Complete service repair manual for John Deere Scrapers 862B Series II, with all the workshop information to maintain, repair, and service like professional mechanics.

John Deere Scrapers 862B Series II workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

tm1725 - 862B Series II Scraper Repair (S.N. 818323-) Technical Manual - Repair.PDF
tm1725 - 862B Series II Scraper Repair (S.N. 818323-) Technical Manual - Repair.epub

Total Pages: 933 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS   862B-II (SN. from 818323)
 Foreword
   Technical Information Feedback Form
   General Information
      Safety
      General Specifications
      Torque Values
      Fuels and Lubricants
   Wheels
      Powered Wheels and Fastenings
   Axles and Suspension System
      Drive Axle Housing and Support
      Differential or Bevel Drive
      Input Drive Shaft and U-Joints
      Non-Powered Wheel Axles
      Axle Shaft, Bearings and Reduction Gears
      Hydraulic System
   Transmission
      Removal and Installation
      Controls Linkage
      Input Drive Shafts and U-Joints
      Gears, Shafts, Bearings and Power Shift Clutch
      Hydraulic System
   Engine
      Removal and Installation
   Engine Auxiliary Systems
      Cold Weather Starting Aids
      Cooling Systems
      Speed Controls
      Intake System
      External Exhaust System
      External Fuel Supply Systems
   Torque Converter
      Housing and Cover
      Converter Turbine, Gears, and Shaft
   Steering System
      Hydraulic System
   Service Brakes
      Active Elements
      Hydraulic System
   Park Brake
      Active Elements
      Hydraulic System
   Miscellaneous Vehicle
      Central Lubrication Systems
   Electrical Systems
      Batteries, Supports and Cables
      Alternator, Regulator and Charging System Wiring
      Lighting System
      Wiring Harness and Switches
      System Controls
   Frame, Chassis or Supporting Structure
      Frame Installation
   Operator's Station
      Operator Enclosure
      Seat and Seat Belt
      Heating and Air Conditioning
   Main Hydraulic System
      Main Hydraulic System
   Scraper and Haulage Device
      Blades or Cutting Edges
      Frames
      Hydraulic System
   Conveyor and Elevating Device
      Conveyor or Mast
      Controls Linkage
      Frames
      Gearbox
      Hydraulic System (S.N. -833883)
      Hydraulic System (S.N. 833884-)
   Dealer Fabricated Tools

tm1725 - 862B Series II Scraper Repair (S.N. 818323-)

Table of Contents

Foreword

Technical Information Feedback Form

Section 00: General Information

Group 0001: Safety

Handle Fluids Safely-Avoid Fires

Prevent Battery Explosions

Prepare for Emergencies

Prevent Acid Burns

Handle Chemical Products Safely

Avoid High-Pressure Fluids

Park Machine Safely

Support Machine Properly

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Remove Paint Before Welding or Heating

Avoid Heating Near Pressurized Fluid Lines

Keep ROPS Installed Properly

Service Tires Safely

Avoid Harmful Asbestos Dust

Practice Safe Maintenance

Use Proper Tools

Dispose of Waste Properly

Live With Safety

Group 0002: General Specifications

862B Series II

862B Series II Drain and Refill Capacities

Group 0003: Torque Values

Unified Inch Bolt and Cap Screw Torque Values

Metric Bolt and Cap Screw Torque Values

Additional Metric Cap Screw Torque Values

Service Recommendations for O-Ring Boss Fittings

Service Recommendations For Flat Face O-Ring Seal Fittings

Service Recommendations for 37° Flare and 30° Cone Seat Connectors

Service Recommendations For Inch Series Four Bolt Flange Fittings

Service Recommendations for Metric Series Four Bolt Flange Fitting

Group 0004: Fuels and Lubricants

Diesel Fuel

Low Sulfur Diesel Fuel Conditioner

Handling and Storing Diesel Fuel

Fuel Tank

Do Not Use Galvanized Containers

Diesel Engine Oil

Hydraulic, Transmission, Drive Axle, and Elevator Gearbox Oils

Grease

Oil Filters

Lubricant Storage

Alternative and Synthetic Lubricants

Mixing of Lubricants

Section 01: Wheels

Group 0110: Powered Wheels and Fastenings

Service Equipment and Tools

Specifications

Remove and Install Wheel

Remove and Install Tire

Check Tire Pressure

Tire Pressures

Section 02: Axles and Suspension System

Group 0200: Drive Axle Housing and Support

Essential Tools

Service Equipment and Tools

Specifications

Remove and Install Axle (Non-Suspension) and Differential

Remove Suspension Axle and Differential

Remove and Install Suspension Axle Frame Bushings

Install Suspension Axle and Differential

Adjust Suspension Axle Height

Adjust Suspension Axle Differential Drive Shaft

Group 0210: Differential or Bevel Drive

Essential Tools

Service Equipment and Tools

Other Material

Specifications

Remove Input Quill and Shaft Assembly

Disassemble and Assemble Input Quill and Shaft

Adjust Cone Point

Adjust Drive Shaft

Disassemble Differential Housing

Assemble Differential Housing

Test Differential Quill

Adjust Differential Housing Preload

Adjust Differential Backlash

Check Tooth Bearing Pattern

Disassemble and Assemble Differential Lock Lines

Disassemble and Assemble Lubrication Parts

Leakage Test With Oil

Disassemble and Assemble Differential Case

Group 0225: Input Drive Shaft and U-Joints

Specifications

Remove and Install Differential Drive Shaft

Disassemble and Assemble Differential Drive Shaft

Group 0230: Non-Powered Wheel Axles

Service Equipment and Tools

Specifications

Disassemble and Assemble Rear Axle

Adjust Rear Axle Bearing Preload

Group 0250: Axle Shaft, Bearings and Reduction Gears

Service Equipment and Tools

Specifications

Disassemble and Assemble Planet Pinion Carrier and Axle Shaft

Adjust Axle Bearings

Group 0260: Hydraulic System

Essential Tools

Specifications

Remove and Install Suspension Axle Lockdown Control Valve

Disassemble and Assemble Suspension Axle Lockdown Control Valve

Remove and Install Suspension Axle Leveling Lockdown Valve

Disassemble and Assemble Suspension Axle Leveling Lockdown Valve

Disassemble and Assemble Leveling Valve

Disassemble and Assemble Lockdown Valve

Remove and Install Differential Oil Filter

Remove and Install Differential Lock Solenoid Valve

Remove and Install Sequence Valve

Disassemble and Assemble Suspension Axle Accumulator

Suspension Axle Accumulator Precharge Procedure

Disassemble and Assemble Triple Pump

Section 03: Transmission

Group 0300: Removal and Installation

Essential Tools

Service Equipment and Tools

Specifications

Remove and Install Transmission

Group 0315: Controls Linkage

Specifications

Remove and Install Shift Lever Linkage

Adjust Transmission Shift Lever Linkage

Remove and Install Hold Pedal-Automatic Transmission

Group 0325: Input Drive Shafts and U-Joints

Specifications

Disassemble and Assemble Transmission Drive Shaft

Group 0350: Gears, Shafts, Bearings and Power Shift Clutch

Essential Tools

Service Equipment and Tools

Other Material

Specifications

Remove and Install Transmission Cover

Cross Section Transmission

Remove and Install Output Shaft

Install Wear Sleeve on Input and Output Shaft

Remove and Install C1 Clutch Pack

Disassemble and Assemble C1 Clutch

Remove and Install Planetary Pack

Disassemble and Assemble Planetary Pack

Disassemble and Assemble C2 Clutch

Disassemble and Assemble Planetary Gear Assembly

Group 0360: Hydraulic System

Service Equipment and Tools

Other Material

Specifications

Disassemble and Assemble Torque Converter Clutch Modulating Control Valve

Remove and Install Suction Screen

Remove and Install Lube Relief Valve

Remove and Install Transmission Oil Filter

Disassemble and Assemble Transmission Oil Filter

Remove and Install Transmission Control Valve

Disassemble and Assemble Transmission Control Valve

Disassemble and Assemble Solenoid Valve Assembly

Section 04: Engine

Group 0400: Removal and Installation

6101 John Deere Engine-Use CTM61

Alternators and Starting Motors-Use CTM77

Essential Tools

Service Equipment and Tools

Other Material

Specifications

Remove and Install Engine

Remove and Install Rear Engine Mount Isolators

Remove and Install Front Engine Mount Isolators

Remove and Install Starter

Disassemble and Assemble Fan Belt Tightener

Remove and Install Fan Drive Support

Disassemble Fan Drive Support

Assemble Fan Drive Support

Remove and Install Engine Oil Pan

Remove and Install Fuel Injection Pump

Remove and Install Fuel Injection Nozzles

Remove Turbocharger

Install Turbocharger

Remove and Install Intake Manifold and Aftercooler

Disassemble and Assemble Intake Manifold and Aftercooler

Inspect Intake Manifold

Air Test Aftercooler

Remove and Install Exhaust Manifold

Section 05: Engine Auxiliary Systems

Group 0505: Cold Weather Starting Aids

Other Material

Specifications

Remove and Install Engine Coolant Heater

Remove and Install Starting Aid Solenoid and Nozzle

Group 0510: Cooling Systems

Essential Tools

Other Material

Specifications

Remove and Install Fan

Remove and Install Radiator

Remove and Install Fan and Alternator Belts

Remove and Install Compressor Belt

Remove and Install Coolant Conditioner-Filter

Group 0515: Speed Controls

Remove and Install Speed Control Linkage

Adjust Engine Speed Control Linkage

Remove and Install Fuel Shut-Off Solenoid

Fuel Shut-Off Solenoid Adjustment

Group 0520: Intake System

Service Equipment and Tools

Other Material

Specifications

Remove and Install Air Cleaner

Remove and Install Precleaner

Test Air Intake System for Leaks

Remove and Install Air Filter Elements

Clean Dusty Primary Element

Clean Oily or Sooty Primary Element

Inspect Element

Group 0530: External Exhaust System

Specifications

Remove and Install Muffler

Group 0560: External Fuel Supply Systems

Specifications

Remove and Install Fuel Tank

Remove and Install Fuel Supply Pump

Remove and Install Water Separator Fuel Filter

Section 06: Torque Converter

Group 0641: Housing and Cover

Specifications

Remove and Install Torque Converter

Group 0651: Converter Turbine, Gears, and Shaft

Service Equipment and Tools

Other Material

Specifications

Disassemble and Assemble Torque Converter Drive

Disassemble and Assemble Torque Converter Housing

Section 09: Steering System

Group 0960: Hydraulic System

Service Equipment and Tools

Other Material

Specifications

Remove and Install Steering Wheel

Remove and Install Steering Column Angle Adjustment Bracket

Disassemble and Assemble Steering Column

Remove and Install Cushion Valve

Disassemble and Assemble Cushion Valve

Remove and Install Steering Priority Valve

Disassemble and Assemble Steering Priority Valve

Remove and Install Steering Valve

Disassemble and Assemble Steering Valve

Remove and Install Steering Cylinder

Disassemble and Assemble Steering Cylinder

Section 10: Service Brakes

Group 1011: Active Elements

Specifications

Inspect Tractor Brakes

Remove Tractor Brakes

Install Tractor Brakes

Disassemble Bowl Hydraulic Brakes

Assemble Bowl Hydraulic Brakes

Burnish Bowl Brake Shoe Facings

Group 1060: Hydraulic System

Specifications

Remove and Install Tractor and Bowl Brake Accumulator

Remove and Install Tractor and Bowl Brake Valve

Disassemble and Assemble Tractor and Bowl Brake Valve

Remove and Install Brake Pedal

Remove and Install Brake Priority Solenoid Valve

Remove and Install Secondary Brake Solenoid Valve

Remove and Install Residual Check Valve

Bleed Brake Hydraulic System

Section 11: Park Brake

Group 1111: Active Elements

Specifications

Remove and Install Park Brake Pads

Disassemble and Assemble Park Brake

Park Brake Adjustment

Group 1160: Hydraulic System

Specifications

Remove and Install Park Brake Release Solenoid Valve

Section 13: Miscellaneous Vehicle

Group 1370: Central Lubrication Systems

Sliding Floor Linkage

Draft Frame

Oscillation Hitch and Steering Arm Pivots

Suspension Axle

Section 16: Electrical Systems

Group 1671: Batteries, Supports and Cables

Service Equipment and Tools

Specifications

Handle Batteries Safely

Procedure for Testing Batteries

Checking Electrolyte Specific Gravity

Check Battery Electrolyte Level and Terminals

Using Booster Batteries-24 Volt System

Charge Battery

Remove and Install Batteries

Adding 12-Volt Accessories

Group 1672: Alternator, Regulator and Charging System Wiring

Alternators and Starting Motors-Use CTM77

Specifications

Remove and Install Alternator

Adjust Fan and Alternator Belts

Group 1673: Lighting System

Remove and Install Brake Light Switch

Remove and Install Turn Signal Flasher

Remove and Install Turn/Warning Light Switch

Remove and Install Worklight and Headlight Switches

Replacing Halogen Bulbs

Group 1674: Wiring Harness and Switches

Essential Tools

Dash Harness (W1) Component Location

Engine Harness (W2) Component Location

Tractor Harness (W3) Component Location

Axle Suspension Harness (W16) Component Location

Side Console Harness (W5) and Relay Harness (W13) Component Location-Automatic Transmission

Side Console Harness (W10) Component Location-Manual Transmission

Automatic Transmission Harness (W8) Component Location

Rear Frame Harness (W11) Component Location

Scraper Harness (W4) Component Location

Manual Transmission Harness (W7) and Solenoid Harness (W14) Component Location

Manual Transmission Control Harness (W9) Component Location

Replace DEUTSCHDEUTSCH is a trademark of the Deutsch Co. Connectors

Install DEUTSCHDEUTSCH is a trademark of the Deutsch Co. Contact

Replace WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Connector

Install WEATHER PACK WEATHER PACK is a trademark of Packard Electric. Contact

Remove Connector Body from Blade Terminals

Group 1675: System Controls

Remove and Install Transmission Control Box

Remove and Install Magnetic Pick-Up

Remove and Install Transmission Control Valve Solenoids

Remove and Install Transmission Hold and Down-Shift Switches

Remove and Install Transmission Controller

Section 17: Frame, Chassis or Supporting Structure

Group 1740: Frame Installation

Service Equipment and Tools

Specifications

Remove and Install Main Frame

Remove and Install Oscillation Hitch

Repair Oscillation Hitch

Welding Repair of Major Structure

Section 18: Operator's Station

Group 1810: Operator Enclosure

Service Equipment and Tools

Specifications

Disassemble and Assemble Windshield Wiper

Adjust Windshield Wiper Park Position

Disassemble and Assemble Canopy With Roof and Panels

Group 1821: Seat and Seat Belt

Other Material

Specifications

Disassemble and Assemble Seat

Disassemble Seat Pedestal

Assemble Seat Pedestal

Adjust Seat

Replace Seat Compressor Filter

Group 1830: Heating and Air Conditioning

Essential Tools

Service Equipment and Tools

Other Material

Specifications

Proper Refrigerant Handling

R134a Refrigerant Cautions

Refrigerant Hoses and Tubing Inspection

R134a Component Oil Charge

R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure

Recover R134a System

Evacuate R134a System

Charge R134a System

Leak Testing

Check and Adjust Compressor Belt Tension

Remove and Install Compressor

Exploded View of Air Conditioning System

Disassemble and Assemble Air Conditioning Compressor

Add Refrigerant Oil to System-R134a

Remove and Install Temperature Control Switch

Adjust Temperature Control Switch

Expansion Valve Bench Test and Adjustment

Remove and Install High and Low Refrigerant Pressure Switches

Remove and Install Blower Motor

Disassemble and Assemble Heater

Section 21: Main Hydraulic System

Group 2160: Main Hydraulic System

John Deere Radial Piston Pump-Use CTM7

Other Material

Specifications

Remove and Install Main Hydraulic Pump

Remove and Install Triple Pump (S.N. -833882)

Disassemble and Assemble Triple Pump (S.N. -833882)

Remove and Install Triple Pump (S.N. 833883-)

Disassemble and Assemble Triple Pump (S.N. 833883-)

Remove and Install Hydraulic Filter

Section 35: Scraper and Haulage Device

Group 3501: Blades or Cutting Edges

Service Equipment and Tools

Specifications

Remove and Install Cutting Edge

Adjust Cutting Edge Level

Apply Hard Surface Welding

Group 3540: Frames

Other Material

Specifications

Remove and Install Bowl

Repair Bowl

Remove and Install Draft Frame

Adjust Draft Frame to Bowl Pivot

Repair Draft Frame

Remove and Install Sliding Floor (S.N. -833883)

Remove and Install Sliding Floor (S.N. 833884-)

Adjust Sliding Floor Rail Guide

Repair Sliding Floor

Remove and Install Ejector Gate (S.N. -833883)

Remove and Install Ejector Gate (S.N. 833884-)

Adjust Ejector Gate (S.N. -833883)

Adjust Ejector Gate (S.N. 833884-)

Repair Ejector Gate

Group 3560: Hydraulic System

Other Material

Specifications

Remove and Install Bowl Control Valve

Disassemble and Assemble Bowl Control Valve

Disassemble and Assemble Anti-Cavitation Valve

Disassemble and Assemble System Relief Valve

Remove and Install Bowl Lift Cylinders

Remove and Install Ejector Gate and Sliding Floor Cylinders

Disassemble and Assemble Bowl Lift Cylinder

Disassemble and Assemble Ejector Gate Cylinder

Disassemble and Assemble Sliding Floor Cylinder

Section 36: Conveyor and Elevating Device

Group 3612: Conveyor or Mast

Essential Tools

Other Material

Specifications

Remove and Install Elevator Chain

Installing Seals-Sealed Elevator Chain-If Equipped

Measure Chain Sag

Adjust Elevator Chain Sag

Adjust Elevator-to-Cutting Edge

Lubricate Non-Sealed Elevator Chain

Remove and Install Adjusting Idler

Disassemble and Assemble Adjusting Idler

Remove and Install Upper Drive Sprocket

Repair Upper Drive Sprocket

Remove and Install Lower Idler

Repair Lower Idler

Group 3615: Controls Linkage

Disassemble and Assemble Elevator Control Linkage

Group 3640: Frames

Specifications

Remove and Install Elevator Frame

Group 3650: Gearbox

Service Equipment and Tools

Other Material

Specifications

Remove and Install Elevator Drive Gearbox

Disassemble Gearbox Housing

Assemble Gearbox Housing

Disassemble and Assemble Planetary and Output Shaft

Group 3660: Hydraulic System (S.N. -833883)

Essential Tools

Service Equipment and Tools

Specifications

Disassemble and Assemble Elevator Charge Pump

Remove and Install Elevator Drive Pump

Remove and Install Elevator Drive Pump Shaft Seal

Disassemble Elevator Drive Pump

Inspect Elevator Drive Pump

Assemble Elevator Drive Pump

Remove Displacement Control Valve

Disassemble Displacement Control Valve

Inspect Displacement Control Valve

Assemble Displacement Control Valve

Remove End Play from Centering Spring Mechanism

Install Displacement Control Valve

Remove and Install Elevator Drive Motor

Disassemble Elevator Drive Motor

Inspect Elevator Drive Motor

Assemble Elevator Drive Motor

Elevator Pump Start-Up Procedure

Remove and Install Manifold

Disassemble and Assemble Manifold

Disassemble and Assemble Relief Valves

Group 3665: Hydraulic System (S.N. 833884-)

Service Equipment and Tools

Other Material

Specifications

Remove and Install Elevator Charge Pump

Remove and Install Elevator Drive Pump

Remove and Install Elevator Drive Pump Shaft and Seal

Remove and Install Multi-Function Valve

Remove and Install Charge Pressure Relief Valve

Remove and Install Displacement Control Valve

Disassemble Elevator Drive Pump

Assemble Elevator Drive Pump

Remove and Install Elevator Drive Motor

Remove and Install Loop Flushing Valve

Remove and Install Motor Charge Relief Valve

Disassemble Elevator Drive Motor

Inspect Elevator Drive Motor

Assemble Elevator Drive Motor

Elevator Pump Start-Up Procedure

Section 99: Dealer Fabricated Tools

Group 9900: Dealer Fabricated Tools

JT38052 Driver

JT38053 Alignment Tool

JT38000 Differential Lifting Tool

JT38001 Axle Jacking Tool

John Deere Scrapers 862B Series II Service Repair Manual (TM1725)