Complete service repair manual for John Deere Motor Graders Models 870G, 870GP, 872G, and 872GP with Engines 6090HDW01, 6090HDW04, with all the shop 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.

TM11209 - John Deere Motor Graders 870G, 870GP, 872G, 872GP Technical Manual - Repair.PDF
TM11209 - John Deere Motor Graders 870G, 870GP, 872G, 872GP Technical Manual - Repair.EPUB

Total Pages: 813 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

MAIN SECTIONS
 Foreword
   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
      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

tm11209 - 870G, 870GP, 872G, and 872GP Motor Grader

Table of Contents

Foreword

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 Oils

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

Group 0003: Torque Values

Metric Bolt and Cap Screw Torque Values

Additional Metric Cap Screw Torque Values

Unified Inch Bolt and Cap Screw Torque Values

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

Service Recommendations for O-Ring Boss Fittings

Service Recommendations for Flared Connections—Straight or Tapered Threads

Service Recommendations For Flat Face O-Ring Seal Fittings

O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations

O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations

O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations

Service Recommendations for Metric Series Four Bolt Flange Fitting

Service Recommendations For Inch Series Four Bolt Flange Fittings

Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations

Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings

Service Recommendations For O-Ring Boss Fittings With Shoulder

Metric 24° O-Ring Seal DIN 20078 Service Recommendations

Section 01: Wheels

Group 0110: Powered Wheels and Fasteners

Wheel Remove and Install

Tire Remove and Install

Section 02: Axles and Suspension Systems

Group 0225: Input Drive Shafts and U-Joints

Transmission-to-Rear Axle Drive Shaft Remove and Install

Transmission-to-Rear Axle Drive Shaft Disassemble and Assemble

Group 0230: Non-Powered Wheel Axles

Front Wheel Hub and Spindle Remove and Install—Non 6WD

Front Wheel Hub and Spindle Disassemble and Assemble—Non 6WD

Front Axle Remove and Install—Non 6WD

Group 0240: Powered Wheel Axles

Front Wheel Hub and Spindle Remove and Install—6WD

Front Wheel Hub and Spindle Disassemble and Assemble—6WD

Front Wheel Hub and Spindle Disassemble and Assemble with Steering Angle Sensor—6WD

6WD Drive Hub Disassemble and Assemble

Planetary Drive Disassemble and Assemble

Planetary Brake Disassemble and Assemble

6WD Bearings Remove and Install

6WD O-Ring Metal Face Seal Remove and Install

Front Axle Remove and Install—6WD

Group 0250: Axle Shafts, Bearings, and Reduction Gears

TeamMate™ II 1400 Series Inboard Planetary Axle—Use CTM138619

Rear Axle Remove and Install

Tandem and Wheel Axle Assembly Remove and Install

Tandem Wheel Axle Assembly Remove and Install

Tandem Wheel Axle Assembly Disassemble and Assemble

Tandem Pivot Disassemble and Assemble

Final Drive Axle Remove and Install

Tandem Drive Shaft Remove and Install

Drive Chain Remove and Install

Group 0260: Hydraulic System

6WD Pump Remove and Install

6WD Pump Disassemble

6WD Pump Assemble

6WD Charge Pump Remove and Install

6WD Engagement Manifold Remove and Install

Differential Lock Pump Remove and Install

6WD Motor Remove and Install

6WD Motor Disassemble and Assemble

Section 03: Transmission

Group 0300: Removal and Installation

DF230 Transmission

Transmission Remove and Install

Group 0360: Hydraulic System

Transmission Charge Pump Remove and Install

Section 04: Engine

Group 0400: Removal and Installation

PowerTech Plus™ 9.0L (6090) John Deere Engine—9.0L Tier 3/Stage IIIA

PowerTech Plus™ 9.0L (6090) John Deere Engine—9.0L Stage II

Engine Remove and Install—9.0L Tier 3/Stage IIIA

Engine Remove and Install—9.0L Stage II

Section 05: Engine Auxiliary System

Group 0510: Cooling System

Fan Blade Remove and Install

Radiator Remove and Install

Hydraulic and Differential Oil Cooler Remove and Install

Transmission Oil Cooler Remove and Install

Fuel Cooler Remove and Install—9.0L

Charge Air Cooler Remove and Install

Group 0560: External Fuel Supply Systems

Fuel Tank Remove and Install

Fast Fill Fuel System Disassemble and Assemble—If Equipped

Section 07: Torsional Isolator

Group 0752: Elements

Torsional Isolator Remove and Install

Section 09: Steering System

Group 0920: Power Steering

Toe-In Check and Adjustment

Group 0960: Hydraulic System

Steering Wheel, Column, and Valve Remove and Install—Standard Controls

Steering Wheel, Column, and Valve Remove and Install—EH Controls

EH Controls Steering Canceling Valve Remove and Install

Steering Cylinder Remove and Install

Hydraulic Cylinder Disassemble and Assemble

Wheel Lean Cylinder Remove and Install

Secondary Steering Accumulator Remove and Install—If Equipped

Section 10: Service Brakes

Group 1011: Active Elements

Service Brake Repair

Group 1060: Hydraulic System

Service Brake Valve Remove and Install

Service Brake Bleeding

Brake Accumulator Remove and Install

Section 11: Park Brake

Group 1111: Active Elements

Park Brake Repair

Section 17: Frame, Chassis or Supporting Structure

Group 1740: Frame Installation

Welding On Machine

Welding Repair of Major Structure

Separate Frames at Articulation Joint

Articulation Bearing Replacement

Rear Platform Remove and Install

Section 18: Operator’s Station

Group 1800: Removal and Installation

Cab Remove and Install

Cab Remove and Install—GP Machine Only

Group 1810: Operator Enclosure

Windowpanes Remove and Install

Cab Door Handle Remove and Install

Cab Door Latch Remove and Install

Rivet Nut Installation

Group 1815: Pedal Assembly

Inching Pedal Remove and Install

Group 1816: Steering Tilt Console

Steering Support Console Remove and Install—Standard Controls

Steering Support Console Remove and Install—EH Controls

Console Tilt Remove and Install

Steering Tilt Assembly Remove and Install

Group 1821: Seat and Seat Belt

Seat Remove and Install

Seat Belt Remove and Install

Armrest Remove and Install

Armrest Remove and Install—EH Controls

Armrest Disassemble and Assemble—EH Controls

Standard Seat Disassemble and Assemble

Deluxe Seat Disassemble and Assemble

Air Suspension Disassemble and Assemble

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

R134a System Recover

R134a System Evacuate

R134a System Charge

Expansion Valve Remove and Install

Freeze Control Switch Remove and Install

Air Conditioning High-Low Pressure Switch Remove and Install

Heater Control Valve Remove and Install

Heater Control Valve Leak Check

Blower Motor Assembly Remove and Install

Compressor Remove and Install—6.8L

Compressor Remove and Install

Condenser Remove and Install

Heater and Air Conditioner Remove and Install

Receiver-Dryer Remove and Install

Accumulator Remove and Install

Compressor Clutch Disassemble and Assemble

Compressor Manifold Inspect

Compressor Relief Valve Remove and Install

Section 19: Sheet Metal and Styling

Group 1921: Grille and Grille Housing

Grille Housing Remove and Install

Section 21: Main Hydraulic System

Group 2160: Hydraulic System

Vacuum Pump Installation

Hydraulic Pump Remove and Install

Hydraulic Pump Disassemble and Assemble (S.N. —667937)

Hydraulic Pump Disassemble and Assemble (S.N. 667938— )

Hydraulic System Manifold Remove and Install

Hydraulic System Manifold Disassemble and Assemble

Soft Start Valve Remove and Install

Soft Start Valve Disassemble and Assemble

Hydraulic Fan Pump Remove and Install

Hydraulic Fan Motor Remove and Install

Hydraulic Fan Motor Disassemble and Assemble

Hydraulic Fan Valve Remove and Install

General Oil Cleanup Procedure

Hydraulic/Hydrostatic Component Failure Cleanup Procedure

Section 34: Grading Device

Group 3415: Controls Linkage

Control Linkage Remove and Install

Group 3440: Frames

NeverGrease™ Pin Joints

Lift Arms Remove and Install

Saddle Locking Cylinder Remove and Install

Saddle Lock Cylinder Disassemble and Assemble

Saddle Frame Remove and Install

Blade Pitch Frame Remove and Install

Draft and Circle Frame Remove and Install

Circle Adjustment

Blade Side Shift Wear Inserts Remove and Install

Group 3450: Circle Gearbox

Circle Drive Gearbox Remove and Install

Circle Drive Gearbox Disassemble and Assemble

Circle Drive Gear Case (With Slip Clutch) Disassemble and Assemble

Circle Rotate Motor Disassemble and Assemble

Circle Rotate Sensor Remove and Install

Group 3460: Hydraulic System

Grader Control Valve Remove and Install

Draft Frame Mount Grader Control Valve Remove and Install—EH Controls

Cab Mount Grader Control Valve Remove and Install—EH Controls

Grader Control Valve Disassemble and Assemble

Midmount Scarifier Valve Section Disassemble and Assemble

Midmount Scarifier Valve Section Disassemble and Assemble—EH Controls

Blade Lift Valve Section Disassemble and Assemble

Blade Lift Valve Section Disassemble and Assemble—EH Controls

Auxiliary (With Float) Valve Section Disassemble and Assemble

Auxiliary (Without Float) Valve Section Disassemble and Assemble

Auxiliary Valve Section Disassemble and Assemble—EH Controls

Wheel Lean, Articulation, Circle Side Shift, Blade Pitch, and Blade Side Shift Valve Section Disassemble and Assemble

Wheel Lean, Articulation, Circle Side Shift, Blade Pitch, Blade Side Shift, and Steering Valve Section Disassemble and Assemble—EH Controls

Circle Rotate Valve Section Disassemble and Assemble

Circle Rotate Valve Section Disassemble and Assemble—EH Controls

Return Check Poppets Disassemble and Assemble

Rotary Manifold Remove and Install

Rotary Manifold Disassemble and Assemble

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

Blade Side Shift Cylinder Remove and Install

Articulation Cylinders Remove and Install

Section 42: Ground Conditioning Tool

Group 4240: Frames

NeverGrease™ Pin Joints

Scarifier/Blade Remove and Install

Midmount Scarifier Remove and Install

Midmount Scarifier Cylinder Remove and Install

Ripper Remove and Install

Ripper Cylinders Remove and Install

Balderson™ Style Front Lift Group Remove and Install

Section 99: Dealer Fabricated Tools

Group 9900: Dealer Fabricated Tools

DF1017—Axle Lift Eye

DF1057—Axle Adjusting Tool

DFRW20 Compressor Holding Fixture

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

DFT1101 Cab and ROPS Lift Bracket

DFT1151—Outboard Bearing Driver

DFT1152—Inboard Bearing Driver

DFT1153—Oil Seal Driver

DFT1225—Rolling Torque Measurement Tool

DFT1250 Lifting Bracket

DFT1282—King Pin Torque Adapter

DFT1308 Transmission Support Bracket

DFT1310—Cab Mount Control Valve Support Bracket

DFT1311—Extension for DFT1250

John Deere Motor Graders 870G, 870GP, 872G, 872GP Service Repair Manual (TM11209)