John Deere 770G 770GP 772G 772GP Motor Grader Workshop Repair Service Manual 6090HDW01 6090HDW04 (TM12142) PDF - MJODTM12142.zip
This is the complete factory service and repair manual for John Deere Motor Graders 770G, 770GP, 772G, and 772GP equipped with 6090HDW01 and 6090HDW04 engines, containing every piece of shop-level guidance needed to maintain, troubleshoot, and overhaul these machines just like a trained technician.
The workshop service and repair manual for John Deere Motor Graders 770G, 770GP, 772G, and 772GP covers:
* 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.
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Total Pages: 803 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Category: Repair
Language: Spanish French English Russian Portuguese
Models: John Deere - Motor Grader - (634754-656508) 6090HDW01 (S3a) 6090HDW04 (S2)
MAIN SECTIONS (SN.634754—656507)
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
tm12142 - 770G, 770GP, 772G, and 772GP Motor Grader
Table of Contents
Foreword
Manual Identification—READ THIS FIRST!
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
Avoid High-Pressure Oils
Work In Ventilated Area
Prevent Fires
Prevent Battery Explosions
Handle Chemical Products Safely
Decommissioning — Proper Recycling and Disposal of Fluids and Components
Prepare for Emergencies
Clean Debris from Machine
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
Service Tires 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
DF180 Transmission
Transmission Remove and Install
Group 0360: Hydraulic System
Transmission Charge Pump Remove and Install
Section 04: Engine
Group 0400: Removal and Installation
John Deere Engine
Engine Remove and Install—Engine 6090HDW01
Engine Remove and Install—Engine 6090HDW04
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
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 Valve Disassemble and Assemble
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
R134a 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
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 (S.N. —637334)
Compressor Remove and Install (S.N. 637335—656507)
Condenser Remove and Install
Heater and Air Conditioner Remove and Install
Receiver-Dryer Remove and Install
Accumulator Remove and Install
Section 19: Sheet Metal and Styling
Group 1910: Engine Enclosure
Engine Service Doors and Side Shields Remove and Install
Engine Covers Remove and Install
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 Valve Remove and Install
Hydraulic Attenuator 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