John Deere Motor Graders 870G, 870GP, 872G, 872GP Service Repair Manual (TM13070X19)
Complete service repair manual for John Deere Motor Graders Models 870G, 870GP, 872G, 872GP (T2/S2), with workshop information to maintain, repair, and rebuild like professional mechanics.
John Deere Motor Graders Models 870G, 870GP, 872G and 872GP 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.
TM13070X19 - John Deere Motor Graders 870G, 870GP, 872G, 872GP Technical Manual - Repair.PDF
TM13070X19 - John Deere Motor Graders 870G, 870GP, 872G, 872GP Technical Manual - Repair.EPUB
Total Pages: 831 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English
870G (PIN: 1DW870G***C656729-678817; 1DW870G***D656729-678817)
870GP (PIN: 1DW870G***C656729-678817; 1DW870G***D656729-678817)
872G (PIN: 1DW872G***C656729-678817; 1DW872G***D656729-678817)
872GP (PIN: 1DW872G***C656729-678817; 1DW872G***D656729-678817)
TABLE OF CONTENTS
Foreword
Manual Identification-READ THIS FIRST!
General Information
Safety
Torque Values
Wheels
Powered Wheels and Fasteners
Axles and Suspension Systems
Input Drive Shafts and U-Joints
Non-Powered Wheel Axles
Powered Wheel Axles
Axle Shafts, Bearings, and Reduction Gears
Hydraulic System
Transmission
Removal and Installation
Hydraulic System
Engine
Removal and Installation
Engine Auxiliary System
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
Pedal Assembly
Steering Tilt Console
Seat and Seat Belt
Heating and Air Conditioning
Sheet Metal and Styling
Engine Enclosure
Grille and Grille Housing
Main Hydraulic System
Hydraulic System
Grading Device
Controls Linkage
Frames
Circle Gearbox
Hydraulic System
Ground Conditioning Tool
Frames
Dealer Fabricated Tools
TABLE OF CONTENTS....1
Section 00: General Information....15
Group 0001: Safety....15
Recognize Safety Information....18
Follow Safety Instructions....19
Operate Only If Qualified....20
Wear Protective Equipment....21
Avoid Unauthorized Machine Modifications....22
Inspect Machine....23
Stay Clear of Moving Parts....24
Avoid High-Pressure Fluids....25
Avoid High-Pressure Oils....26
Work In Ventilated Area....27
Avoid Static Electricity Risk When Refueling....28
Prevent Fires....30
Prevent Battery Explosions....31
Handle Chemical Products Safely....32
Decommissioning — Proper Recycling and Disposal of Fluids and Components....33
Prepare for Emergencies....34
Clean Debris from Machine....35
Use Steps and Handholds Correctly....36
Start Only From Operator's Seat....37
Use and Maintain Seat Belt....38
Prevent Unintended Machine Movement....39
Avoid Work Site Hazards....40
Keep Riders Off Machine....42
Avoid Backover Accidents....43
Avoid Machine Tip-Over....44
Operating or Traveling On Public Roads....45
Inspect and Maintain ROPS....46
Add and Operate Attachments Safely....47
Park and Prepare for Service Safely....48
Service Cooling System Safely....49
Remove Paint Before Welding or Heating....50
Make Welding Repairs Safely....51
Drive Metal Pins Safely....52
Service Tires Safely....53
Group 0003: Torque Values....16
Metric Bolt and Cap Screw Torque Values....56
Additional Metric Cap Screw Torque Values....58
Unified Inch Bolt and Cap Screw Torque Values....60
Service Recommendations for 37° Flare and 30° Cone Seat Connectors....62
Service Recommendations for O-Ring Boss Fittings....64
Service Recommendations for Flared Connections—Straight or Tapered Threads....66
Service Recommendations For Flat Face O-Ring Seal Fittings....68
O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations....70
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations....72
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations....75
Service Recommendations for Metric Series Four Bolt Flange Fitting....78
Service Recommendations For Inch Series Four Bolt Flange Fittings....80
Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations....82
Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings....84
Service Recommendations For O-Ring Boss Fittings With Shoulder....87
Metric 24° O-Ring Seal DIN 20078 Service Recommendations....90
Section 01: Wheels....94
Group 0110: Powered Wheels and Fasteners....94
Wheel Remove and Install....97
Tire Remove and Install....99
Section 02: Axles and Suspension Systems....102
Group 0225: Input Drive Shafts and U-Joints....102
Transmission-to-Rear Axle Drive Shaft Remove and Install....106
Transmission-to-Rear Axle Drive Shaft Disassemble and Assemble....108
Group 0230: Non-Powered Wheel Axles....102
Front Wheel Hub and Spindle Remove and Install—Non 6WD....113
Front Wheel Hub and Spindle Disassemble and Assemble—Non 6WD....117
Front Axle Remove and Install—Non 6WD....124
Group 0240: Powered Wheel Axles....102
Front Wheel Hub and Spindle Remove and Install—6WD....135
Front Wheel Hub and Spindle Disassemble and Assemble—6WD....141
Front Wheel Hub and Spindle Disassemble and Assemble with Steering Angle Sensor—6WD....148
6WD Drive Hub Disassemble and Assemble....102
Planetary Drive Disassemble and Assemble....158
Planetary Brake Disassemble and Assemble....161
6WD Bearings Remove and Install....102
6WD O-Ring Metal Face Seal Remove and Install....102
Front Axle Remove and Install—6WD....183
Group 0250: Axle Shafts, Bearings, and Reduction Gears....102
TeamMate™ II 1400 Series Inboard Planetary Axle—Use CTM138619....191
Rear Axle Remove and Install....192
Tandem and Wheel Axle Assembly Remove and Install....197
Tandem Wheel Axle Assembly Remove and Install....201
Tandem Wheel Axle Assembly Disassemble and Assemble....204
Tandem Pivot Disassemble and Assemble....209
Final Drive Axle Remove and Install....214
Tandem Drive Shaft Remove and Install....230
Drive Chain Remove and Install....236
Group 0260: Hydraulic System....102
6WD Pump Remove and Install....102
6WD Pump Disassemble....102
6WD Pump Assemble....102
6WD Charge Pump Remove and Install....103
6WD Engagement Manifold Remove and Install....103
Differential Lock Pump Remove and Install....291
6WD Motor Remove and Install....103
6WD Motor Disassemble and Assemble....103
Section 03: Transmission....299
Group 0300: Removal and Installation....299
DF230 Transmission....302
Transmission Remove and Install....304
Group 0360: Hydraulic System....299
Transmission Charge Pump Remove and Install....314
Section 04: Engine....317
Group 0400: Removal and Installation....317
John Deere Engine....319
Engine Remove and Install—Engine 6090HDW01....320
Engine Remove and Install—Engine 6090HDW04....333
Section 05: Engine Auxiliary System....334
Group 0510: Cooling System....334
Fan Blade Remove and Install....338
Radiator Remove and Install....341
Hydraulic and Differential Oil Cooler Remove and Install....345
Transmission Oil Cooler Remove and Install....348
Fuel Cooler Remove and Install....351
Charge Air Cooler Remove and Install....353
Group 0560: External Fuel Supply Systems....334
Fuel Tank Remove and Install....361
Fast Fill Fuel System Disassemble and Assemble—If Equipped....366
Section 07: Torsional Isolator....370
Group 0752: Elements....370
Torsional Isolator Remove and Install....373
Section 09: Steering System....375
Group 0920: Power Steering....375
Toe-In Check and Adjustment....378
Group 0960: Hydraulic System....375
Steering Wheel, Column, and Valve Remove and Install—Standard Controls....383
Steering Wheel, Column, and Valve Remove and Install—EH Controls....386
EH Controls Steering Canceling Valve Remove and Install....390
Steering Valve Disassemble and Assemble....392
Steering Cylinder Remove and Install....399
Hydraulic Cylinder Disassemble and Assemble....403
Wheel Lean Cylinder Remove and Install....404
Secondary Steering Accumulator Remove and Install—If Equipped....408
Section 10: Service Brakes....410
Group 1011: Active Elements....410
Service Brake Repair....412
Group 1060: Hydraulic System....410
Service Brake Valve Remove and Install....416
Service Brake Bleeding....419
Brake Accumulator Remove and Install....541
Section 11: Park Brake....422
Group 1111: Active Elements....422
Park Brake Repair....424
Section 17: Frame, Chassis or Supporting Structure....425
Group 1740: Frame Installation....425
Welding On Machine....427
Welding Repair of Major Structure....428
Separate Frames at Articulation Joint....430
Articulation Bearing Replacement....436
Rear Platform Remove and Install....440
Section 18: Operator’s Station....444
Group 1800: Removal and Installation....444
Cab Remove and Install....454
Cab Remove and Install—GP Machine Only....462
Group 1810: Operator Enclosure....444
Windowpanes Remove and Install....471
Cab Door Handle Remove and Install....472
Cab Door Latch Remove and Install....474
Rivet Nut Installation....476
Group 1815: Pedal Assembly....444
Inching Pedal Remove and Install....484
Group 1816: Steering Tilt Console....444
Steering Support Console Remove and Install—Standard Controls....490
Steering Support Console Remove and Install—EH Controls....493
Console Tilt Remove and Install....496
Steering Tilt Assembly Remove and Install....499
Group 1821: Seat and Seat Belt....444
Seat Remove and Install....503
Seat Belt Remove and Install....506
Armrest Remove and Install....508
Armrest Remove and Install—EH Controls....509
Armrest Disassemble and Assemble—EH Controls....511
Standard Seat Disassemble and Assemble....513
Deluxe Seat Disassemble and Assemble....515
Air Suspension Disassemble and Assemble....518
Group 1830: Heating and Air Conditioning....444
Flush and Purge Air Conditioner System....523
R134a Refrigerant Oil Information....526
R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure....528
Condenser Remove and Install....530
Heater and Air Conditioner Remove and Install....534
Receiver-Dryer Remove and Install....539
Accumulator Remove and Install....541
R134a System Recover....543
R134a System Evacuate....544
R134a System Charge....546
Expansion Valve Remove and Install....547
Freeze Control Switch Remove and Install....553
Heater Control Valve Remove and Install....555
Heater Control Valve Leak Check....558
Blower Motor Assembly Remove and Install....559
R134a Refrigerant Cautions and Proper Handling....560
Compressor Remove and Install....561
Section 19: Sheet Metal and Styling....564
Group 1910: Engine Enclosure....564
Engine Service Doors and Side Shields Remove and Install....566
Engine Covers Remove and Install....567
Group 1921: Grille and Grille Housing....564
Grille Housing Remove and Install....577
Section 21: Main Hydraulic System....582
Group 2160: Hydraulic System....582
Hydraulic Pump Remove and Install....586
Hydraulic Pump Disassemble and Assemble (S.N. —667937)....589
Hydraulic Pump Disassemble and Assemble (S.N. 667938— )....595
Hydraulic System Manifold Remove and Install....600
Hydraulic System Manifold Disassemble and Assemble....602
Soft Start Valve Remove and Install....604
Soft Start Valve Disassemble and Assemble....606
Vacuum Pump Installation....608
Hydraulic Fan Pump Remove and Install....609
Hydraulic Fan Motor Remove and Install....612
Hydraulic Fan Valve Remove and Install....614
General Oil Cleanup Procedure....617
Hydraulic/Hydrostatic Component Failure Cleanup Procedure....620
Hydraulic Attenuator Remove and Install....624
Section 34: Grading Device....626
Group 3415: Controls Linkage....626
Control Linkage Remove and Install....630
Group 3440: Frames....626
NeverGrease™ Pin Joints....636
Lift Arms Remove and Install....640
Saddle Locking Cylinder Remove and Install....645
Saddle Lock Cylinder Disassemble and Assemble....648
Saddle Frame Remove and Install....651
Blade Pitch Frame Remove and Install....653
Draft and Circle Frame Remove and Install....657
Circle Adjustment....662
Blade Side Shift Wear Inserts Remove and Install....669
Group 3450: Circle Gearbox....626
Dual Input Circle Drive Gearbox Remove and Install—If Equipped....676
Dual Input Circle Drive Gearbox Disassemble and Assemble—If Equipped....680
Dual Input Circle Drive Gear Case (With Slip Clutch) Disassemble and Assemble—If Equipped....685
Circle Rotate Motor Disassemble and Assemble....692
Circle Rotate Sensor Remove and Install....710
Group 3460: Hydraulic System....626
Grader Control Valve Remove and Install....720
Draft Frame Mount Grader Control Valve Remove and Install—EH Controls....726
Cab Mount Grader Control Valve Remove and Install—EH Controls....730
Grader Control Valve Disassemble and Assemble....733
Midmount Scarifier Valve Section Disassemble and Assemble....736
Midmount Scarifier Valve Section Disassemble and Assemble—EH Controls....739
Blade Lift Valve Section Disassemble and Assemble....742
Blade Lift Valve Section Disassemble and Assemble—EH Controls....745
Auxiliary (With Float) Valve Section Disassemble and Assemble....748
Auxiliary (Without Float) Valve Section Disassemble and Assemble....751
Auxiliary Valve Section Disassemble and Assemble—EH Controls....754
Wheel Lean, Articulation, Circle Side Shift, Blade Pitch, and Blade Side Shift Valve Section Disassemble and Assemble....757
Wheel Lean, Articulation, Circle Side Shift, Blade Pitch, Blade Side Shift, and Steering Valve Section Disassemble and Assemble—EH Controls....760
Circle Rotate Valve Section Disassemble and Assemble....763
Circle Rotate Valve Section Disassemble and Assemble—EH Controls....766
Return Check Poppets Disassemble and Assemble....768
Rotary Manifold Remove and Install....769
Rotary Manifold Disassemble and Assemble....772
Blade Lift, Blade Pitch, and Circle Side Shift Cylinders Remove and Install....774
Blade Side Shift Cylinder Remove and Install....776
Articulation Cylinders Remove and Install....779
Section 42: Ground Conditioning Tool....781
Group 4240: Frames....781
Midmount Scarifier Remove and Install....790
Midmount Scarifier Cylinder Remove and Install....798
Ripper Remove and Install....800
Ripper Cylinders Remove and Install....803
Section 99: Dealer Fabricated Tools....806
Group 9900: Dealer Fabricated Tools....806
DF1057—Axle Adjusting Tool....809
DFT1101 Cab and ROPS Lift Bracket....811
DFT1151—Outboard Bearing Driver....812
DFT1152—Inboard Bearing Driver....813
DFT1225—Rolling Torque Measurement Tool....814
DFT1250 Lifting Bracket....815
DFT1282—King Pin Torque Adapter....817
DFT1308 Transmission Support Bracket....818
DFT1310—Cab Mount Control Valve Support Bracket....820
DFT1311—Extension for DFT1250....821
John Deere Motor Graders 870G, 870GP, 872G, 872GP Service Repair Manual (TM13070X19)
