65 e | motor grader · noram 65et grader safety symbol explanation 1-3 safety 1 refer to and follow...

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65 E T4 FINAL | Motor Grader

Operator’s Manual June, 2018

Part # 34491 S/N: Tier 4 Final 65ET10101 – UP

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NORAM 65ET GRADER

TABLE OF CONTENTS
SAFETY
Safety Messages ....................................1-1

Safety Symbol Explanation ..................1-2

Safety Decal Locations .........................1-6

GENERAL INFORMATION

Intended Use .........................................2-1

Introduction to this Manual .................2-1

Orientation ............................................2-2

Machine Description .............................2-2

Identification Numbers ........................2-3

Component Identification and Locations ..........................................2-5

Electronic Display ...............................2-28

OPERATION

Mounting and Dismounting .................3-1

Daily Pre-Starting Inspection ..............3-1

Rollover Protective Structure (ROPS) .3-3

Driving the Machine .............................3-8

Moldboard and Implement Operation 3-11

NORAM 65ET GRADER

LUBRICATION AND MAINTENANCE - GRADER COMPONENTS

Safety Messages .................................... 4-1

General Information ............................. 4-4

Accessing Lubrication and Check Points .................................... 4-7

Maintenance Intervals ....................... 4-11

Every 10 Hours or Daily ..................... 4-13

Every 50 Hours or Weekly ................. 4-18

Every 100 Hours ................................. 4-22

Every 250 Hours or Monthly .............. 4-24

Every 500 Hours or 3 Months ............ 4-27

Every 500 Hours or 6 Months ............ 4-31

Every 1000 Hours or 6 Months .......... 4-34

Every 2000 Hours or 1 Year ............... 4-37

When Required ................................... 4-41

LUBRICATION AND MAINTENANCE - CUMMINS TIER 4 FINAL

General Information ............................. 5-1

Maintenance Intervals ......................... 5-3

Every 10 Hours or Daily ....................... 5-4

Every 250 Hours or Every 3 Months ... 5-7

Every 500 Hours or Every 6 Months ... 5-8

Every 1000 Hours or 1 Year ............... 5-11

Every 2000 Hours or 2 Years ............. 5-12

When Required ................................... 5-13

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LUBRICATION AND MAINTENANCE - CAT TIER 4 FINAL

General Information .............................6-1

Maintenance Intervals ..........................6-3

Every 10 Hours or Daily .......................6-4

Every 50 Hours or Weekly ....................6-7

Every 250 Hours ...................................6-9

Every 500 Hours ...................................6-9

Every 500 Hours or 1 Year .................6-10

Every 1000 Hours ...............................6-18

Every 1500 Hours ...............................6-18

Every 2000 Hours ...............................6-19

When Required ....................................6-20

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SPECIFICATIONS

Options .................................................7-15

TROUBLESHOOTING

Engine ....................................................8-1

Transmission .........................................8-1

Hydraulics and Implements .................8-2

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SECTION 1: SAFETY

SAFETY MESSAGES

General safety messages appear in this Safety Messages section. Specific safety messages are located in appropriate sections of the manual where a potential hazard may occur if the instructions or procedures are not followed.

Personal SafetyA signal word “DANGER”, “WARNING”, or “CAUTION” is used with the safety alert symbol.

Safety signs with signal word “DANGER”, “WARNING”, or “CAUTION” are located near specific hazards.

DANGER Indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING Indicates a hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

Machine SafetyNOTICE: The word “NOTICE” is used to inform the reader of something that needs to be known to prevent machine damage and/or property damage if a certain procedure is not followed.

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SAFETY SYMBOL EXPLANATION

This is the safety alert symbol. This symbol is used in combination with an exclamation mark or other symbols to alert you to the potential for bodily injury or death.

Read Operator’s Manual and safety signs before operating machine.

Check machine before operating. Machine must be in good operating condition and all safety equipment installed and functioning properly.

Wear personal protective equipment as required by the job. Dress properly. Wear close fitting clothing and confine long hair. Avoid wearing jewelry such as rings, wrist watches, necklaces or bracelets. Consult your employer, site supervisor or OSHA for specific requirements for:

• a hard hat

• safety glasses

• work shoes or boots

• reflective clothing

• hearing protection

• gloves, as needed

Keep spectators away.

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Refer to and follow the Shutdown Procedure before servicing, cleaning, repairing, or transporting machine.

Pressurized fluid can penetrate body tissue and result in serious injury or death. Leaks can be invisible. Keep away from any suspected leak. Relieve pressure in the hydraulic system before searching for leaks, disconnecting hoses, or performing any other work on the system. If you must pressurize the system to find a suspected leak, use an object such as a piece of wood or cardboard rather than your hands. When loosening a fitting where some residual pressure may exist, slowly loosen the fitting until oil begins to leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected under the skin must be removed immediately by a surgeon familiar with this type of injury.

Contact with moving parts can cause death or serious injury.• Keep hands, feet, and clothing away from power-driven parts.

• Wear close-fitting clothing and confine long hair. Avoid wearing jewelry, such as rings, wristwatches, necklaces, or bracelets.

• Keep all shields and guards in place and properly secured.

Explosion and separation of a tire can cause serious injury or death.• Never stand beside the tire when inflating.

• Never inflate beyond the tire manufacturer’s recommended tire pres-sure.

• Always mount, demount or inflate tires with properly trained and quali-fied personal.

Diesel Exhaust Fluid (DEF) may cause eye irritation and can be moderately irritating to the skin. Exposure to decomposition products may cause a health hazard. Serious effects may be delayed following exposure.

DEF is not expected to produce significant adverse health effects when the recommended instructions for use are followed.

• DO NOT breathe DEF vapor or mist.

• DO NOT eat, drink, or smoke when using DEF.

• Avoid DEF contact with eyes, skin, and clothing.

• Wash thoroughly after handling DEF.

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General Safety Messages

• Only responsible persons, delegated to do so, should operate any machine.

• Be sure safety shields, guards, and barriers are in place and in good condition before starting the machine.

• Check to see that all personnel are clear of the machine before starting.

• Place all controls in NEUTRAL or OFF position when shutting the machine down. Apply the park brake. Be sure all controls are in NEUTRAL or OFF position and the park brake is applied before starting the engine.

• When parking the machine for the night, provide the appropriate lighting and marking if the machine is adjacent to a roadway or a construction area where work is in progress.

• DO NOT leave the machine unattended when the engine is running.

• Keep the machine clean. The process of cleaning will reveal loose bolts, hydraulic lines, fittings and other trouble spots.

• Always keep the operator’s platform clean and free from grease, oil, rags, and loose tools to help prevent slipping and falling.

• Before cleaning, adjusting or servicing the machine, shut engine down and place all controls and switches in neutral or off position. Completely lower all attachments, or securely support raised components. A variation of the above procedure may be used if instructed within this manual.

• Refuel the machine only with the engine OFF. Never smoke or have an open flame in area when refueling.

• Refill or check the radiator only when the engine is OFF and the radiator is not hot. Turn cap slowly to the first stop to relieve the pressure before removing the cap.

• Before starting or continuing operation, correct or report any mechanical deficiency that may cause further damage.

• Securely support with suitable blocking the mainframe, moldboard or other components that are suspended or held aloft by slings, hoists, jacks or hydraulic cylinders before working under or between them.

• Make no modifications to your equipment unless specifically requested by NorAm.

• No riders allowed on machine. Only a seated operator, with seat belt securely fastened, is per-mitted on the machine during grading operation or when roading between job sites. Operator’s platform is for properly trained and qualified personnel only.

The following general safety rules are important for safe operation of the machine.

1-4 Safety Symbol Explanation

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Slope Operation SafetyDrive the machine at a speed suitable for the terrain. Avoid sudden stopping, starting or turning. Avoid traveling across slopes. Drive up and down slopes when possible. Safe operating slope depends upon many factors, including:

• Keep moldboard low and close to the ground. Lower moldboard to ground if machine starts to slip.

• Select the same gear when going downhill as would be used going uphill. Select the gear before starting down slope. DO NOT freewheel down slopes or hills.

• Uphill or downhill position of moldboard

• Uneven, rough or slippery ground conditions

• Potential for ground giving way, causing either unplanned forward, reverse, or sideways tilt

• Nearness of ditches, ruts, stumps, or other obstructions and sudden changes in slope

• Travel speed and turning rate

• Front axle only steering versus frame articulation and front axle steering

• Braking performance

• Skill of operator

Safety Decals - InspectSafety decals located on your machine contain important and useful information that will help you operate your equipment safely. To assure that all decals remain in place and in good condition, follow the instructions given below:

• Keep decals clean. Use soap and water, not mineral spirits, abrasive cleaners, or other similar cleaners that will damage the decal.

• Replace any damaged or missing decals. When attaching decals, the temperature of the mount-ing surface must be at least 40°F (5°C). The mounting surface must also be clean and dry.

• When replacing a machine component with a decal attached, replace the decal also.

• Replacement decals can be purchased from your NorAm dealer.

Check Laws And RegulationsKnow and obey all federal, state, and local laws and regulations that apply to your work situation.

Fire ExtinguisherFire extinguisher (not supplied with machine) should be mounted on the machine for easy access to the operator.

Failure to follow any of the preceding safety instructions or those that follow within this manual, could result in serious injury or death. This machine is to be used only for those purposes for which it was intended as explained in this operator’s manual.

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SAFETY DECAL LOCATIONS

1-6 Safety Decal Locations

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SECTION 2: GENERAL INFORMATION

INTENDED USE

The 65ET motor grader is intended for construction and maintenance of dirt and gravel roads, site preparation for paved roads and buildings, and maintenance of road shoulders and ditches.

Always use the machine in accordance with the instructions contained in this Operation and Maintenance Manual, safety signs on the machine, and other material provided by NorAm.

Proper maintenance and repair is essential for safety, and for efficient operation of the machine. DO NOT use the machine if it is not in suitable operating condition.

INTRODUCTION TO THIS MANUAL

This manual provides correct procedures for break-in, driving, operating and maintaining your machine.

Read this manual carefully and keep it tethered to the manual holder on the machine for future reference. If at any time a question arises concerning the equipment, contact an authorized NorAm dealer. Factory trained personnel, genuine replacement parts and the necessary equipment are available for all service requirements.

This machine has been designed and built to give outstanding performance and ease of operation under a variety of operating conditions. To maintain your machine and ensure trouble free operation, the routine maintenance as specified in this manual must be carried out at the recommended intervals. Prior to delivery, the machine was carefully inspected at the factory and by your dealer.

All information in this manual is based on the latest information available at the time of publication. Dimensions and weight are approximate and the illustrations may not show the equipment in standard configuration. Your machine may have product improvements and features not yet contained in this manual.

NorAm reserves the right to make changes at any time without notice or obligation.

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ORIENTATION

References are made throughout this manual to describe location and direction. Unless otherwise specified, reference to direction is from the operator's seat.

MACHINE DESCRIPTION

The grader is a construction machine with a long moldboard blade used to create a flat surface during the grading process. The grader has a front and rear axle, with the engine and operator station located on the rear module.

The grader is articulated between the front and rear axles. Articulation allows the grader to bend at a pivot point between the front and rear modules. Steering is achieved through the front tires, together with front tire lean, and frame articulation.

The moldboard is attached to the turn circle suspended from the front frame by an “A” frame drawbar positioned by a series of hydraulic cylinders.

Power from a Caterpillar C3.4B Tier 4 Final or Cummins QSF3.8 Tier 4 Final engine is delivered through a full power shift transmission, with torque converter, to the rear axle, equipped with a torque proportioning rear differential, and through tandem cases to the rear wheels.

An optional dozer blade, ripper and scarifier implements and cab, with heater and optional air conditioning are available. The cab is ROPS and FOPS certified.

2-2 Orientation

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IDENTIFICATION NUMBERS

The motor grader and major components are identified by serial numbers. The serial numbers are required when ordering parts. For easy reference the identification data should be recorded and kept in a safe 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 and on the left side of the Cat engine.

CUMMINS T4 FINAL ENGINE CAT T4 FINAL ENGINE

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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.

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2-4 Identification Numbers

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COMPONENT IDENTIFICATION AND LOCATIONS

Protective ShieldThe engine and transmission are enclosed to protect personnel from hot and moving parts. An additional guard encloses the cooling fan.

Engine access doors are located on each side of the engine cover. A lock is in the handle (1). Turn the handle clockwise 180° to unlatch and counter-clockwise 180° to latch.

DO NOT operate machine until thoroughly familiar with the location and operation of all controls.

DO NOT operate motor grader with engine enclosure removed or access doors open and unlatched. DO NOT operate with fan guard removed or broken.

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2-5Component Identification and Locations

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When equipped with the Cummins QSF3.8 Tier 4 Final engine, opening the left side engine compartment door provides access to the following:

1 Electronic Control Module (ECM) 6 Fuel Pump2 Crankcase Breather 7 Oil Fill3 Water Pump 8 Water Separator4 Oil Filter 9 Fuel Primer5 Fuel Filter 10 Air Cleaner

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Cummins QSF3.8 Tier 4 Final

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When equipped with the Cummins QSF3.8 Tier 4 Final engine, opening the right side engine compartment door provides access to the following:

1 Air Filter Indicator 10 SCR System 2 Hydraulic Tank Filter 11 Heater Core Shutoff Valve3 Hydraulic Tank Fill 12 Heater Control Circuit Breaker4 Hydraulic Tank Sight Gauge 13 Stud Fuse5 A/C Dryer 14 Main Power Circuit Breaker6 Master Switch 15 Alternator7 Engine Diagnostic Port 16 Washer Fluid Tank8 Fuse Panel 17 Starter9 Turbocharger 18 A/C Condenser

Cummins QSF3.8 Tier 4 Final

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When equipped with the CAT C3.4B Tier 4 Final engine, opening the left side engine compartment door provides access to the following:

1 Engine Electronic Control Module (ECM) 8 Fuel Primer2 Glow Plug Control Unit (GPCU) 9 Water Separator3 Diesel Exhaust Fluid (DEF) Injector 10 Fuel Filter4 Selective Catalytic Reduction (SCR) 11 Engine Oil Filter5 A/C Compressor 12 Engine Oil Fill6 A/C Dryer 13 Hydraulic Tank Access Cover7 Heater Core Shutoff Valve 14 Air Cleaner

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When equipped with the CAT C3.4B Tier 4 Final engine, opening the right side engine compartment door provides access to the following:

1 Hydraulic Tank Filter 10 NOx Sensors2 Hydraulic Filter Gauge 11 Ammonia Sensor (on back of panel)3 Hydraulic Tank Fill 12 Air Filter Indicator4 Hydraulic Tank Sight Gauge 13 Heater Control Circuit Breaker5 Master Switch 14 Main Power Circuit Breaker6 Wait To Disconnect Lamp 15 Alternator7 Engine Diagnostic Port 16 Washer Fluid Tank8 Fuse Panel 17 Engine Oil Dipstick9 Turbocharger 18 Starter

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The radiator access door (1) is located on top of the engine cover. The hydraulic reservoir fill cap (2) and transmission oil fill and dipstick (3) are located behind the right side engine access door.

The fuel fill neck (4) and DEF fill neck (5) are located behind the left side access door.

FOPS and ROPSAll motor graders are equipped with a Roll Over Protection System (ROPS), Falling Object Protection System (FOPS) and a seat belt.

Optional for the 65ET is an enclosed cab with heater and optional air conditioning. The cab is also FOPS and ROPS certified.

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Lock PinsLock pins are provided to prevent unintended movement of components during maintenance or transport.

The articulation lock pin (1) prevents articulation. Store the pin in the storage bracket (2) during operation.

The wheel lean lock pin (1) prevents side-to-side movement of the front steering wheels but does not prevent steering. Remove the wheel lock pin when operating the machine.

The front and rear-mounted implement lock pins (1) prevent lowering of the implement. Install the lock pins whenever traveling between job sites or transporting the motor grader on a trailer.


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LightingTwo work lights (1) are mounted on the front frame facing the moldboard. Two headlights, turn signals, and hazard lights (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 (4) are mounted on top of the canopy or cab facing rearward. Taillights (5), brake lights (5), turn signals (6), and hazard lights (6) are mounted at the rear.

NOTICE: DO NOT use work lights during highway travel.

An LED strobe beacon is available for mounting on the roof of the motor grader.

Mirrors (Optional)Each side of the cab or operator's platform is equipped with adjustable rearview mirrors (1). Before starting operation of the machine, each mirror should be adjusted to provide visibility toward the rear.

NOTICE: DO NOT rely on the mirrors when backing. Always turn around and look for personnel and obstacles.

Mirrors are adjusted by grasping the edges and rotating the mirror.

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Operator’s Door (Cab-Equipped Models) Lockable doors (1) are provided on both sides of the cab.

Rotate the key toward the door to lock or rotate the key away from the door to unlock.

To open a door from the outside, push in the button and pull the door open. To open the door from the inside, push the handle forward and push the door open.

The door can be opened fully and secured to the back of the cab during operation. To release door, pull latch handle (2) on the outside of the cab upward.

NOTE: The same key is used in the ignition, door, and engine access panels.

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 detent in each latch holds the window open.

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Heating (Cab-Equipped Models) The three-speed heater fan is controlled by a Rotary Switch (1). Rotate the switch one notch clockwise, to operate fan in LOW speed. Turn clockwise to increase speed to MEDIUM, and HIGH speeds. Rotate fully counterclockwise to turn OFF heater fan.

NOTE: Coolant will continue to flow through heater core. OFF position stops air flow across heater core.

For summer operation, turn valve cock (2) clockwise to prevent hot engine coolant from flowing to the heater. Turn the valve cock counterclockwise to operate the heater for winter operation.

CAT C3.4B Tier 4 Engine CUMMINS QSF3.8 Tier 4 Engine

Four vents (3) under the seat direct air flow. They may be closed (4) or opened using the fins (5). To direct air flow, rotate the outer circle (6) and partially open fins as desired.

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Seat

Seat AdjustmentsThe seat should be adjusted before operating the machine so all controls are easily reached and the operator is comfortable with good visibility.

1. Height Adjustment - Pull out to lower seat. Push in to raise seat.

2. Fore/Aft Adjustment - Lift lever to move seat assembly forward or rearward.

3. Seat Back Angle - Lift lever to adjust angle of seat back.

4. Lumbar Back Support - Rotate thumbwheel to increase or decrease lumbar support.

5. Arm Rest Angle - Rotate spindle to change angle of arm rest.

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Seat Belt

Seat belt (1) must be worn at all times while operating the machine. To fasten belt, insert latch plate (2) into buckle (3). If belt is too loose, pull free ends of belt until belt fits snugly. If belt needs to be lengthened, pull on buckle or latch plate. To unfasten seat belt, lift up on buckle release lever.

Rear Axle ComponentsThe limited slip differential axle (1) is located in the rear axle. Torque will be transferred from the wheels on the side that is slipping to the side with the most traction.

This machine is equipped with a Rollover Protective Structure (ROPS) and seat belt. The operator must wear the seat belt when operating the machine. The seat belt helps hold the operator inside the protected area of the ROPS. Failure to wear the seat belt could result in the operator being thrown from the seat and crushed if a rollover occurs.

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Front Console

Front Console Indicator LightsThe front console contains two indicator lights that provide information on the status of the headlights.

Light (1) indicates high beam is ON.

Light (2) indicates the head lights are ON.

Saddle Pin Puller Switch (Optional)Switch (1) changes the Circle Shift Lever (2) to the Saddle Pin Puller Lever.

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Hazard Lights SwitchSwitch (3) controls the hazard lights.

Press top of switch to turn ON hazard lights. Press bottom of switch to turn OFF hazard lights.

NOTE: Follow federal, state and local laws regarding road travel of slow-moving vehicles and construction equipment.

Blade Pitch Switch (Optional) Switch (4) changes the Blade Shift Lever (5) to the Blade Pitch Lever.

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Implement Switch (Optional)The optional Implement Switch (6) changes the Scarifier Lever (7) to the Ripper Lever.

To select the Scarifier Option, press the top of the switch. To select the Ripper Option, press the bottom of the switch.

Front Console Tilt LeverLever (1) releases the front console to allow fore/aft movement.

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Front Console Lock LeverLever (1) prevents the movement of the implement, moldboard, articulation and wheel lean levers, and front console.

All levers must be in a neutral position to engage implement lock. The console must be tilted forward to allow the implement lock to engage.

HornThe horn is used to signal others of impending movement or operation of the grader. To activate the horn, push end of Multi-Function Switch (1) in.

Headlights and TaillightsTo activate the taillights, turn the end (1) of the Multi-Function Switch one notch counterclockwise. To activate the taillights and headlights, turn the end of the switch fully counterclockwise (two notches). To turn off headlights and taillights, turn end of the Multi-Function Switch fully clockwise.

High beam is activated by pushing the switch forward (2). To return to low beam, pull the switch rearward (3) and release. To flash the high beam, pull the switch rearward and hold. High beam will be activated until the switch is released.

Turn SignalsTo 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 automatically return to OFF position after turning.

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Standard Style Control ConfigurationNOTE: Applies to all machines except for machines with the CAT control option.

Implement Control LeverLever (1) operates the optional front and rear mounted implements.

NOTICE: 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 switch.

Side Shift Control LeverLever (2) shifts the moldboard side to side or, if the blade pitch switch is activated, changes the pitch of the moldboard.

NOTE: On machines equipped with hydraulic moldboard tilt, the lever changes between moldboard side shift and moldboard tilt control according to the position of the blade pitch toggle switch on top of the steering console.

Circle Rotate Control Lever

Lever (3) rotates the moldboard circle.

NOTICE: 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.

Circle Shift Control LeverLever (4) moves the circle side to side. If the saddle pin switch is activated, the lever controls the saddle lock pin.

NOTE: On machines equipped with the adjustable saddle option the lever changes between circle shift and saddle pin according to the position of the saddle pin switch.

NOTE: On machines with the adjustable saddle option, the pin and the hole in the saddle do not self align. Rotate the saddle using the Left Side Moldboard Height Control Lever and Right Side Moldboard Height Control Lever to align pin and hole in saddle.

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Articulation Control LeverLever (1) operates the articulation cylinders, causing the center of the motor grader to pivot.

Front Wheel Lean Control LeverLever (2) controls the angle of the front wheels.

NOTE: Front wheel lock pin must be manually removed before leaning wheels.

Left Side Moldboard Height Control LeverLever (3) raises, lowers or floats the left side of the moldboard.

Right Side Moldboard Height Control LeverLever (4) raises, lowers or floats the right side of the moldboard.

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Caterpillar Style Control ConfigurationNOTE: Only applies to machines with the CAT control option.

Left Side Moldboard Height Control LeverLever (1) raises, lowers or floats the left side of the moldboard.

Side Shift Control LeverLever (2) shifts the moldboard side to side or, if the blade pitch switch is activated, changes the pitch of the moldboard.

NOTE: On machines equipped with hydraulic moldboard tilt, the lever changes between moldboard side shift and moldboard tilt control according to the position of the blade pitch toggle switch on top of the steering console.

Circle Rotate Control Lever

Lever (3) rotates the moldboard circle.

NOTICE: 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 the frame articulation joint.

Circle Shift Control LeverLever (4) moves the circle side to side. If the saddle pin switch is activated, the lever controls the saddle lock pin.

NOTE: On machines equipped with the adjustable saddle option the lever changes between circle shift and saddle pin according to the position of the saddle pin switch.

NOTE: On machines with the adjustable saddle option, the pin and the hole in the saddle do not self align. Rotate the saddle using Left Side Moldboard Height Control Lever and Right Side Moldboard Height Control Lever to align pin and hole in saddle.

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Articulation Control LeverLever (1) pivots the motor grader frame.

Front Wheel Lean Control LeverLever (2) controls the angle of the front wheels.

NOTE: Front wheel lean has a lock pin which must be removed manually to actuate wheel lean.

Implement Control LeverLever (3) operates the optional front and rear mounted implements.

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.

Right Side Moldboard Height Control LeverLever (4) raises, lowers or floats the right side of the moldboard.

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Right Side Console

Throttle Control LeverLever (1) controls engine speed. Move the lever rearward to decrease engine speed or forward to increase engine speed.

Transmission Control LeverNOTE: The transmission will not shift into gear if the parking brake is applied. A message that the park brake is applied appears in the display (4).

Lever (2) selects direction of travel and the desired speed (gear ratio). While holding down on the Transmission Interlock Button (3) move the shift lever forward to select forward movement or 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 Electronic Display (4).

When shifting from forward to reverse, or increasing or decreasing gears it is not necessary to push down on the interlock button, nor is it necessary to stop the machine. Decreasing engine speed when shifting is recommended to reduce drive line shock loads and surging of the grader between gears.

When in reverse a backup alarm will sound.

Ignition SwitchSwitch (1) is a key-operated, four-position rotary switch that controls engine starting, stopping and accessories.

ACC - Accessories are on and the engine is off.

OFF - Engine and accessories are off. Rotating beacon, turn signals, panel lights and flashers continue to operate.

RUN - Engine operating position. All systems are operating.

START - Activates the starter.

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Work LightsTwo switches control the work lights. The Front Work Lights Switch (2), a two-position switch, controls the front work lights mounted on the front frame and optional work lights mounted on the canopy or cab. The optional Rear Work Lights Switch (3), a two-position switch, controls the rear work lights mounted on the top, rear of the canopy or cab. Both switches illuminate when activated.

NOTICE: DO NOT use work lights when traveling public roads at night. High-mounted work lights can make it difficult for drivers of oncoming vehicles to see nearby obstacles.

Right Side Console Light SwitchThe Right Side Console Dash/Gauge Light Switch (4) activates two lights (5) that illuminate the right side console.

Blower Fan Switch (Cab equipped models)Switch (6), a four-position rotary switch, controls the blower fan for the heating and air conditioning systems.

Wiper and Washers (Cab equipped models)Switch (7) operates the front wiper and washer. Switch (8) operates the rear wiper and washer. The wipers have two speeds.

To operate a wiper, turn the desired switch clockwise one notch for low speed and fully clockwise for high speed. To activate the washers, push and hold the switch.

Rotating Beacon SwitchA rotating beacon is available for installation on the top of the canopy or cab. Power to this beacon is controlled by the Beacon Switch (9).

Defog Fan Switch (Cab equipped models) Switch (10) a three position switch, controls a front and rear defroster fan.

A/C Switch (Cab equipped models)Switch (11) controls the air conditioner compressor. With the switch activated, the compressor is on and the switch is illuminated.

NOTICE: To prevent air conditioner from freezing up, the blower fan should be operated when the A/C Switch is on.

NOTICE: When running the air conditioner the Heater Shutoff Valve should be closed (turn clockwise) to shut off hot water to the heater core.

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Floor and Ceiling Controls

Brake PedalsTwo pedals (1), linked together, control the service brake. The pedals are linked together so either one or both, can be depressed to activate the brakes.

If the Inching Control Switch is off, depressing a brake pedal also disengages the transmission when in 1st, 2nd, and 3rd gear.

Accelerator Control PedalPedal (2) overrides the Throttle Control Lever. Upon release engine speed reverts to throttle control lever setting.

Parking Brake LeverLever (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 BoxA lockable storage box (3) is provided for storing the Operator's Manual. The manual is tethered to the machine.

To open the storage box, push the button (4) in to unlatch the door.

Cab Dome Light SwitchSwitch (1) controls the dome lights in the cab. The dome light is a floodlight for illuminating the entire cab area.

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ELECTRONIC DISPLAY The system incorporates gauges and diagnostics with a LCD (Liquid Crystal Display) of current readings through which the operator may scroll.

Indicator LampsThe indicator lamps illuminate whenever engine or machine errors are active, engine is in a stop/derate state, fuel level is low, or DEF level is low.

1. Left AmberIlluminated when an engine error is active.

2. Left RedIlluminated when engine is in a stop/derate state.

3. Right AmberIlluminated when fuel level is < 5%.

4. Right RedIlluminated when DEF level is < 20% and/or a machine error is active.

Start-Up ScreenThis screen appears for 2 seconds after engine is started.

Control Keys (1) - Functions change, depending on screen being displayed. Key functions will be displayed with each screen.

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Main Operating Screen1. Transmission Gear2. Engine RPM3. Fuel Level

NOTE: When fuel level is < 5% the right amber indicator lamp is illuminated.

4. Menu - Press Control Key associated with icon to enter Menu Screen.

5. Diesel Exhaust Fluid Level (DEF)

NOTE: When DEF level is < 20% the right amber indicator lamp is illuminated.

6. Operator Selected System Functions - Four operator selected system parameters can be monitored in the four quadrant display.

The parameters shown are:

• Engine RPM,

• Engine Coolant Temperature,

• Engine Oil Pressure, and

• Engine Hours.

Refer to Section 4, "When Required", page 4-41 for parameters that can be selected for monitoring.

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7. Regeneration / After-Treatment System Cleaning In-Progress - Displays icon when a regeneration in-prog-ress cycle is active. Regeneration is controlled auto-matically by the engine, unless inhibited by operator input.

8. Regeneration / After-Treatment System Cleaning Force Option - Displays icon when a forced regenera-tion cycle is active. This option is best used immedi-ately following deactivation of the Regeneration Inhibit Option.

9. Regeneration / After-Treatment System Cleaning Inhibit Option - Displays icon when inhibit regenera-tion is active.

NOTICE: DO NOT leave Regeneration Inhibit Option active at all times, only use as needed. Preventing a regeneration / after-treatment system cleaning cycle for long periods of time can cause damage to the after-treatment system.

High exhaust temperatures during a regeneration cycle.

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Menu ScreenDown arrow (1) moves selection box down.

Up arrow (2) moves selection box up.

Right arrow (3) enters selected screen.

ESC (4) exits to previous screen.

Highlight screen name of choice and select by pressing Control Key associated with the right arrow option.

View Engine Diagnostics 1 ScreenView Engine Diagnostics 1 Screen displays the following:

• Engine Speed

• Percent Load (Engine)

• Coolant Temperature

• Fan Percentage

• Fuel Level

• Oil Pressure

• Boost Pressure

• Throttle Command

NOTE: “View Engine Diagnostics 1” Screen is a read only screen. The Up, Down, and Enter Control Keys do not function in “View Engine Diagnostics 1” Screen.

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View Engine Diagnostics 2 ScreenView Engine Diagnostics 2 Screen displays the following:

• Battery

• Manifold Temperature

• Engine Model

• DEF Level

• DEF Temperature

• Hest Lamp

• Inhibit Lamp

• Force Lamp

• SCR Cleaning Lamp

• Regeneration Force Icon

• Regeneration Inhibit Icon

To activate Regeneration Force or Regeneration Inhibit, press the Control Keys associated with the desired arrows. Press the Control Key associated with the “ESC” icon to return to the Menu Screen.

View Transmission Diagnostics ScreenView Transmission Diagnostics Screen displays the following:

• Transmission Oil Temperature

• Torque Converter Temperature

• Current Gear

• Input Shaft Speed

• Output Shaft Speed

• Ratio

• Inching

• Brake

• Transmission Torque Monitoring

NOTE: View Transmission Diagnostics Screen is a read only screen. The Up, Down, and Enter Control Keys do not function in View Transmission Diagnostics Screen.


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View CAN ScreenView CAN Screen displays the following:

• CAN conditions

• Power in Volts

• Current Software Revision

If a problem is present in the CAN system, TCU, ECM or display and an entity is not connected to the CAN system, the line (1) above the entity will not be present.

NOTE: View CAN Screen is a read only screen. The Up, Down, and Enter Control keys do not function in View CAN Screen.

System Settings ScreensSystems Settings Screens allow system settings to be adjusted. To adjust a setting, use up, down, and right enter arrows to select, activate and deactivate setting of choice.

The following system settings are available:

InchingWhen the inching control is in the “OFF (0)” position, the transmission is disconnected through a clutch when the brake pedal is depressed. When the inching control is activated “ON (1)”, the transmission continues to drive the motor grader when the brake pedal is depressed. To activate, press the Control Keys associated with the up or down arrows, followed by the right arrow to select, to turn inching on/off. Press the Control Key associated with the “ESC” icon to return to the Menu Screen.

NOTE: When machine is turned off, inching control is reset to “OFF (0)”.

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Contrast AdjustmentThe Contrast Adjustment Option allows the user to change the contrast of the display screen. To activate, press the Control Keys associated with the up or down arrows, followed by the right arrow to select desired setting.

Press the Control Key associated with the “ESC” icon to return to the Menu Screen.

Arrow up for darker contrast, arrow down for lighter contrast.

Reset All The Reset All Option resets all settings to the default settings. To activate, press the Control Keys associated with the right arrow. Selection box will display during the reset process, once process is complete the selection box will no longer be present.



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AEB Mode RequestThe AEB serves to compensate tolerances (plate clearance and pressure level), which are influencing the filling procedure of the transmission clutches.

Before activating AEB Mode it is necessary to:

• turn Inching “ON (1)”

• raise transmission temperature to 185° F by placing transmission in 6th gear, depressing foot brake, and turning throttle to full

NOTICE: DO NOT let Oil Temperature exceed 187° or Converter Temperature exceed 200°.

NOTE: View Transmission Diagnostic Screen for transmission oil temperature.

• once oil is 185°, apply parking brake

• place transmission in “NEUTRAL”, and ensure engine is idling

Once the required conditions are met, to activate, press the Control Keys associated with the up or down arrows, followed by the right arrow to select desired setting. Select “AEB MODE REQUEST” to begin AEB cycle.


AEB Calibration ScreenWhen AEB Mode Request is active, AEB Calibration Screen is displayed. AEB Calibration Screen displays:

• AEB Cycle Number

• Transmission Oil Temperature

• Engine Speed

• Output Shaft Speed

• Park Brake

Allow the AEB cycle to complete before disengaging the parking brake. The AEB cycle should take between 3 – 5 minutes to complete. After calibration is complete, restart machine and operate as normal.

AEB calibration is only necessary after a Transmission Control Unit (TCU) or transmission repair/replacement, transmission oil and filter change, or to improve shift quality.


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The “Top Left”, “Top Right”, “Bottom Left”, and “Bottom Right” system settings screens allow the user to customize the Main Operating Screen (1).

– Top Left – Top Right

– Bottom Left – Bottom Right

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The following monitored engine and transmission parameters are available.

To select a parameter, press the Control Keys associated with the up or down arrows, once the desired number selection is displayed, press the right arrow to select option. Press the Control Key associated with the “ESC” icon to return to the Menu Screen.

1 Battery Voltage 12 Fuel Pressure

2 Hours 13 Transmission Oil Temperature

3 Engine RPM 14 Coolant Temperature (Metric)

4 Percent Load (Engine) 15 Oil Pressure (Metric)

5 Coolant Temperature 16 Manifold Temperature (Metric)

6 Oil Pressure 17 Boost Pressure (Metric)

7 Intake Manifold Temperature 18 Fuel Temperature (Metric)

8 Boost Pressure 19 Fuel Rate (Metric)

9 Fuel Level 20 Fuel Pressure (Metric)

10 Fuel Temperature 21 Transmission Oil Temperature (Metric)

11 Fuel Rate


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View Errors ScreenView Errors Screen displays:

• Active Error Count

• Active Error Occurrences

• Display Voltage High

• SPN Error Code

• FMI Error Code

• OC (Number of Occurrences)

Active Error ScreenThe Active Error Screen will be displayed at start-up if an error is active and during normal operation if an error becomes active. The Active Error Screen will continue to be displayed every 30 seconds until the error is resolved.

To exit the Active Error Screen, press the Control Key associated with the “ESC” icon.

To view a list of fault codes refer to the 65ET Service Manual.

The right red indicator lamp will be illuminated during an active error.

Active Engine Error Screen

The Active Engine Error Screen will be displayed when an engine error is active.

The left amber indicator lamp will be illuminated during an engine error.

Engine Stop Screen The Engine Stop Screen will be displayed when a shutdown request is received from the engine.

The left amber and left red indicator lamps are illuminated during a shutdown request.


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SECTION 3: OPERATION

MOUNTING AND DISMOUNTING

Use steps and handholds and face machine whenever mounting or dismounting the machine. Maintain a three-point contact with the steps and with the handholds. DO NOT get on or off a moving vehicle.

DAILY PRE-STARTING INSPECTION

For maximum service life of the machine, make a thorough walk-around inspection before starting the engine. Correct any item that requires repair, replacement or adjustment.

Check the following components:

• Tires - Check for worn, cut or improperly inflated tires.

• Moldboard - Check for worn or damaged cutting edges or end bits.

• Circle - Inspect circle area for proper adjustment, worn or damaged wear pads.

• Operator Station - Check damaged or failed instruments. Remove any loose items on the floor.

• Electrical - Look for worn insulation on wires and loose terminals or end connectors.

• Hoses - Check cooling system hoses for leakage. Check hydraulic hoses for leaks from cuts or pinched hoses. Ensure hoses are not twisted, rubbing together or contacting sharp edges.

Look around and under the machine for:

• loose bolts,

• oil or coolant leaks, and

• broken or worn parts.

DO NOT use controls as handholds when mounting and dismounting. Unintended machine or component movement may cause you to fall, resulting in serious injury.


3-1Mounting and Dismounting

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Check the following fluid levels:

NOTE: Clean around fill caps before removing.

• engine oil,

• coolant,

• fuel,

• Diesel Exhaust Fluid (DEF), and

• hydraulic oil.

NOTICE: Accumulated grease and oil on a machine is a fire hazard. Remove the accumulated grease and oil.

• Check for leaks If leaking is observed, find the source and correct the leak. Check the fluid levels more frequently than recommended if leaking is suspected or observed.

• Inspect for and remove any trash build-up in the engine compartment.

• Inspect the cooling system for leaks, faulty hoses, loose clamps, and trash build-up. Correct any leaks and remove any trash from the radiator.

• Inspect the hydraulic system for leaks. Correct any leaks.

• Make sure the covers, shields, and guards are firmly in place. Inspect for damage.

• Inspect the platform for cleanliness and replace the slip-resistant tape if damaged or missing.

• Grease all of the fittings that need to be serviced on a daily basis.


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ROLLOVER PROTECTIVE STRUCTURE (ROPS)

• DO NOT operate machine with ROPS or FOPS removed.

• DO NOT modify ROPS or FOPS in any manner. Unauthorized modifications, such as welding, drilling, cutting, or adding attachments, could weaken the structure and reduce your protection.

If ROPS has been damaged or subjected to a rollover, it must be replaced. DO NOT attempt any repairs.

The ROPS has been certified to a maximum gross machine weight as stated on the label located on the ROPS. Under no circumstances may total gross weight of machine exceed weight specified on ROPS label.

If ROPS must be replaced, be sure to use original parts ordered from NorAm. If rollover occurs:

• Brace yourself and stay on the machine. Keep the seat belt fastened.

• Hold on firmly and lean away from the point of impact.

Seat BeltNOTICE: Seat belts must be worn at all times while operating the machine. Wear seat belt low and snug. Ensure there are no twists in the seat belt webbing.

The seat belt is an essential part of the rollover protection system. It helps keep you in the protected area inside the rollover protective structure. Inspect the seat belt every time it is used, looking for cuts or worn webbing, or any defect in the latch assembly. If any wear or damage is noted, DO NOT operate machine until seat belt is replaced.

If it is necessary to clean belts, use a mild soap solution and lukewarm water. DO NOT use bleach, dye, solvents, or other chemicals which may weaken the belts.

This machine is equipped with a Rollover Protective Structure (ROPS) and seat belts. The operator must wear the seat belt when driving the machine. The seat belt helps hold the operator inside the protected area of the ROPS. Failure to wear the seat belt could result in the operator being thrown from the seat and crushed if a rollover occurs.

3-3Rollover Protective Structure (ROPS)

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Machine Starting Procedure

Preparing to Start Engine

NOTICE: Never push, tow or coast vehicle to start engine.

Before starting engine:

1. Sit in the operator's seat with seat belt buckled.

2. Ensure Parking Brake is applied.

3. Ensure Transmission Control Lever is in neutral position.

NOTICE: Turbocharged engines require lubrication at the turbocharger bearings. To allow time for lubrication, limit engine speed to 1000 rpm for approximately 3-5 minutes before driving machine.

Diesel engine exhaust contains products of combustion which may be harmful to your health. Always start and operate the engine in a well ventilated area and, if in an enclosed area, vent the exhaust to the outside.

Start the engine from the operator’s station. Never short across the starter motor terminals, as this could bypass the engine neutral-start system as well as damage the electrical system.

Make sure no one is working on, underneath, or close to the machine before starting the engine or beginning to move the machine. Make sure the area is free of personnel.

DO NOT use aerosol types of starting aids, such as ether. Such use could result in an explosion and serious injury.

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Starting Engine1. 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. After engine starts, allow coolant to warm and lubricant to circulate for 3-5 minutes. Monitor all warning lights and gauge readings to ensure normal operation.

NOTE: If engine does not start after three attempts, check fuel supply system. The absence of blue or white smoke indicates no fuel is being delivered.

NOTICE: After starting engine, check brakes, steering and implement controls before moving.

Engine Block Heater (Optional)An optional 110 volt electric engine block heater may be installed. The block heater warms the engine fluids to reduce drag on internal components for easier starting.

Connect a grounded extension cord to the heater plug first. Then connect the extension cord to the grounded electrical outlet.

While heaters may be operated continuously, they will last much longer if they are operated only as long as necessary to permit easy engine starting.

Disconnect the extension 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.

To avoid shocks, or other injuries, never use an ungrounded or inadequate extension cord. Always use a grounded 3-wire extension cord with a 3-wire plug rated for at least a 15 amp load and protected by a suitable fuse or circuit breaker.


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Machine Shutdown ProcedureBefore stopping the engine, idle engine for 3 to 5 minutes to allow turbocharger and manifold to cool and prevent possible distortion of components.

To stop engine:

1. Move Transmission Control Lever to NEUTRAL.

2. Apply parking brake.

3. Rotate circle so moldboard is within the width of the tires. Lower moldboard to the ground.

4. Lower front and rear implements to ground or install lock pins in raised implements.

5. Idle engine for 3 to 5 minutes.

6. Turn Ignition Key (1) OFF.

7. Turn Master Switch (2) OFF.

NOTICE: Disconnecting battery too soon will prevent purging of the DEF lines after engine is shut down. Damage to the DEF system and emission control system can occur

NOTICE: If equipped with a CAT engine, DO NOT turn master switch OFF while lamp (3) is illuminated. Lamp remains ON approximately 2 minutes after engine is shut down.

NOTICE: If equipped with a Cummins engine, DO NOT turn master switch OFF for approximately 2 minutes after engine is shut down.

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Engine Speed

Setting Engine SpeedEngine speed is set using the Throttle Control Lever (1) located on the right side console. Move lever rearward to decrease engine speed or forward to increase engine speed.

The Throttle Control Lever can be positioned as desired between low idle and high idle. Typical operating speed will depend upon load and speed but is normally above 1/2 throttle.

NOTICE: 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 valves to stick.

Varying Engine SpeedAfter engine speed has been set by the Throttle Control Lever, engine speed can be increased using the Accelerator Control Pedal (1) on the right side of the floor. When the pedal is released, engine speed returns to the throttle control lever setting.

Increased pedal movement results in increased engine speed.

When driving or operating the motor grader in traffic always set the throttle control lever at low idle. Use the accelerator control pedal to increase engine speed as needed.

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DRIVING THE MACHINE

• Never coast machine with transmission in neutral.

• Select proper gear before starting up or down a hill. for downhill use the same gear or lower as would be used to go uphill.

• DO NOT attempt to decelerate on grades by shifting. reduce engine speed and apply service brakes.

• Reduce speed before turning or applying brakes.

• Always sit in driver's seat, with seat belt fastened, while starting or driving motor grader.

• Shift into forward or reverse at low idle speed. High engine speed shifting may cause sudden movement, resulting in operator injury.

• Downshift or upshift one gear at a time. Wait until engine speed stabilizes before selecting next gear.

• Obey all traffic regulations and be aware of other traffic. Ensure motor grader is equipped with lights and signage according to all federal, state and local regulations. obey flagmen.

• When roading motor grader always carry moldboard within the wheel width and as high as pos-sible.

• Install lock pins in front and rear implements when traveling between job sites.

• When using motor grader to tow, use only the designated rear drawbar.

Power BrakesTwo brake pedals (1), linked together, are located on each side of the front console.

To stop the machine, depress either of the pedals. If the Inching Control is deactivated, the transmission will disengage when either brake pedal is depressed. If the Inching Control is activated, the transmission will continue to drive the machine. The motor grader will slow and stop as applied braking pressure overcomes the torque converter.

NOTE: Greater effort will be required to stop the machine with the inching control activated.

NOTE: With the inching control deactivated, movement may be jerky as the transmission disconnects and reconnects.

Observe the following precautions when driving the motor grader:

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SteeringThe basic method of steering the motor grader is through the front steering wheels. The turning radius can be reduced by using the front wheel lean and frame articulation.

Whenever negotiating a sharp turn, reduce the speed before entering the turn.

Front Wheel LeanNOTICE: Remove front axle wheel lean lock pin (1) before tilting (leaning) wheels. DO NOT operate machine with wheel lean lock pin installed.

Slow machine speed before leaning the wheels 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.

When making heavy cuts or moving heavy loads that tend to push the machine to the side, the wheels can be leaned into the load to counteract the pushing effect. Lean wheels in the direction of the discharge.

To tilt wheels to the left move the Wheel Lean Control Lever (1) forward. To tilt wheels to the right move control lever rearward.

DO NOT use wheel lean when traveling at high speeds. Wheel lean at high speed may result in erratic machine motion.

Know the limits of the machine. Driving across slopes can cause rollover.

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3-9Driving the Machine

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ArticulationNOTICE: An articulation lock pin (1) under the cab must be removed and placed in storage bracket (2) before operating. DO NOT operate machine with articulation lock pin installed.

The motor grader has an articulating frame. Articulating the frame (1) toward the inside of a turn greatly reduces the turning radius, allowing operation in tight quarters.

The 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 edge and risking collapse of the supporting surface. Offsetting also permits better weight concentration behind the blade in severe operating conditions.

Move Articulation Control Lever (1) forward to articulate to the left and rearward to articulate to the right. 1

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MOLDBOARD AND IMPLEMENT OPERATION

The moldboard and optional implements are hydraulically operated. Control levers are located on each side of the front console. By actuating a switch on top of the front console, some control levers operate multiple functions.

The transmission gear and engine speed should be set before engaging the ground with the moldboard or implement. Never overload moldboard to the point that the rear wheels begin to slip. This will alter the grade, increase wear on the tires and cause inefficient operation.

NOTICE: Using moldboard to back drag material should be avoided, if possible. Increased wear on the moldboard guides and damage to the side shift cylinder rod may result.

ImplementNOTICE: Front and rear-mounted implements, if installed, have lock pins (1) that must be removed to lower implement.

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 can not penetrate. The dozer blade may be used to level large piles which are not suitable to drive the front wheels over.

NOTE: Front counterweights or front implements must be installed when rear ripper is installed. Rear ripper and rear counterweights cannot be installed simultaneously.

Scarifier and ripper shanks have two depth positions. Each shank (1) is equipped with a replaceable tooth, 2.

A lock pin (3) holds the shank in place. To remove lock pin, tap on the bottom with a hammer until free. Remove lock pin from the top of the tool bar and remove or reposition the shank.

To install, position shank in tool bar in the desired notch. Insert lock pin from top of tool bar until fully seated.

Keep feet out from under toolbar, shanks may fall when lock pin is removed.

3-11Moldboard and Implement Operation

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The Implement Control Lever (1) raises and lowers the selected implement. The front of the motor grader may be equipped with a scarifier or blade, and the rear of the machine may be equipped with a ripper.

NOTE: DO NOT engage the ground with the front and rear implements at the same time.

If the machine is equipped with the optional ripper and scarifier, the Implement Switch (2) located on the top of the front console, selects the front or rear implement. To operate the front implement, switch should be rocked rearward. To operate the rear implement, switch should be rocked forward.

Before lowering 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 control lever (1) forward to lower selected implement (front or rear). Release lever to return to NEUTRAL position when implement is at desired depth. Pull lever rearward to raise implement.

NOTICE: Never back drag scarifier or ripper teeth. Damage to the tool bar will result.

When the motor grader is equipped with the float option, it has the capability to float the implement and moldboard height. To place implement in float mode, push Implement Control Lever forward. The lever is held in place by a detent. To release detent, pull lever rearward to NEURAL.

Always raise implement completely and insert lock pin when transporting machine between job sites. Unintended lowering of implement at high speed may result in abrupt stopping of machine and cause operator injury.

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3-12 Moldboard and Implement Operation

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Moldboard Side ShiftThe Moldboard Side Shift Lever (1) moves the moldboard side to side. The side shift function adjusts moldboard position without changing the relative grade angle. Shift the moldboard to one side to:

• Prevent tires from traveling too close to an edge.

• Work around objects such as mailboxes, bridge abutments and utility poles.

• Place 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 neutral to stop moldboard movement.

Moldboard PitchMoldboard pitch determines how aggressively the material is handled. Tilt the moldboard forward (1) to create a rolling action of the material. Tilt the moldboard back (2) to slice or cut the material.

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Manual Moldboard Pitch Adjustment1. Lower moldboard to the ground and apply Parking Brake. Moldboard should rest lightly on

ground with no downward pressure.

2. Pull hairpin clip and remove pin from pitch adjuster link.

3. Raise both ends of the moldboard with the moldboard height control levers to allow the moldboard to tilt forward. To tilt moldboard back, lower moldboard. It may also be necessary to move the grader slightly to allow moldboard to rotate back.

4. Set Parking Brake.

5. Insert pin into an appropriate slot where the inner and outer sleeves align on the adjuster link. Secure with hairpin clip.

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 stop moldboard movement.

Moldboard may fall forward and strike and injure you when pitch adjuster link pin is removed.

Keep moldboard on the ground with the moldboard height control levers when adjusting link.

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Moldboard AngleThe angle of the moldboard determines the swath (cutting width) of the moldboard and the amount of material moved. A greater angle decreases the swath of the moldboard but allows material to discharge faster and decreasing the load. Most operations require a moldboard angle of between 15° and 45° from perpendicular.

The moldboard (1) hangs from a circle with external teeth (2) and is rotated by a hydraulically driven gearbox (3). The circle is attached to the front frame by a draw bar (4).

The Circle Turn Control Lever (5) is used to adjust the moldboard angle. Push lever forward to rotate the circle counterclockwise (as viewed from above). Move lever rearward to rotate the circle clockwise. Release lever to return to NEUTRAL and stop circle movement.

NOTICE: The circle allows 360° rotation of the moldboard. It is possible to contact the front tires and rear articulation joint. Use care when operating at extreme angles.

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Moldboard HeightThe height of the moldboard is adjusted through a Right Side Height Control Lever (1) and a Left Side Height Control Lever (2). The levers are adjacent to one another to allow one-handed operation when moving both ends of the moldboard.

When 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 drop lower than desired or be drawn into the material thus, overloading the grader. The moldboard pitch will also effect how aggressively the moldboard cuts and lifts the material.

Move desired (Right or Left) Control Lever rearward (3) to raise moldboard.

Move desired control lever slightly forward (5) to lower moldboard. To engage float detent, move lever fully forward (6). To release from detent, pull lever rearward into neutral (4).

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Saddle Lock Pin (Optional)To allow grading on banks up to 90° an optional rotating saddle is available. A hydraulically operated lock pin (1) secures the saddle (2) to the front module frame. When released the saddle rotates, allowing the circle and moldboard to pivot for side grading.

Five positions are available with the center position used for most types of work. 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 (4), on top of the console. Push lock button forward and press front of the switch to change lever to operate the saddle pin. Move lever forward to unlock the saddle. Move lever rearward to lock the saddle.

NOTE: The hole and pin on the saddle are not self-aligning. Manipulate the blade to rotate the saddle and allow pin to seat properly.

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Bank Slope (Optional)When the motor grader is equipped with the optional rotating saddle, the moldboard can be rotated 90° to either side for grading steep slopes.

To rotate saddle and moldboard to the right:

1. Rotate circle (1) until moldboard (2) is perpendicular to grader.

2. Side shift the moldboard fully right. Shift the circle to the right with the cylinder rod extended approximately 5 inches. Lower moldboard.

3. Disengage saddle lock pin. Using blade lift levers, extend (lower) right moldboard lift cylinder and retract (raise) left moldboard lift cylinder. The moldboard will slide along the ground as the saddle (3) rotates.

NOTE: Raising the moldboard off the ground several times during this process will 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 (4) 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 same time, shift the circle to the right to pivot the complete circle/moldboard assembly upward.

6. Continue operation until moldboard has cleared ground. Use Moldboard Height Control Levers to move moldboard in and out. The moldboard angle can be changed using Circle Turn Lever until desired moldboard angle is reached.

NOTE: When grading a bank, moldboard control can be manipulated easily by leaning the front wheels toward or away from the bank.

To prevent moldboard from striking vehicles or structures, always position moldboard within the wheel width for road travel or transport on a trailer.

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Power-Shift TransmissionThe power-shift transmission uses a single control lever (1). Six forward and two reverse gear ratios may be chosen to provide the correct operating speed for any condition. With the Inching Control Switch deactivated, depressing the brake pedal disconnects the transmission.

NOTICE: DO NOT attempt to tow-start a vehicle with a power-shift transmission. Tow only when necessary to move to a safer location for repair.

Neutral InterlockThe Transmission Control Lever is equipped with a Neutral Interlock Button (2) to prevent unintended machine movement if the lever is moved accidentally. In order to place the machine into gear the button must be depressed while moving the control lever out of neutral.

NOTE: Transmission will not shift into gear unless the parking brake is disengaged.

Engaging TransmissionTo place motor grader in motion:

1. Disengage Parking Brake.

2. While pressing the Neutral Interlock Button move Transmission Control Lever to forward or reverse. The machine will shift into first gear forward or reverse. The selected gear will appear in the digital readout (3).

3. To select higher gear ratios, bump lever to the right. Move one speed at a time and allow the torque converter and engine speed to stabilize before moving to the next speed. To decrease gear ratios bump lever to the left.

NOTICE: DO NOT over-speed engine when down-shifting. Reduce engine speed before selecting a lower gear ratio.

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Inching ControlIf brake pedal is depressed and the Inching Control, displayed on the screen, is deactivated, the transmission will disconnect and will not transfer power to the wheels. The transmission will engage when the brake pedals are released.

If the Inching Control is activated, the transmission will continue to drive the machine. The machine 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 DirectionTo change direction of travel:

1. Reduce engine speed below 3/4 throttle.

2. Move transmission control lever all the way rearward to select reverse and all the way forward to select forward. The machine will automatically down-shift in increments and shift into first gear reverse or first gear forward.

NOTE: It is not necessary to stop machine travel before changing direction. The transmission will modulate clutch engagement as needed.


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Digging

NOTE: Always keep cutting edges in good condition. Dull and worn edges increase power demands on the motor grader.

When starting a ditch, position moldboard so end (right or left) is directly behind and 76 mm (3 in) below the front wheel. Position the other end of the moldboard as high as possible.

The first cut should be slow enough to maintain control of the grader and cut a straight ditch line. Only dig deep enough to create a shallow ditch and line to follow for subsequent passes. Lean the front wheels in the direction of the discharge to counteract the load.

For the second pass, position the wheels inside the ditch and, with a slightly higher speed than the first pass, maintain a 3:1 ratio between width and depth.

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 ditch must be cut alternately to permit the front and rear wheels to travel in the center of the ditch.

Filling Trenches or DitchesWhen required to cast material over the edge of a ditch, fully shift the moldboard toward the ditch so the grader wheels are away from the edge (1). The weight of the motor grader could cause the edge to collapse. Offset the rear module (2) away from the ditch using the articulation capability to move the weight of the machine farther away from an edge.

All material should be discharged from the end of the moldboard and into the ditch.

Electricity or gas explosion can kill. Laser light in cut cable can result in eye damage.

Locate utilities before digging. Call 811 (U.S. only) or 1-888-258-0808 (U.S. or Canada) or local utility companies or national regulating authority.


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Leveling and SmoothingNOTICE: Never push material with the back of the blade. Back dragging will increase wear on the cutting edges and may damage exposed cylinder rods.

When leveling an area of loose material, such as a road bed, 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 material to discharge under the blade.


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Moving a Disabled Machine

Whenever possible, move a disabled machine using a transport trailer. If this is not possible the motor grader can be towed short distance to a more suitable site for field service.

TowingNOTICE: DO NOT tow motor grader faster than 5 mph (8 kph). DO NOT tow motor grader farther than 6 miles (10 km).

Attach a tow bar to the front of the motor grader. Never attach chains or ropes to the ROPS to pull. 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 components.

HaulingInstall frame articulation lock pin and wheel lean lock pin.

Load machine so all wheels are completely on the trailer. Position moldboard within width of trailer and lower. Lock front and rear implements to prevent unintended lowering.

Securely attach motor grader to trailer using the front (1) and rear (2) tie-down locations.

NOTICE: Cover exhaust outlet so wind does not spin turbocharger and damage bearings.

When hauling or towing motor grader insert wheel lean lock pin and articulation lock pin.

DO NOT use cables or rope to tow motor grader. If cable or rope breaks 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.

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SECTION 4: LUBRICATION AND MAINTENANCE - GRADER COMPONENTS

SAFETY MESSAGES

Read the Operation and Maintenance Manual and safety signs before performing maintenance on the machine.

Wear personal protective equipment. Dress properly. Wear close fitting clothing and confine long hair. Avoid wearing jewelry such as rings, wrist watches, necklaces or bracelets. Consult your employer for specific requirements for:

• a hard hat

• safety glasses

• work shoes or boots

• hearing protection, as needed

• gloves, as needed

Keep spectators away.

Refer to and follow the Shutdown Procedure before servicing, cleaning, repairing, or transporting machine. Refer to "Machine Shutdown Procedure", page 3-5 for instructions.

Exhaust fumes can be fatal.

If operating in an enclosed area, remove exhaust fumes with an exhaust pipe extension to the outside.

4-1Safety Messages

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Raised attachment can fall and crush you.

Never work under a raised attachment unless attachment is securely supported with suitable blocking or cylinder stops.

Hot fluid under pressure can scald.

Allow engine to cool before opening radiator cap.

Fuel and fumes can explode and burn.

Shut off engine before refueling. No flame. No smoking.

Battery fumes are flammable and can explode. Keep all burning materials away from battery. Battery explosion can blind. Acid can blind and burn. Tools and cable clamps can make sparks.

DO NOT smoke. Shield eyes and face.

Contact with moving parts can result in serious injury or death.

Shut off engine and wait for all motion to stop before working on machine. Keep all guards and shields in place during operation.


4-2 Safety Messages

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Explosion and separation of a tire or rim parts can cause serious injury or death.

• Use a clip-on air chuck with an in-line pressure gauge and a remote air valve that allows you to stand behind the tread when inflating a tire.

• Never stand beside the tire when inflating.

• Never inflate beyond the tire manufacturer’s recommended tire pressure.

• Always mount, demount or inflate tires with properly trained and qualified personnel.

Make no modifications to this equipment unless specifically recommended by Weiler.

Be sure that all safety devices, including shields, guards and barriers are installed and functioning properly after servicing the machine.

Diesel Exhaust Fluid (DEF) temperatures can reach 149°F to 158°F (65°C to 70°C) during normal engine operation. Stop the engine. Wait for 15 minutes in order to allow the DEF system to be purged and the DEF to cool before service or repair is performed.

The exhaust gas temperature could exceed 1100°F (600°C) during regeneration. High temperature may result in fire, burn, or explosion hazards, which may result in personal injury or death. DO NOT expose flammable material or explosive atmospheres to exhaust gas or to exhaust system components during regeneration.

To prevent fires, routinely clear any combustible material from the engine exhaust system. Tier 4 Final/Stage IV emission compliant exhaust systems use extreme high temperature that can ignite combustible material.

Failure to follow any of the preceding safety instructions or those that follow within this manual, could result in serious injury or death. This machine is to be used only for those purposes for which it was intended as explained in the Operation section of this manual.

4-3Safety Messages

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GENERAL INFORMATION

Proper machine operation depends upon a properly maintained machine. This section provides a list of items to be checked, inspected or changed periodically.

NOTE: Section 4 includes machine lubrication and maintenance instruction but excludes engine lubrication and maintenance instruction. Refer to Section 5 for lubrication and maintenance instructions for the Cummins engine, and Section 6 for lubrication and maintenance instructions for the CAT engine.

When performing maintenance, always park motor grader on level ground with the moldboard on the ground and implements pinned in place or lowered to the ground.

Dispose of all used fluids and filters according to federal, state and local regulations.

Never grease, service or adjust machine with engine running, except as specified in this manual or the service and repair manual.

4-4 General Information

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Welding PrecautionsProper welding procedures are necessary in order to avoid damage to the electronic controls and to the bearings. When possible, remove the component that must be welded from the machine or the engine and then weld the component. If you must weld near an electronic control on the machine or the engine, temporarily remove the electronic control in order to prevent heat related damage. The following steps should be followed in order to weld on an machine or an engine with electronic controls.

1. Turn OFF the engine. Place the engine start switch in the OFF position.

2. Turn the battery disconnect switch to the OFF position.

3. If equipped with a Cummins engine, remove ECM power wire from positive battery terminal before welding.

NOTICE: DO NOT use electrical components (ECM or ECM sensors) or electronic component grounding points for grounding the welder.

4. Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close as possible to the weld. Make sure that the electrical path from the ground cable to the component does not go through any bearing. Use this procedure in order to reduce the possibility of damage to the following components:

• Bearings of the drive train

• Hydraulic components

• Electrical components

• Other components of the machine

5. Never allow welding cables to lay on, near, or across any electrical wiring or electronic component while welding.

6. Protect any wiring harnesses and hydraulic hoses from the debris and weld splatter which is created from welding.

7. Always have a fire extinguisher available when welding.

4-5General Information

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Service IntervalsThe recommended intervals 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 accumulated 1200 hours and a year has passed since hydraulic oil was replaced, change the hydraulic oil now rather than waiting until 2000 hours have passed.

Preventing ContaminationTo prevent contamination when changing oils, filters, etc., always clean the area around the filler caps, level plugs, drain plugs, dipsticks and filters prior to removal.

To prevent dirt entry during greasing, wipe dirt from the grease fittings before attaching grease gun. If any grease fittings are missing, replace them immediately.


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ACCESSING LUBRICATION AND CHECK POINTS

In order to access many of the lubrication and check points during service and maintenance procedures, shielding will need to be removed and the hood opened or removed.

Radiator Fill and Battery Access - All MachinesOpen cover on top of engine compartment to access radiator fill cap (1).

Remove panel (2) on top of engine compartment for access to battery.

After service and maintenance work is complete, shielding must be reinstalled before operating the machine.

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4-7Accessing Lubrication and Check Points

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Lubrication/Fluid Level Check LUBRICATION / FLUID LEVEL CHECK - 65ET T4 FINAL

Interval Hours Ref Identification No. of

PtsType of

Lube Qty Remarks

Every 10 Hours or

Daily

1 Fuel Tank

Ultra Low Sulfur Diesel

(ULSD)

Fill

2 DEF Tank ISO 22241 Fill3 Hydraulic Oil ISO 68 Check sight gauge

4 Transmission Oil

Engine Oil Check dipstick

5 Radiator Coolant

Check level and mixture

Every 50 Hours or Weekly

6 Front Axle Drag Link

2 EPG 2-4 Shots

One each side of front axle.

7 Moldboard Lift Cylinder Balls

4 EPG 2-4 Shots

One on lower end of each lift cylinder.

8 Circle Shift Cylinder Balls

2 EPG 2-4 Shots

One on each end of circle shift cylinder.

9 Draw Bar Pivot Pins

3 EPG 2-4 Shots

One on each side of horizontal pin. One on top of twist pin.

10 Front Axle Pivot Pin

1 EPG 2-4 Shots One on axle pivot pin.

11 Steering Cylinder

2 EPG 2-4 Shots

One on each end of steering cylinder.

12 Front Axle Knuckle Pivot

2 EPG 2-4 Shots

One on each front axle knuckle pivot.

13 Front Axle Spindle Pivot

2 EPG 2-4 Shots

One on each front axle spindle pivot.

14 Front Wheel Lean Cylinder

4 EPG 2-4 Shots

One on each end of wheel lean cylinder. One on each end of connecting rod.

15 Steering Tie Rod Ends

2 EPG 2-4 Shots One each end of tie rod.

16 Moldboard Pitch Adjustment

2 EPG 2-4 Shots

One on each end of moldboard pitch cylinder or adjuster rod.

17 Implement Lift Cylinders

4 - 8 EPG 2-4 Shots

One on each end of any implement installed.

18 Articulation Joint Bearings

4 EPG 2-4 Shots

One on right side of upper and lower articulation joints.

19 Articulation Cylinders

4 EPG 2-4 Shots

One on each end of both articulation cylinders.

20 Circle Turn 1 Graphite A/R Lubricate and clean.

21 Moldboard Slide Bars

2 Graphite A/R Lubricate and clean.

4-8 Accessing Lubrication and Check Points

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NOTE: References 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).

LUBRICATION / FLUID LEVEL CHECK - 65ET T4 FINAL Interval Hours Ref Identification

No. of Pts

Type of Lube Qty Remarks

Every 250

Hours or Weekly

22 Universal Joints (Drive Shaft)

3 EPG 1-2 Shots

One on universal joint at each end of drive shaft.

23 Rear Axle Housing

1 THF 5.5 Gal Check

24 Circle Turn Gearbox

1 80/90 0.2 Gal Check

25 Tandem Drive Case

2 80/90 3 Gal Each Check, one each side.

EPG - Extreme Pressure Grease (NLGI GRADE 2, LITHIUM COMPLEX) Number of shots based on use of hand type lubrication gun (1 Shot = 1.5 grams or 0.5 oz approx. SAE 80/90 - 80W-90 GEAR OIL (API GL-5 & MT-1)ISO68 - ANTIWEAR HYDRAULIC FLUID, ISO GRADE 68Ultra Low Sulfur Diesel (ULSD) Fuel, S< 15 ppmISO 22241; Diesel Exhaust Fluid (DEF)Graphite - Water-based graphite paint - dry film lubricantCoolant - 50/50 Solution - Clean water & ethylene glycol or propylene glycol-base

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4-10 Accessing Lubrication and Check Points

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MAINTENANCE INTERVALS

The maintenance intervals outlined in the following maintenance section are based on normal operating conditions. When operating under severe conditions, the maintenance intervals should be shortened.

SERVICE HOURS - 65ET T4 FINAL Interval Hours Identification RemarksEvery 10 Hours

or DailyCooling Fan CheckBackup Alarm Test


Wheel Lug Nuts Check / RetorqueHoses and Clamps Inspect / Replace

Every 100 Hours

Neutral Start Interlock Propel Lever TestPropel Lever Interlock Button

Test

Foot Brake TestEvery 250 Hours

or Monthly Tire Inflation Pressure Check

Every 500 Hours or 3 Months

Hydraulic Oil Filter CheckHydraulic Oil Strainers CleanFan Clearance CheckROPS and FOPS Check


Battery CheckBattery Cables and Connections

Check

Radiator / Oil Cooler CleanRadiator Pressure Cap CheckEngine Coolant Check

Every 1000 Hours or 6

MonthsTransmission Oil and Filter Change

Every 2000 Hours or Yearly

Hydraulic Oil Change ChangeRear Axle Housing Oil ChangeTandem Drive Case Oil ChangeCircle Turn Gearbox Oil ChangeFront Wheel Bearing Grease

Change

4-11Maintenance Intervals

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When Required

Washer Fluid FillParking Brake Cable (Transmission End)

Adjust

Parking Brake Cable (Lever End)

Adjust

Parking Brake Switch Adjust / ReplaceRadiator / Oil Cooler CheckCircle Guide AdjustMoldboard Cutting Edge ReplaceLights ReplaceMoldboard Guides AdjustBattery ChargeBattery ReplaceBattery Cables Inspect / Replace

SERVICE HOURS - 65ET T4 FINAL Interval Hours Identification Remarks

4-12 Maintenance Intervals

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EVERY 10 HOURS OR DAILY

Fuel - Check / Add

• DO NOT smoke around diesel fuel.

• DO NOT add gasoline, alcohol, gasohol or dieselhol (a mixture of diesel fuel and alcohol) to die-sel fuel because of increased fire or explosion 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.

• Clean filler cap area and keep free of debris.

• DO NOT fill tank to capacity, allow room for expansion.

• If original fuel tank cap is lost, replace it with a new cap and tighten securely.

• Wipe up spilled fuel immediately.

• The quality of the fuel used is important to maintaining a dependable machine. Fuels must be clean, well-refined and noncorrosive to fuel system parts.

Open access door on left side of machine to add fuel. Clean area around fuel cap (1). After filling tank, replace and tighten fuel cap.

NOTICE: The use of ultra-low sulfur fuel (15 ppm) is required.

Fuel and fumes can explode and burn.

Shut off engine before refueling. No flame. No smoking.

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Diesel Exhaust Fluid (DEF) - Check / Add

Take care when dispensing DEF. DEF that has been spilled will attack paint and metal. Spills should be cleaned immediately. All surfaces should be wiped clean and rinsed with water.

Shut off engine before filling tank. Fill tank at the end of each day.

NOTICE: Stopping the engine immediately after the engine has been working under load can result in overheating of engine components. Refer to "Machine Shutdown Procedure", page 3-6 to allow the engine to cool and to prevent excessive temperatures in the turbocharger housing and DEF injector.

NOTICE: Allow at least 2 minutes after engine has stopped before turning master switch OFF. Disconnecting battery power too soon will prevent purging of the DEF lines after engine is shutdown.

DEF capacity: 5 gal (19 L)

To add DEF to the machine, open access door, left of the engine access door on the left side of the machine. The DEF cap is colored blue. Clean area around DEF cap. Remove cap (1) and place in a clean area. After filling tank, replace and tighten DEF cap.

NOTICE: DO NOT use agriculture grade urea solutions. DO NOT use any fluids that do not meet “ISO 22241-1” requirements in SCR emissions reduction systems. Use of these fluids can result in numerous problems including damage to SCR equipment and a reduction in NOx conversion efficiency.

NOTE: DEF level is shown on electronic display panel.

Use caution when dispensing DEF near an engine that has recently been running. Spilling DEF onto hot components may cause the release of ammonia vapors. DO NOT breathe ammonia vapors. DO NOT clean up any spills with bleach.

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4-14 Every 10 Hours or Daily

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Hydraulic Oil - Check Check the hydraulic oil level in the reservoir with engine off. A sight gauge (1) is located inside the right side of the engine cover. Oil level should be between the marks of the glass when the engine is 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.

Transmission Oil - Check Check transmission oil level with oil hot and engine operating 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 engine hood cover.

3. Remove dipstick (1) by turning handle counterclockwise. Check oil level using dipstick. Oil level should be between minimum and maximum marks on the dipstick. If incorrect, add or drain oil to adjust to proper level.

4. Install dipstick and tighten.

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Radiator Coolant - Check

Check coolant level with engine cold.

1. Open access cover (1) on top of engine cover.

2. Turn radiator cap (2) slowly to remove any remaining pressure in the system and remove. Check level visually. Coolant level should be even with the bottom of the fill tube.

NOTICE: Use a 50:50 mix of high quality antifreeze and clean water for maximum coolant performance.

3. Install and tighten radiator cap.

Cooling Fan - Check Check for damage to fan. Check the fan to make sure it is securely mounted. Tighten the bolts, if necessary.

Hot fluid under pressure can scald. Allow engine to cool before opening radiator cap. Check the coolant level when the engine is stopped and cool.

Coolant should be kept off skin. Follow instructions on coolant filter and antifreeze container.

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Backup Alarm - Test1. Turn the ignition switch to RUN.

2. With the engine OFF, slightly move propel lever (1) to the REVERSE position.

NOTE: The backup alarm should sound immediately. The backup alarm should continue to sound until the propel lever is moved to the NEUTRAL position or to the FORWARD position.

3. Contact a NorAm dealer if backup alarm does not function properly.

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EVERY 50 HOURS OR WEEKLY

Front Axle Drag Link - GreaseOne fitting (1) on each side of front axle. 2-4 shots each.

Moldboard Lift Cylinder Balls - Grease One fitting (1) on lower end of each lift cylinder. 2-4 shots each.

Circle Shift Cylinder Balls - Grease One fitting (2) on each end of circle shift cylinder. 2-4 shots each.

Draw Bar Pivot Pins - Grease One fitting (1) on each end of the horizontal pin and one fitting (2) is located on top of the twist pin. 2-4 shots each.

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4-18 Every 50 Hours or Weekly

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Front Axle Pivot Pins - Grease One fitting (1) on front axle pivot pin. 2-4 shots.

Steering Cylinder - Grease One fitting (2) on each end of steering cylinder. 2-4 shots each.

Front Axle Knuckle Pivot - Grease One fitting (1) on each of two front axle knuckle pivots. 2-4 shots each.

Front Axle Spindle Pivot - Grease One fitting (2) on each of two front axle spindle pivots. 2-4 shots each.

Front Wheel Lean Cylinder - Grease One fitting (3) on each end of wheel lean cylinder.

One fitting (4) on each end of connecting rod.2-4 shots each.

Tie Rod Ends - Grease One fitting (5) on each end of tie rod. 1-2 shots each.

4-19Every 50 Hours or Weekly

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Moldboard Pitch Adjustment - Grease One fitting (1) on each end of moldboard pitch cylinder or optional manual adjuster rod. 2-4 shots each.

Implement Lift Cylinders - Grease One fitting (1) located on each end of any implement cylinders installed. 2-4 shots each.

Articulation Joint Bearings - Grease One fitting is located on the right side of the upper (1) and lower (2) articulation joints. 2-4 shots each.

Articulation Cylinders - Grease One fitting (3) is located at each end of both articulation cylinders. 2-4 shots each.


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Moldboard and Circle Turn - Clean / Lubricate Grease and clean moldboard slide bars (1) and circle turn (2) with graphite paint.

Wheel Lug Nuts - CheckCheck to ensure wheel lug nuts (1) are installed and tight on all wheels. Use a torque wrench to verify the front and rear wheel lug nuts are torqued to 440–475 N•m (325–350 lb-ft).

Hoses and Clamps - Inspect / Replace

Inspect all hoses for wear and damage, including, cracking, softness, loose clamps, damaged end fittings, cut or ballooning outer coverings, exposed wires, and crushed or kinked areas.

If wear and damage is present, replace.

Pressurized fluid can penetrate body tissue and result in serious injury or death. Leaks can be invisible. keep away from any suspected leak. Relieve pressure in the hydraulic system before searching for leaks, disconnecting hoses, or performing any other work on the system. If you must pressurize the system to find a suspected leak, use an object such as a piece of wood or cardboard rather than your hands. When loosening a fitting where some residual pressure may exist, slowly loosen the fitting until oil begins to leak. Wait for leaking to stop before disconnecting the fitting. Fluid injected under the skin must be removed immediately by a surgeon familiar with this type of injury.

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EVERY 100 HOURS

Neutral Start Interlock - Propel Lever Test

1. Shut engine OFF.

2. Pull park brake ON.

3. Move propel lever out of NEUTRAL.

4. Turn the ignition key to start the engine. Display panel will instruct operator to return the propel lever to NEUTRAL.

NOTE: Engine must not start with propel lever out of NEUTRAL.

5. Return propel lever to NEUTRAL.

6. Start the engine.

7. Contact a NorAm dealer if propel lever neutral start interlock does not function properly.

Propel Lever Interlock Button - Test

1. Start engine.

2. DO NOT press propel lever interlock button and move propel lever out of NEUTRAL.

NOTE: Transmission must not engage.

3. Contact a NorAm dealer if propel lever interlock button does not function properly.

Serious injury or death can result if machine moves and strikes a bystander. Keep everyone away from the machine.


4-22 Every 100 Hours

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Foot Brake - Test

1. Engage foot brake.

2. Start engine.

3. Turn inching control ON.

4. Place machine in first gear.

5. Increase engine speed to full throttle.

NOTE: Machine must not move.

6. Contact a NorAm dealer if foot brake does not function properly.


4-23Every 100 Hours

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EVERY 250 HOURS OR MONTHLY

Universal Joints (Drive Shaft) - Grease One fitting (1) on the universal joint at each end of the drive shaft. 1-2 shots each.

One fitting (2) on rear end, slip joint, of drive shaft. 2-4 shots.

Rear Axle Housing - Check Oil Level Remove fill plug (1) on rear axle center housing. Oil level should be even with bottom of hole. Add oil as necessary.

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4-24 Every 250 Hours or Monthly

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Circle Turn Gearbox - Check Oil Level Position machine on a level surface. Lower 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.

Tandem Drive Case - Check Remove oil level check plug (1) on side of tandem case. Oil level should be even with bottom of hole. Remove fill plug (2) and add fluid until level with bottom of check plug hole.

Repeat for tandem case on other side.

4-25Every 250 Hours or Monthly

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Tire Inflation Pressure - Check

• Be sure tires are properly inflated to specified pres-sure. inspect tires periodically for damage.

• Check tires only when tires are cool to avoid under inflation.

• Check the pressure in the 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 cold inflation pressure allows for variation due to heat buildup.

DO NOT inflate tires with flammable gases or with air from systems that use alcohol injectors. An explosion with injury's could result.

DO NOT stand directly in front of tire while performing maintenance. Always stand to one side and extend arm to filler valve.

4-26 Every 250 Hours or Monthly

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EVERY 500 HOURS OR 3 MONTHS

Hydraulic Oil Filter - Change

Change hydraulic filter when oil is cool.

1. Loosen fill cap (1) to release pressure.

2. Remove bolts (2) attaching filter cover (3) to oil tank. Carefully remove cover, spring, cap and o-ring from top of tank.

3. Remove element (4) 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 to 47–53 N•m (35–40 lb-ft).

Hot fluid can burn. Fluid is under pressure. Turn cap slowly to relieve pressure before removing.

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4-27Every 500 Hours or 3 Months

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Hydraulic Oil Strainers - Clean Two strainers, a filler strainer and suction strainer, are used in the hydraulic system. Clean strainers when the filter element is changed and the hydraulic tank is drained.

1. Remove fill cap to release pressure (1).

2. Remove bolts (2) attaching the filler strainer (3) to the oil tank. Carefully remove cover and o-ring from top of tank. Discard o-ring.

NOTICE: Clean hands before and after inserting in hydraulic oil tank.

3. Clean strainer using a commercial, non-flammable, non-toxic solvent. Use compressed air (limited to 207 kPa (30 psi) to blow-dry strainer. Blow air from inside out.

4. Remove drain plug (4) and drain hydraulic oil from tank.

5. Remove access cover (5).

6. Clean suction strainer (6) using compressed air (limited to 207 kPa (30 psi).

7. Flush tank.

8. Install new o-ring on fill cap cover. Attach fill cap cover to oil tank and tighten bolts.

9. Fill hydraulic oil tank. Install fill cap and lock.

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4-28 Every 500 Hours or 3 Months

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Fan Clearance - Check Engine must be “OFF”. Refer to "Machine Shutdown Procedure", page 3-6.

1. Place Master Switch (1) in “OFF” position.



NOTICE: Disconnecting battery too soon prevents purging of the DEF lines. Damage to the DEF system and emission control system can occur.

NOTE: Cooling system must be full.

2. Check the clearance between the shroud and the fan. The gap between the edge of the shroud and the tip of the fan blade must be checked in four equally spaced positions.

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ROPS and FOPS - Inspect The motor grader is equipped with a Roll Over Protection System (ROPS) and Falling Object Protection System (FOPS) and a seat belt. An optional enclosed cab is available which is also ROPS and FOPS certified.

If the motor grader has rolled over or the ROPS or FOPS has been damaged, it must be replaced to provide the original amount of protection. Damage may be caused by rollover, striking an object while being hauled on a trailer, rocks falling on the top canopy, etc.

NOTICE: DO NOT attempt to weld or straighten ROPS or FOPS components.

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 mounting bolts (2) to 311–447 N•m (230–330 ft-lbs).

2. Check the operator's seat and seat belt mounting bolts (1). Torque seat belt and eyelet anchor bolts to 54–61 N•m (40–45 ft-lbs). Inspect the seat belt for tears, rips, worn or stretched areas. Replace any worn or damaged parts.

If ROPS/FOPS is replaced, use correct hardware as specified in the Parts Manual and correct torque values are applied to mounting bolts.


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All maintenance checks and inspections listed in previous maintenance intervals must be performed at this time in addition to those listed under this maintenance interval.

Battery - Check

The 12V battery is "Maintenance Free" and does not require electrolyte level checks.

NOTICE: Whenever working around battery, turn master switch OFF.

NOTICE: Disconnecting battery too soon will prevent purging of the DEF lines after engine is shut down. Damage to the DEF system and emission control system can occur.

NOTICE: If equipped with a CAT engine, DO NOT turn master switch OFF while lamp is illuminated. Lamp remains ON approximately 2 minutes after engine is shut down.


Keep the battery clean and protect terminals with terminal boots.

Testing Battery1. Remove the top panel.

2. Perform a load-test on batteries to determine the state of charge. If state of charge is low, charge batteries.

If battery does not charge, replace battery. Refer to "Battery - Replace", page 4-48.

Battery fumes are flammable and can explode. Keep all burning materials away from battery. Battery explosion can blind. Acid can blind and burn. Tools and cable clamps can make sparks.

DO NOT smoke. Shield eyes and face.

Battery posts, terminals and related accessories contain lead compounds, chemicals known to the state of California to cause cancer and reproductive harm. Wash hands after handling.


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Battery Cables and Connections - Check

1. Turn Master Switch (1) OFF.




2. Inspect battery cables and connections for cracks or corrosion.

3. Replace broken terminals, connectors, or cables.

4. Clean corroded connections with a battery brush or a wire brush.

5. Remove all debris from surrounding surfaces.

Radiator / Oil Cooler - Clean Check radiator/oil cooler for debris and restrictions. Remove louvered side panels and rear radiator cover and blow compressed air (not to exceed 207 kPa {30 psi}) from the back of the motor grader into the engine compartment. This is the opposite direction of normal air flow. Refer to Engine Operation and Maintenance Manual supplied with machine for additional information.

Extinguish all smoking materials and open flames when working around batteries. Battery gas is highly flammable.


Wear safety glasses or goggles when cleaning with compressed air.

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Radiator Pressure Cap - Check NOTICE: An incorrect or malfunctioning cap can result in loss of coolant and the engine running hot.

Ensure the correct radiator cap (1) is being used. Inspect rubber seal of pressure cap and radiator fill neck for damage.

Refer to Engine Operation and Maintenance Manual for complete instructions.

Engine Coolant - Check Check engine coolant when engine temperature is cold.

NOTICE: Over-concentration of antifreeze or use of high silicate antifreeze can cause damage to the engine.

Check antifreeze concentration. Use a mixture of 50:50 antifreeze to protect engine to -25°F (-32°C) year-round.

If antifreeze levels are low, fill antifreeze reservoir.

Hot fluid can scald. Fluid is under pressure. Remove cap only when engine is cold. Release cap slowly to first stop and allow pressure to dissipate.

Coolant should be kept off skin. Follow precautions outlined on anti-freeze container.

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Transmission Oil and Filter - Change Change transmission oil and filter at the same time.

1. Support bottom transmission cover and remove bolts securing rear of cover and lower rear of cover to the ground.

2. Remove plug and drain transmission oil.

3. Clean filter area before removing filter (1). Discard filter.

4. Apply thin film of new, clean oil to sealing ring on the new filter and install.

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 obtained and tighten it now by hand about 1/3 to 1/2 turn.

5. Install drain plug and refill transmission to correct level on dipstick. Start engine and do final check with oil temperature above 80–90° C (176–194° F).

NOTE: At every oil change, the ZF-Fine filter must be replaced. In addition, ZF recommends to start the autonomous calibration of the shifting elements (AEB).

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Procedure to start AEB:NOTE: AEB will not start with any fault codes on display except fault “F6”.

1. Warm up transmission.

The message “Normal operating messages” is displayed.

2. Stop engine.

3. Turn on key switch.

4. Scroll through display to AEB.

NOTE: From main screen press Menu, select System Settings, then select AEB Mode Request.

5. Move shift lever to N position.

6. Engage park brake.

7. Start engine

8. Set engine speed to 800 rpm.

9. Press button of the display to start AEB.

The message “ST” is displayed if the start conditions are ok.

NOTE: The button must not be released before TCU has started the AEB or quit with an error code.

10. Hold button until AEB has started.

The message “K1” will be displayed. (Information about the AEB state)

NOTE: TCU has started the AEB and goes on adjusting K1, K2, ..., KR. (Button may be released)

11. Wait until AEB has finished.

The message “OK” will be displayed. AEB has been successful.


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DisplaySymbol Meaning Remarks

ST AEB - Starter button is pressed

K1...K4, KV, KRCalibrating clutch K1...K4,KV,KR

_ and KxWait for start, initialization of clutch Kx

= and KxFast fill time determination of clutch Kx

= and KxCompensating pressure determination of clutch Kx

OKCalibration for all clutches finished

Transmission stays in neutral, you have to restart the TCU (ignition off/on) after removing AEB starter.

STOPAEB canceled (activation stopped)

Transmission stays in neutral, you have to restart the TCU (ignition off/on)

STOP and KxAEB stopped, clutch Kx can’t be calibrated


Spanner and KxKx couldn’t be calibrated, AEB finished


Engine speed too low, -> raise engine speed Engine speed too high, -> lower engine speed Transmission oil temperature too low, -> heat up transmissionTransmission oil temperature too high, -> cool down transmission

FTTransmission temperature not in defined range during calibration


FB

Operating mode not NORMAL or transmission temperature sensor defective or storing of calibrated values to EEPROM - has failed


FO Output speed_not_zeroTransmission stays in neutral, you have to restart the TCU (ignition off/on)

FN Shift lever not in neutral positionTransmission stays in neutral, you have to restart the TCU (ignition off/on)

FP Parkbrake_not_appliedTransmission stays in neutral, you have to restart the TCU (ignition off/on)

STOPAEB - Starter was used incorrect or is defective


E

E

T

T


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EVERY 2000 HOURS OR 1 YEAR

Hydraulic Oil -Change NOTE: Change hydraulic oil filter and strainers whenever changing hydraulic oil.

Change hydraulic oil when oil is cold.

1. Remove hydraulic tank fill cap.

2. Open access door.

3. Remove plug (1) and open valve (2) to drain oil. Use a suitable container to catch drain oil. Dispose of waste oil according to federal, state and local regulations.

4. When drained, close valve and install plug. Fill with 62.5 L (16.5 gal) of clean 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.

Fluid in the hydraulic cylinders and lines is under pressure. Lower implements to ground, shut off engine and move control levers several times to relieve pressure.

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4-37Every 2000 Hours or 1 Year

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Rear Axle Housing Oil - Change Change oil in rear axle housing with oil temperature at or near normal operating temperature.

1. Remove level check plug (1) at rear of center housing.

2. Remove drain plug (2) and allow oil to drain. Catch drain oil in suitable container.

NOTE: Allow adequate time for oil to drain from axle sections into center housing.

3. After oil is drained, clean area around drain and install drain plug.

4. Fill axle at center housing until level is even with bottom of check plug.

NOTE: Allow adequate time for oil to fill axle sections.

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4-38 Every 2000 Hours or 1 Year

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Tandem Drive Case Oil - Change Change tandem case oil when oil is warm.

NOTE: On right side tandem case the drain plug is at the front. On the left side the drain plug is at the rear. To aid drainage, use a jack to raise end of case opposite of drain plug.

1. Remove fill plug on top of tandem case.

2. Remove drain plug (1) from bottom inside of tandem case. Allow oil to drain into a suitable container. Dispose of waste fluid according to federal, state and local laws.

3. Clean area around drain and replace plug.

4. Remove check plug (2). 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.

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Circle Turn Gearbox Oil - Change 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 and replace plug.

3. Remove breather (1) and add oil until level with check plug hole (2).

Front Wheel Bearing Grease - Change 1. Loosen bolts (1) and remove front wheel bearing

cover (2).

2. Remove grease and clean bearing housing.

3. Repack bearing housing with grease (approximately 0.9 L (0.95 qt) per side)

4. Replace cover and torque cover bolts to 41–54 N•m (30–40 lb-ft).


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WHEN REQUIRED

Washer Fluid - Fill Fill washer fluid reservoir (1) with clean fluid.

NOTICE: DO NOT operate washer pump without fluid in the reservoir.

Parking Brake - Check 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 check / adjust the switch position.

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4-41When Required

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Parking Brake Cable (Transmission End) - Adjustment 1. Support bottom transmission cover and remove bolts

(1) securing rear of cover (2). Lower rear of cover to the ground, allowing cover to hang from front pivot bolts.

2. Loosen jam nuts (4) retaining cable to the bracket. Adjust cable (5) by raising or lowering jam nuts on cable end.

3. Tighten jam nuts and verify parking brake lever operation.

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4-42 When Required

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Parking Brake Cable (Lever End) - Adjustment1. Remove bolts and washers (1) securing rear cover (2)

to floor. Remove rear cover.

NOTE: It is not necessary to remove the seat but greater access will be gained if it is removed.

2. Remove the cotter pin and clevis pin from the parking brake lever (3).

3. Loosen the jam nut (1) and turn the link (2) counterclockwise to loosen the cable and clockwise to tighten the cable. If further adjustment is required, loosen the jam nuts securing the cable to the floor and adjust to provide more or less cable.

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4-43When Required

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Parking Brake Switch - Adjust / ReplaceThe 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. Remove top place (2).

2. Remove storage box (3)

3. Loosen the retaining bolts (1) on the switch mounting plate (2).

4. Pull the brake lever up to the third notch.

5. With the ignition switch in RUN, slide the parking brake switch up or down until the parking brake lamp appears on the display. Tighten the retaining bolts on the switch mounting plate.

6. Release the parking brake lever. Verify that the parking brake message appears between the 2nd and 3rd notch.

7. Replace cover and storage box.

Radiator / Oil Cooler - Check Check radiator/oil cooler for debris and restrictions. Remove louvered side panels and rear radiator cover and blow compressed air (not to exceed 207 kPa {30 psi}) from the back of the motor grader into the engine compartment. This is the opposite direction of normal air flow.

Wear safety glasses or goggles when cleaning with compressed air.

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Circle Guide - Adjust The circle and circle guides must be kept clean and adjusted properly. Improper adjustment will cause excessive tooth wear and poor angle control.

Adjust vertical spacing before radial spacing.

1. Clean circle guides and bottom of circle so measurements are accurate. Support circle using jack stands, allowing moldboard to hang from circle.

2. Use a feeler gauge to measure clearance between the top of the circle (1) and the draw bar (2). Start with the guide closest to the circle motor making sure vertical clearance (3) does not exceed 1.52 mm (0.060 in.). To reduce clearance, remove shims (4).

3. Using machine hydraulics, rotate circle 360° to ensure that it turns freely.

4. Turn circle so that a motor pinion gear tooth is aligned between the center of the pinion gear (1) and the front guide 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 (0.030 in.) clearance.

6. Tighten jam nuts on front guide. Torque jam nuts to 270–300 N•m (200–225 lb-ft).

7. Loosen circle guide nuts and jam nuts (1) and radial clearance adjusting screws (2) on rear guide (opposite of circle motor).

8. Set clearance between inner circle guide and curved circle guide wear plates to 0.030 in. (0.76 mm) using adjusting screws. Torque circle guide nuts to 470–540 N•m (350–400 lb-ft).

9. Tighten jam nuts on rear guide. Torque jam nuts to 270–300 N•m (200–225 lb-ft).

10. Rotate circle 360° to ensure that it turns freely. If circle does not turn freely, readjust the tooth clearance at the front guide. DO NOT exceed 1.52 mm (0.060 in.) clearance.

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Moldboard Cutting Edge - Replace Cutting edges and end bits should be replaced when worn or damaged. End bits and cutting edges are interchangeable from left to right.

1. Raise moldboard. Place suitable 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.

Moldboard Guides - Adjust Moldboard guide clearance must be checked to prevent looseness and excessive wear of the moldboard guides. Loosen nuts (1) and adjust set screws (2) until clearance is 0.76–1.52 mm (0.030–0.060 in). Re-tighten nuts.

Never work under raised equipment. Use suitable blocking to prevent moldboard from dropping.

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Battery - ChargeNever 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 components to the ground.

DO NOT use a booster battery or charger of more than 12 volts.

Always observe correct polarity when installing batteries or using a booster battery to jump start the engine. Connect positive to positive and negative to negative.

Always turn the master switch OFF when charging the battery in the motor grader with a battery charger.

Inside the right side access panel is a Master Switch for the electrical system. Before charging the battery, turn the master switch OFF and remove key to prevent others from activating any electrical circuits.

1. Remove top panel.

2. Attach charging device (booster battery or battery charger) to terminals of the battery. Observe polarity, connecting positive to positive before connecting negative to negative.

3. Allow battery time to charge. Longer charges at lower current are recommended.

4. Disconnect charging device, negative terminal before positive terminal.

5. Turn master switch ON.

6. Start engine using normal starting procedures.

Batteries contain sulfuric acid. in case of contact with skin, flush affected area with water for five minutes. Seek medical attention immediately. Avoid contact with the skin, eyes or clothing. wear eye protection when working near batteries.


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Battery - Replace

The 12 volt battery is "Maintenance Free" and does not require electrolyte level checks.

NOTICE: Whenever working around the battery, disconnect the Master Switch.


• If equipped with a CAT engine, DO NOT turn master switch OFF while lamp is illuminated. Lamp remains ON approximately 2 minutes after engine is shut down.

• If equipped with a Cummins engine, DO NOT turn master switch OFF for approximately 2 min-utes after engine is shut down.

Keep the battery clean and protect terminals with terminal boots.

1. Turn ignition switch OFF and remove key.

2. Turn master switch OFF and remove key.

3. Remove the top panel.

4. Disconnect negative cable from battery.

5. Disconnect positive cable from battery.

6. Remove nuts from retaining bracket (1). Remove bracket.

7. Remove battery. Dispose of old battery according to federal, state and local laws.

8. Secure new battery in place with bracket. Torque bolts to 34 N•m (25 lb-ft).

9. Connect positive cable to positive terminal on battery.

10. Connect negative cable to negative terminal on battery.

11. Install top panel. Torque bolts to 122–136 N•m (90–100 lb-ft).



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Battery Cables - Inspect / Replace

1. Place Master Switch (1) in OFF position.


• If equipped with a CAT engine, DO NOT turn mas-ter switch OFF while lamp (2) is illuminated. Lamp remains ON approximately 2 minutes after engine is shut down.

• If equipped with a Cummins engine, DO NOT turn master switch OFF for approximately 2 minutes after engine is shut down.

2. Inspect battery cables and connections for cracks or corrosion.

3. Replace broken terminals, connectors, or cables.

4. Clean corroded connections with a battery brush or a wire brush until shiny.

5. Remove any and all debris from surrounding surfaces.

Lights - ReplaceBulbs 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 replacements installed.



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SECTION 5: LUBRICATION AND MAINTENANCE - CUMMINS TIER 4 FINAL




GENERAL INFORMATION

Master Switch - Battery Ground Disconnect The Master Switch (1) is inside the right side engine access door. When in the OFF (vertical) position the ground circuit to batteries is opened. Turn switch OFF and remove key when the machine will be parked for long time periods or while servicing. To operate machine, turn Master Switch ON.


NOTICE: DO NOT turn master switch OFF for approximately 2 minutes after engine is shut down.


Failure to turn master switch off before servicing may result in electrical shock or damage to machine components.

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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 accumulated 1200 hours and a year has passed since hydraulic oil was replaced, change the hydraulic oil now rather than waiting until 2000 hours have passed.

Preventing ContaminationTo prevent contamination when changing oils, filters, etc., always clean the area around the filler caps, level plugs, drain plugs, dipsticks and filters prior to removal. To prevent dirt entry during greasing, wipe dirt from the grease fittings before attaching grease gun. All grease fittings are equipped with caps which must be removed before attaching grease gun. Reinstall cap after wiping off excess grease to prevent dirt entry.

Accessing Lubrication and Check PointsIn order to access many of the lubrication and check points during service and maintenance procedures, shielding will need to be removed and the hood opened or removed.



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65ET T4 FINAL SERVICE HOURSInterval Hours Identification Remarks

Every 10 Hours or Daily

Crankcase Breather Tube CheckFuel-Water Separator CheckEngine (Lubricating) Oil Level

Check

Engine Accessory Drive Belt and Tensioner

Check

Air Filter Restriction CheckDust Ejection Valve CheckAir Intake Piping Check

Every 250 Hours or Monthly

Charge-Air Piping CheckCharge-Air Cooler Check


Fuel Filters ChangeEngine (Lubricating) Oil and Filters

Change

Engine Coolant Antifreeze CheckCooling Fan Belt Tensioner Check

Every 1000 Hours or 1 Year

Radiator Pressure Cap CheckBelt-Driven Fan Hub Check

Every 2000 Hours or Yearly

Engine Coolant ChangeRadiator Hoses Check

When Required

Air Filter Outer Element ReplaceAir Filter Secondary Element

Replace

Engine CleanFuses Replace


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Crankcase Breather Tube - Check

Remove crankcase breather tube (1) from engine.

If crankcase breather tube contains sludge, debris, or ice, clean the tube with a strong detergent in hot water. Dry tube with compressed air.

If crankcase breather tube is uncleanable or contains cracks and other damage, replace crankcase breather tube.

Refer to “Cummins QSF3.8 Operation and Maintenance Manual” for complete instructions.

Fuel-Water Separator - Check Check the fuel sediment bowl (1) on the fuel/water separator for water and debris and drain if necessary.

WEAR APPROPRIATE EYE AND FACE PROTECTION WHEN USING COMPRESED AIR. FLYING DEBRIS AND DIRT CAN CAUSE PERSONAL INJURY.

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Engine (Lubricating) Oil Level - Check 1. Park machine on a level surface. Allow engine oil to drain into the sump for 15 minutes after the

engine has stopped before checking level.

2. Remove dipstick (1) and check level. Oil level should be above minimum mark and below maximum mark.

3. Remove fill cap (2) and add or remove oil to obtain proper fill level between minimum and maximum marks.

NOTE: The amount required to change the level from the minimum mark to the maximum mark is 1.5 L (1.6 qt).

NOTICE: Never operate engine with oil level below L (low) mark or above H (high) mark. Poor engine performance or engine damage can occur.

Engine Accessory Drive Belt and Tensioner - Check

To remove drive belt (1) insert 3/8 in. drive breaker bar into the square hole on the tensioner (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 align properly with all pulley grooves.

Contact with rotating fan or entanglement in drive belt can cause serious injuries. DO NOT place head, body or limbs near a rotating fan or belts. DO NOT check belts with engine running.

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Air Filter Restriction - Check Located on the right side of the machine on the air cleaner outlet, is a filter restriction indicator (1). If the indicator is showing red, the outer filter is plugged and needs to be replaced. Refer to "Air Filter Outer Element - Replace", page 5-13.

Dust Ejection Valve - Check If equipped with a Pre-Cleaner Exhaust Aspirator, a dust ejection valve will not be present.

Purge the dust ejection valve (1) of dust by squeezing the valve until it opens. This may have to be performed multiple times depending on the severity of dust or debris found in the valve. If debris is not able to be purged from the valve, remove the valve and clean out by hand.

Inspect dust ejection valve. If damage is found, replace.

NOTICE: Before removing dust ejection valve, clean surrounding area.

Refer to “Cummins QSB3.3 Operation and Maintenance Manual” for complete instructions.

Air Intake Piping - Check Inspect intake piping (1) for wear and damage, loose clamps, corrosion under clamps and hoses, and/or punctures.

Clean or replace intake piping if needed


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EVERY 250 HOURS OR EVERY 3 MONTHS


Charge-Air Piping - Check Inspect the charge-air piping (1) and hoses for wear and damage, including, leaks, holes, cracks, or loose connections. If hose clamps are loose, tighten.


Charge - Air Cooler - Check 1. Remove grate.

2. Inspect charge-air cooler (1) for dirt and debris blocking the fins. Check for wear and damage.


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EVERY 500 HOURS OR EVERY 6 MONTHS


Fuel Filters - Change Refer to the Engine Operation and Maintenance Manual supplied with machine for additional information.

1. Drain the fuel from the primary filter (1) through the filter drain (2) into a suitable container and dispose of properly.

2. Remove the filter and dispose of properly.

3. Remove the secondary fuel filter (3) and dispose of properly.

NOTE: Over-tightening of the filter will distort threads, filter element seal or filter.

Priming the Fuel SystemIt 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.

To Prime the System:1. Loosen the knob on the filter head (1).

2. Pump the primer (2) until the lever stiffens and it is difficult to pump.

3. Push the primer in close to the filter head.

4. Tighten the knob into the filter head.

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 personal injury or death.

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Engine (Lubricating) Oil and Filters - Change 1. Change oil filter (1) when the engine oil is changed.

NOTE: The o-ring can stick on the filter head. Make sure it is removed before installing the new filter.

2. Remove plug (2) on bottom of the engine oil pan and drain oil into a suitable container. Dispose of waste oil according to federal, state and local regulations.

3. Clean area around oil filter. Remove oil filter using filter wrench. 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.

NOTICE: DO NOT over-tighten. Over-tightening can damage the filter.

6. Install plug in engine oil pan. Torque to 17 ft-lb (24 Nm).

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.

NOTICE: Engine oil pressure MUST be indicated on the gauge within 15 seconds after starting. If oil pressure is NOT registered within 15 seconds, shut off engine immediately to avoid engine damage. Confirm that the correct oil level is in the oil pan.

9. Check oil level using dipstick. If necessary, add oil until level is between minimum and maximum marks on dipstick. Check filter and drain plug for leakage.

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Engine Coolant Antifreeze - Check NOTICE: Over-concentration of antifreeze or use of high silicate antifreeze can cause engine damage.

Check the antifreeze concentration. Use a mixture of 50% water and 50% ethylene glycol or propylene glycol-base antifreeze to protect the engine to -25°F (-32°C) year-around.

To check antifreeze concentration:

1. Place a drop of coolant on a refractometer window and shut the lid.

2. Look through the eyepiece and focus.

3. Record the freeze point protection for either ethylene glycol or propylene glycol coolants.

NOTICE: Antifreeze is essential in every climate.


Accessory Drive Belt Tensioner - Check

To remove drive belt (1) insert 3/8 in. drive breaker bar into the square hole on the tensioner (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 align properly with all pulley grooves.


DO NOT place head, body or limbs near a rotating fan or belts. DO NOT check belts with engine running.

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Radiator Pressure Cap - Check The cooling system is designed to use a pressure cap (1) to prevent the coolant from boiling. An incorrect or malfunctioning cap can result in the loss of coolant and the engine running hot.

Inspect for Reuse• Ensure the correct radiator cap is being used.

• Inspect the rubber seal of the pressure cap for damage.

• Inspect the radiator fill neck for cracks or other damage.

• Pressure test the radiator cap. The pressure cap MUST seal within 2 psi (14 kPa) of the value stated on the cap, or it MUST be replaced.


Belt-Driven Fan Hub - Check Refer to “Cummins QSF3.8 Operation and Maintenance Manual” for instructions.

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EVERY 2000 HOURS OR 2 YEARS

Engine Coolant - ChangeChange engine coolant when engine temperature is cold.

1. Remove radiator cap. Open heater valve (1) to allow heater core to drain.

2. Remove plug on water pump. 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 and antifreeze to bottom of fill neck.

6. With cap off, start and allow engine to idle until temperature is normal and thermostat has opened. Stop engine and check fluid level. Add additional coolant, as necessary.

7. Install radiator cap and tighten. Secure radiator cover.


Radiator Hoses - CheckCheck all hoses for cracks, cuts, or collapsing.

NOTE: The silicone engine coolant hose will exhibit swelling due to the elasticity of the hose.

If damage is found, replace damaged hoses.


Hot fluid under pressure can scald.

Allow engine to cool before opening radiator cap.

Coolant should be kept off skin. Follow precautions outlined on anti-freeze container.

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WHEN REQUIRED

Air Filter Outer Element - Replace An indicator (1) mounted on the air cleaner cover will turn red when the outer air filter element requires replacement.

1. Remove air cleaner end cover (2).

2. Carefully remove outer element (3) taking care not to disturb the inner element or knock any dirt off the outer element.

NOTICE: DO NOT clean element and reuse as doing so reduces the 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 secondary element every third time the outer element is replaced.

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Air Cleaner Secondary Element - Replace Change air filter inner element every third time the outer element is changed.

NOTICE: DO NOT clean inner element.

1. Remove air filter outer element and replace, as necessary. Refer to "Air Filter Outer Element - Replace", page 5-13.

2. Remove inner element (1) by pulling on it and discard.

3. Install new inner element by firmly pressing it into place. Be sure inner element is seated properly.

4. Install outer element and cover.

Engine - Clean

Steam is the preferable method of cleaning an engine. If steam is not available, use a solvent to clean the engine.

NOTICE: Protect all electrical components, openings, and wiring from the full force of the cleaner spray nozzle.

When using a steam cleaner, wear safety glasses or a face shield and protective clothing. Hot steam can cause serious personal injury.

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Fuses - Replace If an electrical circuit does not work, check the fuse panel (1) under the right side console and/or the fuse panel (2) inside the right engine compartment. Fuses may have blown, breaking the circuit. Be sure to locate the cause of the blown fuse before replacing. Automotive push-type fuses are used.

To access a fuse, remove the bolts on the front of the control panel and lift top up.

A card (3) showing fuse locations for fuse panel (1) functions, and amperage ratings, is attached to the harness in the console.

(1) DEF Suction Heat Relay

(2) DEF Pressure Heat Relay

(3) DEF Return Relay

(4) Start Inhibit Relay

(5) Supply Module Relay

(6) 24 V Neutral Start Relay

(7) Aftertreatment Relay

(8) J1939 Datalink Fuse

(9) Aftertreatment Fuse

(10) ECM Fuse

(11) Supply Module Fuse

(12) DEF Heat Relay Fuse

NOTICE: Turn off Master Switch before working on electrical system.

NOTICE: Always replace fuses with an equal amperage fuse.

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1. SEAT - 10A 2. DISPLAY - 7.5A 3. BLADE PITCH - 30A 4. DEFOG FANS - 30A 5. HIGH BEAMS - 10A 6. HEAD LIGHT - 10A 7. HORN - 5A 8. IGN SWITCH - 7.5A 9. TAIL LIGHTS - 5A10. LED STROBE - 5A11. PWR SOCKET - 10A12. TURN SIGNAL / HAZARD - 10A13. BRAKE SWITCH - 5A

14. FUEL SENDER - 5A15. DOME / DASH LIGHTS - 7.5A16. WORK LIGHTS - 30A17. TRANS. SHIFT LEVER SENSOR - 5A18. TRANSMISSION - 7.5A19. CONVERTER - 30A20. OPEN21. OPEN22. WIPERS - 15A23. A/C - 30A24. HEATER - 30A25. ENG ECU FUSE - 30A

ENG ECU FUSE IS LOCATED NEAR RH SIDE OF HYD TANK INSIDE ENG COMPARTMENT

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SECTION 6: LUBRICATION AND MAINTENANCE - CAT TIER 4 FINAL




GENERAL INFORMATION

Master Switch - Battery Ground DisconnectInside the right side engine access door is a Master Switch (1). When in the OFF (vertical) position the ground circuit to batteries is opened. Turn switch OFF and remove key when the machine will be parked for long time periods or while servicing. To operate machine, turn Master Switch ON.

NOTICE: DO NOT turn master switch OFF while lamp (2) is illuminated. Lamp remains ON approximately 2 minutes after engine is shut down.


Wait to Disconnect LampWhen lamp is illuminated DO NOT place the master switch in the OFF position.


Failure to turn master switch off before servicing may result in electrical shock or damage to machine components.

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Service IntervalsThe 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 accumulated 1200 hours and a year has passed since hydraulic oil was replaced, change the hydraulic oil now rather than waiting until 2000 hours have passed.

Preventing ContaminationTo prevent contamination when changing oils, filters, etc., always clean the area around the filler caps, level plugs, drain plugs, dipsticks and filters prior to removal. To prevent dirt entry during greasing, wipe dirt from the grease fittings before attaching grease gun. All grease fittings are equipped with caps which must be removed before attaching grease gun. Reinstall cap after wiping off excess grease to prevent dirt entry.

Accessing Lubrication and Check PointsIn order to access many of the lubrication and check points during service and maintenance procedures, shielding will need to be removed and the hood opened or removed.



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65ET T4 FINAL SERVICE HOURSInterval Hours Identification Remarks

Every 10 Hours

Engine Coolant Level CheckEngine Air Cleaner Service Indicator

Check

Engine Air Precleaner Check / CleanEngine Oil Level CheckFuel System Primary Filter / Water Separator

Drain


Hoses and Clamps Inspect / ReplaceFuel Tank Water and Sediment

Drain

Every 250 Hours Engine Oil Sample ObtainEvery 500 Hours Fan Clearance Check

Every 500 Hours or 1 Year

Engine Air Cleaner Primary Element

Clean / Replace

Engine Air Cleaner Secondary Element

Inspect / Replace

Engine Oil and Filter ChangeFuel Filters ChangeRadiator Clean

Every 1000 Hours Water Pump Inspect

Every 1500 Hours Engine Crankcase Breather Element

Replace

Every 2000 Hours

Aftercooler Core InspectEngine Mounts InspectStarting Motor InspectTurbocharger Inspect

When Required

DEF Filler Screen CleanDEF Tank FlushEngine CleanEngine Air Cleaner Primary Element

Clean / Replace

Engine Air Cleaner Secondary Element

Inspect / Replace

Fuel System PrimeFuses Replace


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Refer to the Engine Operation and Maintenance Manual supplied with the machine for engine maintenance information.

Engine Coolant Level - Check

Fill to within 1/2” (13mm) of bottom of fill pipe with a low-silicate (ethylene glycol) antifreeze and clean water mixture.

NOTE: Never add pure antifreeze to a cooling system. We recommend using a 50/50 mixture. Never use high-silicate antifreeze that is higher than a 60/40 mixture.

1. Remove the cooling system fill cap (1) slowly in order to relieve pressure.

2. Maintain the coolant level within 1/2” (13 mm) of the bottom of the fill pipe.

3. Clean the cooling system fill cap and check the condition of the fill cap gaskets. Replace the cooling system fill cap if the fill cap gaskets are damaged. Reinstall the cooling system fill cap.

4. Inspect the cooling system for leaks.

Engine Air Cleaner Service Indicator - Check When red indicator reaches the window on indicator (1) replace air filter element. Push button (2) to reset indicator.

DO NOT remove element until the indicator show it needs to be replaced.

NOTICE: The air restriction indicator will not function properly if:

• Element is damaged or not seated properly in housing.

• Air cleaner element body is damaged. If so, unfiltered air may enter engine.

• Air transfer duct between air cleaner and engine is damaged or the clamps are loose.

• Air duct between air cleaner and restriction indicator is damaged or pinched.

Hot fluid under pressure can scald. Allow engine to cool before opening radiator cap. Check the coolant level when the engine is stopped and cool.

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Engine Air Precleaner - Check / Clean 1. Remove cover (1).

2. Check for an accumulation of dirt and debris in body (2).

3. Clean body.

4. Install cover and wing nut.

NOTE: When the engine is operated in dusty applications, more frequent cleaning is required.

Engine Oil Level - Check 1. Park machine on a level surface. Allow engine oil to

settle for 5 minutes after the engine has stopped before checking level.

2. Remove dipstick (1) and check level. Oil level should be above minimum mark and below maximum mark.

3. Remove fill cap (2) and add or remove oil to obtain proper fill level between minimum and maximum marks.

4. Install the fill cap (2).

NOTE: DO NOT overfill crankcase. The oil level must not be above the FULL RANGE on the dipstick.

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Fuel System Primary Filter / Water Separator - Drain

NOTICE: Ensure the engine is stopped before any servicing or repair is performed.

NOTICE: The water separator can be under suction during normal engine operation. Ensure the drain valve is tightened securely to help prevent air from entering the fuel system.

1. Install a suitable tube onto drain. Open the drain valve, located on bottom of separator (1) and allow the fluid to drain into a suitable container.

2. Close the drain valve. Remove tube from drain. Dispose of the drained fluid in accordance with local regulations and mandates.

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately.

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EVERY 50 HOURS OR WEEKLY


Hoses and Clamps - Inspect / Replace

If inspecting the engine in operation, always use proper inspection procedure to avoid a fluid penetration. Refer to the Engine Operation and Maintenance Manual, General Hazard Information” for additional instructions.

1. Inspect all hoses for leaks that are caused by the following conditions:

• Cracking

• Softness

• Loose Clamps

2. Replace hoses that are cracked or soft. Tighten any loose clamps.

3. Check for the following conditions:

• End fittings that are damaged or leaking

• Outer covering that is chafed or cut

• Exposed wire that is used for reinforcement

• Outer covering that is ballooning locally

• Flexible part of the hose is kinked or crushed

• Armoring is embedded in the outer covering

A constant torque hose clamp can be used in place of any standard hose clamp. Ensure the constant torque hose clamp is the same size as the standard clamp.

Due to extreme temperature changes, the hose will harden. Hardening of the hoses will cause hose clamps to loosen. This can result in leaks. A constant torque hose clamp will help to prevent loose hose clamps.



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Fuel Tank Water and Sediment - DrainFuel quality is critical to the performance and to the service life of the engine. Water in the fuel can cause excessive wear to the fuel system. Condensation occurs during the heating and cooling of fuel. The condensation forms as the fuel passes through the fuel system and returns to the fuel tank. This causes water to accumulate in the fuel tank. Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel.

1. Drain fuel tank water and sediment by loosening the drain plug (1) on the bottom of the fuel tank. Loosen the plug enough so any water will drain out, then, retighten plug.

2. Refer to the Engine Operation and Maintenance Manual supplied with the machine for engine maintenance information.

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EVERY 250 HOURS All maintenance checks and inspections listed in previous maintenance intervals must be performed at this time in addition to those listed under this maintenance interval.

Engine Oil Sample - Obtain Refer to the Engine Operation and Maintenance Manual supplied with the machine for instructions.

EVERY 500 HOURS


Fan Clearance - Check Refer to the Engine Operation and Maintenance Manual supplied with the machine for instructions.

6-9Every 250 Hours

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Engine Air Cleaner Primary Element - Clean / Replace NOTICE: Never run engine without an air cleaner element installed. Never run engine with a damaged air cleaner element. DO NOT use air cleaner elements with damaged pleats, gaskets or seals. Dirt entering the engine causes premature wear and damage to engine components. Air cleaner elements help to prevent airborne debris from entering the air inlet.

NOTICE: Never service the air cleaner element with the engine running since this will allow dirt to enter the engine.

If the air cleaner element becomes plugged, the air can split the material of the air cleaner element. Unfiltered air will drastically accelerate internal engine wear.

• Check precleaner and the dust bowl daily for accumulation of dirt and debris. Remove any dust and debris, as needed.

• Operating in dirty conditions may require more frequent service of the air cleaner element.

• The air cleaner element should be replaced at least one time per year. This replacement should be performed regardless of the number of cleanings.

Replace the dirty air cleaner elements with clean air cleaner elements. Before installation, the air cleaner elements should be throughly checked for tears and/or holes in the filter material. Inspect the gasket or the seal of the air cleaner element for damage.

NOTICE: The primary air cleaner element can be used up to six times if the element is properly cleaned and properly inspected. Replace the primary element at least once a year, regardless of number of cleanings.

An indicator (1) mounted on the air cleaner cover will turn red when the outer air filter element requires cleaning.

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1. Remove the cover (2).

2. Carefully remove the primary element (3) taking care not to disturb the inner element or knock any dirt off the outer element.

3. Cover the air inlet with tape to keep dirt out.

4. Clean the inside of the air cleaner cover and body with a clean, dry cloth.

5. Remove tape from the air inlet.

6. Install cleaned or new element in filter assembly by firmly pressing into place.

7. Install air cleaner cover.

8. Reset air cleaner service indicator, 4.

NOTE: Replace the secondary element (3) for every three cleanings of the primary air cleaner element.

Refer to “CAT C3.4B Industrial Engine Operation and Maintenance Manual” for complete instructions.

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Cleaning Primary Air Cleaner ElementNOTICE: The primary air cleaner element can be used up to six times if the element is properly cleaned and properly inspected. Replace the primary element at least once a year, regardless of number of cleanings.

NOTICE: Take extreme care to avoid damaging air cleaner elements. DO NOT tap or strike air cleaner element. DO NOT wash primary air cleaner element. Use low pressure 30 psi (207 kPa) pressurized air or vacuum cleaning to clean primary air cleaner element. DO NOT use air cleaner elements with damaged pleats, gaskets, or seals.

Inspect air filter element for damage to pleats, seals, gaskets, and outer cover before cleaning. Replace damaged air cleaner element.

To clean air cleaner element using pressurized air:

NOTE: When cleaning primary air cleaner filter, always begin with the inside of the filter to force dirt particles toward the outside.

1. Aim air hose so air flows along length of filter. Follow the direction of the pleats to prevent damage to filter. DO NOT aim air directly at the face of the pleats.

To clean air cleaner element using vacuum:

1. Clean the inside of the filter with pressurized air prior to cleaning the outside with the vacuum.

2. Vacuum the outside of the filter.

Personal injury can result from air pressure. personal injury can result without following proper procedure.

When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 30 psi (205 kPa) for cleaning purposes.


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Engine Air Cleaner Secondary Element - Inspect / Replace Change air filter inner element every third time the outer element is cleaned.

NOTICE: DO NOT clean the inner element. The secondary air cleaner element is not serviceable.

1. Remove air filter outer element and clean or replace, as necessary. Refer to "Engine Air Cleaner Primary Element - Clean / Replace", page 6-20.

2. Remove inner element (1) by pulling on it an discard.

3. Install new inner element by firmly pressing it into place. Be sure inner element is seated properly.

4. Install outer element and cover.


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Engine Oil and Filter - Change

NOTICE: Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

DO NOT drain engine oil when engine is cold. Drain oil pan when oil is warm.

Change oil filter (1) when the engine oil is changed.

1. With the engine temperature above 70°C (158°F), turn engine OFF.

2. Remove plug (2) on bottom of the engine oil pan and drain oil into a suitable container. Dispose of waste oil according to federal, state and local regulations.

3. Clean area around oil filter. Remove oil filter using filter wrench. 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.

NOTICE: DO NOT fill oil filters with oil before installing. Contaminated oil can cause accelerated wear to engine components.

NOTICE: DO NOT over-tighten. Over-tightening can damage the filter.

6. Install plug in engine oil pan.

7. Remove oil fill cap (3) and add 6.2 L (6.5 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 plug for leakage.

Hot oil and hot components can cause personal injury.

DO NOT allow hot oil or hot components to contact skin.

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Fuel Filters - Change Refer to Engine Operation and Maintenance Manual supplied with machine for instructions.

NOTICE: Ensure the engine is stopped before any servicing or repair is performed.

1. Drain the fuel from the primary filter (1) through the filter drain, located on bottom of filter, into a suitable container and dispose of properly.

2. Remove the filter and dispose of properly.

3. Remove the secondary fuel filter (2) and dispose of properly.

NOTE: Over-tightening of the filter will distort threads, filter element seal or filter.

Priming the Fuel SystemIt 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.

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the ignition switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately.

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To Prime the System:1. Pump the primer on filter head (1) until the primer

stiffens and it is difficult to pump, approximately 80 pumps.


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Radiator - Clean

Pressurized air is the preferred method for removing loose debris. Direct the air in the opposite direction of the air flow. Hold the nozzle approximately 1/4” (6 mm) away from the fins. Slowly move the air nozzle in a direction that is parallel with the tubes. This movement will remove debris that is between the tubes.

Pressurized water may also be used for cleaning. The maximum water pressure for cleaning purposes must be less than 40 psi (275 kPa). Use pressurized water in order to soften mud. Clean the core from both sides.

Use a degreaser and steam for removal of oil and grease. Clean both sides of the core. Wash the core with detergent and hot water. Thoroughly rinse the core with clean water.

After cleaning, state the engine and accelerate the engine to high rpm. This procedure will help in the removal of debris and drying of the core. Stop the engine. Use a light bulb behind the core in order to inspect the core for cleanliness. Repeat the cleaning, if necessary.

Inspect the fins for damage. Bent fins may be opened with a “comb”. Inspect these items for good condition:

• welds

• mounting brackets

• air lines

• connections

• clamps and seals

Make repairs, if necessary.

Personal injury can result from air pressure. Personal injury can result without following proper procedure.

When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 30 psi (205 kPa) for cleaning purposes.


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EVERY 1000 HOURS

Water Pump - Inspect Visually inspect water pump for leaks.


EVERY 1500 HOURS

Engine Crankcase Breather Element - Replace Refer to “CAT C3.4B Industrial Engine Operation and Maintenance Manual” for complete instructions.

6-18 Every 1000 Hours

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EVERY 2000 HOURS

Aftercooler Core - Inspect Inspect aftercooler for these items: damaged fins, corrosion, dirt, grease, insects, leaves, oil, and other debris. If necessary, clean the after cooler core.


Engine Mounts - Inspect Inspect the engine mounts for deterioration and for proper bolt torque.


Starting Motor - Inspect Check the starting motor for correct operation. Check the electrical connections and clean the electrical connections.


Turbocharger - Inspect Refer to “CAT C3.4B Industrial Engine Operation and Maintenance Manual” for complete instructions.

6-19Every 2000 Hours

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WHEN REQUIRED

DEF Filler Screen - CleanRefer to “CAT C3.4B Industrial Engine Operation and Maintenance Manual” for complete instructions.

DEF Tank - Flush Refer to “CAT C3.4B Industrial Engine Operation and Maintenance Manual” for complete instructions.

Engine - Clean

Steam is the preferable method of cleaning an engine. If steam is not available, use a solvent to clean the engine.

NOTICE: Protect all electrical components, openings, and wiring from the full force of the cleaner spray nozzle.

Engine Air Cleaner Primary Element - Clean / Replace Refer to "Engine Air Cleaner Primary Element - Clean / Replace", page 6-10.

Engine Air Cleaner Secondary Element - Inspect / Replace Refer to "Engine Air Cleaner Secondary Element - Inspect / Replace", page 6-13.

Fuel System - Prime Refer to "Priming the Fuel System", page 6-15.

When using a steam cleaner, wear safety glasses or a face shield and protective clothing. Hot steam can cause serious personal injury.

6-20 When Required

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Fuses - Replace If an electrical circuit does not work, check the fuse panel (1) under the right side console and/or the fuse panel (2) inside the right engine compartment. Fuses may have blown, breaking the circuit. Be sure to locate the cause of the blown fuse before replacing. Automotive push-type fuses are used.

To access a fuse, remove the bolts on the front of the control panel and lift top up.

A card (3) showing fuse locations for fuse panel (1) functions, and amperage ratings, is attached to the harness in the console.

(1) ECM Relay

(2) Auxiliary Power Relay

(3) SCR Relay

(4) Neutral Start Relay

(5) Engine ECM Fuse

(6) Engine Fan Fuse

(7) DEF Pump, SCR Fuse

(8) Engine ECM Fuse

(9) DEF Sensor Fuse

(10) Engine ECM Relay Fuse

NOTICE: Turn off Master Switch before working on electrical system.

NOTICE: Always replace fuses with an equal amperage fuse.

1

1. SEAT - 10A 2. DISPLAY - 7.5A 3. BLADE PITCH - 30A 4. DEFOG FANS - 30A 5. HIGH BEAMS - 10A 6. HEAD LIGHT - 10A 7. HORN - 5A 8. IGN SWITCH - 7.5A 9. TAIL LIGHTS - 5A10. LED STROBE - 5A11. PWR SOCKET - 10A12. TURN SIGNAL / HAZARD - 10A13. BRAKE SWITCH - 5A

14. FUEL SENDER - 5A15. DOME / DASH LIGHTS - 7.5A16. WORK LIGHTS - 30A17. TRANS. SHIFT LEVER SENSOR - 5A18. TRANSMISSION - 7.5A19. CONVERTER - 30A20. OPEN21. OPEN22. WIPERS - 15A23. A/C - 30A24. HEATER - 30A25. ENG ECU FUSE - 30A

ENG ECU FUSE IS LOCATED NEAR RH SIDE OF HYD TANK INSIDE ENG COMPARTMENT

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7 3

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121620

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SECTION 7: SPECIFICATIONS

65ET CUMMINS Tier 4 Final EngineModel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cummins QSF3.8 Tier 4

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vertical, In-line, 4-Cycle Diesel

Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 L (229 cu. in.)

Bore and Stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 mm x 115 mm (3.74 in. x 4.53 in.)

Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged and Charge Air Cooled

Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Water

Rated Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89.5 kW (120 hp)

Maximum Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 488 Nm (360 lb-ft) @ 1500 RPM

Rated Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2200 RPM

Low Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 950 +/- 50 RPM

High Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2200 +/- 50 RPM

Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.2 : 1

Firing Order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4-3

Weight (Wet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .374 kg (825 lb)

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65ET CAT Tier 4 Final EngineModel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAT C3.4B Tier 4

Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-4, In-Line, 4 Stroke Cycle Diesel

Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 L (207 cu. in.)

Bore and Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 mm x 110 mm (3.9 in. x 4.33 in.)

Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged

Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water

Rated Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.5 kW (120 hp)

Maximum Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 Nm (361 lb-ft) @ 1400 RPM

Rated Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2200 RPM

Low Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 950 +/- 50 RPM

High Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2200 +/- 50 RPM

Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CAT

Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1 : 1

Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3-4-2

Weight (Net Dry, approximate) with standard equipment . . . . . . . . . . . . . . . . . . . . 270 Kg (595.2 lb)

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Torque ConverterMake and Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF Model F&S W300

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixed Stator

Stall Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.870 : 1

Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 mm (11.81 in)

Converter Stall Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1872 +/- 50 RPM

TransmissionMake and Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF Model 6 WG115

Type . . . . . . . . . . . . . . Hydrodynamic Full Power Shift, Long Drop Countershaft with Helical Gears

Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Forward, 2 Reverse

Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . Full Powershift w/ Electronic Single Control Shifter

Transmission Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . .Selectable, Incorporated with Brake Pedal

Pump Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear

Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22.4 GPM @ 2000 RPM Engine Speed

Clutch Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16–18 bar (232–260 psi)

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Transmission Ratios and Theoretical Travel Speeds

SteeringControl 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 Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40o from Center

Diameter and Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.5 X 198 mm (2.50 X 7.80 in)

Minimum Turning Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.7 m (18 ft 9 in)

Forward ReverseRatio Mph Km / hr Ratio Mph Km / hr

1 5.202 2.8 4.5 4.939 2.8 4.52 3.367 4.3 6.9 2.078 6.8 10.93 2.191 6.8 10.9 N/A N/A N/A4 1.418 10.3 16.6 N/A N/A N/A5 0.944 15.8 25.4 N/A N/A N/A6 0.611 24.0 38.6 N/A N/A N/A

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ArticulationType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic with Upper and Lower Joints

Upper Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Floating Steel

Lower Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixed Flange Steel

Maximum Angle from Center. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25o

Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Cylinder Diameter and Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76.0 x 276 mm (3.00 x 10.88 in)

Tires15.0 x 19.5, 8 ply G2 tubeless, traction type tires mounted on 12.25 in. wide rims

Inflation Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 kPa (25 psi)

Loaded Tire Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490.3 mm (19.3 in)

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Fluid CapacitiesFuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 L (32 gal)

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.5 L (7 gal)

A/C Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . .R134A, 2 lbs 5 oz - 2lbs 10 oz, 40 psi on the low side

Engine Oil (with Filter) . . .Cat = 8.3 L (2.2 gal).........................................Cummins = 10.6 L (2.8 gal)

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.75 L (0.2 gal)

Electrical SystemType. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Volt Negative Ground

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Qty = 1, 1000 CCA @ 0o F

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cat = 14V, 120AMP.......Cummins = 14V, 135AMP

Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Tone 108 dB

Backup Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 dB minimum

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Power BrakesType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self-Adjusting, Wet Multi-Disc Integral with Rear Axle

Disc Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302 mm (11.89 in)

Number of Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Foot-Operated Hydraulic Power Brake

Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Circuit

Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ISO 68 Hydraulic Oil

Operating Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.5 bar (950 psi)

Accumulator Charging Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 bar (2000 psi)

Torque Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22,000 Nm (15,913 lb-ft)

Park BrakeMake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ZF

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disc

Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380 mm (14.96 in)

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Tandem DriveConstruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Oil Bath

Chain Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Pitches, Slip Fit Connecting Link

Drive Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:1

Front AxleConstruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Strength Welded Steel

Oscillation Angle from Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18o

Front Wheel Lean Angle from Center. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18o

Ground Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.3 in (516 mm)

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Rear AxleConstruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heavy Duty Cast Iron

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Semi-Floating

Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heat-Treated Steel with Tapered Roller Bearings

Axle Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.5 mm (2.5 in)

Total Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6 : 1

Ground Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.6 in (370 mm)

Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Super Max TracR (Torque Proportioning)

Hydraulic PumpMake 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 L/min) @ 2200 RPM

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Hydraulic Control ValveMake and Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Husco 5000 Series

Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multi-Section, Open-Center, Parallel, 4-Way,

3-Position, Spring Return to Neutral

Number of Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Hydraulic SystemImplement Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1850 psi (127.6 bar)

Steering Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 psi (103.4 bar)

Filter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Full Flow, Pleated Paper

Filter Micron Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nominal, 25 Absolute

Filter Bypass Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138kPa (20psi)

DrawbarConstruction . . . . . . . . . . . . . . . . . .A-Frame Welded Steel

Connection . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .Pin

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CircleConstruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Welded 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 Pinion Gear Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.83 : 1

Wear Surface Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172 in2 (1110 cm2)

Wear Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Replaceable Inserts

Circle Turn Gearbox and MotorGearbox Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic-Driven Worm

Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 : 1

Motor Make and Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Eaton Fluid Power T Series

Motor Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Geroller

Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9 in.3 / Rev. (20.3 cc / Rev.)

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MoldboardType 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ”Roll Away” Involute Curve with Replaceable

Cutting Edges and BitsActuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic Driven Side Shift and Mechanical Pitch

Moldboard DimensionsStandard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 ft x 21 in x .063in (3.050 m x 533.4 mm x 16mm)

Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 ft x 21 in x .063in (3.660 m x 533.4 mm x 16mm)

Ground ClearanceMaximum Pitch Angle (minimum clearance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 in (178 mm)

Normal Pitch Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.8 in (325 mm)

Minimum Pitch Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 in (381 mm)

Blade Pitch AngleNormal Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.0o

Minimum Pitch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.0o

Maximum Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107.5o

Blade Side ShiftLeft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 in (432 mm)

Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 in (508 mm)

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Moldboard Reach (10 ft Moldboard)

Reach Outside Rear Wheels w/ Straight FrameLeft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1 in (994 mm)

Right. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.0 in (1067 mm)

Reach Outside Rear Wheel w/ Frame ArticulatedLeft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.4 in (1508 mm)

Right. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.8 in (1594 mm)

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Operation WeightsMachine Operating Weight w/ Scarifier and Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . 17000 lb (7711 kg)

Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5510 lb (2499 kg)

Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11490 lb (5212 kg)

Blade Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9165 lb (4156 kg)

Scarifier Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4300 lb (1950 kg)

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OPTIONS

ScarifierAttachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front

Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parallelogram

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two Shank Positions, 10o Tilt

Tooth Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 in (127 mm)

Maximum Ripping Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.25 in (1048 mm)

Maximum Ground Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5 in (445 mm)

Ground Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.0 in (152 mm) or 8.5 in (216 mm)

Scarifier Penetration Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4300 lb (1950 kg)

Total Vehicle Length with Scarifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279.2 in (7092 mm)

Dozer BladeAttachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 ft (7 m)

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RipperAttachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear

Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parallelogram

Number of Teeth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Standard, 5 Maximum

Tooth Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18.75 in (476 mm) Minimum

Maximum Ripping Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 in (1905 mm)

Ripper Penetration Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9100 lb (4128 kg)

Total Vehicle Length with Ripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 ft (8.1 m)

Moldboard ExtensionsExtensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 in (610 mm)

90o Bank Slope SaddleType. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Pin Release

Rotation from Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90o

Moldboard Pitch CylinderBore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.50 in (63.5 mm)

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.00 in (203.2 mm)

Rod Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 in (25.4 mm)

7-16 Options

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CabFeatures include Cloth Air Suspension Seat, Floor mats, Heater/Pressurizer, Tiltable Windshield, Sliding Rear Window, Two-Lockable Full-Size Doors, Coat Hook, Lunch box 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 Differential

Engine Coolant Heater Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Volts

7-17Options

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7-18 Options

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7-19Options

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SECTION 8: TROUBLESHOOTING

NOTICE: This section is provided as an aid for troubleshooting the motor grader. It is not intended to replace a qualified mechanic. 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 correctly and safely.

ENGINE

Refer to the Cummins, or Cat, Operation and Maintenance Manual included with the motor grader for engine troubleshooting.

TRANSMISSION PROBLEM POSSIBLE CAUSE CORRECTION

Transmission will not operate

Electrical connections loose

Low oil levelCheck electrical continuity

Transmission operation poor or jerky

Electrical connections loose

Torque converter worn

Check electrical continuity

Replace torque converter

Transmission overheating or torque converter slipping

Low oil level

Oil cooler air flow blocked

Torque converter worn

Fill system with oil

Clean radiator of blockage

Replace torque converter

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HYDRAULICS AND IMPLEMENTS PROBLEM POSSIBLE CAUSE CORRECTION

All Hydraulic Functions fail to operate

Pump wornLow oil levelFaulty system relief valveRestricted pump suction line

Contact an authorized dealerAdd oilContact an authorized dealerClean suction strainer

Slow operation or loss of power in all circuits

Pump wornRestricted pump suction lineFaulty system relief valve

Contact an authorized dealerClean suction strainerContact an authorized dealer

Hydraulic oil overheats

Oil level low or highBlocked filter element

Adjust oil levelReplace filter element

Moldboard does not hold grade

Circle guides out of adjustment Lift cylinder leaksDrawbar pins wornCutting edges worn

Adjust guidesRebuild or replace cylinderReplace pinsReplace cutting edges

Moldboard angle changes under load or does not rotate

Excessive pinion tooth backlashWorn or broken circle or pinion gear teethCircle guides to tight

Adjust circle guides to correct backlashReplace circle or pinion gear

Adjust circle guides

Front or rear implement does not operate

Malfunctioning switchMalfunctioning solenoidSticking cartridge spoolImplement lift cylinder(s) leaks

Replace switchReplace solenoidClean or replace cartridgeRebuild or replace cylinder(s)

Side shift or pitch functions operate erratically

Malfunctioning switchMalfunctioning solenoidSticking cartridge spoolInternal cylinder leakageInternal swivel assembly leakage

Replace switchReplace solenoidClean or replace cartridgeRebuild or replace cylinderRebuild or replace swivel

8-2 Hydraulics and Implements

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AA/C Switch - (Cab Equipped) 2–26Accelerator Control Pedal 2–27Active Engine Error Screen 2–38Active Error Screen 2–38AEB Calibration Screen 2–35AEB Mode Request 2–35Articulation 3–10Articulation Control Lever
- Caterpillar Style Configuration 2–24Articulation Control Lever

- Standard Style Configuration 2–22

BBank Slope (Optional) 3–18Blade Pitch Switch (Optional) 2–18Blower Fan Switch (Cab Equipped) 2–26Brake Pedals 2–27

CCab Dome Light Switch 2–27CAT

Accessing Lubrication and Check Points 6–2

Aftercooler Core - Inspect 6–19Cleaning Primary Air Cleaner

Element 6–12DEF Filler Screen - Clean 6–20DEF Tank - Flush 6–20Engine - Clean 6–20Engine Air Cleaner Element

- Inspect / Replace 6–20Engine Air Cleaner Primary Element

- Clean / Replace 6–10, 6–20Engine Air Cleaner Secondary Element

- Inspect / Replace 6–13Engine Air Cleaner Service Indicator

- Check 6–4Engine Air Precleaner - Check / Clean 6–5Engine Coolant Level - Check 6–4Engine Crankcase Breather Element

- Replace 6–18Engine Mounts - Inspect 6–19Engine Oil and Filter - Change 6–14Engine Oil Level - Check 6–5

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Engine Oil Sample - Obtain 6–9Fan Clearance - Check 6–9Fuel Filters - Change 6–15Fuel System - Prime 6–20Fuel System Primary Filter / Water

Separator - Drain 6–6Fuel Tank Water and Sediment - Drain 6–8Fuses - Replace 6–21General Information 6–1Hoses and Clamps - Inspect / Replace 6–7Maintenance

10 Hours or Daily 6–450 Hours or Weekly 6–7250 Hours 6–9500 Hours 6–9500 Hours or 1 Year 6–101000 Hours 6–181500 Hours 6–182000 Hours 6–19When Required 6–20

Maintenance Intervals 6–3Preventing Contamination 6–2Priming the Fuel System 6–15Radiator - Clean 6–17Service Intervals 6–2Starting Motor - Inspect 6–19Switch

Master 6–1Turbocharger - Inspect 6–19Wait to Disconnect Lamp 6–1Water Pump - Inspect 6–18

aterpillar Style Control Configuration 2–23ircle Rotate Control Lever

- Caterpillar Style Configuration 2–23ircle Rotate Control Lever

- Standard Style Configuration 2–21ircle Shift Control Lever

- Caterpillar Style Configuration 2–23ircle Shift Control Lever

- Standard Style Configuration 2–21omponent Identification and Locations 2–5ontrast Adjustment 2–34ontrols

Accelerator Control Pedal 2–27Brake Pedals 2–27

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CumminsAccessing Lubrication and

Check Points 5–2Air Filter Outer Element - Replace 5–13Air Filter Restriction - Check 5–6Air Intake Piping - Check 5–6Belt-Driven Fan Hub - Check 5–11Charge-Air Cooler - Check 5–7Charge-Air Piping - Check 5–7Cooling Fan Belt Tensioner - Check 5–10Crankcase Breather Tube - Check 5–4Dust Ejection Valve - Check 5–6Engine - Clean 5–14Engine Accessory Drive Belt and

Tensioner - Check 5–5Engine Air Cleaner Secondary Element

- Replace 5–14Engine Coolant - Change 5–12Engine Coolant Antifreeze - Check 5–10Engine Oil - Check 5–5Engine Oil and Filter - Change 5–9Fuel Filters - Change 5–8Fuel-Water Separator - Check 5–4Fuses - Replace 5–15General Information 5–1Maintenance

10 Hours or Daily 5–4250 Hours or 3 Months 5–7500 Hours or 6 Months 5–81000 Hours or 1 Year 5–112000 Hours or 2 Years 5–12When Required 5–13

Maintenance Intervals 5–3Preventing Contamination 5–2Priming the Fuel System 5–8Radiator Hoses - Check 5–12Radiator Pressure Cap - Check 5–11Service Intervals 5–2Switch

Master 5–1

DDaily Pre-Starting Inspection 3–1Defog Fan Switch 2–26Digging 3–21Driving the Machine 3–8

EElectronic Display 2–28

Active Engine Error Screen 2–38Active Error Screen 2–38AEB Calibration Screen 2–35Electronic Display Navigation 2–39Engine Stop Screen 2–38Indicator Lamps 2–28Main Operating Screen 2–29Menu Screen 2–31Reset All 2–34Start-Up Screen 2–28System Settings Screens 2–33View CAN Screen 2–33View Engine Diagnostics 1 Screen 2–31View Engine Diagnostics 2 Screen 2–32View Errors Screen 2–38View Transmission Diagnostics

Screen 2–32Engine Speed

Setting Engine Speed 3–7Varying Engine Speed 3–7

Engine Stop Screen 2–38

FFilling Trenches or Ditches 3–21Fire Extinguisher 1–5Floor and Ceiling Controls 2–27FOPS and ROPS 2–10Front Console 2–17Front Console Indicator Lights 2–17Front Console Lock Lever 2–20Front Console Tilt Lever 2–19Front Wheel Lean Control Lever

- Caterpillar Style Configuration 2–24Front Wheel Lean Control Lever

- Standard Style Configuration 2–22Front Wiper Switch 2–26Front Work Lights Switch 2–26

INDEX

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GGeneral Information 4–4General Safety Messages 1–4Grader Components

Accessing Lubrication and Check Points 4–7

Articulation Cylinders - Grease 4–20Articulation Joint Bearings - Grease 4–20Backup Alarm - Test 4–17Battery - Charge 4–47Battery - Check 4–31Battery - Replace 4–48Battery Access 4–7Battery Cables - Inspect / Replace 4–49Battery Cables and Connections

- Check 4–32Check/Add Diesel Exhaust

Fluid (DEF) 4–14Circle Guide - Adjust 4–45Circle Shift Cylinder Balls - Grease 4–18Circle Turn Gearbox

- Check Oil Level 4–25Circle Turn Gearbox Oil - Change 4–40Cooling Fan - Check 4–16Draw Bar Pivot Pins - Grease 4–18Engine Coolant - Check 4–33Fan Clearance - Check 4–29Foot Brake - Test 4–23Front Axle Drag Link - Grease 4–18Front Axle Knuckle Pivot - Grease 4–19Front Axle Pivot Pins - Grease 4–19Front Axle Spindle Pivot - Grease 4–19Front Wheel Bearing Grease

- Change 4–40Front Wheel Lean Cylinder - Grease 4–19Fuel - Check / Add 4–13Hoses and Clamps - Inspect / Replace 4–21Hydraulic Oil - Change 4–37Hydraulic Oil - Check 4–15Hydraulic Oil Filter - Change 4–27Hydraulic Oil Strainers - Clean 4–28Implement Lift Cylinders - Grease 4–20Lights - Replace 4–49Lubrication/Fluid Level Check 4–8

INDEX

Maintenance10 Hours or Daily 4–1350 Hours or Weekly 4–18100 Hours 4–22250 Hours or Monthly 4–24500 Hours or 3 Months 4–27500 Hours or 6 Months 4–311000 Hours or 6 Months 4–342000 Hours or 1 Year 4–37When Required 4–41

Maintenance Intervals 4–11Moldboard and Circle Turn

- Clean / Lubricate 4–21Moldboard Cutting Edge - Replace 4–46Moldboard Guides - Adjust 4–46Moldboard Lift Cylinder Balls

- Grease 4–18Moldboard Pitch Adjustment - Grease 4–20Neutral Start Interlock

- Propel Lever Test 4–22Parking Brake - Check 4–41Parking Brake Cable (Lever End)

- Adjustment 4–43Parking Brake Cable (Transmission End)

- Adjustment 4–42Preventing Contamination 4–6Propel Lever Interlock Button - Test 4–22Radiator / Oil Cooler - Check 4–44Radiator / Oil Cooler - Clean 4–32Radiator Coolant - Check 4–16Radiator Fill 4–7Radiator Pressure Cap - Check 4–33Rear Axle Housing - Check Oil Level 4–24Rear Axle Housing Oil - Change 4–38Service Intervals 4–6Steering Cylinder - Grease 4–19Switch

Parking Brake 4–44Tandem Drive Case - Check 4–25Tandem Drive Case Oil - Change 4–39Tie Rod Ends - Grease 4–19Tire Inflation Pressure - Check 4–26Transmission Oil - Check 4–15Transmission Oil and Filter - Change 4–34Universal Joints (Drive Shaft)

- Grease 4–24Washer Fluid - Fill 4–41Wheel Lug Nuts - Check 4–21

NORAM 65ET GRADER

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HHazard Lights Switch 2–18Headlights 2–20Heating (Cab Equipped) 2–14Heating (Cab-Equipped Models) 2–14Horn 2–20Hydraulic Moldboard Pitch

Adjustment (Optional) 3–14

IIdentification Numbers 2–3Ignition Switch 2–25Implement Control Lever

- Caterpillar Style Configuration 2–24Implement Control Lever

- Standard Style Configuration 2–21Implement Operation 3–11Implement Switch (Optional) 2–19Inching 2–33Indicator Lamps 2–28Intended Use 2–1Introduction to this Manual 2–1

LLeft Side Moldboard Height Control Lever

- Caterpillar Style Configuration 2–23Left Side Moldboard Height Control Lever

- Standard Style Configuration 2–22Leveling and Smoothing 3–22Lever

Articulation Control - Caterpillar Style Configuration 2–24

Articulation Control - Standard Style Configuration 2–22

Circle Rotate Control - Caterpillar Style Configuration 2–23

Circle Rotate Control - Standard Style Configuration 2–21

Circle Shift Control - Caterpillar Style Configuration 2–23

Circle Shift Control - Standard Style Configuration 2–21

Front Console Lock 2–20Front Console Tilt 2–19Front Wheel Lean Control

- Caterpillar Style Configuration 2–24

Front Wheel Lean Control - Standard Style Configuration 2–22

Implement Control - Caterpillar Style Configuration 2–24

Implement Control - Standard Style Configuration 2–21

Left Side Moldboard Height Control - Caterpillar Style Configuration 2–23

Left Side Moldboard Height Control - Standard Style Configuration 2–22

Parking Brake 2–27Right Side Moldboard Height Control

- Caterpillar Style Configuration 2–24Right Side Moldboard Height Control

- Standard Style Configuration 2–22Side Shift Control

- Caterpillar Style Configuration 2–23Side Shift Control

- Standard Style Configuration 2–21Throttle Control 2–25Transmission Control 2–25

Lighting 2–12Lights

Front Console Indicator 2–17Headlights 2–20Taillights 2–20Turn Signals 2–20

Lock Pins 2–11

MMachine Description 2–2Machine Safety 1–1Machine Shutdown Procedure 3–6Machine Starting Procedure 3–4Main Operating Screen 2–29Manual Moldboard Pitch Adjustment 3–14Menu Screen 2–31Mirrors (Optional) 2–12Moldboard Angle 3–15Moldboard Height 3–16Moldboard Pitch Operation 3–13Moldboard Side Shift Operation 3–13Monitored Engine and

Transmission Parameters List 2–37Mounting and Dismounting 3–1Moving a Disabled Machine 3–23

INDEX

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OOperating Engine

Machine Shutdown Procedure 3–6Machine Starting Procedure 3–4Preparing to Start Engine 3–4Starting Engine 3–5

Engine Block Heater (Optional) 3–5Operator’s Door (Cab-Equipped Models) 2–13Orientation 2–2

PParking Brake Lever 2–27Parking Brake Switch - Adjust / Replace 4–44Personal Safety 1–1Power Brakes 3–8Power-Shift Transmission 3–19Protective Shield 2–5

RRear Axle Components 2–16Rear Wiper Switch 2–26Rear Work Lights Switch 2–26Regeneration / After-Treatment

System Cleaning Force Option 2–30Regeneration / After-Treatment

System Cleaning Inhibit Option 2–30Regeneration / After-Treatment

System Cleaning In-Progress 2–30Reset All 2–34Right Side Console 2–25Right Side Console Light Switch 2–26Right Side Moldboard Height Control Lever

- Caterpillar Style Configuration 2–24Right Side Moldboard Height Control Lever

- Standard Style Configuration 2–22Rollover Protective Structure (ROPS) 3–3ROPS and FOPS - Inspect 4–30Rotating Beacon Switch 2–26

SSaddle Lock Pin (Optional) 3–17Saddle Pin Puller Switch (Optional) 2–17Safety

Machine 1–1Messages 1–1Personal 1–1ROPS and FOPS - Inspect 4–30

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afety Decal Locations 1–6afety Decals - Inspect 1–5afety Messages 1–1, 4–1afety Symbol Explanation 1–2eat 2–15eat Adjustments 2–15eat Belt 2–16, 3–3ide Shift Control Lever

- Caterpillar Style Configuration 2–23ide Shift Control Lever

- Standard Style Configuration 2–21lope Operation Safety 1–5pecifications

90 Degree Bank Slope Saddle 7–16Articulation 7–5Cab 7–17CAT C3.4B Tier 4 Final Engine 7–2Circle 7–11Circle Turn Gearbox and Motor 7–11Cummins QSF3.8 Tier 4 Final Engine 7–1Cylinders 7–13Dozer Blade 7–15Drawbar 7–10Electrical System 7–6Engine Coolant Heater 7–17Fluid Capacities 7–6Front Axle 7–8Hydraulic Control Valve 7–10Hydraulic Pump 7–9Hydraulic System 7–10Moldboard 7–12Moldboard Extensions 7–16Moldboard Pitch Cylinder 7–16Moldboard Reach (10 ft Moldboard) 7–13Operation Weights 7–14Park Brake 7–7Power Brakes 7–7Rear Axle 7–9Ripper 7–16Scarifier 7–15Steering 7–4Tandem Drive 7–8Tires 7–5Torque 7–18Torque Converter 7–3Transmission 7–3Transmission Ratios and Theoretical

Travel Speeds 7–4tandard Style Control Configuration 2–21

NORAM 65ET GRADER

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Start-Up Screen 2–28Steering

Front Wheel Lean 3–9Storage Box 2–27Switch

A/C - (Cab Equipped) 2–26Blower Fan (Cab Equipped) 2–26Cab Dome Light 2–27Defog Fan 2–26Front Wiper 2–26Front Work Lights 2–26Hazard Lights Switch 2–18Ignition 2–25Optional Blade Pitch Switch 2–18Optional Implement Switch 2–19Optional Saddle Pin Puller Switch 2–17Rear Wiper 2–26Rear Work Lights 2–26Right Side Console Light 2–26Rotating Beacon 2–26

System Settings Screens 2–33

TTaillights 2–20Throttle Control Lever 2–25Transmission 3–19

Changing Direction 3–20Engaging 3–19Inching Control 3–20Neutral Interlock 3–19

Transmission Control Lever 2–25Troubleshooting

Engine 8–1Hydraulics and Implements 8–2Transmission 8–1

Turn Signals 2–20

VView CAN Screen 2–33View Engine Diagnostics 1 Screen 2–31View Engine Diagnostics 2 Screen 2–32View Errors Screen 2–38View Transmission Diagnostics Screen 2–32

WWelding 4–5Windows (Cab-Equipped Models) 2–13

INDEX

NORAM 65ET GRADER

REVISION HISTORY

Revision Date Pages Description

65E T4 Final October 2015

3449110/2015 All First Edition Tier 4 Final Operation and

Maintenance Manual Released.

65E T4 FinalJanuary 2016

3449101/2016 4-5 First Edition/First Revision Tier 4 Final Operation

and Maintenance Manual Released.

65E - 34491 06/2018 Back Cover Updated Prop 65.

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WARNING: Breathing diesel engine exhaust exposes you to chemicals known to the State of alifornia to cause cancer and birth defects or other reproductive harm.

• Always start and operate the engine in a well-ventilated area.

• If in an enclosed area, vent the exhaust to the outside.

• Do not modify or tamper with the exhaust system.

• Do not idle the engine except as necessary.

or more information go to www.P65Warnings.ca.gov/diesel.

When operated in California, any off-road diesel vehicle may be subject to the California Air Resources Board In-Use Off-Road Diesel Vehicle Regulation. It

therefore could be subject to retrofit or accelerated turnover requirements to reduce emissions of air pollutants. For more information, please visit the California Air

Resources Board website at http://www.arb.ca.gov/msprog/ordiesel/ordiesel.htm.

Original instructionsCopyright 2018. All rights reserved.

Weiler815 Weiler Drive, P.O. Box 289

Knoxville, IA 50138 USA

65 e | motor grader · noram 65et grader safety symbol explanation 1-3 safety 1 refer to and follow...

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