Actuator Driver Circuit Voltage Above Normal or Shorted to High Source 718 4 Autoshift Low Gear Actuator Driver Circuit Voltage Below Normal or Shorted to Low Source 718 11 Autoshift Low Gear Actuator Driver Root Cause Not Known 719...

Page 712: ...rmal or Shorted to Low Source 730 3 Intake Air Heater 2 Circuit Voltage Above Normal or Shorted to High Source 734 3 Transmission Overdrive Solenoid Driver Circuit Voltage Above Normal or Shorted to High Source 734 4 Transmission Overdrive Solenoid Driver Circuit Voltage Below Normal or Shorted to Low Source 777 2 Transmission Torque Converter Clutch Solenoid Driver Data Erratic Intermittent or In...

Page 713: ...mal or Shorted to High Source 1075 3 Electric Lift Pump for Engine Fuel Supply Circuit Voltage Above Normal or Shorted to High Source 1075 4 Electric Lift Pump for Engine Fuel Supply Circuit Voltage Below Normal or Shorted to Low Source 1076 3 Fuel Injection Pump Fuel Control Solenoid Driver Circuit Voltage Above Normal or Shorted to High Source 1076 4 Fuel Injection Pump Fuel Control Solenoid Dri...

Page 714: ...rmal Operational Range Most Severe Level 1124 16 Generator Alternator Winding Temperature Data Valid but Above Normal Operational Range Moderately Severe Level 1124 0 Generator Alternator Winding 1 Temperature Data Valid but Above Normal Operational Range Most Severe Level 1125 16 Generator Alternator Winding 2 Temperature Data Valid but Above Normal Operational Range Moderately Severe Level 1125 ...

Page 715: ... Data Valid but Below Normal Operational Range Least Severe Level 1129 3 Intake Manifold 3 Pressure Sensor Circuit Voltage Above Normal or Shorted to High Source 1129 4 Intake Manifold 3 Pressure Sensor Circuit Voltage Below Normal or Shorted to Low Source 1131 3 Intake Manifold 2 Temperature Sensor Circuit Voltage Above Normal or Shorted to High Source 1131 4 Intake Manifold 2 Temperature Sensor ...

Page 716: ...4 Temperature Abnormal Rate of Change 1133 15 Intake Manifold 4 Temperature Data Valid but Above Normal Operational Range Least Severe Level 1136 3 ECM Internal Temperature Sensor Circuit Voltage Above Normal or Shorted to High Source 1136 4 ECM Internal Temperature Sensor Circuit Voltage Below Normal or Shorted to Low Source 1136 2 ECM Internal Temperature Data Erratic Intermittent or Incorrect 1...

Page 717: ...rature Cylinder 3 Data Valid but Above Normal Operational Range Moderately Severe Level 1139 18 Exhaust Gas Temperature Cylinder 3 Data Valid but Below Normal Operational Range Moderately Severe Level 1139 31 Exhaust Gas Temperature Cylinder 3 Data Valid but Above or Below Normal Condition Exists 1140 0 Exhaust Gas Temperature Cylinder 4 Data Valid but Above Normal Operational Range Most Severe Le...

Page 718: ...emperature Cylinder 7 Data Valid but Above Normal Operational Range Most Severe Level 1143 4 Exhaust Gas Temperature Sensor Circuit Cylinder 7 Voltage Below Normal or Shorted to Low Source 1143 3 Exhaust Gas Temperature Sensor Circuit Cylinder 7 Voltage Above Normal or Shorted to High Source 1143 16 Exhaust Gas Temperature Cylinder 7 Data Valid but Above Normal Operational Range Moderately Severe ...

Page 719: ...re Cylinder 10 Data Valid but Above Normal Operational Range Moderately Severe Level 1146 18 Exhaust Gas Temperature Cylinder 10 Data Valid but Below Normal Operational Range Moderately Severe Level 1146 31 Exhaust Gas Temperature Cylinder 10 Data Valid but Above or Below Normal Condition Exists 1147 0 Exhaust Gas Temperature Cylinder 11 Data Valid but Above Normal Operational Range Most Severe Le...

Page 720: ...mperature Cylinder 14 Data Valid but Above Normal Operational Range Most Severe Level 1150 4 Exhaust Gas Temperature Sensor Circuit Cylinder 14 Voltage Below Normal or Shorted to Low Source 1150 3 Exhaust Gas Temperature Sensor Circuit Cylinder 14 Voltage Above Normal or Shorted to High Source 1150 16 Exhaust Gas Temperature Cylinder 14 Data Valid but Above Normal Operational Range Moderately Seve...

Page 721: ...as Temperature Sensor Circuit Cylinder 17 Voltage Below Normal or Shorted to Low Source 1153 18 Exhaust Gas Temperature Cylinder 17 Data Valid but Below Normal Operational Range Moderately Severe Level 1153 31 Exhaust Gas Temperature Cylinder 17 Data Valid but Above or Below Normal Condition Exists 1154 3 Exhaust Gas Temperature Sensor Circuit Cylinder 18 Voltage Above Normal or Shorted to High So...

Page 722: ...Inlet Temperature Data Erratic Intermittent or Incorrect 1173 16 Turbocharger 2 Compressor Inlet Temperature Data Valid but Above Normal Operational Range Moderately Severe Level 1173 3 Turbocharger 2 Compressor Inlet Temperature Circuit Voltage Above Normal or Shorted to High Source 1173 4 Turbocharger 2 Compressor Inlet Temperature Circuit Voltage Below Normal or Shorted to Low Source 1173 2 Tur...

Page 723: ...vere Level 1178 18 Turbocharger 3 Compressor Inlet Pressure Data Valid but Below Normal Operational Range Moderately Severe Level 1178 3 Turbocharger 3 Compressor Inlet Pressure Sensor Circuit Voltage Above Normal or Shorted to High Source 1178 4 Turbocharger 3 Compressor Inlet Pressure Sensor Circuit Voltage Below Normal or Shorted to Low Source 1179 16 Turbocharger 4 Compressor Inlet Pressure Da...

Page 724: ...5 Pre Oil Filter Pressure Data Valid but Above Normal Operational Range Least Severe Level 1208 2 Pre Oil Filter Pressure Data Erratic Intermittent or Incorrect 1208 3 Pre Oil Filter Pressure Sensor Circuit Voltage Above Normal or Shorted to High Source 1208 4 Pre Oil Filter Pressure Sensor Circuit Voltage Below Normal or Shorted to Low Source 1209 3 Exhaust Gas Pressure Sensor Circuit Voltage Abo...

Page 725: ... Driver 2 Circuit Condition Exists 1245 5 Engine Timing Actuator Driver 2 Circuit Current Below Normal or Open Circuit 1245 6 Engine Timing Actuator Driver 2 Circuit Current Above Normal or Grounded Circuit 1245 31 Engine Timing Actuator Driver 2 Circuit Error Condition Exists 1265 4 Engine Oil Burn Valve Solenoid Driver Circuit Voltage Below Normal or Shorted to Low Source 1265 3 Engine Oil Burn ...

Page 726: ...ition Coil Prognostic Cylinder 7 Data Valid but Above Normal Operational Range Least Severe Level 1274 11 Ignition Coil Internal Spark Cylinder 7 Root Cause Not Known 1275 4 Ignition Coil Cylinder 8 Voltage Below Normal or Shorted to Low Source 1275 15 Ignition Coil Prognostic Cylinder 8 Data Valid but Above Normal Operational Range Least Severe Level 1275 11 Ignition Coil Internal Spark Cylinder ...

Page 727: ...ce 1284 15 Ignition Coil Prognostic Cylinder 17 Data Valid but Above Normal Operational Range Least Severe Level 1284 11 Ignition Coil Internal Spark Cylinder 17 Root Cause Not Known 1285 4 Ignition Coil Cylinder 18 Voltage Below Normal or Shorted to Low Source 1285 15 Ignition Coil Prognostic Cylinder 18 Data Valid but Above Normal Operational Range Least Severe Level 1285 11 Ignition Coil Intern...

Page 728: ...lug 4 Voltage Data Valid but Below Normal Operational Range Least Severe Level 1298 4 Spark Plug Cylinder 5 Voltage Below Normal or Shorted to Low Source 1298 15 Spark Plug Prognostic Cylinder 5 Data Valid but Above Normal Operational Range Least Severe Level 1298 11 Spark Plug Flash over Cylinder 5 Root Cause Not Known 1298 15 Engine Spark Plug 5 Voltage Data Valid but Above Normal Operational Ra...

Page 729: ...11 Spark Plug Flash over Cylinder 12 Root Cause Not Known 1306 4 Spark Plug Cylinder 13 Voltage Below Normal or Shorted to Low Source 1306 15 Spark Plug Prognostic Cylinder 13 Data Valid but Above Normal Operational Range Least Severe Level 1306 11 Spark Plug Flash over Cylinder 13 Root Cause Not Known 1307 4 Spark Plug Cylinder 14 Voltage Below Normal or Shorted to Low Source 1307 15 Spark Plug P...

Page 730: ... Cylinders Condition Exists 1322 3 Engine Misfire Multiple Cylinder Circuit Voltage Above Normal or Shorted to High Source 1322 4 Engine Misfire Multiple Cylinder Circuit Voltage Below Normal or Shorted to Low Source 1323 17 Exhaust Gas Temperature Deviation Low for Cylinder 1 Data Valid but Below Normal Operational Range Least Severe Level 1323 16 Exhaust Gas Temperature Deviation High for Cylind...

Page 731: ...d but Above Normal Operational Range Most Severe Level 1326 18 Exhaust Gas Temperature Cylinder 4 Data Valid but Below Normal Operational Range Moderately Severe Level 1326 31 Engine Misfire Cylinder 4 Condition Exists 1326 31 Engine Misfire Cylinder 4 Condition Exists 1326 31 Engine Misfire Cylinder 4 Condition Exists 1327 17 Exhaust Gas Temperature Deviation Low for Cylinder 5 Data Valid but Bel...

Page 732: ...Gas Temperature Cylinder 8 Data Valid but Above Normal Operational Range Most Severe Level 1330 18 Exhaust Gas Temperature Cylinder 8 Data Valid but Below Normal Operational Range Moderately Severe Level 1330 31 Engine Misfire Cylinder 8 Condition Exists 1331 17 Exhaust Gas Temperature Deviation Low for Cylinder 9 Data Valid but Below Normal Operational Range Least Severe Level 1331 16 Exhaust Gas...

Page 733: ...4 Data Valid but Below Normal Operational Range Least Severe Level 1336 16 Exhaust Gas Temperature Deviation High for Cylinder 14 Data Valid but Above Normal Operational Range Moderately Severe Level 1336 18 Exhaust Gas Temperature Cylinder 14 Data Valid but Below Normal Operational Range Moderately Severe Level 1337 17 Exhaust Gas Temperature Deviation Low for Cylinder 15 Data Valid but Below Nor...

Page 734: ...el Pump Pressurizing Assembly 1 Mechanical System Not Responding Properly or Out of Adjustment 1348 4 Fuel Pump Pressurizing Assembly 2 Circuit Voltage Below Normal or Shorted to Low Source 1348 3 Fuel Pump Pressurizing Assembly 2 Circuit Voltage Above Normal or Shorted to High Source 1348 7 Fuel Pump Pressurizing Assembly 2 Mechanical System Not Responding Properly or Out of Adjustment 1349 3 Inj...

Page 735: ...ne Cylinder 3 Knock Data Valid but Above Normal Operational Range Most Severe Level 1354 4 Engine Cylinder 3 Knock Sensor Circuit Voltage Below Normal or Shorted to Low Source 1354 3 Engine Cylinder 3 Knock Sensor Circuit Voltage Above Normal or Shorted to High Source 1354 15 Engine Cylinder 3 Knock Data Valid but Above Normal Operational Range Least Severe Level 1354 16 Engine Cylinder 3 Knock Da...

Page 736: ...3 Engine Cylinder 7 Knock Sensor Circuit Voltage Above Normal or Shorted to High Source 1358 15 Engine Cylinder 7 Knock Data Valid but Above Normal Operational Range Least Severe Level 1358 16 Engine Cylinder 7 Knock Data Valid but Above Normal Operational Range Moderately Severe Level 1359 0 Engine Cylinder 8 Knock Data Valid but Above Normal Operational Range Most Severe Level 1359 4 Engine Cyli...

Page 737: ...ylinder 11 Knock Sensor Circuit Voltage Above Normal or Shorted to High Source 1362 15 Engine Cylinder 11 Knock Data Valid but Above Normal Operational Range Least Severe Level 1362 16 Engine Cylinder 11 Knock Data Valid but Above Normal Operational Range Moderately Severe Level 1362 0 Engine Cylinder 11 Knock Data Valid but Above Normal Operational Range Most Severe Level 1363 15 Engine Cylinder ...

Page 738: ...ne Cylinder 14 Knock Sensor Circuit Voltage Above Normal or Shorted to High Source 1366 15 Engine Cylinder 15 Knock Data Valid but Above Normal Operational Range Least Severe Level 1366 16 Engine Cylinder 15 Knock Data Valid but Above Normal Operational Range Moderately Severe Level 1366 0 Engine Cylinder 15 Knock Data Valid but Above Normal Operational Range Most Severe Level 1366 4 Engine Cylind...

Page 739: ...nder 18 Knock Sensor Circuit Voltage Above Normal or Shorted to High Source 1369 15 Engine Cylinder 18 Knock Data Valid but Above Normal Operational Range Least Severe Level 1369 16 Engine Cylinder 18 Knock Data Valid but Above Normal Operational Range Moderately Severe Level 1369 3 Engine Cylinder 18 Knock Sensor Circuit Voltage Above Normal or Shorted to High Source 1370 16 Engine Cylinder 19 Kn...

Page 740: ... but Below Normal Operational Range Moderately Severe Level 1381 17 Fuel Supply Pump Inlet Pressure Data Valid but Below Normal Operational Range Least Severe Level 1381 15 Fuel Supply Pump Inlet Pressure Data Valid but Above Normal Operational Range Least Severe Level 1382 15 Fuel Filter suction side Differential Pressure Data Valid but Above Normal Operational Range Least Severe Level 1382 2 Fue...

Page 741: ...Data Valid but Above Normal Operational Range Moderately Severe Level 1390 18 Engine Gas Control Valve Inlet Pressure Data Valid but Below Normal Operational Range Moderately Severe Level 1442 2 Engine Electronic Fuel Valve 1 Position Data Erratic Intermittent or Incorrect 1443 2 Engine Electronic Fuel Valve 2 Position Data Erratic Intermittent or Incorrect 1484 31 Additional Auxiliary Diagnostic ...

Page 742: ...c Start Alarm Circuit Voltage Below Normal or Shorted to Low Source 1661 3 Engine Automatic Start Lamp Driver Circuit Voltage Above Normal or Shorted to High Source 1661 4 Engine Automatic Start Lamp Driver Circuit Voltage Below Normal or Shorted to Low Source 1662 2 Vehicle Cab Temperature Thermostat Data Erratic Intermittent or Incorrect 1662 3 Vehicle Cab Temperature Thermostat Enable Circuit V...

Page 743: ... Manifold 6 Temperature Data Valid but Above Normal Operational Range Moderately Severe Level 1803 0 Intake Manifold 6 Temperature Data Valid but Above Normal Operational Range Most Severe Level 1803 3 Intake Manifold 6 Temperature Circuit Voltage Above Normal or Shorted to High Source 1803 4 Intake Manifold 6 Temperature Circuit Voltage Below Normal or Shorted to Low Source 1803 10 Intake Manifol...

Page 744: ...d for High Current Current Above Normal or Grounded Circuit 2448 6 AC Output Current has exceeded the Shutdown threshold for High Current Current Above Normal or Grounded Circuit 2452 31 kW Overload on GenSet Condition Exists 2452 0 kW Electrical Load Signal Data Valid but Above Normal Operational Range Most Severe Level 2452 6 Generator Total Real Power Circuit Current Above Normal or Grounded Ci...

Page 745: ...mal Update Rate 2791 12 EGR Valve Controller Bad Intelligent Device or Component 2791 13 EGR Valve Controller Out of Calibration 2791 11 EGR Actuator Driver Circuit Root Cause Not Known 2791 15 EGR Valve Control Circuit Calculated Over Temperature Data Valid but Above Normal Operational Range Least Severe Level 2791 15 EGR Valve Control Circuit Temperature Data Valid but Above Normal Operational R...

Page 746: ... 2 Feedback Position Does Not Match Desired Root Cause Not Known 2807 4 Engine Fuel Shutoff Valve Driver 2 Circuit Voltage Below Normal or Shorted to Low Source 2807 2 Engine Fuel Shutoff Valve Driver 2 Data Erratic Intermittent or Incorrect 2946 16 Mixer Inlet Relative Humidity Data Valid but Above Normal Operational Range Moderately Severe Level 2946 18 Mixer Inlet Relative Humidity Data Valid b...

Page 747: ...ibration 3050 0 Catalyst Over Temperature Data Valid but Above Normal Operational Range Most Severe Level 3050 16 Catalyst Over Temperature Data Valid but Above Normal Operational Range Moderately Severe Level 3050 11 Catalyst Face Plugged Root Cause Not Known 3050 31 Catalyst Missing Condition Exists 3050 11 Catalyst Face Plugged Root Cause Not Known 3050 13 Catalyst Efficiency Out of Calibration...

Page 748: ...X Sensor Data Erratic Intermittent or Incorrect 3234 9 Aftertreatment Outlet NOx Sensor Abnormal Update Rate 3241 31 Aftertreatment Exhaust Gas Temperature 1 Swapped Condition Exists 3241 4 Aftertreatment Exhaust Gas Temperature 1 Circuit Voltage Below Normal or Shorted to Low Source 3241 3 Aftertreatment Exhaust Gas Temperature 1 Circuit Voltage Above Normal or Shorted to High Source 3241 2 After...

Page 749: ... Shorted to High Source 3251 4 Aftertreatment Particulate Filter Differential Pressure Sensor Circuit Voltage Below Normal or Shorted to Low Source 3251 31 Aftertreatment Particulate Filter Differential Pressure Sensor Autozero Failure Condition Exists 3251 2 Aftertreatment Particulate Filter Differential Pressure Sensor Data Erratic Intermittent or Incorrect 3251 16 Aftertreatment Particulate Fil...

Page 750: ...lity Root Cause Not Known 3451 17 Engine Multiple Cylinder Spark Voltage Data Valid but Below Normal Operational Range Least Severe Level 3451 15 Engine Multiple Cylinder Spark Voltage Data Valid but Above Normal Operational Range Least Severe Level 3451 2 Engine Multiple Cylinder Spark Voltage Data Erratic Intermittent or Incorrect 3451 3 Engine Multiple Cylinder Spark Voltage Circuit Voltage Abo...

Page 751: ...ensor 2 Data Erratic Intermittent or Incorrect 3468 3 Engine Gas Temperature Sensor 2 Circuit Voltage Above Normal or Shorted to High Source 3468 4 Engine Gas Temperature Sensor 2 Circuit Voltage Below Normal or Shorted to Low Source 3469 3 Engine Gas Control Valve Outlet Pressure 2 Circuit Voltage Above Normal or Shorted to High Source 3469 4 Engine Gas Control Valve Outlet Pressure 2 Circuit Vol...

Page 752: ... Sensor Supply 6 Circuit Voltage Above Normal or Shorted to High Source 3514 4 Sensor Supply 6 Circuit Voltage Below Normal or Shorted to Low Source 3548 15 Waste Oil Reservoir Level Data Valid but Above Normal Operational Range Least Severe Level 3549 3 Post Oil Filter Pressure Sensor Circuit Voltage Above Normal or Shorted to High Source 3549 4 Post Oil Filter Pressure Sensor Circuit Voltage Bel...

Page 753: ...mal or Shorted to Low Source 3556 2 Aftertreatment Fuel Injector 1 Data Erratic Intermittent or Incorrect 3556 7 Aftertreatment Fuel Injector 1 Mechanical System Not Responding Properly or Out of Adjustment 3556 5 Aftertreatment Fuel Injector 1 Circuit Current Below Normal or Open Circuit 3556 16 Aftertreatment Fuel Injector 1 Data Valid but Above Normal Operational Range Moderately Severe Level 3...

Page 754: ...t Responding or Out of Adjustment 5421 5 Engine Turbocharger Wastegate Actuator Current Below Normal or Open Circuit 5421 6 Engine Turbocharger Wastegate Actuator Current Above Normal or Grounded Circuit 5571 7 High Pressure Common Rail Fuel Pressure Relief Valve Mechanical System not Responding or Out of Adjustment The fuel rail high pressure relief valve has opened at a lower than expected press...

Page 755: ...tage Above Normal or Shorted to High Source 520216 4 Interstage Air Pressure 2 Circuit Voltage Below Normal or Shorted to Low Source 520217 15 Genset Controller Internal Temperature Data Valid but Above Normal Operational Range Least Severe Level 520218 31 Utility Contact failed to close Condition Exists 520218 31 Utility Contact failed to open Condition Exists 520219 11 Engine Common AC Power Cir...

Page 756: ... Condition Exists 520248 31 Battle Short Mode Active Condition Exists 520249 31 Delayed Shutdown Condition Exists 520250 31 Genset Controlled Shutdown In Process Condition Exists 520251 31 Engine Normal Shutdown Condition Exists 520251 31 Engine Shutdown Condition Exists 520251 31 Fail to Shutdown Condition Exists 520252 31 Engine Shutdown Not Announced Condition Exists 520253 31 Normal engine shu...

Page 757: ...r Diagnostic has detected an error Condition Exists 520275 3 Generator Speed Load Governing Bias Circuit Voltage Above Normal or Shorted to High Source 520275 4 Generator Speed Load Governing Bias Circuit Voltage Below Normal or Shorted to Low Source 520275 2 Generator Speed Load Governing Bias Circuit Data Erratic Intermittent or Incorrect 520276 31 Real Power kW Failure to Meet Demand Condition ...

Page 758: ...nput 8 Active Condition Exists 520305 31 Auxiliary Device 2 Input 9 Active Condition Exists 520306 31 Auxiliary Device 2 Input 10 Active Condition Exists 520307 31 Auxiliary Device 2 Input 11 Active Condition Exists 520308 31 Auxiliary Device 2 Input 12 Active Condition Exists 520309 2 Alternator Frequency Data Erratic Intermittent or Incorrect 520310 31 Generator Shutdown Malfunction Condition Ex...

Page 759: ...31 Brake Inactivity Condition Exists 520327 7 Exhaust Gas Recirculation Cooler Bypass Valve Mechanical System Not Responding Properly or Out of Adjustment 520328 2 PCC Communication Network Data Erratic Intermittent or Incorrect 520328 2 PCC Communication Network Data Erratic Intermittent or Incorrect 520329 3 Alternator Control Circuit Voltage Above Normal or Shorted to High Source 520329 4 Alter...

Page 760: ...2 03 Intake Manifold Pressure Sensor voltage above normal 102 04 Intake Manifold Pressure Sensor voltage below normal 102 10 Intake Manifold Pressure Sensor abnormal rate of change 105 03 Intake Manifold Air Temperature Sensor voltage above normal 105 04 Intake Manifold Air Temperature Sensor voltage below normal 110 03 Engine Coolant Temperature Sensor voltage above normal 110 04 Engine Coolant T...

Page 761: ... intermittent or incorrect 654 5 Cylinder 4 Injector current below normal 654 6 Cylinder 4 Injector current above normal 654 7 Cylinder 4 Injector not responding properly 655 2 Cylinder 5 Injector erratic intermittent or incorrect C6 6 engine only 655 5 Cylinder 5 Injector current below normal C6 6 engine only 655 6 Cylinder 5 Injector current above normal C6 6 engine only 655 7 Cylinder 5 Injecto...

Page 762: ...t below normal 1347 06 Fuel Rail 1 Pressure Valve Solenoid current above normal 2882 02 Engine Operation Mode Selector Switch erratic intermittent or incorrect Event Codes SPN FMI Description 107 15 High Air Filter Restriction 173 15 High Exhaust Temperature 97 15 High Fuel Water Separator Water Level 100 17 Low Engine Oil Pressure Warning 100 01 Low Engine Oil Pressure Shutdown 110 15 High Engine...

Page 763: ...sition Sensor Test 51 4 Engine Throttle Valve 1 Position Voltage Below Normal Valve Position Sensor Test 91 3 Accelerator Pedal Position 1 Voltage Above Normal Analog Throttle Position Sensor Circuit Test 91 4 Accelerator Pedal Position 1 Voltage Below Normal Analog Throttle Position Sensor Circuit Test 97 15 Water In Fuel Indicator High least severe Fuel Contains Water 100 2 Engine Oil Pressure E...

Page 764: ...ail 1 Pressure High most severe 3 Fuel Rail Pressure Problem 157 2 Engine Injector Metering Rail 1 Pressure Erratic Intermittent or Incorrect Fuel Rail Pressure Problem 157 3 Engine Injector Metering Rail 1 Pressure Voltage Above Normal Engine Pressure Sensor Open or Short Circuit Test 157 4 Engine Injector Metering Rail 1 Pressure Voltage Below Normal Engine Pressure Sensor Open or Short Circuit ...

Page 765: ...esent a fault 594 31 Engine Idle Shutdown Driver Alert Mode This code indicates that an engine idle shutdown is about to occur This code does not represent a fault 623 5 Red Stop Lamp Current Below Normal Indicator Lamp Circuit Test 623 6 Red Stop Lamp Current Above Normal Indicator Lamp Circuit Test 624 5 Amber Warning Lamp Current Below Normal Indicator Lamp Circuit Test 624 6 Amber Warning Lamp...

Page 766: ...correct Test 654 5 Engine Injector Cylinder 04 Current Below Normal Injector Solenoid Circuit Test 654 6 Engine Injector Cylinder 04 Current Above Normal Injector Solenoid Circuit Test 654 20 Engine Injector Cylinder 04 Data Drifted High Injector Data Incorrect Test 654 21 Engine Injector Cylinder 04 Data Drifted Low Injector Data Incorrect Test 676 5 Engine Glow Plug Relay Current Below Normal Gl...

Page 767: ...oost Pressure High moderate severity 2 Intake Manifold Air Pressure Is High 1127 18 Engine Turbocharger 1 Boost Pressure Low moderate severity 2 Intake Manifold Air Pressure Is Low 1188 5 Engine Turbocharger Wastegate Actuator 1 Position Current Below Normal Solenoid Valve Test 1188 6 Engine Turbocharger Wastegate Actuator 1 Position Current Above Normal Solenoid Valve Test 1209 3 Engine Exhaust G...

Page 768: ... Normal Throttle Switch Circuit Test 2970 2 Accelerator Pedal 2 Low Idle Switch Erratic Intermittent or Incorrect Idle Validation Switch Circuit Test 3217 3 Aftertreatment 1 Intake O2 Voltage Above Normal Oxygen Level Test 3217 4 Aftertreatment 1 Intake O2 Voltage Below Normal Oxygen Level Test 3217 5 Aftertreatment 1 Intake O2 Current Below Normal Oxygen Level Test 3217 6 Aftertreatment 1 Intake ...

Page 769: ...ntial Pressure Problem 3251 16 Particulate Trap Differential Pressure High moderate severity 2 Diesel Particulate Filter Collects Excessive Soot 3251 17 Particulate Trap Differential Pressure Low least severe 1 Diesel Particulate Filter Has Differential Pressure Problem 3509 2 Sensor Supply Voltage 1 Erratic Intermittent or Incorrect 5 Volt Sensor Supply Circuit Test 3510 2 Sensor Supply Voltage 2...

Page 770: ...Regeneration Diesel Particulate Filter Active Regeneration Was Interrupted 5324 7 Engine Glow Plug 1 Not Responding Properly Glow Plug Starting Aid Test 5325 7 Engine Glow Plug 2 Not Responding Properly Glow Plug Starting Aid Test 5326 7 Engine Glow Plug 3 Not Responding Properly Glow Plug Starting Aid Test 5327 7 Engine Glow Plug 4 Not Responding Properly Glow Plug Starting Aid Test 5357 31 Engin...

Page 771: ...von 58 Diese technische Unterlage darf weder kopiert noch dritten Personen ohne unsere Erlaubnis 26 06 10 17 Schwarz mitgeteilt werden Index Nr Datum Name Film K3 ZFN 904 Ä N D E R U N G E N Erstellt Geprüft Freigegeben Name Schwarz Sieger Abteilung TE AB TE AB Datum 03 05 13 03 10 01 Description of the fault codes for ERGO Control EST37 ...

Page 772: ...remove faults in display description sz insert high low voltage limits for 12V 24 V devices add fault code for overtemp torqueconverter change SCT and DCT sz several corrections so engine derating fault sz add customer JCB V826 00 05 12 9 remove faultcodes 0x66 0x68 0x6C 0x6D sz add faultcode 0xC4 0xC6 joystick status indicator V828 00 06 29 10 add custommer O K add O K specific faults 00 09 14 11...

Page 773: ...or high velocity and high load 05 02 18 23 Add engine torque power overload and output torque overload faultcodes Change FMI from 15 to 0 V916 05 06 20 24 Add warning code for high output torque V917 06 04 11 25 change description of lockup clutch failure V918 06 10 17 26 no new faultcodes in version V919 V919 07 05 24 27 no new faultcodes in version V920 V920 ...

Page 774: ...T O P h f e d a b c g special symbols a h left character right character 1 3 Display during operation Symbol meaning remarks 1F 1R 2F 2R 3F 3R 4F 5F 6F LF LR actual gear and direction left digit shows actual gear right digit shows actual direction limp home gear F or R no gear Clutch Cutoff F or R flashing direction F or R selected while turbine speed is too high CAUTION gear will engage if turbin...

Page 775: ...t is detected spanner WT warning torque converter temperature changes between actual gear direction while driving in neutral only displayed if no fault is detected spanner WE warning high engine speed changes between actual gear direction while driving in neutral only displayed if no fault is detected spanner WV warning high output speed velocity changes between actual gear direction while driving...

Page 776: ... AEB finished Transmissions stays in neutral you have to restart the TCU ignition off on E engine speed too low raise engine speed E engine speed too high lower engine speed T transmission oil temperature too low heat up transmission T transmission oil temperature too high cool down transmission FT transmission temperature not in defined range during calibration Transmissions stays in neutral you ...

Page 777: ... sensor supply voltage AU1 is out of the specified range Calibration is aborted FO and Stop Outputspeed is not zero Calibration is aborted SL and Stop sensor voltage below specified rangel Calibration is aborted SU and Stop sensor voltage above specified rangel Calibration is aborted IL and Stop sensor position for released pedal out of specified range Calibration is aborted IU and Stop sensor pos...

Page 778: ...eutral to gear and the operator shifts the gear selector into forward or reverse the TCU will select the limp home gear If output speed is less than a threshold for reversal speed and TCU has changed into the limp home gear and the operator selects a shuttle shift TCU will shift immediately into the limp home gear of the selected direction If output speed is greater than the threshold TCU will shi...

Page 779: ...RECTION SELECT SIGNAL TCU detected a wrong signal combination for the direction cable from shift lever to TCU is broken cable is defective and is contacted to battery voltage or vehicle ground shift lever is defective TCU shifts transmission to neutral OP Mode transmission shutdown check the cables from TCU to shift lever check signal combinations of shift lever positions F N R fault is taken back...

Page 780: ...nection measured by TCU and output signal axle connection don t fit axle can t be connected or disconnected due to mechanical problem one of the cables from feedback axle connection switch to TCU is broken OP Mode normal check the cables from TCU to feedback axle connection switch check signals of the feedback axle connection switch all 17 5060 4 148 S C TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO ...

Page 781: ...o connection to TCU customer specific check the cable from TCU to customer specific function no 1 device check the connectors from customer specific function no 1 device to TCU check the resistance of customer specific function no 1 device 1 see chapter 4 Z Funkt ion1 1A 5070 4 151 S C TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO 2 TCU detected a wrong voltage at the output pin that looks like a s c...

Page 782: ...nector has no connection to TCU customer specific check the cable from TCU to customer specific function no 2 device check the connectors from customer specific function no 2 device to TCU check the resistance of customer specific function no 2 device 1 see chapter 4 Z Funkt ion2 1D 5080 4 154 S C TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO 3 TCU detected a wrong voltage at the output pin that look...

Page 783: ...on to TCU customer specific function no 3 device has an internal defect connector has no connection to TCU customer specific check the cable from TCU to customer specific function no 3 device check the connectors from customer specific function no 3 device to TCU check the resistance of customer specific function no 3 device 1 see chapter 4 Z Funkt ion3 21 5090 3 32 S C TO BATTERY VOLTAGE AT CLUTC...

Page 784: ...lerances of load sensor availability of retarder depends on default load ohne CAN 24 5100 4 70 S C TO GROUND OR O C AT LOAD SENSOR INPUT the measured voltage is too low cable is defective and is contacted to vehicle ground cable has no connection to TCU load sensor has an internal defect connector pin is contacted to vehicle ground or is broken retarder function is affected TCU uses default load O...

Page 785: ...temperature sensor all Sisu 27 5120 3 76 S C TO BATTERY VOLTAGE OR O C AT RETARDER TORQUECONVERTER TEMPERATURE SENSOR INPUT the measured voltage is too high cable is defective and is contacted to battery voltage cable has no connection to TCU temperature sensor has an internal defect connector pin is contacted to battery voltage or is broken no reaction TCU uses default temperature OP Mode normal ...

Page 786: ...o low cable is defective and is contacted to vehicle ground sensor has an internal defect connector pin is contacted to vehicle ground TCU uses default value OP Mode normal check the cable from TCU to the sensor check the connectors check the parking brake sensor all 2B 5313 12 135 INCHSENSOR SIGNAL MISMATCH the measured voltage from CCO and CCO2 signal don t match cable is defective sensor has an...

Page 787: ...GLE SENSOR INPUT the measured voltage is too high cable is defective and is contacted to battery voltage cable has no connection to TCU sensor has an internal defect connector pin is contacted to battery voltage or is broken TCU uses default value OP Mode normal check the cable from TCU to the sensor check the connectors check the DLM STEERING ANGLE SENSOR all 2F 5137 4 127 S C TO GROUND DLM STEER...

Page 788: ...check the speed sensor all Sisu 33 5140 12 42 LOGICAL ERROR AT ENGINE SPEED INPUT TCU measures a engine speed over a threshold and the next moment the measured speed is zero cable connector is defective and has bad contact speed sensor has an internal defect sensor gap has the wrong size OP Mode substitute clutch control check the cable from TCU to the sensor check the connectors check the speed s...

Page 789: ...de substitute clutch control if a failure is existing at output speed TCU shifts to neutral OP Mode limp home check the cable from TCU to the sensor check the connectors check the speed sensor check the sensor gap This fault is reset after power up of TCU all Sisu 37 5160 3 40 S C TO BATTERY VOLTAGE OR O C AT INTERNAL SPEED INPUT TCU measures a voltage higher than 7 00 V at speed input pin cable i...

Page 790: ...l if a failure is existing at turbine speed TCU shifts to neutral OP Mode limp home check the cable from TCU to the sensor check the connectors check the speed sensor all Sisu 3B 5170 4 37 S C TO GROUND AT OUTPUT SPEED INPUT TCU measures a voltage less than 1 00V at speed input pin cable connector is defective and is contacted to vehicle ground speed sensor has an internal defect special mode for ...

Page 791: ...the cable from TCU to the sensor This fault is reset after power up of TCU all Sisu 40 5190 2 146 GEAR RANGE RESTRICTION SIGNAL CAN signal for gear range restriction is defective cluster controller is defective interference on CAN Bus no gear range restriction check cluster controller check wire of CAN Bus check cable to cluster controller Case 40 5200 2 146 FCAN MESSAGE GEAR RANGE SELECT ZF_3_IDE...

Page 792: ...ne controller check wire of CAN Bus check cable to engine controller IES 52 5240 9 101 EAMODUL1 TIMEOUT Timeout of CAN message EAM1 from I O controller interference on CAN Bus CAN wire connector is broken CAN wire connector is defective and has contact to vehicle ground or battery voltage TCU shifts to neutral and uses substitute gear selector OP Mode normal check I O controller check wire of CAN ...

Page 793: ... is broken CAN wire connector is defective and has contact to vehicle ground or battery voltage OP Mode normal check display computer check wire of CAN Bus check cable to display computer JCB Kalm ar 54 5260 9 103 GEAR RANGE SELECT TIMEOUT Timeout of CAN message Gear Range Select ZF_3_IDENT interference on CAN Bus CAN wire connector is broken CAN wire connector is defective and has contact to vehi...

Page 794: ...nector is broken CAN wire connector is defective and has contact to vehicle ground or battery voltage TCU keeps old auto man selection old Clutch cutoff selection and old Clutch Cuttoff Setting OP Mode normal check cluster controller check wire of CAN Bus check cable to cluster controller John Deere 55 5270 9 177 FRONT WHEEL DRIVE STATUS TIMEOUT Timeout of CAN message Front Wheel Drive Status V_ID...

Page 795: ...of CAN message EEC3 from EEC controller interference on CAN Bus CAN wire connector is broken CAN wire connector is defective an has contact to vehicle ground or battery voltage OP Mode substitute clutch control check EEC controller check wire of CAN Bus check cable to EEC controller J1939 59 5310 2 108 TEST MODE SIGNAL CAN signal for test mode status is defective cluster controller is defective in...

Page 796: ... kept check cluster controller check wire of CAN Bus check cable to controller John Deere 5E 5360 2 113 CCO REQUEST SIGNAL CAN signal for CCO request is defective cluster controller is defective interference on CAN Bus last selection is kept check cluster controller check wire of CAN Bus check cable to controller John Deere 5F 5370 2 114 SHIFT LEVER SIGNAL CAN signal for shift lever is defective I...

Page 797: ...erence on CAN Bus no reaction TCU uses default PTO torque signal OP Mode normal check I O controller check wire of CAN Bus check cable to I O controller Liebh err 63 5410 2 118 DRIVING MODE SIGNAL CAN signal for driving mode is defective I O controller is defective interference on CAN Bus no reaction TCU uses default driving mode signal OP Mode normal check I O controller check wire of CAN Bus che...

Page 798: ...troller J1939 6E 5470 2 144 EEC2 TIMEOUT Timeout of CAN message EEC2 from EEC controller interference on CAN Bus CAN wire connector is broken CAN wire connector is defective and has contact to vehicle ground or battery voltage no reaction TCU uses default signal accelerator pedal in idle position OP Mode normal check EEC controller check wire of CAN Bus check cable to EEC controller J1939 71 5480 ...

Page 799: ...nectors from gearbox to TCU check the regulator resistance 1 check internal wire harness of the gearbox 1 see chapter 4 all Sisu 74 5490 3 23 S C TO BATTERY VOLTAGE AT CLUTCH K2 the measured resistance value of the valve is out of limit the voltage at K2 valve is too high cable connector is defective and has contact to battery voltage regulator has an internal defect TCU shifts to neutral OP Mode ...

Page 800: ...eck the connectors from gearbox to TCU check the regulator resistance 1 check internal wire harness of the gearbox 1 see chapter 4 all Sisu 78 5500 4 12 S C TO GROUND AT CLUTCH K3 the measured resistance value of the valve is out of limit the voltage at K3 valve is too low cable connector is defective and has contact to vehicle ground cable connector is defective and has contact to another regulat...

Page 801: ...HI Proto T10 7E 5550 3 168 S C TO BATTERY VOLTAGE AT ENGINE DERATING DEVICE cable connector is defective and is contacted to battery voltage engine derating device has an internal defect no reaction OP Mode normal check the cable from TCU to the engine derating device check the connectors from backup alarm device to TCU check the resistance 1 of backup alarm device SHI Proto T10 7F 5550 5 167 O C ...

Page 802: ...ct to TCU regulator has an internal defect TCU shifts to neutral OP Mode limp home if failure at another clutch is pending TCU shifts to neutral OP Mode TCU shutdown check the cable from TCU to the gearbox check the connectors from gearbox to TCU check the regulator resistance 1 check internal wire harness of the gearbox 1 see chapter 4 all 84 5520 3 26 S C TO BATTERY VOLTAGE AT CLUTCH KV the meas...

Page 803: ... contact to battery voltage regulator has an internal defect TCU shifts to neutral OP Mode limp home if failure at another clutch is pending TCU shifts to neutral OP Mode TCU shutdown check the cable from TCU to the gearbox check the connectors from gearbox to TCU check the regulator resistance 1 check internal wire harness of the gearbox 1 see chapter 4 all Sisu 88 5530 4 15 S C TO GROUND AT CLUT...

Page 804: ...U power down even if fault vanishes loose connection OP Mode normal check the cable from TCU to the valve check the connectors check the resistance of valve 1 see chapter 4 all 8B 5535 3 142 S C TO BATTERY VOLTAGE AT DLM TRANSVERSAL OUTPUT TCU detected a wrong voltage at the output pin that looks like a s c to battery voltage cable is defective and is contacted to battery voltage device has an int...

Page 805: ...LAMP OUTPUT TCU detected a wrong voltage at the output pin that looks like a s c to battery voltage cable is defective and is contacted to battery voltage device has an internal defect connector pin is contacted to battery voltage no reaction OP Mode normal check the cable from TCU to the device check the connectors check the resistance of device 1 see chapter 4 all 8F 5536 5 181 O C DLM INDICATOR...

Page 806: ... internal defect connector pin is contacted to battery voltage no reaction OP Mode normal check the cable from TCU to the backup alarm device check the connectors from backup alarm device to TCU check the resistance 1 of backup alarm device 1 see chapter 4 all 93 5560 5 2 O C AT RELAY REVERSE WARNING ALARM TCU detected a wrong voltage at the output pin that looks like a o c for this output pin cab...

Page 807: ...ormal check the cable from TCU to the starter interlock relay check the connectors from starter interlock relay to TCU check the resistance 1 of starter interlock relay 1 see chapter 4 all 96 5570 5 5 O C AT RELAY STARTER INTERLOCK TCU detected a wrong voltage at the output pin that looks like a o c for this output pin cable is defective and has no connection to TCU starter interlock relay has an ...

Page 808: ...he connectors from park brake solenoid to TCU check the resistance 1 of park brake solenoid 1 see chapter 4 John Deere 99 5580 5 8 O C AT PARK BRAKE SOLENOID TCU detected a wrong voltage at the output pin that looks like a o c for this output pin cable is defective and has no connection to TCU park brake solenoid has an internal defect connector has no connection to TCU no reaction optional some c...

Page 809: ...r clutch solenoid to TCU check the resistance 1 of converter clutch solenoid 1 see chapter 4 6WG 9C 5590 5 68 S C TO BATTERY VOLTAGE AT CONVERTER LOCK UP CLUTCH SOLENOID TCU detected a wrong voltage at the output pin that looks like a s c to battery voltage cable is defective and is contacted to battery voltage converter clutch solenoid has an internal defect connector pin is contacted to battery ...

Page 810: ...oid 1 see chapter 4 6WG 9F 5600 5 83 S C TO BATTERY VOLTAGE AT RETARDER SOLENOID TCU detected a wrong voltage at the output pin that looks like a s c to battery voltage cable is defective and is contacted to battery voltage retarder solenoid has an internal defect connector pin is contacted to battery voltage no reaction OP mode normal check the cable from TCU to the retarder solenoid check the co...

Page 811: ...0 5 86 O C AT DIFFLOCK OR AXLE CONNECTION SOLENOID TCU detected a wrong voltage at the output pin that looks like a o c for this output pin cable is defective and has no connection to TCU difflock solenoid has an internal defect connector has no connection to TCU no reaction OP mode normal check the cable from TCU to the difflock solenoid check the connectors from difflock solenoid to TCU check th...

Page 812: ...ted to battery voltage no reaction OP mode normal check the cable from TCU to the warning device check the connectors from warning device to TCU check the resistance 1 of warning device 1 see chapter 4 all A7 5630 4 157 S C TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO 4 TCU detected a wrong voltage at the output pin that looks like a s c to vehicle ground cable is defective and is contacted to vehic...

Page 813: ...cific function no 4 device check the connectors from customer specific function no 4 device to TCU check the resistance of customer specific function no 4 device 1 see chapter 4 Z Funkt ion4 AA 5640 4 160 S C TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO 5 TCU detected a wrong voltage at the output pin that looks like a s c to vehicle ground cable is defective and is contacted to vehicle ground custo...

Page 814: ...m TCU to customer specific function no 5 device check the connectors from customer specific function no 5 device to TCU check the resistance of customer specific function no 5 device 1 see chapter 4 Z Funkt ion5 AD 5650 4 163 S C TO GROUND AT CUSTOMER SPECIFIC FUNCTION NO 6 TCU detected a wrong voltage at the output pin that looks like a s c to vehicle ground cable is defective and is contacted to...

Page 815: ...ion no 6 device to TCU check the resistance of customer specific function no 6 device 1 see chapter 4 Z Funkt ion6 B1 5660 2 60 SLIPPAGE AT CLUTCH K1 TCU calculates a differential speed at closed clutch K1 If this calculated value is out of range TCU interprets this as slipping clutch low pressure at clutch K1 low main pressure wrong signal at internal speed sensor wrong signal at output speed sen...

Page 816: ...Mode limp home if failure at another clutch is pending TCU shifts to neutral OP Mode TCU shutdown check pressure at clutch K3 check main pressure in the system check sensor gap at internal speed sensor check sensor gap at output speed sensor check signal at internal speed sensor check signal at output speed sensor replace clutch all Sisu B4 5675 2 63 SLIPPAGE AT CLUTCH K4 TCU calculated a differen...

Page 817: ...t closed clutch KR If this calculated value is out of range TCU interprets this as slipping clutch low pressure at clutch KR low main pressure wrong signal at internal speed sensor wrong signal at turbine speed sensor wrong size of the sensor gap clutch is defective TCU shifts to neutral OP Mode limp home if failure at another clutch is pending TCU shifts to neutral OP Mode TCU shutdown check pres...

Page 818: ...is out of range TCU interprets this as slipping clutch low pressure at converter lockup clutch low main pressure wrong signal at engine speed sensor wrong signal at turbine speed sensor wrong size of the sensor gap clutch is defective check pressure at converter lockup clutch check main pressure in the system check sensor gap at engine speed sensor check sensor gap at turbine speed sensor check si...

Page 819: ...ine brake solenoid 1 see chapter 4 6WG BF 5750 5 170 O C AT ENGINE BRAKE TCU detected a wrong voltage at the output pin that looks like a o c for this output pin cable is defective and has no connection to TCU engine brake solenoid has an internal defect connector has no connection to TCU no reaction OP mode normal check the cable from TCU to the engine brake solenoid check the connectors from eng...

Page 820: ...normal check the cable from TCU to joystick status indicator check the connectors from joystick status indicator to TCU check the resistance 1 of joystick status indicator Case all C5 5770 3 131 S C TO BATTERY VOLTAGE AT JOYSTICK STATUS INDICATOR TCU detected a wrong voltage at the output pin that looks like a s c to battery voltage cable is defective and is contacted to battery voltage joystick s...

Page 821: ... connectors from OVERTEMP NEUTRAL INDICATOR to TCU check the resistance 1 of OVERTEMP NEUTRAL INDICATOR Shins ung C8 5780 3 134 S C TO BATTERY VOLTAGE AT OVERTEMP NEUTRAL INDICATOR TCU detected a wrong voltage at the output pin that looks like a s c to battery voltage cable is defective and is contacted to battery voltage overtemp status indicator has an internal defect connector pin is contacted ...

Page 822: ...from EEC controller interference on CAN Bus CAN wire connector is broken CAN wire connector is defective an has contact to vehicle ground or battery voltage OP Mode substitute clutch control check EEC controller check wire of CAN Bus check cable to EEC controller J1939 D1 5810 3 54 S C TO BATTERY VOLTAGE AT POWER SUPPLY FOR SENSORS TCU measures more than 6V at the pin AU1 5V sensor supply see faul...

Page 823: ...e contacted to battery voltage cable or connectors are defect and are contacted to vehicle ground permanent power supply KL30 missing TCU has an internal defect shift to neutral OP Mode TCU shutdown check fuse check cables from gearbox to TCU check connectors from gearbox to TCU replace TCU all Sisu D6 5840 2 58 ERROR VALVE POWER SUPPLY VPS2 TCU switched on VPS2 and measured VPS2 is off or TCU swi...

Page 824: ...ble from TCU to the valve check the connectors check the resistance of valve 1 see chapter 4 all D9 5545 5 O C AT DLM LONGITUDINAL OUTPUT TCU detected a wrong voltage at the output pin that looks like a o c for this output pin cable is defective and has no connection to TCU device has an internal defect connector has no connection to TCU no reaction OP Mode normal check the cable from TCU to the v...

Page 825: ...isplay has an internal defect no reaction OP Mode normal check the cable from TCU to the display check the connectors at the display change display all E4 5860 4 49 S C TO GROUND AT DISPLAY OUTPUT TCU sends data to the display and measures allways a high voltage level on the connector cable or connectors are defective and are contacted to vehicle ground display has an internal defect no reaction O...

Page 826: ...tive no reaction OP Mode normal replace TCU often shown together with fault code F2 all Sisu F2 5900 13 56 CONFIGURATION LOST TCU has lost the correct configuration and can t control the transmission interference during saving data on non volatile memory TCU is brand new or from another vehicle transmission stay neutral OP Mode TCU shutdown Reprogramm the correct configuration for the vehicle e g ...

Page 827: ...OP Mode limp home request Deere F5 5930 7 173 CLUTCH FAILURE AEB was not able to adjust clutch filling parameters One of the AEB Values is out of limit transmission stay neutral OP Mode TCU shutdown check clutch TCU shows also the affected clutch on the Display all Sisu F6 5930 13 174 CLUTCH ADJUSTMENT DATA LOST OR INCHPEDAL CALIBRATION DATA LOST TCU was not able to read correct clutch adjustment ...

Page 828: ...open circuit R12 R1G R2G short cut to ground R12 R R1G 0 R2G R or R1G R R2G 0 for s c to ground G is connected to vehicle ground short cut to battery R12 R R1G 0 R2G R or R1G R R2G 0 for s c to battery G is connected to battery voltage 4 2 cable P power supply 1 2 TCU Actuator Sensor U Bat Gnd C chassis open circuit R12 R1P R1C R2P R2C short cut to ground R12 0 R1C R2C 0 R1P R2P short cut to batte...

Page 829: ...ISTORY Revision Date Pages Description 65E_s1_00 03 2006 AII First Edition Service Manual Released 65E_s2_00 06 2013 All Tier III Tier IV Update Second Edition Service Manual Released Updated to Tier III Tier IV engines added Electronic Display added AEB Starter and added Air Conditioner ...

Page 830: ...erated in California any off road diesel vehicle may be subject to the California Air Resources Board In Use Off Road Diesel Vehicle Regulation It therefore could be subject to retrofit or accelerated turnover requirements to reduce emissions of air pollutants For more information please visit the California Air Resources Board website at http www arb ca gov msprog ordiesel ordiesel htm ...

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