John Deere 670C 670CH 672CH 770C 770CH 772CH Motor Graders Repair Technical Manual TM1607

[Martin Welker]

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John Deere 670C 670CH 672CH 770C 770CH 772CH Motor Graders Repair Technical Manual TM1607
Size: 139.68 MB
Format: PDF
Language: English
Brand: John Deere
Type of Machine: Motor Graders
Type of Manual: Repair Technical Manual
Model: John Deere 670C 670CH 672CH 770C 770CH 772CH Motor Graders
Part Number: TM1607
Publication Date: 2017
Number of Pages: 1336 Pages

Contents:
tm1607 Service ADVISOR™
tm1607 Service ADVISOR™ (1)
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 Property
Service Tires Safely
Avoid Harmful Asbestos Dust
Practice Safe Maintenance
Use Proper Tools
Dispose of Waste Properly
Live With Safety
670C, 670CH, and 672CH Specifications
Drain and Refill Capacities — 670C, 670CH and 672CH
770C, 770CH, and 772CH Specifications
Drain and Refill Capacities — 770C, 770CH and 772CH
Hardware Torque Specifications
Metric Bolt and Screw Torque Values
Additional Metric Cap Screw Torque Values
Unified Inch Bolt and Screw Torque Values
Check Oil Lines And Fittings
Service Recommendations for O-Ring Boss Fittings
Service Recommendations For Flat Face O-Ring Seal Fittings
Service Recommendations for Metric Series Four Bolt Flange Fitting
Service Recommendations For Inch Series Four Bolt Flange Fittings
Service Recommendations for Flared Connections—Straight or Tapered Threads
Diesel Fuel
Lubricity of Diesel Fuels
Diesel Fuel Storage
Low Sulfur Diesel Fuel Conditioner
Do Not Use Galvanized Containers
Fuel Tank
Diesel Engine Oil, Hydraulic Reservoir And Wheel Motor Oil
Transmission, Differential Housing, Tandem Drive, And Circle Drive Gear Box Oil
Grease
Alternative and Synthetic Lubricants
Lubricant Storage
Mixing of Lubricants
Engine Coolant
Specifications
Remove and Install Rim Assembly
Remove Tire
Install Tire
Essential Tools
Service Equipment and Tools
Other Material
Specifications (1)
Install Differential Case Assembly in Repair Stand
Cover
Input Housing and Bevel Pinion Shaft—Cross Sectional View
Cover—Exploded View
Cover and Bevel Pinion Shaft
Cover and Bevel Pinion Shaft (1)
Determine Differential Drive Shaft Cone Point Shim Pack
Cover (1)
Cover (2)
Differential Assembly With Differential Lock Cross Sectional View
Hydraulic Connections
Remove Differential Assembly From Case
Disassemble, Assemble, and Test Differential Lock Quill
Disassemble Differential Housing
Remove and Install Ring Gear
Assemble Differential Housing
Install Differential Assembly into Case
Adjust Differential Bearing Preload
Install Differential Lock Lines
Adjust Differential Backlash
Specifications (2)
Remove and Install Transmission to Rear Axle Drive Shaft
Disassemble and Assemble Transmission to Rear Axle Drive Shaft
Other Material (1)
Specifications (3)
Remove and Install Front Wheel Hub and Spindle
Remove and Install Front Wheel Hub
Remove and Install Front Axle
Service Equipment and Tools (1)
Other Material (2)
Specifications (4)
Identification of Standard Speed or High Speed Hydraulic Front Wheel Drive
Rear Axle and Tandem Assembly—Cross Sectional View
Rear Axle—Cross Sectional View
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 Final Drive Axle
Install Final Drive Axle
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 (1)
Assemble Final Drive Axle Housing (1)
Remove and Install Drive Chain
Disassemble and Assemble Tandem Wheel Axle Assemblies
Inspect Metal Face Seals
Cross Section of HFWD Motor and Planetary Drive
Remove Planetarys
Disassemble and Inspect First Planet Pinion Carrier Assembly
Assemble First Planet Pinion Carrier Assembly
Disassemble and Inspect Second Planet Pinion Carrier Assembly
Assemble Second Planet Pinion Carrier Assembly
Disassemble and Inspect Brake Backing Plate Assembly
Assemble Brake Backing Plate Assembly
Disassemble and Inspect Planet Brake Piston Housing
Assemble Planet Brake Piston Housing
Disassemble and Inspect HFWD Wheel Hub
Assemble and Adjust Wheel Bearings
Final Assembly of Planetarys
Remove and Install Front Axle (With HFWD)
Service Equipment and Tools (2)
Specifications (5)
Identification of Standard Speed or High Speed Hydraulic Front Wheel Drive (1)
Remove and Install HFWD Pump
HFWD Pump—Exploded View
HFWD Pump End Cover—Exploded View
HFWD Pump Main Housing—Exploded View
HFWD Rotating Assembly and Shaft—Exploded View
Disassemble HFWD Pump
Assemble HFWD Pump
Remove and Install Differential Lock Pump
Remove and Install Differential Lock Filter
Disassemble and Assemble Differential Lock Filter
Remove and Install Differential Lock and Park Brake Valve
Disassemble and Assemble Differential Lock and Park Brake Valve
Disassemble and Assemble Differential Lock Solenoid Valve
Disassemble and Assemble Park Brake Solenoid Valve
Remove and Install Flow Divider
Disassemble and Assemble Flow Divider
Disassemble and Assemble HFWD High Pressure and Charge Relief Manifold
Disassemble and Assemble Solenoid Valve
Disassemble and Assemble HFWD Charge Filter
Disassemble and Assemble HFWD Return Filter
Disassemble Wheel Motor
Inspect Wheel Motor Parts
Assemble Wheel Motor
Adjust Motor Shaft End Play
Disassemble and Assemble HFWD Wheel Case Relief Valve
HFWD Start-Up Procedure
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.
Service Equipment and Tools (3)
Other Material (3)
Specifications (6)
Remove and Install Transmission
Install Transmission Harness (SN 567438—)
Essential Tools (1)
Other Material (4)
Specifications (7)
Transmission Repair Stand
Use Proper Lifting Equipment (1)
Lifting Transmission
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 Charge Pump Group
Charge Pump Group
Install Charge Pump Group to Front Housing
Accumulator 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 Rear Housing to Front Housing
Install Seal Rings
Install JDG1102 Lifting Tool
Install Idler Shaft
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
Front Housing Assembly Front View
Front Housing Assembly Rear View
Install Dowel Pins
Install Auxiliary Pump Output Gear Assembly
Install Charge Pump Output Gear Assembly
Install Pump Idler Gear Assembly
Install Output Group
Use Proper Lifting Equipment (2)
Install Clutch Stack Lift Tool
Align Idler Gears
Install Oil Trough
Install Seal Rings (1)
Install Rear Housing
Install Idler Shafts
Install Control Valve Group
Install Accumulator Group (1)
Remove Sixth Stage Bearing Retainer
Bearing Adjustment of Sixth Stage Assembly
Install Brake Assembly
Install Charge Pump to Front Housing
Install Drive Hub (1)
Install Slip Yoke Assembly (1)
Specifications (8)
Remove and Install Transmission Charge Pump
Disassemble and Assemble Transmission Filter
6081 John Deere Engine Repair—Use CTM86
6068 John Deere Engine Repair—Use CTM104
Essential Tools (2)
Service Equipment and Tools (4)
Other Material (5)
Specifications (9)
Remove and Install Engine—6081
Remove Turbocharger—6081 Engine
Prelube Turbocharger
Perform Axial Bearing End Play Test
Install Turbocharger—6081 Engine
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
Belt Tensioner Spring Check
DFT1150 Transmission Support Bracket
Specifications (10)
Remove and Install Engine Coolant Heater
Remove and Install Engine Air Heater (700 Series)
Remove and Install Engine Air Heater (600 Series)
Specifications (11)
Other Material (6)
Remove and Install Fan Pulley
Disassemble and Assemble Fan Pulley
Remove and Install Fan Belt Adjuster
Fan Belt Tensioner Spring Check
Remove and Install Fan Shroud (SN —5687703)
Remove and Install Fan Shroud (SN 5687704— )
Remove and Install Fan Drive Assembly
Disassemble and Assemble Drive Hub
Remove and Install Radiator
Remove and Install Oil Cooler
Remove and Install Aftercooler
Specifications (12)
Other Material (7)
Remove and Install Speed Control Linkage—670C
Remove and Install Speed Control Linkage—770C
Remove and Install Rotary Ejector Precleaner 700 Series Machine, Option
Remove and Install Aspirated Air Cleaner and Muffler—700 Series Machine, Option
Remove and Install Air Cleaner
Remove and Install Muffler
Specifications (13)
Remove and Install Fuel Tank
Disassemble and Assemble Fuel Tank (SN 566855— )
Specifications (14)
Remove and Install Torsional Isolator
Specifications (15)
Check and Adjust Toe-In (With HFWD)
Check and Adjust Toe-In (Without HFWD)
Remove and Install Front Axle Bellcrank (With HFWD)
Essential Tools (3)
Service Equipment and Tools (5)
Other Material (8)
Specifications (16)
Disassemble Steering Valve
Assemble Steering Valve
Remove and Install Steering Wheel, Column, and Valve
Remove and Install Counterbalance Valve
Front Steering Cylinder (Without HFWD)—Cross Section
Disassemble Front Steering Cylinder (Without HFWD)
Assemble Front Steering Cylinder (Without HFWD)
Front Steering Cylinder—Exploded View
Rear Steering Cylinder—Exploded View
Disassemble and Inspect Front and Rear Steering Cylinder
Assemble Front and Rear Steering Cylinder
Wheel Lean Cylinder—Exploded View
Disassemble Wheel Lean Cylinder
Assemble Wheel Lean Cylinder
Essential Tools (4)
Other Material (9)
Specifications (17)
Brake Components—Cross Section
Brake Backing Plate—Exploded View
Disassemble and Assemble Service Brake Elements
Brake Piston Packings—Vacuum Leakdown Test
Brake Piston Packings—High Pressure Leakdown Test
Remove and Install Brake Valve
Disassemble and Assemble Brake Valve
Bleeding Service Brake
Remove and Install Brake Accumulator
Other Material (10)
Specifications (18)
Disassemble and Assemble Park Brake
Remove Brake Piston (1)
Remove Brake Hub (1)
Remove Clutch Disks and Separator Plates (1)
Remove Brake Housing (1)
Park Brake Group (1)
Apply High Flex Form-in-Place Gasket to Brake Housing (1)
Install Brake Assembly Using High Flex Form-in-Place Gasket (1)
Install Brake Housing With Gasket (1)
Install Brake Hub (1)
Install Clutch Disk and Separator Plates (1)
Assemble Brake Piston (1)
Install Brake Cover (1)
Other Material (11)
Specifications (19)
Handle Batteries Safely
Procedure for Testing Batteries
Check Battery Electrolyte Level and Terminals
Using Booster Batteries—24-Volt System
Charge Battery
Remove and Install Batteries
Replacing Batteries
Adding 12-Volt Accessories
John Deere Engine Accessories—Bosch Alternator Repair—Use CTM77
Specifications (20)
Remove and Install Alternator
Specifications (21)
Replace Headlights and Work Lights
Replace Rear Stop, Tail, Signal and Warning Lights
Replace Rear Work Lights
Replace Front Signal Lights
Remove and Install Halogen Lights
Essential Tools (5)
Specifications (22)
Remove and Install Rear Steering Sensor
Adjust Rear Steering Sensor
Saddle Locking Pin Switch Adjustment
Remove and Install Transmission Controller
Remove and Install HFWD Controller
Remove and Install Engine Controller—CH Models Only
Service Parts Kits
Replace SURE-SEAL™ Connectors
Replace CPC, Large MATE-N-LOK and METRIMATE™ Pin Type Connectors
Replace METRI-PACK™ Connectors
Replace Circular AMP™ Connectors
Replace CPC Blade Type Connectors
Replace Small MATE-N-LOK™ Socket Connector
Replace Small MATE-N-LOK™ Pin Connector
Replace DEUTSCH™ Connectors
Replace DEUTSCH™ Rectangular or Triangular Connectors
Install DEUTSCH™ Contact
Replace WEATHER PACK™ Connector
Replace SURE-SEAL™ Connector with WEATHER PACK™ Connector
Replace CINCH™ Connectors
Install CINCH™ Contact
Remove Connector Body from Blade Terminals
Install WEATHER PACK™ Contact
Remove and Install HFWD Front Sensor
Remove and Install Output Shaft Speed Pickup
Remove and Install Air Heat Controller (If Equipped)
John Deere Engine Accessories—Starter Repair—Use CTM77
Specifications (23)
Remove and Install Starter Motor
Specifications (24)
Welding on Machine
Welding Repair of Major Structure
Separate Engine and Equipment Frame
Remove and Install Front Engine Cover Support
Remove and Install Tank and Reservoir Support
Remove and Install Fan Support
Service Equipment and Tools (6)
Specifications (25)
Remove and Install Cab
Other Material (12)
Specifications (26)
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
Front Windshield Wiper—Exploded View
Remove, Install and Adjust Front Windshield Wiper
Remove and Install Rear Wiper
Remove and Install Rear Headliner
Disassemble and Assemble Seat
Disassemble and Assemble Tether Strap
Disassemble and Assemble Seat Belt
Disassemble and Assemble Manual Suspension Seat
Essential Tools (6)
Service Equipment and Tools (7)
Other Material (13)
Specifications (27)
R134A Refrigerant Cautions
Proper Refrigerant Handling
Flush Air Conditioner System
Purge Air Conditioner System
R134A Compressor Oil Information
R134A Compressor Oil Charge Check
R134A Compressor Oil Removal
R134A Component Oil Charge
Recycling and Charging Station Installation Procedures
R134A Refrigerant Recovery
Evacuate R134A System
Charge R134A System
Leak Testing
Belt Tensioner Spring Check (1)
Refrigerant Hoses and Tubing Inspection
Remove and Install Compressor
Remove and Install High Pressure Switch
High Pressure Switch Test
Disassemble and Assemble Compressor Clutch—R134A
Check Clutch Hub Clearance—R134A
Inspect Compressor Manifold—R134A
Disassemble, Inspect and Assemble Compressor—R134A
Remove and Install Condenser
Remove and Install Evaporator and Expansion Valve
Dryer
Remove and Install Compressor Relief Valve—R134A
Remove and Install Low Pressure Switch
Low Pressure Switch Test
Thermostat Switch Bench Test
Disassemble and Assemble Blower Motor
Remove and Install 20,000 BTU Heater
Remove and Install 20,000 BTU Heater Hoses and Controls (SN —567031)
Remove and Install 20,000 BTU Heater Hoses and Controls (SN 567032— )
Remove and Install 40,000 BTU Heater Hoses and Controls
Remove and Install Cab Roof Heater
Remove and Install Cab Roof Heater Hoses
Remove and Install Defog Ducts
DFRW20 Compressor Holding Fixture
Anti Seize Lubricant
Specifications (28)
Remove and Install Grille Housing
Service Equipment and Tools (8)
Specifications (29)
Remove and Install Main Hydraulic Pump
Remove and Install Main Hydraulic Pump Control Valve
Disassemble and Assemble Main Hydraulic Pump Control Valve
Disassemble and Assemble Main Hydraulic Pump
Disassemble and Assemble Soft Start Solenoid Valve (If Equipped)
Remove and Install System Relief Valve
Disassemble and Assemble Main Hydraulic Oil Filter
Remove and Install Hydraulic Fluid Reservoir
Service Equipment and Tools (9)
Specifications (30)
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
Other Material (14)
Specifications (31)
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 (1)
Adjusting Circle Clearance
Install and Adjust Blade Side Shift Wear Inserts
Measure and Adjust Blade Side Shift Clearance
Service Equipment and Tools (10)
Other Material (15)
Specifications (32)
Disassemble and Assemble Circle Gearbox
Disassemble and Assemble Circle Drive Gearbox (With Slip Clutch)
Service Equipment and Tools (11)
Other Material (16)
Specifications (33)
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 (1)
Remove and Install Blade Lift, Blade Tilt and Circle Side Shift Cylinders
Disassemble Blade Lift, Tilt, Sideshift, or Circle Sideshift Cylinder
Assemble Blade Lift, Tilt, Sideshift, or Circle Sideshift Cylinder
Remove and Install Scarifier
Remove and Install Ripper
Service Equipment and Tools (12)
Other Material (17)
Specifications (34)
Disassemble Ripper and Scarifier Cylinders
Assemble Ripper and Scarifier Cylinders