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NorAM 65E Turbo, Service Manual

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65E Turbo Motor Grader

Service Manual

Section 7

Hydraulics

Service 1.00_2006.03

7-xii

Cartridge Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48
Pitch/Side Shift and Front/Rear Implement Selector Valve Removal  . . . . . . . . . . . . . . . . . . . . . . 7-50
Pitch/Side Shift and Front/Rear Implement Selector Valve Installation   . . . . . . . . . . . . . . . . . . . . 7-51
Circle Shift/Saddle Pin Selector Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
Circle Shift/Saddle Pin Selector Valve Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53

Hydraulic Swivel  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55

Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55
Disassembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
Inspection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
Assembly   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58

Circle Turn Hydraulic Motor   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60

Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62

Circle Turn Gearbox  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63

Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
Disassembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64
Assembly   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66

Cylinders  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68

Lift Cylinder Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68
Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69
Circle Shift Cylinder Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71
Circle Shift Cylinder Installation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72
Moldboard Side Shift Cylinder Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73
Moldboard Side Shift Cylinder Installation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73
Moldboard Pitch Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Moldboard Pitch Cylinder Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75
Articulation Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75
Articulation Cylinder Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77
Wheel Lean Cylinder Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  . 7-78
Wheel Lean Cylinder Installation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
Steering Cylinder Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80
Steering Cylinder Installation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81
Steering Cylinder Adjustment  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82
Front End Attachment Cylinder Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84
Front End Attachment Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85
Rear Ripper Cylinder Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
Rear Ripper Cylinder Installation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
Bank Slope Cylinder Removal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87
Bank Slope Cylinder Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
Cylinder Disassembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-89
Cylinder Inspection and Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  . 7-90

Hydraulic Oil Filter And Strainers  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-93

Hydraulic Filter   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-93
Hydraulic Strainers  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-94

Eaton Publication #6-623 for L2 Series Gear Pumps

Eaton Publication #7-145 for T Series Geroler Motors

Summary of Contents for 65E Turbo

Page 1: ...65E TURBO M Opera 65E TURBO M Opera Grader Manual June 2005 EFF S N 9101 Catalog 4472 65E TURBO M Opera 65E TURBO M Opera Service Manual 65E TURBO Motor Grader ...

Page 2: ... in standard condition For exact information about 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 the Company The installation and or use of such products could have negative effects upon t...

Page 3: ...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 4: ...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 5: ...e 1 00_2006 03 IV CONTENTS OVERVIEW Engine Section 1 Operator s Platform and Controls Section 2 Transmission Section 3 Front Axle Section 4 Rear Axle and Tandem Section 5 Electrical Section 6 Hydraulics Section 7 Moldboard and Implement Section 8 ...

Page 6: ...Service Manual Section 1 Engine Service 1 00_2006 03 ...

Page 7: ......

Page 8: ...te 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 handholds 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 9: ...efore 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 ...

Page 10: ...ing 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 loc...

Page 11: ...e 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 s...

Page 12: ...on 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 p...

Page 13: ...k 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 ...

Page 14: ...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: ...65E Turbo Motor Grader Service Manual Section 1 Engine Service 1 00_2006 03 1 x This page intentionally left blank ...

Page 16: ...vice 1 00_2006 03 Section 1 Engine 1 xi CONTENTS General Information 1 1 Engine Protection and Diagnostics 1 1 Diagnostics 1 2 Specifications 1 3 Engine Electrical 1 4 Electronic Control Module ECM 1 4 Fuses 1 5 QSB Fault Code Information 1 6 ...

Page 17: ...65E Turbo Motor Grader Service Manual Section 1 Engine Service 1 00_2006 03 1 xii This page intentionally left blank ...

Page 18: ... Protection and Diagnostics The NORAM 65E grader uses amber and red warning lights to signal the operator when the engine elec tronic control module ECM detects an engine fault or problem Depending on the severity of the engine problem the ECM may decrease engine power or shut the engine down after warning the operator with flashing warning lights The amber CHECK ENGINE light 1 is located on the r...

Page 19: ... and stay on If active fault codes are recorded both lights will come on momentarily then begin to flash the code of the recorded fault s See page 1 14 of Section 1 in the Cummins Operation and Maintenance Manual for examples of the flashing sequences and corresponding fault code The lights will flash out each code two times before advancing to the next code To skip to the next fault code momentar...

Page 20: ...ers 4 Displacement 4 5 L 275 cu in Bore and Stroke 102 mm x 138 mm 4 02 in x 5 42 in Aspiration Turbocharged Cooling Water Gross Power and Rated Speed 82 kW 110 GHP Maximum Torque 414 Nm 305 lb ft 1500 RPM Rated Speed 2200RPM Low Idle Speed 900 50 RPM High Idle Speed 2350 50 RPM Fuel Pump Bosch VP30 Compression Ratio 17 3 1 Firing Order 1 3 4 2 Weight Wet 338 Kg 745 Ib ...

Page 21: ...ction 1 Engine Service 1 00_2006 03 1 4 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 left hand side of the flywheel area 2 1 ...

Page 22: ...her wiring details Symptom Engine Characteristics Possible Cause Engine dies No engine lights with key ON 5A Fuse blown 13A wire Engine dies Engine cranks Will not start No smoke 5A Fuse blown 13A wire Engine will not run No fault codes Three 7 5A fuses blown Wires 31B 31C 31D None Engine will run One of 7 5A fuses blown Engine will not start Engine cranks No smoke 10 A Fuses powering fuel injecti...

Page 23: ...pin 9 of the OEM harness Engine will not respond to remove throttle input 135 Yellow P100 3 100 3 High voltage detected at oil pressure signal pin 33 of the engine harness Default value used for oil pressure No engine protection for oil pressure 141 Yellow P100 4 100 4 Low voltage detected at oil pressure signal pin 33 of the engine harness Default value used for oil pressure No engine protection ...

Page 24: ...ernor will not work Trip information data that is based on mileage will be incorrect 243 None P121 4 513 4 Error detected in the exhaust brake relay enable control circuit at pin 42 of the engine harness Exhaust brake will not work 245 None S033 4 647 4 Error detected in the fan clutch relay enable circuit at pin 31 of the engine harness Electronic control module ECM can not control the engine coo...

Page 25: ...ellow S233 2 1077 2 VP44 fuel pump controller battery voltage measurement is outside the range between 6 and 24 VDC Engine will lose power and may shut down 367 Red P190 11 1078 11 VP44 fuel pump speed position sensor signal lost Fueling to injectors disabled and engine will shut down 368 Yellow S254 8 1078 8 The VP44 fuel pump controller can not achieve the timing value being commanded by the eng...

Page 26: ... detected at the throttle position sensor 5 VDC supply pin 29 of the OEM harness Engine idles when idle validation switch indicates idle and ramps up to a default set speed when idle validation switch indicates off idle 391Yellow S017 11 632 11 Error detected in VP44 power supply relay enable circuit at pin 43 of the engine harness Possible no effect on performance or engine may not run 415 Red P1...

Page 27: ... die or run rough 442 Yellow P168 0 168 0 Voltage detected at ECM power supply pins 38 39 and 40 of the engine harness indicates the ECM supply voltage is above the maximum system voltage level None on performance 443 Yellow S2321 620 1 Low voltage detected at throttle position sensor 5 VDC supply pin 29 of the OEM harness Engine idles when idle validation switch indicates idle and ramps up to a d...

Page 28: ...e torque curves Normal torque curve is used 529 Yellow S0513 703 3 Error detected in the Dual Output Driver B circuit pin 21 of the engine harness The device controlled by the Dual Output Driver B signal will not function properly 551Yellow P0914 0914 Idle validation signals on pins 25 and 26 of the OEM harness indicate no voltage on either pin Engine will only idle 599 Red S02514 64014 The dual o...

Page 29: ...65E Turbo Motor Grader Service Manual Section 1 Engine Service 1 00_2006 03 1 12 This page intentionally left blank ...

Page 30: ...Service Manual Section 2 Operator s Platform and Controls Service 1 00_2006 03 ...

Page 31: ......

Page 32: ...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 handholds when climbing on or off machine Controls may move and inadvertently cause machine travel or implement movement 7 Do not permit anyone but the o...

Page 33: ...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 34: ...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 35: ...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 36: ...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 37: ...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 38: ...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 39: ...65E Turbo Motor Grader Service Manual Section 2 Operator s Platform and Controls Service 1 00_2006 03 2 x This page intentionally left blank ...

Page 40: ...ional and Other Left Hand Controls 2 10 Removal 2 10 Installation 2 12 Steering Wheel 2 13 Removal 2 13 Installation 2 13 Side View Mirror 2 14 Mirror Removal 2 14 Mirror Support Removal 2 14 Mirror Support Installation 2 14 Mirror Installation 2 14 Rear View Mirror 2 15 Removal 2 15 Installation 2 15 Console Tilt Mechanism 2 16 Removal 2 16 Installation 2 17 Control Lock 2 18 Removal 2 18 Install...

Page 41: ...on 2 Operator s Platform and Controls Service 1 00_2006 03 2 xii Throttle Linkage Engine Speed Adjustment 2 30 Low Idle Setting 2 30 High Idle Setting 2 31 Throttle Lever Adjustment 2 32 Throttle Pedal Adjustment 2 33 Door Latch Adjustment 2 34 ...

Page 42: ... 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 43: ...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 44: ...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 45: ...65E Turbo Motor Grader Service Manual Section 2 Operator s Platform and Controls Service 1 00_2006 03 2 4 Cab ...

Page 46: ...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 47: ...65E Turbo Motor Grader Service Manual Section 2 Operator s Platform and Controls Service 1 00_2006 03 2 6 ...

Page 48: ...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 49: ... 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 50: ... 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 51: ...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 52: ...06 03 Section 2 Operator s Platform and Controls 2 11 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 53: ... 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 54: ...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 55: ...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 56: ... 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 57: ... 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 58: ...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 59: ...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 60: ...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 61: ...m and Controls Service 1 00_2006 03 2 20 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 62: ...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 63: ...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 64: ... 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 65: ... 00_2006 03 2 24 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 66: ...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 67: ...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 68: ...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 69: ...rator s Platform and Controls Service 1 00_2006 03 2 28 Brake Valve Plunger Clearance Adjustment Step 1 Adjust set screw 7 to provide a clearance of 0 02 inch between plunger of brake valve 5 and bracket 4 Step 2 Lock set screw 7 in place with jam nut 8 ...

Page 70: ... 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 71: ... 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 72: ... 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 73: ...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 74: ...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 75: ...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 76: ...Service Manual Section 3 Transmission Service 1 00_2006 03 ...

Page 77: ......

Page 78: ... 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 handholds 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 79: ...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 80: ...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 81: ...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 82: ...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 83: ...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 84: ...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 ...

Page 85: ...65E Turbo Motor Grader Service Manual Section 3 Transmission Service 1 00_2006 03 3 x This page intentionally left blank ...

Page 86: ... 1 00_2006 03 Section 3 Transmission 3 xi CONTENTS Mounting Transmission onto Engine 3 2 ZF Description of the Fault Codes for ERGO Control EST37 Manual ZF Technical Data Description Operation Maintenance Diagnostic System Manual ZF Repair Manual ...

Page 87: ...65E Turbo Motor Grader Service Manual Section 3 Transmission Service 1 00_2006 03 3 xii This page intentionally left blank ...

Page 88: ... Electrical section for con verter information The transmission and converter can be viewed by removing the vent covers on each side of the machine Transmission error fault codes are displayed on the transmission display located on the RH instrument panel at the operator s platform In order of occurrence this section contains the following information Procedure for mounting the transmission onto e...

Page 89: ...ing surfaces between transmission housing and engine flywheel housing No gasket or sealant is used between surfaces Step 2 Using a suitable lifting device position transmission 4 onto engine flywheel housing 3 as follows a Align flywheel slots 1 with bolt heads 6 b Align turbine spud shaft 5 with engine pilot diameter 2 5 6 4 3 3 4 2 1 ...

Page 90: ...ecure transmission housing to engine flywheel housing using 12 bolts Torque bolts to 47 Nm 35 Ib ft Step 5 Remove two mounting bolts from electronic control module ECM 1 Remove module from engine Step 6 Remove two mounting bolts from cover plate 1 Remove plate from engine to access flywheel bolt holes and transmission flex plate threaded holes 1 1 1 ...

Page 91: ...65E Turbo Motor Grader Service Manual Section 3 Transmission Service 1 00_2006 03 3 4 Step 7 Turn engine crankshaft 1 until one of four flywheel bolt holes 2 is aligned with access hole 3 1 2 3 ...

Page 92: ...through access hole 2 align flywheel bolt hole 1 with transmission flex plate threaded hole 3 Step 9 Apply Loctite 242 blue to threads of bolt not shown Secure flywheel to transmission flex plate using bolt Torque bolt to 47 Nm 35 Ib ft Step 10 Repeat previous three steps for other three bolts 1 2 3 1 ...

Page 93: ...er Service Manual Section 3 Transmission Service 1 00_2006 03 3 6 Step 11 Install cover plate 1 onto engine using two mounting bolts Step 12 Install electronic control module ECM 1 onto engine using two mounting bolts 1 1 ...

Page 94: ...e darf weder kopiert noch dritten Personen ohne unsere Erlaubnis 21 03 05 13 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 Diendorfer Sieger Abteilung ACET5 TE AB Datum 2005 04 05 03 10 01 Description of the fault codes for ERGO Control EST37 document created for customer Five Star jjjj 04 tt ...

Page 95: ...ZF Friedrichshafen AG 05 04 05 Faultcodes ERGO Control EST37A Seite 2 von 30 Index of changes date index comment software version ...

Page 96: ...l 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 turbine speed drops NN not neutral...

Page 97: ... direction while driving in neutral only displayed if no fault is detected spanner WR warning retarder temperature changes between actual gear direction while driving in neutral only displayed if no fault 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 sp...

Page 98: ...s in neutral you have to restart the TCU ignition off on E engine speed too low Ö raise engine speed E engine speed too high Ö lower engine speed T transmission oil temperature too low Ö heat up transmission T transmission oil temperature too high Ö cool down transmission FT transmission temperature not in defined range during calibration Transmissions stays in neutral you have to restart the TCU ...

Page 99: ...s 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 position for pressed pedal out ...

Page 100: ...tor 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 shift the transmission into neu...

Page 101: ...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 if TCU detects a valid signal for the direction at the shift lever 13 5020 12 LOGICAL ERROR AT E NGINE D ERAT...

Page 102: ...SMISSION SUMP 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 check the cable from TCU to the sensor check the connectors check the temperature sen...

Page 103: ...cable is defective and is contacted to vehicle ground temperature sensor has an internal defect connector pin is contacted to vehicle ground no reaction TCU uses default temperature OP Mode normal check the cable from TCU to the sensor check the connectors check the temperature sensor 29 5130 3 S C TO BATTERY VOLTAGE OR O C AT P ARKING BRAKE SENSOR INPUT the measured voltage is too high cable is d...

Page 104: ...0 V at speed input pin cable is defective and is contacted to battery voltage cable has no connection to TCU speed sensor has an internal defect connector pin is contacted to battery voltage or has no contact OP Mode substitute clutch control check the cable from TCU to the sensor check the connectors check the speed sensor 32 5140 4 S C TO GROUND AT ENGINE SPEED INPUT TCU measures a voltage less ...

Page 105: ...T TCU measures a voltage less than 0 45V at speed input pin cable connector is defective and is contacted to vehicle ground speed sensor has an internal defect OP Mode 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 36 5150 12 LOGICAL ERROR AT TURBINE SPEED ...

Page 106: ... LOGICAL ERROR AT INTERNAL SPEED INPUT TCU measures a internal speed over a threshold and at 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 sensor check the sensor gap This fault ...

Page 107: ... Mode substitute clutch control 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 check the sensor gap This fault is reset after power up of TCU 3E 5180 2 OUTPUT SPEED ZERO DOESN T FIT TO OTHER SPEED SIGNALS if transmission is not neutral and the shifting has finished TCU measures out...

Page 108: ...imit the voltage at K1 valve is too low cable connector is defective and has contact to vehicle ground cable connector is defective and has contact to another regulator output of the 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 connect...

Page 109: ...t of limit cable connector is defective and has no contact 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 77 55...

Page 110: ...able connector is defective and has 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 82 5510 ...

Page 111: ...efective and has contact to vehicle ground cable connector is defective and has contact to another regulator output of the 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 che...

Page 112: ... O C AT CLUTCH KR the measured resistance value of the valve is out of limit cable connector is defective and has no contact 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 ...

Page 113: ... an internal defect connector has no connection to TCU 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 94 5570 4 S C TO GROUND AT RELAY STARTER INTERLOCK TCU detected a wrong voltage at the output pin that looks like a s c to vehicle ground cable is defe...

Page 114: ...OP Mode normal 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 A4 5620 4 S C TO GROUND AT WARNING SIGNAL OUTPUT 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 warning device h...

Page 115: ...slipping clutch low pressure at clutch K1 low main pressure wrong signal at internal speed sensor wrong signal at output 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 pressure at clutch K1 check main pressure in the system check sensor gap at internal spe...

Page 116: ...IPPAGE AT CLUTCH K4 TCU calculated a difference speed at TCU calculates a differential speed at closed clutch K4 If this calculated value is out of range TCU interprets this as slipping clutch low pressure at clutch K4 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...

Page 117: ... shutdown check pressure at clutch KR check main pressure in the system check sensor gap at internal speed sensor check sensor gap at turbine speed sensor check signal at internal speed sensor check signal at turbine speed sensor replace clutch B7 5700 0 OVERTEMP SUMP TCU measured a temperature in the oil sump that is over the allowed threshold no reaction OP Mode normal cool down machine check oi...

Page 118: ...connector pin is contacted to vehicle ground no reaction OP Mode 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 C5 5770 3 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 defe...

Page 119: ...are supplied from AU1 check the power supply at the pin AU1 should be appx 5V fault codes no 21 to no 2C may be a reaction of this fault D3 5820 4 LOW VOLTAGE AT BATTERY measured voltage at power supply is lower than 10 V 12V device lower than 18 V 24V device shift to neutral OP Mode TCU shutdown check power supply battery check cables from batteries to TCU check connectors from batteries to TCU D...

Page 120: ...ends data to the display and measures allways a high voltage level on the connector cable or connectors are defective and are contacted to battery voltage display 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 E4 5860 4 S C TO GROUND AT DISPLAY OUTPUT TCU sends data to the display and measures allways a h...

Page 121: ...or from another vehicle transmission stay neutral OP Mode TCU shutdown Reprogramm the correct configuration for the vehicle e g with cluster controller F3 5910 13 APPLICATION ERROR something of this application is wrong transmission stay neutral OP Mode TCU shutdown replace TCU This fault occurs only if an test engineer did something wrong in the application of the vehicle F5 5930 7 CLUTCH FAILURE...

Page 122: ...ZF Friedrichshafen AG description of fault codes for ERGO Control 97 09 18 Seite 29 von 30 ...

Page 123: ...round R 12 R R 1G 0 R 2G R or R 1G R R 2G 0 for s c to ground G is connected to vehicle ground short cut to battery R 12 R R 1G 0 R 2G R or R 1G R R 2G 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 R 12 R 1P R 1C R 2P R 2C short cut to ground R 12 0 R 1C R 2C 0 R 1P R 2P short cut to battery R 12 0 R 1C R 2C...

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Page 178: ...Order No 5871 146 002 ZF ERGOPOWER 6 WG 115 ZF Passau GmbH Donaustr 25 71 D 94 034 Passau ...

Page 179: ...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 180: ...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 181: ...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 182: ... 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 183: ...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 184: ... 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 185: ...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 186: ...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 187: ...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 188: ...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 189: ...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 190: ...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 191: ...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 192: ... 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 193: ...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 194: ...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 195: ... 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 196: ...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 197: ...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 198: ...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 199: ... 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 200: ...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 201: ...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 202: ...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 203: ...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 204: ...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 205: ...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 206: ...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 207: ...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 208: ...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 209: ...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 210: ...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 211: ...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 212: ...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 213: ...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 214: ...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 215: ...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 216: ...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 217: ...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 218: ...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 219: ...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 220: ...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 221: ...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 222: ...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 223: ...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 224: ...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 225: ...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 226: ...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 227: ...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 228: ... 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 229: ...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 230: ...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 231: ...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 232: ...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 233: ...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 234: ...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 235: ...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 236: ...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 237: ...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 238: ...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 239: ...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 240: ... 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 241: ...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 242: ... 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 243: ...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 244: ...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 245: ... 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 246: ...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 247: ...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 248: ...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 249: ...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 250: ...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 251: ...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 252: ... 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 253: ... 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 254: ...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 255: ... 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 256: ... 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 257: ...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 258: ... 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 259: ...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 260: ...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 261: ... 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 262: ...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 263: ...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 264: ...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 265: ...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 266: ...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 267: ...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 268: ...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 269: ...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 270: ...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 271: ... 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 272: ...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 273: ... 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 274: ...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 275: ...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 276: ...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 277: ...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 278: ...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 279: ...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 280: ... 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 281: ... 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 282: ...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 283: ...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 284: ...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 285: ...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 286: ...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 287: ...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 288: ...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 289: ...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 290: ... 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 291: ...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 292: ...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 293: ...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 294: ...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 295: ...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 296: ...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 297: ...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 298: ...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 299: ...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 300: ... 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 301: ...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 302: ...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 303: ...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 304: ...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 305: ...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 306: ...Service Manual Section 4 Front Axle Service 1 00_2006 03 ...

Page 307: ......

Page 308: ...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 handholds 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 309: ... 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 310: ...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 311: ...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 312: ...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 313: ...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 314: ...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 316: ...t Axle Disassembly and Repair 4 9 LH Steering Knuckle and King Pin Removal 4 9 RH Steering Knuckle and King Pin Removal 4 12 LH Steering Knuckle and King Pin Installation 4 13 RH Steering Knuckle and King Pin Installation 4 18 LH Wheel Lean Pivot Pin Removal 4 19 LH Wheel Lean Pivot Pin Installation 4 21 RH Wheel Lean Pivot Pin Removal 4 22 RH Wheel Lean Pivot Pin Installation 4 22 Axle Oscillatio...

Page 317: ...65E Turbo Motor Grader Service Manual Section 4 Front Axle Service 1 00_2006 03 4 xii This page intentionally left blank ...

Page 318: ...lacement 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 is received by the steering wheel all pump flow is being directed to the mai...

Page 319: ...trol 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 138 4 mm 3 00 x 5 45 in Torque Values Front Wheel Lug Nuts 440 475 Nm 325 3...

Page 320: ...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 321: ...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 322: ... 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 323: ...g hoist or lift Step 2 Spin a front tire and mark the centerline using a scribe Repeat for the other tire Step 3 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 4 If toe in is incorrect loosen tie rod clamp bolts 2 3 Adjust length of tie rod by turning...

Page 324: ... 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 325: ...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 326: ...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 327: ...4 10 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 328: ...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 329: ...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 330: ...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 331: ...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 332: ...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 333: ...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 334: ...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 335: ...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 336: ...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 337: ...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 338: ...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 339: ...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 340: ...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 341: ... 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 342: ... 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 343: ...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 344: ... 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 345: ... 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 346: ...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...

Page 347: ...65E Turbo Motor Grader Service Manual Section 4 Front Axle Service 1 00_2006 03 4 30 This page intentionally left blank ...

Page 348: ...Please reference Eaton Publication C STCU TS002 pdf on this CD for further information on the Steering Control Unit ...

Page 349: ...Service Manual Section 5 Rear Axle and Tandem Service 1 00_2006 03 ...

Page 350: ......

Page 351: ...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 handholds when climbing on or off machine Controls may move and inadvertently cause machine travel or implement movement 7 Do not permit anyone but the operato...

Page 352: ...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 353: ...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 354: ... 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 355: ...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 356: ...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 357: ...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 358: ...65E Turbo Motor Grader Service Manual Section 5 Rear Axle and Tandem Service 1 00_2006 03 5 x This page intentionally left blank ...

Page 359: ...riveshaft 5 7 Removal 5 7 Installation 5 7 Rear Axle And Tandem Drive Assembly 5 8 Installation 5 8 Brakes Maintenance and Adjustment 5 9 General 5 9 Specifications 5 10 Service Brake 5 10 Parking Brake 5 11 Troubleshooting 5 11 Bleeding The Brakes 5 12 Parking Brake Cable Adjustment 5 13 Transmission End Adjustment 5 13 Lever End Adjustment 5 14 Parking Brake Switch 5 15 Brake Pedal 5 16 Pedal St...

Page 360: ...ection 5 23 Installation 5 23 Parking Brake Friction Pad Replacement 5 24 Rear Axle 5 24 Programmed Maintenance Schedule 5 24 Replacing Lube Oil 5 25 Assembling Leak Proof Components 5 26 Side Final Drives 5 26 Disassembly 5 26 Assembly 5 31 Center Section Unit 5 33 Disassembly 5 33 Assembly 5 38 Tandem Drive 5 48 Disassembly 5 48 Assembly 5 52 ...

Page 361: ...to 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 side SPECIFICATIONS Rear Axle Manu...

Page 362: ... 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 disconnecting brake lines be sure to have a container ready...

Page 363: ...rear chassis rails to support the chassis Step 6 Carefully roll 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 as...

Page 364: ...ove 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 Rotat...

Page 365: ...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 366: ... 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 367: ... 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 368: ...th 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 369: ...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 370: ...he 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 the transmission sump w...

Page 371: ...ystem 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 screw Inspect for leaks ...

Page 372: ...ineffective 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 373: ...m 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 374: ...but 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 375: ...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 376: ... 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 che...

Page 377: ...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 378: ...out 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 l...

Page 379: ...DISASSEMBLY 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 380: ...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 381: ... and Tandems 5 21 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 382: ...master 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 ...

Page 383: ...6 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 s...

Page 384: ...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 385: ...006 03 Section 5 Rear Axle and Tandems 5 25 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 386: ...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 387: ...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 388: ... Rear Axle and Tandems Service 1 00_2006 03 5 28 Step 5 Undo screws and remove reaction spring from brake piston Step 6 Use compressed air and draw out brake piston Step 7 Remove screw lock plate and washer retaining side gear carrier to wheel shaft ...

Page 389: ...3 Section 5 Rear Axle and Tandems 5 29 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 390: ...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 391: ... 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 392: ... 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 393: ... Rear Axle and Tandems 5 33 Center Section Unit Disassembly Step 1 Loosen screws retaining bevel pinion support to center case Remove unit from center case and position on proper stand Step 2 Loosen pinion nut position reaction tool on drive flange for unlocking wrench ...

Page 394: ...xle and Tandems Service 1 00_2006 03 5 34 Step 3 Remove drive flange Step 4 Remove bevel pinion from support Hammer on shank end being careful not to damage threads Step 5 Remove inner race of pinion shank bearing pre load shims spacer and remove lip seal ...

Page 395: ...ve 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 396: ...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 397: ...nd Tandems 5 37 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 398: ...ith 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 thr...

Page 399: ...ce 1 00_2006 03 Section 5 Rear Axle and Tandems 5 39 Step 4 Mount side gears with relevant bevel thrust washers on spider Step 5 Position spider assembly in half case Step 6 Position the second half case matching reference marks and lock screws ...

Page 400: ...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 401: ...rface 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 S...

Page 402: ...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 403: ...shims 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 loa...

Page 404: ... 5 44 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 405: ...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 406: ...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 407: ...compound position spacer on studs Mount ring gear using sealant on matching surfaces Using sealing compound insert side final drive assembly apply medium thread locking compound on nuts lock with a torque of 151 168 Ib ft 20 5 22 7 daNm Follow same assembling operations to assemble final drive assembly on opposite side ...

Page 408: ... 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 409: ...le and Tandems 5 49 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 410: ...65E Turbo Motor Grader Service Manual Section 5 Rear Axle and Tandems Service 1 00_2006 03 5 50 Step 11 Remove plug 2 with fitting then remove plugs 1 3 4 and 5 ...

Page 411: ...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 412: ...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 413: ... 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 othe...

Page 414: ...p 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 pl...

Page 415: ...e and Tandems 5 55 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 416: ...one 7 with CM 183 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 High side is end of rear axle with oil fill plug ...

Page 417: ...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 Torque all cap screws to 2...

Page 418: ...urbo Motor Grader Service Manual Section 5 Rear Axle and Tandems Service 1 00_2006 03 5 58 Step 41 Apply pipe dope to threads of plugs 1 2 3 4 and 5 Install plug 2 with fitting then install plugs 1 3 4 and 5 ...

Page 419: ...and 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 420: ...stening 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 cov...

Page 421: ...Service Manual Section 6 Electrical Service 1 00_2006 03 ...

Page 422: ......

Page 423: ...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 handholds 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 424: ... 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 425: ...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 426: ...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 427: ...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 428: ...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 429: ...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 431: ...10 Horn 6 10 Reverse Alarm 6 10 Special Equipment 6 10 Front and Rear Wiper Motors 6 10 Special Tools 6 11 Troubleshooting 6 12 Preliminary Troubleshooting 6 13 Troubleshooting Chart 6 16 Batteries 6 17 Battery Removal 6 17 Battery Installation 6 18 Component Locations 6 19 Front Console 6 19 Instrument Panel Group 6 21 Below Instrument Panel 6 22 Right Hand Side of Grader 6 23 Left Hand Side of G...

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Page 433: ...the horizontal position and is disabled when the key is in the vertical position to break the electrical continuity The electrical system is protected by two high amperage fusible links between the starting solenoid and the ignition switch in addition to standard automotive type fuses Wiring harnesses are grouped together according to location or function An indicator monitor on the front console ...

Page 434: ...OLENOIDS 2A 2A START ON OFF ACC FUSE FUSE 30A 53 GY 58 PK 10A TO CONVERTER PIN 9 13 OR 30A FUSE 61 OR 2A 2A 2A 2A BANK SLOPE SOLENOIDS 2A 2A ADJUSTMENT SWITCH 1 BLOWER SWITCH 5A 2 H 61H OR M L 61M OR 61L OR 2 BLADE PITCH SOLENOIDS 2A 2A M COMPRESSER MOTOR M L H BATTERY 1 RD THERMISTOR BLOWER M 0 BK 24V RED 5 0 BK 31S RD S 0 BK F 31M RD H P M 0 BK 0 BK 31D RD 31C RD C D E 0 BK 0 BK 23 PIN ENGINE CO...

Page 435: ... 49A GY 2 0 BK TO BRAKE LIGHTS 44A RD 0 BK 10 PSI 0 BK BRAKE DIFFERENTIAL PRESSURE SWITCH STARTER RELAY STARTER MOTOR 87 33B YL 4 85 87a ASA WH 1 RD 21A WH ENGINE 60 PIN CONNECTOR ENGINE SHUT DOWN RED RED ALTERNATOR WARNING MAIN POWER RELAY HOURMETER 6 FUSE 12 OR 5A 30 YL 6 B 1 RD 86 30 START ON OFF ACC 21 WH 1 RD BATTERY TURN SIGNAL SWITCH 0 BK COLD START ACTUATOR SOLENOID 27 RD 28 BK 29 GY ALTER...

Page 436: ...T BU DIAGNOSTIC 89 LT BU FILTER SWITCH 77 LT BU 80 LT BU SHIFT LEVER D C B A 82 LT BU 83 YL SPEEDOMETER 84 LT BU 87 YL 89 LT BU 90 LT BU 92 LT BU 93 LT BU 95 GN 96 GN 97 GN AS LT BU CONVERTER 1 6 9 8 7 5 4 2 3 12 10 11 99A LT BU 99 LT BU 88 LT BU 88A LT BU 65A RD 30A FUSE 65 RD 26 RD 13 OR FUSE 5A FUSE 7 5A FUSE 7 5A AS LT BU GROUND 0 BK TO BACK UP ALARM RELAY TO PARK BRAKE SWITCH TO CHECK TRANSMI...

Page 437: ...1 1 3 2 41L PK 41H DK GN 7 4 FUSE 41T BR 1 10A TO BRAKE PRESSURE SWITCH 41TA BR 44A RD GAUGE BACK LIGHTS RIGHT TAILLIGHT RD BL BRAKE RD BRAKE WH 46A PK TO MAIN POWER RELAY 43 OR 1 RD MULTI FUNCTION SWITCH 8 5A HORN PUSH BUTTON 10A FUSE 46 BR FLASHER C START ON OFF ACC 1 RD 10A FUSE 18 PK HAZARD LIGHT SWITCH 10A 64 GN 9 FUSE 64A GN 6 3 5 48 GR 2 47 YL LEFT TAILLIGHT BL HORN WH LEFT REAR TURN SIGNAL...

Page 438: ...SSION TEMPERATURE GAUGE I G 32GT LT BU FUSE 7 5A DEFROSTER FAN SWITCH 3 2 5A 1 63 OR 62A OR 62B OR 30A FUSE 0 BK 3 3 1 30A FUSE WIPER SWITCH B 63P OR 63W OR W H 62 OR 63H OR L 63L OR P 63B OR B WIPER MOTOR WASHER PUMP M M 62P OR 62B OR 62L OR 62H OR 62W OR C A B D 0 BK 0 BK AIR CONDITIONING SWITCH 30A FUSE 500 OR 0 BK 510 OR RD 511 OR RD PRESSURE SWITCH 512 OR RD RELAY 86 30 87a 85 87 COMPRESSOR 5...

Page 439: ... 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 440: ...al circuit Voltage is measured in volts VOLTMETER Instrument for measuring force in volts of electrical current Voltmeters are connected in par allel to the points 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 ...

Page 441: ...0 degrees F Type Group 27 12 Volt Maintenance Free Capacity 72 Amp Hours No of Plates 14 per Cell 84 per Battery Weight 19 1 kg 42 Ib with Electrolyte Terminals Post Type Alternator Make Model Bosch Type Brush Type with Integral Voltage Regulator Rating 95 Amps Mounting Drive Engine Mounting with Belt Drive Starting Motor Make Denso R2 7 Type 12 Volt with Solenoid Rating 3 2 kW 4 2 Horsepower 12V ...

Page 442: ... Fiam 40310 Type EEC Approved 12 Volt Sound Power High Tone 130 Db Reverse Alarm Make Model Preco lnc Model 380 Type Electronic Solid State Sealed Polarity Protected Voltage 6 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 L...

Page 443: ...06 03 Section 6 Electrical 6 11 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 444: ... 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 445: ...ve 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 IMPORTANT Turn OFF master switch before replacing fuses Isolate cause of blown fuse before replacing fuse Always...

Page 446: ... Electrical Service 1 00_2006 03 6 14 Step 3 Fuses are located under instrument panel 1 on right hand side of seat Raise instrument panel for access Step 4 Engine control fuses 1 are located at left hand rear side of engine near flywheel housing 1 1 ...

Page 447: ... all connections are tight and clean and that there are no frayed wires which may cause shorts opens grounds or high resistance in the system 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 four bolts 2 and radiator grill four clamp bolts 3 NOTE Batteries are maintenance free and do n...

Page 448: ...es sary Solenoid does not move pinion into engagement with flywheel Open in starter activation circuit Disconnect wire 21A at starter sole noid 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 asse...

Page 449: ... is running Step 1 Ensure engine is turned OFF I Step 2 Open right side engine compartment access door and place master switch 1 in OFF key position horizontal Step 3 Remove four bolts 1 securing lower rear engine compartment panel then remove panel Step 4 Remove four clamp bolts 2 securing upper radiator grill cover then remove cover Turn OFF master switch before working around batteries 1 ...

Page 450: ... of 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 wit...

Page 451: ...her 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 The amber indicator lights are transmission discon nect clutch and park brake The red warning lights are check brakes check transmission alternator and engine shutdown Front Console Blade...

Page 452: ...rbo Motor Grader Service Manual Section 6 Electrical Service 1 00_2006 03 6 20 Flasher Relay Hourmeter Multifunction Switch Turn Signals Taillights Headlights High and Low Beam Selection Horn Behind Hourmeter ...

Page 453: ...65E Turbo Motor Grader Service Manual Service 1 00_2006 03 Section 6 Electrical 6 21 Instrument Panel Group ...

Page 454: ...5E Turbo Motor Grader Service Manual Section 6 Electrical Service 1 00_2006 03 6 22 Below Instrument Panel Main Power Relay Transmission Control Unit TCU Throttle Position Sensor TPS Back up Alarm Relay ...

Page 455: ... Motor Grader Service Manual Service 1 00_2006 03 Section 6 Electrical 6 23 Right Hand Side of Grader Starter Oil Pressure Sensor Alternator Battery Disconnect 12 24 Volt Converter Fuses for 12 24 Volt Converter ...

Page 456: ...65E Turbo Motor Grader Service Manual Section 6 Electrical Service 1 00_2006 03 6 24 Starter Relay Neutral Start Relay ...

Page 457: ...65E Turbo Motor Grader Service Manual Service 1 00_2006 03 Section 6 Electrical 6 25 Brake Differential Pressure Switch ...

Page 458: ...bo Motor Grader Service Manual Section 6 Electrical Service 1 00_2006 03 6 26 Left Hand Side of Grader Engine Temperature Sender Engine Electronic Control Module ECM Oil Pressure Switch Engine ECM Power Fuses ...

Page 459: ...65E Turbo Motor Grader Service Manual Service 1 00_2006 03 Section 6 Electrical 6 27 Engine Diagnostic Connectors Engine Diagnostic Connectors Connected for Flashing Out Engine Codes ...

Page 460: ...65E Turbo Motor Grader Service Manual Section 6 Electrical Service 1 00_2006 03 6 28 Injection Pump Relay ...

Page 461: ...65E Turbo Motor Grader Service Manual Service 1 00_2006 03 Section 6 Electrical 6 29 Park Brake Switch ...

Page 462: ...ice Manual Section 6 Electrical Service 1 00_2006 03 6 30 Bottom of Grader Brake Lights Pressure Switch Transmission Inching Pressure Switch Accessed through Bottom Cover of Grader Below Operator Platform Below Operator Platform ...

Page 463: ...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 464: ...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 465: ...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 466: ...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 467: ...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 468: ...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 469: ...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 ...

Page 470: ......

Page 471: ...Service Manual Section 7 Hydraulics Service 1 00_2006 03 ...

Page 472: ......

Page 473: ...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 handholds 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 474: ... 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 475: ...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 476: ...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 477: ...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 478: ...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 479: ...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 481: ...otor 7 13 Adjustments 7 14 Control Lever Linkage 7 14 Adjustments 7 15 Disassembly And Repair 7 18 Pump 7 18 Removal 7 19 Installation 7 22 Control Valve 7 25 Valve Removal 7 25 Valve Disassembly 7 28 Valve Assembly 7 29 Valve Installation 7 30 Valve Sections 7 33 Standard Section Disassembly 7 34 Float Section Disassembly 7 35 Inspection 7 36 Standard Section Assembly 7 37 Float Section Assembly ...

Page 482: ...hift Cylinder Installation 7 72 Moldboard Side Shift Cylinder Removal 7 73 Moldboard Side Shift Cylinder Installation 7 73 Moldboard Pitch Cylinder Removal 7 74 Moldboard Pitch Cylinder Installation 7 75 Articulation Cylinder Removal 7 75 Articulation Cylinder Installation 7 77 Wheel Lean Cylinder Removal 7 78 Wheel Lean Cylinder Installation 7 79 Steering Cylinder Removal 7 80 Steering Cylinder I...

Page 483: ... 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 485: ...65E Turbo Motor Grader Service Manual Service 1 00_2006 03 Section 7 Hydraulics 7 3 HYDRAULIC SCHEMATIC ...

Page 486: ...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 487: ...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 488: ...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 489: ...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 490: ...t cover Step 3 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 p...

Page 491: ...lockwise 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 valve Torque bolts to 47 53 N...

Page 492: ...ted 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 Remove four bolts 1 securing RH side vent cover 2 then remove vent cover Step 3 Remove cap from test point 1 on front half of tandem pump at rear of transmission Step...

Page 493: ...emove 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 Control Flow C Excess Flow D L...

Page 494: ...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 495: ...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 496: ...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 497: ... 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 498: ...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 499: ...rader Service Manual Section 7 Hydraulics Service 1 00_2006 03 7 18 DISASSEMBLY AND REPAIR Pump The pump 2 is attached to the back of the transmission 1 A direct drive shaft through the transmission drives the pump 1 2 ...

Page 500: ...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 501: ... 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 502: ...ection 7 Hydraulics 7 21 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 503: ...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 504: ...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 505: ...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 506: ... 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 cavita tion 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 507: ...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 508: ... 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 509: ... 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 able...

Page 510: ...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 511: ...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 512: ...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 513: ... 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 514: ...osition 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 515: ... 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 516: ...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 517: ...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 518: ...stallation 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 519: ...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 520: ...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 521: ...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 522: ...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 523: ...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 524: ...r replace the valve Hoses And Fittings Hoses from the control 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...

Page 525: ...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 526: ...dle 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 circle selector valve...

Page 527: ...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 528: ...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 529: ...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 530: ...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 531: ...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 532: ...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 533: ...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 534: ... 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 535: ...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 536: ...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 537: ...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 538: ...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 539: ...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 540: ...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 541: ...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 542: ...03 Section 7 Hydraulics 7 61 Step 5 Remove coupler 1 Step 6 Remove bolts 2 attaching adapter 3 to gear box Remove adapter Step 7 Disassemble motor as needed Refer to Eaton publication 7 145 November 1996 for T Series Geroler Motors at the end of this section ...

Page 543: ...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 544: ... to Section 19 Moldboard and Implements 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 545: ...move 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 546: ... 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 547: ...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 548: ...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 549: ... 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 550: ...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 551: ...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 552: ...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 553: ...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 554: ...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 555: ...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 556: ... 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 557: ... 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 558: ...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 559: ...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 560: ...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 561: ...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 562: ...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 563: ... 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 564: ...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 565: ... 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 566: ...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 567: ...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 568: ... 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 569: ...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 570: ...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 571: ...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 572: ...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 573: ...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 574: ... 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 575: ...refully remove fill cap cover and O ring from top of reservoir Discard O ring IMPORTANT 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 ...

Page 576: ...Please reference Eaton Publication 06 623 pdf on this CD for further information on the L2 Series Gear Pump ...

Page 577: ...Please reference Eaton Publication 07 145 pdf on this CD for further information on the T Series Geroler Motor ...

Page 578: ...Service Manual Section 8 Moldboard and Implement Service 1 00_2006 03 ...

Page 579: ......

Page 580: ...ployer 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 handholds 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 581: ...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 582: ...ers 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 ...

Page 583: ...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 584: ... 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 585: ...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 586: ...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 587: ...65E Turbo Motor Grader Service Manual Section 8 Moldboard and Implement Service 1 00_2006 03 8 x This page intentionally left blank ...

Page 588: ...t Dozer Blade 8 4 Rear Ripper 8 4 Troubleshooting 8 4 Troubleshooting Chart 8 5 Disassembly And Repair 8 6 Drawbar 8 6 Removal 8 6 Installation 8 6 Circle 8 7 Removal 8 7 Installation 8 9 Swivel Yoke 8 12 Removal 8 12 Installation 8 12 Moldboard 8 14 Removal 8 14 Installation 8 15 Saddle 8 16 Removal 8 16 Installation 8 17 Front Scarifier 8 20 Removal 8 20 Installation 8 20 Front Dozer Blade 8 21 ...

Page 589: ...65E Turbo Motor Grader Service Manual Section 8 Moldboard and Implement Service 1 00_2006 03 8 xii This page intentionally left blank ...

Page 590: ...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 591: ... 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 592: ...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 Moveable 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 593: ...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 594: ...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 595: ... 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 596: ...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 597: ...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 598: ... 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 599: ...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 600: ...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 601: ...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 602: ...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 603: ...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 604: ...ft 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 0...

Page 605: ...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 606: ...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 607: ...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 608: ... 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 609: ...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 610: ...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 611: ...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 612: ... 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 613: ...rvice 1 00_2006 03 8 24 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 ...

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