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NorAM 65E Turbo, Operator'S Manual

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NorAM 65E Turbo Operator'S Manual Download Page 83

NORAM 65ET GRADER

 

3-21

Lubrication and Maintenacne

3

NOTE:  

The procedure to adjust the engine valve lash for the C4.4 engine is different from conventional engines, 

due to the altered valve opening and closing events.

Setting The Valve Lash

(A) Angled feller gauge

(1) Adjustment screw

(2) Locking screw

WARNING: 

ACCIDENTAL ENGINE STARTING CAN CAUSE INJURY OR DEATH TO PERSONNEL. 

TO PREVENT ACCIDENTAL ENGINE STARTING, TURN THE IGNITION SWITH TO THE OFF 
POSITION AND PLACE A DO NOT OPERATE TAG AT THE IGNITION SWITCH LOCATION.

1. Remove the valve mechanism cover. Refer to the Cat Engine 
Manual, Disassembly and Assembly, “Valve Mechanism Cover - 
Remove and Install” for the removal procedure.

NOTE:  

When the valve mechanism cover is removed or 

installed, the electrical harness must be checked. Do not trap the 
injector harness when the valve mechanism cover is installed. Do 
not allow the harness to be in contact with the valve mechanism 
cover. Renew the harness, if the harness is damaged.

Table 1

Illustration 2

Illustration 3

Summary of Contents for 65E Turbo

Page 1: ...NORAM 65ET GRADER 01 SectTitle 0 65E TURBO Motor Grader Operator s Manual June 2009 EFF S N 9500 Catalog 13961 ...

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

Page 3: ...NORAM 65ET GRADER 0 1 SAFETY 0 1 GENERAL INFORMATION 1 1 OPERATION 2 1 LUBRICATION AND MAINTENANCE 3 1 SPECIFICATIONS 4 1 TROUBLESHOOTING 5 1 CONTENTS ...

Page 4: ...NORAM 65ET GRADER 0 2 ...

Page 5: ... IS USED TO WARN OPERATORS AND OTHERS TO EXERCISE EVERY APPROPRIATE MEANS TO AVOID A SURPRISE INVOLVEMENT WITH MACHINERY DANGER THE WORD DANGER DENOTES A FORBIDDEN PRACTICE IN CONNECTION WITH A SERIOUS HAZARD FAILURE TO FOLLOW THE CAUTION WARNING DANGER AND STOP INSTRUCTIONS MAY RESULT IN SERIOUS BODILY INJURY OR DEATH MACHINE SAFETY Additional precautionary statements ATTENTION and IMPORTANT are ...

Page 6: ...odify or alter machine or any of its components or machine functions without first consulting an authorized dealer 12 Do not operate machine without ROPS or FOPS in place and in good condition 13 Install all shields before starting or operating machine 14 Do not operate an unsafe machine If items are found during inspection that render a machine unsafe be sure any malfunctions are remedied before ...

Page 7: ...laws concerning slow moving emblems flashers rotating beacons and licensing requirements 21 Obey flagmen safety signals and signs 22 Dim vehicle lights when meeting a vehicle at night Make sure lights are adjusted to prevent blinding oncoming drivers 23 Reduce speed before turning or applying brakes 24 Use extreme caution and avoid hard application of brakes when towing 25 Always check overhead cl...

Page 8: ...hicle 11 Always turn master switch to the off position when maintaining or servicing machine 12 When using compressed air for cleaning parts use safety glasses with side shields or goggles Limit pressure to 30 psi 13 Escaping diesel hydraulic fluid under pressure can penetrate skin causing serious injury 14 DO NOT use your hand to check for leaks Use a piece of cardboard to search for leaks Stop e...

Page 9: ... safe 9 Keep equipment clean and properly maintained 10 Do not drive equipment near open fires 11 Never use fuel for cleaning purposes 12 Arrange fuel purchases so that summer grade fuels are not held over and used in winter OPERATOR AREA 1 The motor grader is equipped with Roll Over Protection System ROPS and a Falling Object Protection System FOPS which must be maintained in a serviceable condit...

Page 10: ...hine They are intended for your personal safety and for those working with you Please take this manual and walk around your machine to note the content and location of these warning signs Review these warning signs and the operating instructions detailed in this manual with the operators of this machine ...

Page 11: ...n the top canopy etc IMPORTANT Do not attempt to weld or straighten ROPS or FOPS components ROPS FOPS MAINTENANCE AND INSPECTION To continue to provide the maximum protection available the ROPS and FOPS must be maintained for the life of the machine Every 500 hours or three months 1 Check torque of cab and ROPS mounting bolts Torque cab mounting bolts 1 to 745 814 N m 550 600 ft lbs Torque ROPS mo...

Page 12: ...1 NORAM 65ET GRADER 0 8 Safety 0 ...

Page 13: ...y the dealer to ensure that it is delivered in optimum condition To maintain this condition and ensure trouble free operation it is important that the routine services as specified in this manual are carried out at the recommended intervals All data given in this book is subject to production variations Dimensions and weights are approximate only and the illustrations do not necessarily show equip...

Page 14: ... and rear mounted attachments to compliment the use of the mid mounted moldboard References will be made throughout this manual to describe location and direction Unless otherwise specified reference to direction is from the operator s seat TERMINOLOGY Front and rear modules are separated at the articulation pins in front of the cab The moldboard is suspended from the front frame through a series ...

Page 15: ...place away from the machine The vehicle serial number and point of manufacture is stamped into the serial tag 1 placed on the left side of the steering column The vehicle serial number 1 is also stamped into to right side of the frame below the operators platform An engine identification plate 1 is located on the top of the Cummins engine left picture The identification plate is located on the lef...

Page 16: ... 1 4 General Information 1 The differential identification plate 1 is located on the right tandem support The transmission identification plate 1 is located on the front side of the transmission below the drive shaft 1 1 ...

Page 17: ...OPERATE WITH FAN AND BELT GUARDS REMOVED OR BROKEN Engine access doors are located on each side of the engine cover A lock is in the handle 1 Turn the handle 180 to unlatch The left side door provides access to the following CUMMINS ENGINE CAT ENGINE 1 Engine air filter 1 Engine air filter 2 Primary fuel filter 2 Primary fuel filter 3 Secondary fuel filter 3 Secondary fuel filter 4 Engine oil dips...

Page 18: ...witch 1 Electric master switch 2 Brake reservoirs 2 Brake reservoirs 3 Engine oil filter 3 Washer fluid tank On top of the engine cover is the radiator access door 1 The hydraulic reservoir fill cap 2 is inside the right side door panel The transmission oil fill neck and dipstick 1 is located behind the right side access door 1 2 3 1 2 3 1 2 1 ...

Page 19: ...imates The cab is also FOPS and ROPS certified LOCK PINS Lock pins are provided to prevent accidental movement of hydraulic cylinders during maintenance or transport The articulation lock pin 1 prevents articulation and should be stored in the storage bracket 2 during operation except when loading machine on a trailer The wheel lean lock pin 1 prevents side to side movement of the front steering w...

Page 20: ...hts and turn signals 2 are mounted at the front of the machine Two optional work lights 3 may be mounted on the top of the cab facing forward Two optional work lights 1 are mounted on top of the cab facing rearward Turn signals taillight brake lights 2 are mounted at the rear IMPORTANT Do not use work lights for highway travel 1 2 3 1 2 ...

Page 21: ... Front Console 2 Right Side Console 3 Floor and Ceiling Controls The following information provides a general overview of location and function but does not provide detailed operational information Thoroughly read Section 2 Operation for details on how to use controls and read instruments before operating the machine WARNING DO NOT OPERATE MACHINE UNTIL THOROUGHLY FAMILIAR WITH THE LOCATION AND OP...

Page 22: ...lock to engage Articulation Control Lever The articulation control lever 1 operates the articulation cylinders causing the center of the motor grader to pivot Front Wheel Lean Control Lever The front wheel lean has a lock pin which must be removed manually to actuate wheel lean The front wheel lean control lever 2 controls the angle of the front wheels Left Side Moldboard Height Control Lever The ...

Page 23: ...ctivated changes the pitch of the moldboard Circle Rotate Control Lever CAUTION ROTATING THE MOLDBOARD CAN CAUSE CONTACT WITH THE FRONT TIRES AND THE REAR MODULE USE CAUTION AT EXTREME MOLDBOARD ANGLES TO PREVENT DAMAGE TO THE TIRES OR ARTICULATION PINS The circle rotate control lever 3 rotates the circle and consequently the moldboard Circle Shift Control Lever NOTE On machines equipped with the ...

Page 24: ...lement Control Leverl NOTE Front and rear mounted implements each have a lock pin which must be removed manually to raise and lower the implement otherwise equipment damage will result NOTE On machines equipped with front and rear implements the lever control changes between front and rear implements according to the position of the implement function switch The implement control lever 3 operates ...

Page 25: ...move the shift lever forward to select forward movement or move the lever rearward to select rearward movement The transmission will shift into first gear forward or first gear reverse Move the lever to the right to increase transmission speeds and to the left to decrease The selected gear will be displayed on the digital display 4 When shifting from forward to reverse or increasing or decreasing ...

Page 26: ...e console Blower Fan Switch Cab equipped models This four position rotary switch 6 controls the blower fan for the heating and air conditioning systems There are three fan speeds Wiper and Washers Cab equipped models The front wiper switch 7 operates the front wiper and washer The rear wiper switch 8 operates the rear wiper and washer The wipers have two speeds Rotating Beacon Switch A rotating be...

Page 27: ...error message will automatically display on the main menu Pressing the button below the Menu circle 1 enters into the menu screen to view diagnostics Main Display Screen Menu Screen Use the buttons below the up and down arrows to move the box over the name of the screen you wish to enter Use the button below the right arrow to enter screen Esc always exits to previous screen View Engine Diagnostic...

Page 28: ...n 1 View Engine Diagnostics 2 Screen View Transmission Diagnostics Screen View Can Screen View Errors Screen Number of active errors is displayed constantly Occurrences of displayed error and error descriptions scroll continuously on the display ...

Page 29: ...der when the brake pedal is depressed To activate press the button under the menu icon on the display Scroll down the menus using the button under the down arrow icon Highlight system settings and press the button under the right arrow icon Scroll down until inching is displayed To select inching menu press the button under the right arrow icon Press the up or down arrows followed by the right arr...

Page 30: ...rking brake lever 1 engages and disengages the parking brake and transmission A thumb operated lock release button 2 on the end of the lever releases the ratchet mechanism When engaged the parking brake indicator on the display will illuminate Storage Box On the left floor of the cab is a lockable storage box 3 Inside is a slot for storing the Operator s Manual and a chain lanyard to prevent the m...

Page 31: ...hile welding is in progress 4 Always have an assistant standing by with a fire extinguisher to put out any fires that may start due to welding procedures 5 Always clean area of any grease fuel or oil before welding Battery Charging Never make or break any of the charging circuit connections including the connection at the batteries when the engine is running Never short any of the charging compone...

Page 32: ...ng any electrical circuits 1 Remove battery box cover under the radiator grill 2 Attach charging device booster battery or battery charger 1 to terminals of one battery at a time Observe polarity connecting positive to positive 2 before connecting negative to negative 3 3 Allow battery time to charge Longer charges at lower current are recommended 4 Disconnect charging device negative terminal bef...

Page 33: ...KS OR SLIPS IT MAY WHIP WITH SUFFICIENT FORCE TO CAUSE SERIOUS INJURY WHEN USING A CHAIN ATTACH CHAIN WITH HOOK OPEN SIDE FACING UP SO IF THE HOOK SLIPS IT WILL DROP DOWN INSTEAD OF FLYING UP Attach a tow bar to the front of the motor grader If chains are used they must be of sufficient size to handle the load If possible operate the engine to provide steering braking and lubrication to rotating c...

Page 34: ...1 NORAM 65ET GRADER 1 22 General Information 1 ...

Page 35: ...e instrument panel is located on the right To open the storage compartment turn the handle counterclockwise Rotate the handle clockwise to close To open the instrument panel remove bolt and lift up the top of the panel OPERATOR S DOOR CAB EQUIPPED MODELS Doors are provided on both sides of the cab for operator convenience The handle is located midway up the door 1 and includes a lock to protect ag...

Page 36: ...in the seat pull knob 1 out to raise the seat and give a stiffer ride Push in on the knob to lower the seat or soften the ride Fore Aft Adjustment While sitting in the seat pull lever 2 toward the center of the machine and slide seat forward or backward Once in the desired position release bar to lock seat into position Back Cushion Adjustment On the left side of the lower seat cushion is a lever ...

Page 37: ...osition Seat Belt WARNING THIS MACHINE IS EQUIPPED WITH A SEAT BELT ALWAYS USE THE SEAT BELT WHEN OPERATING MACHINE Each machine is equipped with an adjustable seat belt 1 To adjust the length of the belt hold the receptacle side of the belt taught and slide latch 2 into desired position To close seat belt insert hook 3 into latch To open seat belt pull up on latch and remove hook from latch 1 2 1...

Page 38: ... 1 Push or pull the front console into the desired position and release lever WINDOWS CAB EQUIPPED MODELS The front and rear windows open for ventilation Open the rear window by releasing the latch 1 on the left side of the cab and slide the window to the right The front window is hinged at the top Two latches 1 at the bottom can be released and the front window will pivot forward A de tent in eac...

Page 39: ... front switch 1 controls the front work lights and the rear switch 2 controls the rear work lights Two work lights are mounted so they face down to the moldboard area two on top of the cab facing forward and two on top of the cab facing rearward To activate the front work lights the top flood lights and the moldboard lights activate the front switch The light in the switch will illuminate To turn ...

Page 40: ...n signals and flasher lamps are mounted at the front and rear of the machine alongside the headlights and taillights They provide visibility and information to other drivers To activate turn signals move multi function switch up 4 to signal a right turn or down 5 to signal a left turn When the turn has been completed move multi function switch to center position NOTE Multi function switch does not...

Page 41: ...tch MIRRORS Optional Each side of the cab or operator s platform is equipped with adjustable rear view mirrors 1 Before starting operation of the machine each mirror should be adjusted to provide visibility toward the rear IMPORTANT Do not rely on the mirrors when backing Always turn around and look for personnel and obstacles Mirrors can be adjusted by grasping the edges and rotating the mirror i...

Page 42: ...low through heater core OFF position stops air flow across heater core For summer operation turn valve cock 1 clockwise to prevent hot water from flowing to the heater Turn the valve cock counterclockwise to operate the heater for winter operation Cummins engine is shown on the left and the Cat engine is shown on the right CUMMINS ENGINE CAT ENGINE Four vents 1 under the seat direct air flow They ...

Page 43: ...rcuits 7 Park Brake Error message will be on the display screen Indicates park brake is engaged 8 Clutch Error message will be on the display screen Indicates the clutch on the transmission has been disengaged Illumination occurs when the inching switch is off and the brakes are applied BRAKES Two brake pedals 1 are located on each side of the front console in front of the operator The pedals are ...

Page 44: ...into gear the button should be depressed while moving the control lever NOTE Transmission will not shift into gear unless the parking brake is disengaged ENGAGING TRANSMISSION To place motor grader in motion 1 Disengage parking brake 2 While pressing the neutral interlock button move transmission control lever to forward or reverse position The machine will automatically shift into first gear forw...

Page 45: ... will slow and stop as foot pressure is increased on the brake pedal Inching control is always reset to the deactivated mode when the key switch is turned off CHANGING DIRECTION To change direction of travel 1 Reduce engine speed below 3 4 throttle 2 Move lever all the way rearward to select reverse and all the way forward to select forward The machine will automatically downshift in increments an...

Page 46: ...or leakage Check hydraulic hoses for leaks from cuts or pinched hoses Ensure hoses are not twisted rubbing together or contacting sharp edges 4 Circle Inspect circle area for proper adjustment worn or damaged wear pads 5 Engine Check for engine leakage 6 Cab Check damaged or failed instruments Remove any loose items on the floor 7 Electrical Look for worn insulation on wires and loose terminals or...

Page 47: ... to 1000 rpm for approximately 3 5 minutes before driving machine STARTING ENGINE Warm Engine Starting 1 Insert key in the ignition switch and turn clockwise to START Hold in position until engine starts or for a maximum of 30 seconds whichever occurs first and release to the RUN position 2 If engine does not start within 30 seconds wait two minutes to allow starter to cool before repeating 3 Afte...

Page 48: ...urn clockwise to START If engine water temperature is not above 100F the preset shot of ether is injected into the engine while the engine is cranking 3 Once engine starts immediately pull throttle control lever rearward to idle engine Once ether has burned out increase throttle control lever to between 1 4 and 1 2 throttle Allow coolant and lubricant to circulate for at least 5 minutes before app...

Page 49: ...ON CORD FROM THE GROUNDED ELECTRICAL OUTLET FIRST AND THEN FROM THE HEATER BEFORE STARTING THE ENGINE INSPECT THE HEATER WIRES PERIODICALLY FOR BROKEN OR FRAYED WIRES AND OR WIRE COVERINGS IF WIRES AND OR COVERINGS ARE BROKEN OR FRAYED DO NOT USE THE HEATER While heaters may be operated continuously they will last much longer if they are operated only as long as necessary to permit easy engine sta...

Page 50: ...be positioned as desired between low idle lever fully rearward and high idle lever fully front Typical operating speed will depend upon load and speed but is normally above 1 2 throttle Do not allow engine to idle more than 10 minutes Combustion chamber temperatures may drop enough to prevent fuel from burning completely Carbon can develop clogging injector spray holes and piston rings and causing...

Page 51: ...SPEED BEFORE TURNING OR APPLYING BRAKES 7 ALWAYS SIT IN DRIVER S SEAT WHILE STARTING OR DRIVING MOTOR GRADER 8 SHIFT INTO FORWARD OR REVERSE AT LOW IDLE SPEED HIGH ENGINE SPEED SHIFTING MAY CAUSE SUDDEN MOVEMENT RESULTING IN OPERATOR INJURY 9 DOWNSHIFT OR UPSHIFT ONE GEAR AT A TIME WAIT UNTIL ENGINE SPEED STABILIZES BEFORE SELECTING NEXT GEAR 10 OBEY ALL TRAFFIC REGULATIONS AND BE AWARE OF OTHER T...

Page 52: ...IGH SPEEDS The wheels may by leaned into a turn to decrease the radius and create a more aggressive bite particularly on soft or slippery surfaces After the turn is complete straighten the wheels before resuming normal speed When crossing a steep incline tilt the wheels into the incline to increase traction CAUTION KNOW THE LIMITS OF THE MACHINE DRIVING ACROSS SLOPES CAN CAUSE ROLLOVER When making...

Page 53: ...e motor grader is typically operated in a non articulated position for large open areas or for road maintenance The articulated frame allows offsetting 2 the front tires from the rear tires This is accomplished by articulating away from the inside of a turn When used with the moldboard and circle shifted to one side the motor grader can move material over the edge of a wall without overloading the...

Page 54: ...mplement The front of the motor grader may be equipped with an optional dozer or scarifier The rear of the motor grader may be equipped with an optional ripper They are hydraulically operated The scarifier and ripper can be used to break out hard packed material that the moldboard does not penetrate The dozer blade may be used to level large piles which are not suitable to drive the front wheels o...

Page 55: ... an implement into the ground start the motor grader moving in either first or second gear Move the throttle control lever forward so engine speed is at least 3 4 of maximum Move implement lever forward to lower selected implement front or rear Release lever to return to a neutral position when implement is at desired depth Pull lever rearward to raise implement CAUTION ALWAYS RAISE IMPLEMENT COMP...

Page 56: ...e discharge of material Material is normally discharged between the rear tires or beyond the rear tires Avoid driving on discharged material The moldboard side shift lever moves the moldboard right or left Move lever forward to shift moldboard to the right Pull lever rearward to shift moldboard to the left Release lever to a neutral position to stop moldboard movement Moldboard Pitch Moldboard pit...

Page 57: ...lip Hydraulic Moldboard Pitch Optional An optional hydraulic moldboard pitch cylinder is available to allow adjustment from the operator s seat The hydraulic moldboard pitch is controlled by the side shift control lever when the blade pitch switch 1 is activated Move the lever forward to tilt the moldboard forward Move the lever rearward to tilt back Release the lever to return to a neutral positi...

Page 58: ...t to one another to allow one handed operation when moving both ends of the moldboard The motor grader is equipped with moldboard float this allows the moldboard to rise and fall to follow the contour of the ground without operator adjustment This is especially helpful when cleaning debris or snow on existing roads or extreme hard pack On softer surfaces the weight of the moldboard may cause it to...

Page 59: ...k For grading up to a 90 bank the saddle should be rotated to the farthest hole 3 allowing the blade and circle to hang from the side of the frame The saddle pin is controlled by the circle side shift control lever and saddle pin puller switch on top of the console not shown in picture Push lock button forward and press front of the switch to change lever to operate the saddle pin Move lever forwa...

Page 60: ...ll release side pressure on frame 4 Continue step 3 until lock pin is aligned with last hole in the saddle Lock saddle using saddle lock pin 5 Raise both sides of the moldboard slightly from the ground Raise right side of the moldboard 1 and turn the circle counterclockwise so the right end of the blade is close to the front tire This prevents the left side of the moldboard from dragging At the sa...

Page 61: ...Discharge the material under the rear module between the rear wheels If the material accumulates under the machine it should be cast aside with a cleaning pass before taking another cut For the cleaning pass the moldboard should be tilted forward slightly to handle more material A deeper ditch requires more cleaning passes and side casting of material If a V ditch is required each side of the ditc...

Page 62: ...straighten the frame and center the circle under the machine Angle the moldboard nearly perpendicular to the machine Raise the blade high enough to allow most of the material to discharge under the blade Excess material will discharge to the side Several passes may be required to evenly distribute material over desired area On the final pass moldboard height should be sufficient to allow all mater...

Page 63: ...RISKS IN A CLOSED CONTAINER SUCH AS A FUEL TANK THEY ARE MORE EXPLOSIVE THAN PURE GASOLINE DO NOT USE THESE BLENDS ADDITIONALLY DIESELHOL IS NOT APPROVED DUE TO POSSIBLE INADEQUATE LUBRICATION OF THE FUEL INJECTION SYSTEM SECTION 3 LUBRICTATION AND MAINTENANCE CLEAN FILLER CAP AREA AND KEEP FREE OF DEBRIS KEEP CONTROL OF THE FUEL NOZZLE WHILE FILLING FUEL TANKS DO NOT FILL TANK TO CAPACITY ALLOW R...

Page 64: ...ENGINE CAUTION FAILURE TO TURN MASTER SWITCH OFF MAY RESULT IN ELECTRICAL SHOCK OR DAMAGE TO MACHINE COMPONENTS SERVICE INTERVALS The recommended intervals listed on the chart should be adjusted when operating in severe conditions Time intervals should be checked when the machine reaches either the number of hours or the time allotment whichever comes first As an example if the motor grader has ac...

Page 65: ...ments Check hydraulic system for loose connections and pinched or rubbing hoses Check electrical system for loose connections and plugs pinched or rubbing wires and harnesses After 50 hours of operation perform the following Change transmission oil filter element Change hydraulic oil filter element Change fuel filter Clean fuel sediment Check all air intake connections Check all cooling system con...

Page 66: ...MPLETE SHIELDING MUST BE REINSTALLED BEFORE OPERATING THE MACHINE ENGINE ACCESS Located on each side of the hood is a hinged lockable access door The Cummins engine is shown on the left the Cat engine is shown on the right Open the left side access door to access Air filter elements 1 Fuel tank fill neck 4 Fuel filter 2 Engine oil fill neck 5 Engine oil dipstick 3 Washer fluid 6 CUMMINS ENGINE CAT...

Page 67: ...cover is accesses to the radiator fill cap 1 The hydraulic reservoir fill 2 is located inside the right side access panel door The batteries are at the rear of the machine under the grill 1 To remove the batteries the lower rear panel 2 must be removed Remove the six bolts and washers 3 on the lower panel for battery removal When installing grill torque bolts to 34 N m 25 lb ft Torque lower rear p...

Page 68: ...marks NOTE The amount required to change the level from the minimum mark to the maximum mark is 0 95 L 1 qt CUMMINS ENGINE CAT ENGINE Operation 2 Check Engine Coolant WARNING COOLING SYSTEM IS PRESSURIZED DO NOT REMOVE RADIATOR CAP WHEN HOT CAUTION COOLANT SHOULD BE KEPT OFF SKIN ADHERE TO PRECAUTIONS OUTLINED ON COOLANT FILTER AND ANTI FREEZE CONTAINER Check coolant level with engine cold 1 Open ...

Page 69: ...perating at idle speed 1 Park machine on a flat level area Place transmission control lever in neutral and set the parking brake Allow engine to idle with transmission oil temperature between 80 90 C 176 194 F 2 Open access door on the right side of the shell 3 Remove dipstick 1 by turning handle counterclockwise Check oil level using dipstick Oil level should be between minimum and maximum marks ...

Page 70: ...e glass when the engine is turned off If oil level is low 1 Slowly turn cap 2 counterclockwise Allow any pressure to release before removing cap 2 Add hydraulic oil until oil level is in the middle of the sight gauge 3 Install reservoir cap and tighten Operation 6 Check Air Filter Restriction Located on the right side of the machine on the air cleaner outlet is a filter restriction indicator 1 If ...

Page 71: ... made to number of shots assumes the use of a standard grease gun Each shot or pump is the equivalent of 1 5 grams 0 05 oz Operation 8 Lubricate Moldboard Lift Cylinder Balls One fitting 1 on lower end of each lift cylinder Lubricate with 2 4 shots each Operation 9 Lubricate Circle Shift Cylinder Balls One fitting 2 on each end of circle shift cylinder Lubricate with 2 4 shots each Operation 10 Lu...

Page 72: ...cate with 2 4 shots each Operation 14 Lubricate Front Axle Spindle Pivot One fitting 2 on each of two front axle spindle pivots Lubricate with 2 4 shots each Operation 15 Lubricate Front Wheel Lean Cylinder One fitting 3 on each end of wheel lean cylinder One fitting 4 on each end of connecting rod Lubricate fittings with 2 4 shots each Operation 16 Lubricate Tie Rod Ends One fitting 5 on each end...

Page 73: ...rticulation Joint Bearings One fitting is located on the right side of the upper 1 and lower 2 articulation joints Lubricate with 2 4 shots each Operation 20 Lubricate Articulation Cylinders One fitting 3 is located at each end of both articulation cylinders Lubricate with 2 4 shots each Operation 21 Lubricate and Clean Moldboard and Circle Turn Lubricate and clean moldboard slide bars and circle ...

Page 74: ...tires with a tire pressure gauge Normal pressure is 25 psi Improper inflation is a large contributor to tire failures Under inflation will cause damage to the cords Excessive flexing of the sidewalls may cause breaks and cord separation Continuous operation builds up heat and pressure in the tire Recommended inflation pressures allow for variation due to heat buildup If 24 hour operation does not ...

Page 75: ...er 2 and relieve pressure on the tensioner Lift belt from pulleys and remove Examine belt for damage such as tears or cracks Move tensioner through its full range of motion ensuring free movement and no binding Tensioner pulley must rotate freely To install drive belt relieve pressure on the tensioner with the breaker bar Position belt on all pulleys ensuring correct routing Ribs on belt must alig...

Page 76: ...Make sure sealing ring is removed and clean filter mounting surface 4 Apply a thin film of new oil to new filter sealing ring 5 Install new filter and tighten until sealing ring contacts mounting surface Tighten an additional 3 4 turn WARNING DO NOT OVERTIGHTEN OVERTIGHTENING CAN DAMAGE THE FILTER 6 Install plug in engine oil pan 7 Remove oil fill cap 3 and add 9 5 L 10 qt of oil 8 Start engine an...

Page 77: ...r moldboard to ground so draw bar is level Remove oil check plug 1 Oil level should be even with bottom of hole To add oil remove breather 2 Add oil until even with bottom of check hole Install oil check plug and breather Operation 29 Check Tandem Drive Case Remove oil level check plug 1 on side of tandem case Oil level should be even with bottom of hole To add oil remove fill plug 2 and add fluid...

Page 78: ...distort threads filter element seal or filter CUMMINS ENGINE CAT ENGINE Priming the Fuel System It will be necessary to manually prime the fuel system 1 if one of the following conditions exist The fuel injection pump is replaced The fuel lines are replaced Start up after an extended period of time CUMMINS ENGINE CAT ENGINE WARNING CONTACT WITH HIGH PRESSURE FUEL MAY CAUSE FLUID PENETRATION AND BU...

Page 79: ...er in close to the filter head 4 Tighten the knob into the filter head CAT ENGINE INSTRUCTIONS 1 Pump the primer on filter head 1 until the primer stiffens and it is difficult to pump WARNING CONTACT WITH HIGH PRESSURE FUEL MAY CAUSE FLUID PENETRATION AND BURN HAZARDS HIGH PRESSURE FUEL SPRAY MAY CAUSE A FIRE HAZARD FAILURE TO FOLLOW THESE INSPECTION MAINTENANCE AND SERVICE INSTRUCTIONS MAY CAUSE ...

Page 80: ...fill cap to release pressure shown on page 3 8 2 Remove bolts 1 attaching filter cover 2 to oil tank Carefully remove cover spring cap and o ring from top of tank 3 Remove element 3 and discard according to federal state and local regulations 4 Inspect o ring for cuts tears or deterioration Replace if necessary 5 Install new element o ring cap and spring Secure cover over spring Torque cover bolts...

Page 81: ...RTANT Clean hands before and after inserting in hydraulic oil tank 3 Reach into hydraulic oil tank with clean hand Unscrew suction strainer 4 and o ring from hydraulic tank Discard o ring 4 Clean both strainers using a commercial non flammable non toxic solvent Use compressed air limited to 207 kPa 30 psi to blow dry strainers Blow air from inside out 5 Replace o ring and install suction strainer ...

Page 82: ... 3 4 turn WARNING DO NOT OVERTIGHTEN OVERTIGHTENING CAN DAMAGE THE FILTER 6 Install plug in engine oil pan 7 Remove oil fill cap 3 and add 9 5 L 10 qt of oil 8 Start engine and allow to idle for 3 to 5 minutes to circulate oil Turn off engine and wait 15 minutes 9 Check oil level using dipstick If necessary add oil until level is between minimum and maximum marks on dipstick Check filter and drain...

Page 83: ...ARTING TURN THE IGNITION SWITH TO THE OFF POSITION AND PLACE A DO NOT OPERATE TAG AT THE IGNITION SWITCH LOCATION 1 Remove the valve mechanism cover Refer to the Cat Engine Manual Disassembly and Assembly Valve Mechanism Cover Remove and Install for the removal procedure NOTE When the valve mechanism cover is removed or installed the electrical harness must be checked Do not trap the injector harn...

Page 84: ... until the correct specification is achieved c After each adjustment tighten the valve adjustment screw locknut to 21 5 to 32 5 N m 15 9 to 24 lb ft while the valve adjustment screw 1 is held in position 3 Rotate the crankshaft by 180 degrees in the direction of engine rotation until the piston of No 3 cylinder is at the top center position on the compression stroke The exhaust valves and the inle...

Page 85: ...ilter 1 3 Apply thin film of new clean oil to sealing ring on the filter and install 4 Install drain cap and refill transmission to correct level on dipstick Start engine and do final check with oil temperature above 80 90 C 176 194 F The mounting of the filter must be carried out as follows Cover the gasket with a small amount of oil Screw the filter in until contact with the sealing surface is o...

Page 86: ...1 NORAM 65ET GRADER 3 24 Lubrication and Maintenance 3 Operation 36 Check Cat Engine Valves Check Cat engine valves every 1000 hours Contact local Cat service center See Operation 35 ...

Page 87: ...Use a suitable container to catch fluid Dispose of waste coolant according to federal state and local regulations 3 After draining flush radiator with clean water and a commercial flushing agent Use suitable container to catch fluid Dispose of flush water in the same manner as waste coolant 4 Close heater valve and replace plug on water pump 5 Fill radiator with a 50 50 mixture of clean soft water...

Page 88: ... oil 5 Replace fill cap 6 Start engine and operate implement controls to ensure all lines are filled 7 Stop engine and check oil level on sight gauge Add oil to bring level to the middle of the gauge as necessary Slowly remove fill cap to allow pressure to release from tank Operation 39 Change Rear Axle Housing Oil Change oil in rear axle housing with oil temperature at or near normal operating te...

Page 89: ...lug 4 Remove check plug Fill case using top fill plug until oil level is even with bottom of check plug Repeat for other side NOTE Tandem drive case must be level to check fill level Operation 41 Circle Turn Gearbox 1 Remove drain plug from the bottom of gearbox and drain fluid in a suitable container Dispose of waste fluid according to federal state and local laws 2 Clean area around drain plug a...

Page 90: ...the number 1 cylinder is at TDC For 3 9 L and 5 9 Engines without EGR align the crankshaft speed indicator ring on the front of the crankshaft so that the unpunched area of the crankshaft speed indicator ring is at the 12 o clock position If both number 1 cylinder rocker levers are loose move to the following steps If both number 1 cylinder rocker levers are not loose rotate the crankshaft 360 deg...

Page 91: ...ge gap in the crankshaft speed indicator ring to the 5 o clock position 2 The dowel pin could also be visible in the 9 o clock position 1 Check that both number 1 cylinder rocker levers are loose If they are not loose rotate the crankshaft 360 degrees and recheck 4 With the engine in this position lash can be measured on the following rocker levers E Exhaust I Intake ...

Page 92: ...t of specification loosen the locknut and adjust the lash to nominal specifications 5 Rotate the crankshaft 360 degrees Following the same steps and specifications as previously stated measure lash for the following rocker levers E Exhaust I Intake Four cylinder 2E 3I 4E and 4I Reset if out of specification 6 Install the gasket and rocker lever cover 7 Connect the batteries 8 Operate the engine an...

Page 93: ...king Brake Check parking brake lever It should engage between the 2nd and 3rd notch The right console display will indicate the parking brake is engaged If the brake is not engaged at this time adjust at the lower linkage If the display does not indicate when the parking brake is applied adjust the linkage at the lever and the switch location Parking Brake Cable Adjustment Transmission End 1 Loose...

Page 94: ...e Parking Brake Switch The parking brake switch 1 sends an electronic signal to the transmission that keeps the transmission from shifting into gear or causes the transmission to shift out of gear When the cable is replaced or adjusted at the lever end the switch operation should be verified and adjusted as necessary 1 Open the storage area to the left of the seat Loosen the retaining bolts 1 on t...

Page 95: ... amount of dust an element will hold 3 Install element in filter assembly by firmly pressing into place 4 Install end cover and secure latches Cover must provide seal NOTE Replace the inner safety element every third time the outer element is replaced Operation 47 Radiator Oil Cooler Check radiator oil cooler for debris and restrictions Remove louvered side panels and rear radiator cover and blow ...

Page 96: ...de center lock nut 2 Loosen circle guide nuts and jam nuts 3 of radial clearance adjusting screws on front guide 5 With one flank of gear tooth in contact with one circle tooth measure the clearance between the two teeth on the opposite side using a feeler gauge Clearance should be between 0 76 1 52mm 0 030 0 060 in If clearance is incorrect turn adjusting screws of front guide to provide 0 76 mm ...

Page 97: ...le blocks or stands under the circle Lower circle so it rests on blocks 2 Remove nuts 1 and bolts attaching cutting edge 2 or end bits 3 to moldboard 3 Remove any mud or debris from moldboard contact surfaces If edge is to be reversed clean mounting surfaces of cutting edge 4 Attach cutting edge to moldboard Secure with countersink carriage bolts Operation 50 Moldboard Guides Moldboard guide clear...

Page 98: ...CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER AND REPRODUCTIVE HARM WASH HANDS AFTER HANDLING Replacing Batteries 1 Remove the lower rear panel 2 Disconnect negative cable from both batteries 3 Disconnect positive cable from both batteries 4 Remove nuts from retaining rods Remove angle bracket 5 Use carrier straps to lift and remove batteries Dispose of old batteries according to fede...

Page 99: ... console IMPORTANT Turn off master switch before working on electrical system IMPORTANT Always replace fuses with an equal amperage fuse Operation 53 Lights Bulbs and sealed beams are replaceable as individual items For brake and turn signal flasher bulbs remove screws 1 to access the bulb For headlights and work lights remove screws 2 holding the lens covers The sealed beams can be unplugged and ...

Page 100: ...1 NORAM 65ET GRADER 3 38 Lubrication and Maintenance 3 ...

Page 101: ...NORAM 65ET GRADER 3 39 Lubrication and Maintenacne 3 ...

Page 102: ...1 NORAM 65ET GRADER 3 40 Lubrication and Maintenance 3 ...

Page 103: ...Bore and Stroke 107 mm x 124 mm 4 21 in x 4 88 in Aspiration Turbocharged Charge Air Cooled Cooling Water Gross Power at Rated Speed 82 Kw 110 GHP Maximum Torque 488 N m 360 Lb Ft 1500 RPM Rated Speed 2200 Low Idle Speed 900 50 RPM High Idle Speed 2350 50 RPM Fuel Pump Bosch VP30 Compression Ratio 17 2 1 Firing Order 1 3 4 2 Weight Wet 371 Kg 818 lbm SECTION 4 SPECIFICATIONS ...

Page 104: ...ged Charge Air Cooled or After Cooled Cooling Water Gross Power at Rated Speed 85 Kw 114 GHP Maximum Torque 414 N m 380 Lb Ft 1400 RPM Rated Speed 2200 Low Idle Speed 900 50 RPM High Idle Speed 2200 50 RPM Fuel Pump CAT Compression Ratio 16 2 1 Firing Order 1 3 4 2 Weight Wet 378 Kg 833 lbm Torque Converter Make and Model ZF Model F S W300 Type Fixed Stator Stall Ratio 1 870 1 Diameter 300 mm 11 8...

Page 105: ... with Brake Pedal Pump Type Gear Capacity 22 4 GPM 2000 RPM Engine Speed Clutch Pressure 16 18 bar 232 260 psi Transmission Ratios and Theoretical Travel Speeds Steering Control Unit Make and Model Eaton Fluid Power Series 5 Load Sense Steering Valve Type Front Axle Hydrostatic Orbitrol Pump Gear Displacement 120 cm3 rev 7 33 in3 rev Relief Pressure 1650 psi Number of Cylinders 1 Maximum Turn Angl...

Page 106: ...sure 172 kPa 25 psi Loaded Tire Radius 490 3 mm 19 3 in Fluid Capacities Fuel Tank 156 2 L 41 3 gal Cooling System Canopy 19 7 L 5 2 gal Cooling System Cab with Heater 20 8 L 5 5 gal Engine Oil with Filter Cat 7 L 7 4 qt Cummins 8 L 8 4 qt Transmission 12 3 L 3 25 gal Tandem Case each 11 4 L 3 0 gal Hydraulic System 68 2 L 18 0 gal Rear Axle 20 8 L 5 5 gal Circle Gearbox 0 57 L 0 6 qt Electrical S...

Page 107: ...lic Oil Reservoir Capacity each 238 cm3 14 5 in3 Operating Pressure 30 bar 435 psi Torque Capacity 22 000 N m 15 913 lb ft Pedal Ratio 4 1 Park Brake Make ZF Type Disc Size 380 mm 14 96 in Tandem Drive Construction 1 2 in Steel Plate Rectangular Section Drive Axles and Shafts Mounted on Tapered Roller Bearings Mounting Independently Oscillating Direct to Rear Axle Oscil 44 5 mm 1 75 in Pitch in Oi...

Page 108: ...Clearance 14 6 in 370 mm Diffential Super Max TracR Torque Proportioning Hydraulic Pump Make and Model Eaton Fluid Power L2 Tandem Pump Type Tandem Gear Implement Steering Section Displacement 2 33 in3 38 2 cm3 per Revolution Fan Drive Section Displacement 1 30 in3 21 3 cm3 per Revolution Maximum Flow to Implement Steering Section 20 gpm 72 9 L min 2200 RPM Maximum Flow to Fan Drive 11 1 gpm 42 0 ...

Page 109: ...ed T Section with Integral Teeth Segments Top Gear Size 52 7 in 1339 mm OD x 40 5 in 1028 mm ID x 1 5 in 38 1 mm Depth Vertical Gear Size 47 0 in 1241 mm OD x 44 5 in 1130 mm ID x 4 0 in 102 mm Depth Angle 360o Continuous Rotation Speed 1 12 RPM Circle to Pinon Gear Ratio 9 83 1 Wear Surface Area 172 in2 1110 cm2 Wear Plates 4 Replaceable Inserts Circle Turn Gearbox and Motor Gearbox Type Hydrauli...

Page 110: ...2 ft x 16 38 in x 063in 3 660 m x 416 mm x 16mm Ground Clearance Normal Pitch Angle 13 3 in 338 mm Minimum Pitch Angle 15 4 in 391 mm Blade Pitch Angle Normal Pitch 62 0o Minimum Pitch 53 0o Maximum Pitch 107 5o Blade Side Shift Left 17 in 432 mm Right 20 in 508 mm Moldboard Reach 10 ft Moldboard Reach Outside Rear Wheels w Straight Frame Left 39 1 in 994 mm Right 42 0 in 1067 mm Reach Outside Rea...

Page 111: ...ecifications 4 Cylinders Operation Weights Machine Operating Weight w Scarifier and Cab 16600 lb 7574 kg Front Axle 5360 lb 2431 kg Rear Axle 11340 lb 5143 kg Blade Pressure 9165 lb 4156 kg Scarifier Pressure 4300 lb 1950 kg ...

Page 112: ...al Vehicle Length with Scarifier 279 2 in 7092 mm Dozer Blade Attachment Front Dimensions 96 in x 24 in 2438 mm x 610 mm Maximum Ground Clearance 20 3 in 516 mm Maximum Digging Depth 3 0 in 76 2 in Total Vehicle Length with Dozer Blade 273 2 in 6939 mm Ripper Attachment Rear Linkage Parallelogram Number of Teeth 3 Standard 5 Maximum Tooth Spacing 18 75 in 476 mm Minimum Maximum Ripping Width 75 in...

Page 113: ...lude Cloth Air Suspension Seat Floormats Heater Pressurizer Tiltable Windshield Sliding Rear Window Two Lockable Full Size Doors Coat Hook Lunchbox Location Dome Light Front and Rear Windshield Wipers and Washers Inside Mirror Head Liner and optional Air Conditioner Glass Tinted Safety Glass EEC Approved Heater 40 000 Btu hr 90o F Diffential Cold Weather Starting Type Automatic Ether Assist Engine...

Page 114: ...1 NORAM 65E GRADER 4 12 Specifications 4 ...

Page 115: ...c If repairs are required beyond routine maintenance the machine should be returned to the dealer who has the correct tools facilities and knowledge to perform repairs to the correct and safe specifications Engine Refer to the Cummins or Cat Operation and Maintenance Manual included with the motor grader for engine troubleshooting Transmission SECTION 5 TROUBLESHOOTING ...

Page 116: ...1 NORAM 65E GRADER 5 2 Troubleshooting 5 Hydraulics and Implements ...

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