NorAM 65E Turbo User manual

65E
TURBO
|
M
Oper
a
65E
TURBO
| M
Opera
Grader
M
anual
June, 2005
EFF. S/N 9101
Catalog #4472
65E
TURBO
|
M
Oper
a
65E
TURBO
|
M
Oper
a
Service Manual
65E
TURBO
| Motor Grader

65E Turbo Motor Grader
Service Manual
Service 1.00_2006.03 I
PROPRIETARY NOTICE
The contents of this manual are proprietary data of the manufacturer. Reproduction or use of any part for other than the
operation and maintenance of this equipment is permissible only if expressly authorized in writing by the manufacturer.
Additional copies may be obtained from your dealer.
COMPANY POLICY
Company policy, which is one of continuous improvement, reserves the right to change prices and to make changes in
design and specification at any time without notice and without obligation to modify units previously built.
All data given in this book is subject to production variations. Dimensions and weights are approximate only and the
illustrations do not necessarily show machines in standard condition. For exact information about any particular
machine please consult your dealer.
PARTS AND ACCESSORIES
Genuine parts and accessories have been specifically designed for these machines. We would like to point out that
"non-genuine" parts and accessories have NOT been examined and released by the Company. The installation and or
use of such products could have negative effects upon the design characteristics of your machine and thereby affect its
safety. The company is not liable for any damage caused by the use of "non-genuine" parts and accessories.
MODEL CODES
The range of machines listed may not be available in all countries or markets therefore, for the latest information con-
sult your local dealer.
SPARE PARTS
To maintain operating efficiency, use OEM original spare parts. When ordering parts, give the following information:
• Machine model
• Machine and engine serial numbers
• Part number from the Parts Catalog
Model 65E
Engine Type / HP Cummins / 110 HP

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TOTHE OWNER
The machine was designed to power and propel itself. It is intended to move material in the normal
and customary applications.
Do not modify or alter or permit anyone else to modify or alter this machine or any of its components
mechanical function without first consulting your dealer.
Your safety and the safety of those around you depend upon the care and good judgment you use while
operating this equipment. Read the safety precautions carefully.
After you have operated the machine for 50 hours, take your machine and this manual to your selling
dealer. They will perform the factory recommended 50-hour service. You will be responsible for the
cost of lubricants, fluids, filters and other items replaced as part of normal maintenance. Prior to
taking the machine to your selling dealer for service, it is recommended that you contact them to
determine any other charges for which you may be responsible.
IMPROVEMENTS
The manufacturer is continually striving to improve its products. We reserve the right to make improvements or
changes when it becomes practical and possible to do so, without incurring any obligation to make changes or additions
to the equipment sold previously.
All data given in this book is subject to product variations. Dimensions and weights are approximate only and the illus-
trations do not necessarily show machines in standard condition. For exact information about any particular machine,
please consult your dealer.

65E Turbo Motor Grader
Service Manual
Service 1.00_2006.03 III
The symbol above is used throughout this book whenever personal safety is
involved. Take time to read and follow the instructions. Be careful!
Pictures in this manual may show protective shielding open or removed to
better illustrate a particular feature or adjustment.
Be certain, however, to close or replace all shielding before operating the machine.
!

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Service Manual
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CONTENTS OVERVIEW
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1
Operator’s Platform and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 2
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 4
Rear Axle and Tandem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 6
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 7
Moldboard and Implement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 8

Service Manual
Section 1: Engine
Service 1.00_2006.03

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SAFETY PRECAUTION INFORMATION
UNSAFE OPERATING PRACTICES AND IMPROPER USE OF THE MACHINE AND ITS
ATTACHMENTS ON THE PART OF THE OPERATOR OR SERVICE TECHNICIAN CAN RESULT
IN INJURIES. OBSERVE THE FOLLOWING SAFETY PRECAUTIONS AT ALL TIMES:
1. Read the Operator's Manual carefully before using the machine. Lack of operating
knowledge can lead to accidents.
2. OSHA requires that all operators be instructed on the proper operation of the machine
before they operate the unit.
3. Only allow properly trained and qualified persons to operate and service the motor
grader.
4. Wear proper safety equipment as required by the job, such as hard hats, safety glasses,
ear protection, heavy gloves, reflective vests, etc. Consult your employer, site
supervisor or OSHA for specific requirements.
5. To prevent falls, use assist rails and steps when getting on and off the machine. Keep
steps and platform clear of mud, oil, grease, snow, tools, and debris.
6. Do not use controls or hoses as handholds when climbing on or off machine. Controls
may move and inadvertently cause machine travel or implement movement.
7. Do not permit anyone but the operator to ride on the motor grader. There is no safe
place for extra riders.
8. Do not allow children to operate the machine or ride on the machine at anytime.
9. Never use moldboard or implements as a personnel lift.
10. Do not use the machine as scaffolding or a work platform.
11. Replace all missing, illegible or damaged safety decals.
12. Keep safety decals free of dirt and grime.
13. Do not modify or alter or permit anyone to modify or alter machine or any of its
components or machine functions without first consulting an authorized dealer.
14. Do not operate machine without ROPS or FOPS in place and in good condition.
!

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15. Install all shields before starting or operating machine.
16. Do not operate an unsafe machine. If items are found during inspection that render a
machine unsafe, be sure any malfunctions are remedied before accepting responsibility
for operation.
17. Always properly tie down the machine to a truck or trailer before transport.
18. Do not start engine or operate controls while standing beside the vehicle. Always sit in
the seat when starting engine or operating controls.
19. Do not operate an unsafe machine. Be sure that any reported problems have been
repaired and all shielding is in place before accepting responsibility for machine
operation.
20. Do not bypass transmission neutral start switch. Consult an authorized dealer if the
neutral start controls malfunction. Use jumper cables only in the recommended
manner. Improper use can result in a runaway vehicle.
21. Check brakes, steering and implement controls before moving. Advise maintenance
personnel of malfunctions before operating. Be sure malfunctions are remedied before
accepting responsibility for operation.
22. Avoid accidental contact with the transmission control lever while the engine is
running. Unexpected movement may result from such contact.
23. Do not get off or on the vehicle while it is moving.
24. Lower unlocked implements to the ground, apply parking brake and shut off the engine
before getting off the machine.
25. Do not use machine to carry loose objects or attach implements in ways other than
intended.
26. Before starting the engine, be sure that all operating controls are in neutral and the
parking brake is engaged.
27. Install lock pins in front and rear mounted implements before transporting machine
between job sites.
28. Do not park on a steep incline.
29. Do not operate the vehicle in an enclosed building without adequate ventilation.
Exhaust fumes can cause death.
30. If the power steering or engine ceases to operate, stop the vehicle immediately.
31. Stop the engine and relieve pressure before connecting or disconnecting hydraulic,
steering or fuel lines.
32. Tighten all connections before starting engine or pressurizing lines.

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33. Remember that the vehicle, if abused or incorrectly used, can be dangerous and
become a hazard to the operator and bystanders.
34. Noise levels can exceed recommended levels when working between buildings or in
confined areas on canopy equipped machines or cab equipped machines with doors
and windows open. Use ear protection when warranted.
35. Always look in the direction of travel when moving machine. Be sure personnel in the
area are clear before moving machine or implements. If someone arrives in operating
area, stop machine immediately.
36. When transporting or travelling on roads, position moldboard within width of machine.
37. When driving on roads have consideration for other road users. Pull to the side of the
road so following traffic may pass. Maintain a safe distance from other vehicles. Yield
right of way to loaded machines.
38. Obey federal, state and local laws concerning slow-moving emblems, flashers, rotating
beacons and licensing requirements.
39. Obey flagmen, safety signals and signs.
40. Dim vehicle lights when meeting a vehicle at night. Make sure lights are adjusted to
prevent blinding oncoming drivers.
41. Reduce speed before turning or applying brakes.
42. Always check overhead clearance, especially when transporting. Be aware of low,
overhanging obstacles, such as trees and bridges.
43. Know the exact location of gas lines, utility lines, sewers, overhead and buried power
lines and other obstructions before operating in an area.
44. Use a signal person in congested areas or when people are around.
45. Use extreme caution when operating on slopes. Avoid traveling across slopes. Drive up
and down slopes whenever possible.
46. If slopes cannot be avoided, keep moldboard low and close to the machine. If machine
starts to slip, lower moldboard to the ground.
47. To avoid overturns, drive the vehicle with care and at speeds compatible with safety,
especially when operating over rough ground, when crossing ditches or slopes and
when turning.
48. Select the same gear when going downhill as you would going uphill. Select the gear
before starting down the slope.
49. Do not coast or freewheel machine down hills or slopes.

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50. After operating the engine, never touch the muffler, exhaust pipe, engine or radiator
until they have had time to cool.
51. Dress appropriately - wear relatively tight-fitting clothing when operating or servicing
the machine. loose or torn clothing can catch in moving parts or controls.
52. Wear an approved safety hat when operating the machine and while in any work area.
53. When driving the machine on a road or highway, use warning lights or warning devices
as may be required by local or state government regulations. head lights, warning
lights and SMV signs are available through your dealer.
54. Keep the machine clean. Do not allow trash, debris or other articles to accumulate in
the cab, floor or foot control pedal area that may hinder safe machine operation.
55. Do not allow unauthorized personnel to service or maintain this machine. Do not
perform any work that is not authorized.
56. Machine should not be serviced with anyone in the operator's seat unless that person
is qualified and is assisting in the service procedure. Be sure operator can see
mechanic.
57. Always use external supports when working under any linkage or raised part of the
machine. Lower implements to ground whenever possible.
58. Do not service the grader with the engine running unless the grader is properly and
securely supported with all six wheels off the ground.
59. Use caution when servicing the unit around moving parts.
60. The cooling system operates under pressure that is controlled by the radiator cap. It is
dangerous to remove the cap while the system is hot. Always turn cap slowly to the first
stop and allow pressure to escape before removing the cap entirely.
61. The hydraulic system operates under pressure that is controlled by the reservoir cap.
Always turn cap slowly to relieve pressure before removing cap entirely or
disconnecting any hydraulic lines.
62. Do not smoke while refueling the vehicle. Keep any type of open flame away. Wait for
the engine to cool before refueling.
63. Keep vehicle, particularly brakes and steering, maintained in a reliable and satisfactory
condition to ensure your safety and comply with legal requirements.
64. To prevent fire or explosion, keep open flames away from battery or cold weather
staring aids. To prevent sparks which could cause explosion, use jumper cables
according to instructions.

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65. Do not attempt to service air conditioning system, if equipped. It is possible to be
severely frostbitten or injured by escaping refrigerant. Special equipment and
instruments are required to service air conditioning system. See an authorized dealer
for service.
66. Stop the engine before performing any service on the vehicle.
67. Always turn master switch to the "OFF" position when maintaining or servicing
machine.
68. When using compressed air for cleaning parts, use safety glasses with sideshields or
goggles. Limit pressure to 30 psi.
69. Escaping diesel/hydraulic fluid under pressure can penetrate skin causing serious
injury.
70. DO NOT use your hand to check for leaks. Use a piece of cardboard to search for leaks.
• Stop engine and relieve pressure before connecting or disconnecting lines.
• Tighten all connections before starting engine or pressurizing lines.
• If fluid is injected into skin, obtain medical attention immediately or gangrene may
result.
71. Fuel oil in the injection system is under high pressure and can penetrate the skin.
Unqualified persons should not remove or attempt to adjust a pump, injector nozzle or
any other part of the fuel injector system. Failure to follow these instructions can result
in serious injury.
72. Continuous long-term contact with used engine oil may cause skin cancer. Avoid
prolonged contact with used engine oil. Wash skin promptly with soap and water.
73. Wheels can be very heavy. Handle with care and ensure, when stored, that they cannot
fall and cause injury.
74. When checking tire inflation pressure, stand to the side in case of explosion.
75. Never use reconditioned tire rims.
76. If brakes are to be serviced, the machine must be secured to prevent movement.
77. Dispose of all drained fluids and removed filters properly.
78. If any servicing or adjustments require the battery to be disconnected, disconnect the
negative (-) ground cable.
79. When servicing electrical components, disconnect the negative (-) ground cable.
80. If welding is required on the machine, disconnect the negative (-) ground cable. Failure
to disconnect the battery may result in damage to the electrical components.

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81. If welding is required on an attachment, remove the attachment from the machine.
82. Give complete and undivided attention to the job at hand so that complete control of
the machine is maintained at all times.
83. Under no circumstances should gasoline, alcohol or blended fuels be added to diesel
fuel. These combinations can create an increased fire or explosive hazard. In a closed
container, such as a fuel tank, these blends are more explosive than pure gasoline.
84. Refuel the machine outdoors with the engine shut off. Replace the fuel cap securely.
Use an approved fuel container. Do not smoke when handling fuel. Avoid spilling fuel.
85. Never remove the fuel cap or refuel with the engine running.
86. No not smoke while refueling the machine or when standing near fuel. Keep any type of
open flame away.
87. Maintain control of the fuel filler nozzle when filling the tank.
88. Do not fill the fuel tank to capacity. Allow room for expansion.
89. Wipe up spilled fuel immediately.
90. Always tighten the fuel tank cap securely.
91. If the original fuel tank cap is lost, replace it with a genuine replacement cap. A non
approved cap may not be safe.
92. Keep equipment clean and properly maintained.
93. Do not drive equipment near open fires.
94. Never use fuel for cleaning purposes.
95. The motor grader is equipped with Roll Over Protection System (ROPS) and a Falling
Object Protection System (FOPS) which must be maintained in a serviceable condition.
96. Do not modify, drill, weld or alter the ROPS or FOPS in anyway. Doing so could render
you liable to legal prosecution in some countries.
97. Never attempt to straighten or weld any part of the main frame or retaining brackets
that have suffered damage. By doing so the structure may be weakened and safety
compromised. Replace all damaged parts.
98. Be careful when driving under bridges or working in confined spaces with low
headroom.
99. Never attach chains or ropes to the ROPS or FOPS for pulling purposes.
100. Never take unnecessary risks even though the ROPS and FOPS provide protection.

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OSHA REQUIREMENTS NOW MAKE IT THE EMPLOYER'S RESPONSIBILITY TO FULLY
INSTRUCT EACH OPERATOR IN THE PROPER AND SAFE OPERATION OF ALL OPERATIVE
EQUIPMENT. BOTH EMPLOYER AND EMPLOYEE SHOULD THOROUGHLY FAMILIARIZE
THEMSELVES WITH THE MACHINE OPERATION.
Some pictures in this manual show safety shields removed or open to
show parts being serviced or for clarity. all shields should be closed or
replaced prior to operating the machine.
Fasten seat belt before starting engine!

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CONTENTS
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Engine Protection and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Electronic Control Module (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
QSB Fault Code Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

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Section 1: Engine
GENERAL INFORMATION
The NORAM 65E Grader is equipped with a Cummins™ QSB4.5 engine. Detailed operation and mainte-
nance information for the engine is located in the Cummins™ Operation and Maintenance Manual. Please
refer to the Cummins™ manual for engine troubleshooting and diagnostic help. If further service is required,
please contact the local Cummins™ dealer or call the Cummins Customer Assistance Center,
1-800-343-7357.
Engine Protection and Diagnostics
The NORAM 65E grader uses amber and red warning lights to signal the operator when the engine elec-
tronic control module (ECM) detects an engine fault or problem. Depending on the severity of the engine
problem, the ECM may decrease engine power or shut the engine down after warning the operator with
flashing warning lights.
The amber “CHECK ENGINE” light, 1, is located on the
right-hand instrument panel below the engine water tem-
perature gauge and engine oil pressure gauge.
The red “SHUT DOWN ENGINE” light, 1, is located on
the front console above the steering wheel. To alert the
operator of an engine problem, the red light will flash for
30 seconds prior to the engine automatically shutting
down.
1
1

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Diagnostics
Using the engine warning lights, engine fault codes may be retrieved from the engine ECM using the follow-
ing procedure:
Step 1: Turn the key switch to the “OFF” position.
Step 2: Connect the diagnostic electrical connectors, 1,
together, located on the left-hand side of the engine
compartment.
Step 3: Turn key switch to the “ON” position. Move the
throttle handle to the low idle position.
Step 4: Look at the amber “CHECK ENGINE” light and
the red “SHUT DOWN ENGINE” light. If no active fault
codes are recorded on the ECM, both lights will come
on and stay on. If active fault codes are recorded, both
lights will come on momentarily, then begin to flash the
code of the recorded fault(s). See page 1-14 of
Section 1 in the Cummins™ Operation and
Maintenance Manual for examples of the flashing
sequences and corresponding fault code. The lights will
flash out each code two times before advancing to the
next code. To skip to the next fault code, momentarily
move the throttle handle to full throttle, and then return it
to the low idle position.
Step 5: Record the fault codes.
Step 6: Look up the fault codes on pages 1-6 through
1-11 and correct the fault.
Step 7: Turn the key switch to the “OFF” position.
Step 8: Disconnect the diagnostic electrical connectors
from each other, replacing the cap and plug in the
electrical harness located on the left-hand side of
engine compartment.
1

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SPECIFICATIONS
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cummins QSB4.5
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vertical, In-line, 4-Cycle Diesel
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 L (275 cu. in.)
Bore and Stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 mm x 138 mm (4.02 in. x 5.42 in.)
Aspiration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged
Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Water
Gross Power and Rated Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 kW (110 GHP)
Maximum Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414 Nm (305 lb-ft) @ 1500 RPM
Rated Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2200 RPM
Low Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .900 +/- 50 RPM
High Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2350 +/- 50 RPM
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch VP30
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.3 : 1
Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
Weight (Wet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338 Kg (745 Ib)