Complete service repair manual for John Deere Motor Graders 670C, 670CH, 672CH, 770C, 770CH, 772CH Series II, with all the workshop information to maintain, repair, and rebuild like professional mechanics.

John Deere Motor Graders 670C, 670CH, 672CH, 770C, 770CH, 772CH 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.

TM1915 - John Deere Motor Graders 670C, 670CH, 672CH, 770C, 770CH, 772CH Series II Technical Manual - Repair.PDF
TM1915 - John Deere Motor Graders 670C, 670CH, 672CH, 770C, 770CH, 772CH Series II Technical Manual - Repair.epub

Total Pages: 804 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
Foreword
   Technical Information Feedback Form
   General Information
      Safety
   Wheels
      Powered Wheels and Fastenings
   Axles and Suspension Systems
      Input Drive Shafts and U-Joints
      Non-Powered Wheel Axles
      Axle Shafts, Bearings, and Reduction Gears
      Hydraulic System
      Dealer Fabricated Tools
   Transmission
      Removal and Installation
      Gears, Shafts, Bearings and Power Shaft Clutch
      Hydraulic System
   Engine
      Removal and Installation
      Dealer Fabricated Tools
   Engine Auxiliary System
      Cold Weather Starting Aids
      Cooling System
      External Fuel Supply Systems
   Torsional Isolator
      Elements
   Steering System
      Power Steering
      Hydraulic System
   Service Brakes
      Active Elements
      Hydraulic System
   Park Brake
      Active Elements
   Frame, Chassis or Supporting Structure
      Frame Installation
   Operator’s Station
      Removal and Installation
      Operator Enclosure
      Seat and Seat Belt
      Heating and Air Conditioning
      Dealer Fabricated Tools
   Sheet Metal and Styling
      Covers and Guards
      Hood or Engine Enclosure
      Grille and Grille Housing
   Main Hydraulic System
      Hydraulic System
   Grading Device
      Controls Linkage
      Frames
      Circle Gearbox
      Hydraulic System
   Ground Conditioning Tool
      Frames
      Hydraulic System

tm1915 - C Series II Motor Graders

Table of Contents

Foreword

Technical Information Feedback Form

Section 00: General Information

Group 001: Safety

Recognize Safety Information

Follow Safety Instructions

Operate Only If Qualified

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

Inspect Machine

Stay Clear of Moving Parts

Avoid High-Pressure Fluids

Beware of Exhaust Fumes

Prevent Fires

Prevent Battery Explosions

Handle Chemical Products Safely

Dispose of Waste Properly

Prepare for Emergencies

Use Steps and Handholds Correctly

Start Only From Operator's Seat

Use and Maintain Seat Belt

Prevent Unintended Machine Movement

Avoid Work Site Hazards

Keep Riders Off Machine

Avoid Backover Accidents

Avoid Machine Tip Over

Operating or Traveling On Public Roads

Inspect and Maintain ROPS

Add and Operate Attachments Safely

Park And Prepare For Service Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Drive Metal Pins Safely

Section 01: Wheels

Group 0110: Powered Wheels and Fastenings

Remove and Install Tire

Section 02: Axles and Suspension Systems

Group 0225: Input Drive Shafts and U-Joints

Remove and Install Transmission to Rear Axle Drive Shaft

Disassemble and Assemble Transmission to Rear Axle Drive Shaft

Group 0230: Non-Powered Wheel Axles

Other Material

Specifications

Remove and Install Front Wheel Hub and Spindle

Remove and Install Front Wheel Hub

Remove and Install Front Axle—(SN —592109)

Remove and Install Front Axle—(SN 592110— )

Group 0250: Axle Shafts, Bearings, and Reduction Gears

Service Equipment and Tools

Other Material

TEAMMATE TEAMMATE is a trademark of Deere & Company II 1400 Series Inboard Planetary Axle—Use CTM43

Remove and Disassemble Rear Axle

Assemble and Install Rear Axle

Remove and Install Tandem and Wheel Axle Assembly

Remove and Install Tandem Rear Wheel Axle Assembly

Remove and Install Tandem Front Wheel Axle Assembly

Disassemble and Assemble Tandem Pivot

Remove and Install Final Drive Axle (S.N. —562099)

Remove and Install Final Drive Axle (S.N. 562100— )

Disassemble Final Drive Axle Housing

Assemble Final Drive Axle Housing

Remove Brake Backing Plate, Brake Disks and Separator Plate

Brake Disk Inspection

Install Brake Backing Plate, Disks and Separator Plates

Remove and Disassemble Planet Pinion Carrier

Assemble and Install Planet Pinion Carrier

Remove and Disassemble Tandem Drive Shaft

Assemble and Install Tandem Drive Shaft

Disassemble Final Drive Axle Housing

Assemble Final Drive Axle Housing

Remove and Install Drive Chain

Disassemble and Assemble Tandem Wheel Axle Assemblies

Inspect Metal Face Seals

HFWD Lean Yoke Assembly Repair

HFWD Drive Hub Assembly Disassemble and Assemble

Planetary Drive Disassemble and Assemble

Planetary Brake Disassemble and Assemble

HFWD Bearings Remove and Install

HFWD O-Ring Metal Face Seal Remove and Install

Remove and Install Front Axle With HFWD

Group 0260: Hydraulic System

Remove and Install HFWD Pumps

Disassemble and Assemble HFWD Pump

Remove and Install Differential Lock Pump

Remove and Install Differential Lock and Park Brake Valve

Disassemble and Assemble Differential Lock and Park Brake Valve

HFWD Motor Repair

Group 0299: Dealer Fabricated Tools

DFT1151—Outboard Bearing Driver

DFT1152—Inboard Bearing Driver

DFT1153—Oil Seal Driver

DF1017—Axle Lift Eye

DF1057—Axle Adjusting Tool

DFRW103—Yoke Holding Tool Tool may be purchased. Order JDG924.

DFT1225—Rolling Torque Measurement Tool

Section 03: Transmission

Group 0300: Removal and Installation

Service Equipment and Tools

Other Material

Remove and Install Transmission

Install Transmission Harness

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

Essential Tools

Other Material

Use Proper Lifting Equipment

Mounting Transmission on Repair Stand

Remove Yoke Assembly

Install Slip Yoke Assembly

Remove Output Oil Seal

Install Output Oil Seal

Remove and Install Oil Drain Plug

Remove Drive Hub

Install Drive Hub

Remove and Install Charge Pump Group

Remove Accumulator Group

O-Ring Adapter

90° Male Elbow

Transmission Accumulator

Install Accumulator Group

Remove Valve Assembly

Remove Gaskets and Plate from Rear Housing

Disassemble Valve Assembly

Remove Relief Valve

Remove Main Regulator Assembly

Remove Temperature Sensor

Remove Plugs

Valve Assembly

Assemble Valve Assembly

Install Temperature Sensor

Install Main Regulator Assembly

Install Relief Valve

Install Proportional Solenoid Assembly

Install Gasket to Rear Housing

Install Plate and Gasket

Install Valve Assembly

Control Valve Cap Screws

Cap Screw Tightening Sequence and Torque Specifications

Park Brake Group

Remove and Disassemble Park Brake

Remove Brake Piston

Remove Brake Hub

Remove Clutch Disks and Separator Plates

Remove Brake Housing

Apply High Flex Form-In-Place Gasket to Brake Housing

Install Brake Assembly Using High Flex Form-in-Place Gasket

Install Brake Housing With Gasket

Install Brake Hub

Install Clutch Disk and Separator Plates

Assemble Brake Piston

Install Brake Cover

Remove Idler Shafts

Remove Hex Cap Screws

Remove Rear Housing

Rear Housing—Front View

Remove Bore Sleeves

Install Bore Sleeves

Remove Bearing Cup

Install Bearing Cup

Remove Lube Relief Valve

Rear Housing—Rear View

Install Lube Relief Valve

Install Pluget

Remove First Stage Oil Seal

Install First Stage Oil Seal

Install Seal Rings

Install JDG1102 Lifting Tool

Install Idler Shafts

Remove and Install Oil Trough Assembly

Remove All Stage Assemblies

Remove Clutch Stack Nest Lift Plate

Gear Stage Assembly

First Stage Assembly

Disassemble First Stage Shaft Assembly

Assemble First Stage Shaft Assembly

Second Stage Clutch Assembly (Directional Clutch)

Third Stage Clutch Assembly (Directional Clutch)

Disassemble Second and Third Stage Clutch Assembly

Remove Clutch Return Spring

Remove Clutch Piston

Assemble Second and Third Stage Clutch Assembly

Fourth Stage Clutch Assembly (Speed Clutch)

Fifth Stage Clutch Assembly (Speed Clutch)

Disassemble Fourth and Fifth Stage Clutch Assembly (Speed Clutch)

Assemble Fourth and Fifth (Speed Clutch)

Sixth Stage Assembly

Disassemble Sixth Stage Assembly

Assemble Sixth Stage Assembly

Remove Output Group

Disassemble Output Group

Output Group

Assemble Output Group

Install Output Group Assembly

Arrange Stage Assemblies Into Clutch Stack Nest Fixture

Disassemble Front Housing Assembly

Disassemble Pump Output Gear Assembly

Assemble Pump Output Gear Assembly

Remove Pump Idler Gears and Disassemble

Assemble Pump Idler Gear Assemblies

Remove and Install Bearing Cups

Install Pump Drive Gear Assemblies

Install Output Group

Use Proper Lifting Equipment

Install Clutch Stack Lift Tool

Install Stage Assembly

Install Oil Trough

Install Seal Rings

Install Rear Housing

Install Idler Shafts

Install Control Valve Group

Install Accumulator Group

Remove Sixth Stage Bearing Retainer

Bearing Adjustment of Sixth Stage Assembly

Install Brake Assembly

Install Charge Pump to Front Housing

Install Drive Hub

Install Slip Yoke Assembly

Group 0360: Hydraulic System

Specifications

Remove and Install Transmission Charge Pump

Disassemble and Assemble Transmission Filter

Section 04: Engine

Group 0400: Removal and Installation

Engine Remove and Install—6068

Remove and Install Engine—6081

Remove and Install Engine Oil Pan—6068 Engine

Remove and Install Engine Oil Pan—6081 Engine

Bleed the Fuel System—670C

Bleed the Fuel System—770C

Relieve Fuel System Pressure

Replace Rectangular Fuel Filter Element

Replace Fuel Filter Check Valve

Belt Routing

Group 0499: Dealer Fabricated Tools

DFT1150 Transmission Support Bracket

Section 05: Engine Auxiliary System

Group 0505: Cold Weather Starting Aids

Engine Coolant Heater Repair

Group 0510: Cooling System

Fan Pulley Repair

Fan Belt Adjuster Repair

Fan Shroud Repair

Fan Drive Assembly

Fan Drive Hub Repair

Radiator Repair

Oil Cooler Repair

Aftercooler Repair

Group 0560: External Fuel Supply Systems

Fuel Tank Remove and Install (S.N. —589368)

Fuel Tank Remove and Install (S.N. 589369— )

Section 07: Torsional Isolator

Group 0752: Elements

Torsional Isolator Repair

Section 09: Steering System

Group 0920: Power Steering

Check and Adjust Toe-In (HFWD or Non-HFWD)

Group 0960: Hydraulic System

Essential Tools

Service Equipment and Tools

Other Material

Disassemble Steering Valve

Assemble Steering Valve

Remove and Install Steering Wheel, Column, and Valve

Remove and Install Counterbalance Valve

Disassemble Front Steering Cylinder (Without HFWD)

Assemble Front Steering Cylinder (Without HFWD)

Disassemble and Inspect Front Steering Cylinder

Assemble Front Steering Cylinder

Disassemble and Assemble Rear Steering Cylinder

Disassemble Wheel Lean Cylinder

Assemble Wheel Lean Cylinder

Section 10: Service Brakes

Group 1011: Active Elements

Essential Tools

Other Material

Specifications

Brake Components—Cross Section

Brake Backing Plate—Exploded View

Disassemble and Assemble Service Brake Elements

Brake Piston Packings—Vacuum Leak Down Test

Brake Piston Packings—High Pressure Leak Down Test

Group 1060: Hydraulic System

Remove and Install Brake Valve

Disassemble and Assemble Brake Valve

Bleeding Service Brake

Remove and Install Brake Accumulator

Section 11: Park Brake

Group 1111: Active Elements

Other Material

Disassemble and Assemble Park Brake

Remove Brake Piston

Remove Brake Hub

Remove Clutch Disks and Separator Plates

Remove Brake Housing

Park Brake Group

Apply High Flex Form-in-Place Gasket to Brake Housing

Install Brake Assembly Using High Flex Form-in-Place Gasket

Install Brake Housing With Gasket

Install Brake Hub

Install Clutch Disk and Separator Plates

Assemble Brake Piston

Install Brake Cover

Section 17: Frame, Chassis or Supporting Structure

Group 1740: Frame Installation

Welding on Machine

Welding Repair of Major Structure

Remove and Install Front Engine Cover Support (S.N. —589368)

Remove and Install Tank and Reservoir Support (With Reservoirs)

Fan Support

Section 18: Operator’s Station

Group 1800: Removal and Installation

Service Equipment and Tools

Remove and Install Cab

Group 1810: Operator Enclosure

Other Material

Specifications

Remove and Install Windowpanes

Remove and Install Cab Doors

Remove and Install Door Latch

Remove and Install Inside Assist Handle—Left Door

Remove and Install Windshield Washer

Remove, Install, and Adjust Front Windshield Wiper

Remove and Install Rear Wiper

Remove and Install Rear Headliner

Group 1821: Seat and Seat Belt

Disassemble and Assemble Seat, Armrest, and Seat Belt

Disassemble and Assemble Seat with Mechanical Suspension and Tether Strap

Disassemble and Assemble Seat Slide

Disassemble and Assemble Lumbar Support and Control

Disassemble and Assemble Seat Riser

Disassemble and Assemble Air or Mechanical Suspension Seat with Headrest

Group 1830: Heating and Air Conditioning

Refrigerant Cautions and Proper Handling

Flush and Purge Air Conditioner System

R134a Refrigerant Oil Information

R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure

Recover R134a Refrigerant

Evacuate R134a System

Charge R134a System

Remove and Install Compressor

Remove and Install High Pressure Switch

Disassemble and Assemble Compressor Clutch

Inspect Compressor Manifold

Remove and Install Condenser

Evaporator and Expansion Valve

Remove and Install Receiver/Dryer

Remove and Install Accumulator

Remove and Install Compressor Relief Valve

Remove and Install Low Pressure Switch

Remove and Install 20,000 BTU Heater

Remove and Install 20,000 BTU Heater Hoses and Controls

Remove and Install 40,000 BTU Heater Hoses and Controls

Remove and Install Cab Roof Heater

Group 1899: Dealer Fabricated Tools

DFRW20 Compressor Holding Fixture

Section 19: Sheet Metal and Styling

Group 1900: Covers and Guards

Anti Seize Lubricant

Group 1910: Hood or Engine Enclosure

Engine Enclosure Remove and Install (S.N. 589369— )

Group 1921: Grille and Grille Housing

Grille Housing Repair (S.N. —589368)

Grille Housing Repair (S.N. 589369— )

Section 21: Main Hydraulic System

Group 2160: Hydraulic System

Service Equipment and Tools

Remove and Install Main Hydraulic Pump

Disassemble and Assemble Main Hydraulic Pump

Remove and Install System Relief Valve

Remove and Install Hydraulic Fluid Reservoir (S.N. —589368)

Hydraulic Fluid Reservoir Remove and Install (S.N. 589369— )

Remove and Install Attenuator

Section 34: Grading Device

Group 3415: Controls Linkage

Service Equipment and Tools

Remove and Install Steering Support and Console

Change Two Hand Blade Lift Pattern to One Hand Blade Lift Pattern

Remove and Install Steering Tilt Assembly

Remove and Install Console Tilt Linkage

Group 3440: Frames

Other Material

Remove and Install Lift Arms, Saddle Frame and Locking Pin Bracket

Disassemble and Assemble Locking Pin

Remove and Install Draft, Circle, and Blade Tilt Frame

Remove and Install Draft, Circle, and Blade Tilt Frame

Circle Adjustment

Install and Adjust Blade Side Shift Wear Inserts

Measure and Adjust Blade Side Shift Clearance

Group 3450: Circle Gearbox

Service Equipment and Tools

Other Material

Disassemble and Assemble Circle Gearbox

Disassemble and Assemble Circle Drive Gearbox (With Slip Clutch)

Group 3460: Hydraulic System

Service Equipment and Tools

Other Material

Remove and Install Grader Control Valve

Disassemble and Assemble Grader Control Valve

Disassemble and Assemble Blade Lift or Scarifier Valve Section

Disassemble and Assemble Wheel Lean, Rear Steer, Circle Side Shift, Blade Tilt, or Blade Side Shift Valve Section

Disassemble and Assemble Circle Rotate Valve Section

Disassemble and Inspect Return Check Poppets

Disassemble and Assemble Priority Control Valve

Disassemble and Assemble Rotate Motor

Remove and Install Rotary Manifold

Disassemble and Assemble Rotary Manifold

Remove and Install Saddle Locking Pin Solenoid Valve

Disassemble and Assemble Saddle Locking Pin Solenoid Valve

Disassemble and Assemble Crossover Relief Valve

Remove and Install Counterbalance Valve

Remove and Install Blade Lift, Blade Tilt and Circle Side Shift Cylinders

Disassemble Blade Lift, or Circle Side Shift Cylinder

Assemble Blade Lift or Circle Side Shift Cylinder

Disassemble and Assemble Blade Tilt and Blade Side Shift Cylinders

Section 42: Ground Conditioning Tool

Group 4240: Frames

Remove and Install Scarifier

Remove and Install Ripper

Group 4260: Hydraulic System

Service Equipment and Tools

Other Material

Specifications

Disassemble Scarifier Cylinders

Assemble Scarifier Cylinders

Disassemble and Assemble Ripper Cylinder

John Deere Motor Graders 670C, 670CH, 672CH, 770C, 770CH, 772CH Series II Service Repair Manual (TM1915)