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John Deere

670A and 672A


Motor Grader
Repair

TM-1188 (Dee-87)
LITHO IN U.S.A.
TO JOHN DEERE DEALERS

IMPORTANT: Please remove this page and route through your


service department.

This is a complete revision for TM-1188, JD670-A and JD672-A


Motor Graders Repair.

Binder and tabs from old manual may be saved and used with
this bound manual.

The new pages are dated (Dee-87). Listed below is a brief


explanation of "WHAT" was changed and "WHY" it was changed.

This manual was revised:


To clarify assembly of clutch plate disks.
To update engine section and add engine CTM-4.
To add Weather PackTM electrical connectors information.
To update hydraulic section and add radial piston pump CTM-7.
To add serial number breaks and new art on pump drive assemblies.
To add information on cylinder piston cap seals.
JD670-A and JD672-A Motor Graders Section and Group Contents
TM- 1188 (Dee-87) l-1

JD670-A AND JD672-A MOTOR GRADERS


Technical Manual
TM-1188 (Dee-87)

SECTION AND GROUP CONTENTS

SECTION I - GENERAL INFORMATION SECTION 5 - ENGINE AUXILIARY SYSTEMS


Group I - Contents (not used) Group 0505 - Cold Weather Starting Aids
Group II - Introduction and Safety Information Group 0510 - Cooling Systems
Group III - General Specifications Group 0515 - Speed Controls
Group IV - Predelivery, Delivery and After-Sales Group 0520 - Intake System
Services Group 0540 - Mounting Frame
Group V - Lubrication Group 0560 - External Fuel Supply Systems
Group 0599 - Specifications and Special Tools
SECTION 1 - WHEELS
Group 0110 - Powered Wheels and Fastenings SECTION 8 - TRANSFER DRIVE
Group 0120 - Non-Powered Wheels and Group 0841 - Housings and Covers
Fastenings Group 0851 - Gears, Shafts, Bearings
Group 0199 - Specifications and Special Tools Group 0899 - Specifications and Special Tools

SECTION 2 - AXLES AND SUSPENSION SYSTEMS SECTION 9 - STEERING SYSTEM


Group 0201 - Drive Axle Housing and Support Group 0920 - Power Steering
Group 0210 - Differential or Bevel Drive Group 0960 - Hydraulic System
Group 0250 - Axle Shafts, Bearing and Group 0999 - Specifications and Special Tools
Reduction Gears
Group 0260 - Hydraulic System SECTION 10 - SERVICE BRAKES
Group 0299 - Specifications and Special Tools Group 1011 - Active Elements
Group 1015 - Controls Linkage
SECTION 3 - TRANSMISSION Group 1060 - Hydraulic System
Group 0315 - Controls Group 1099 - Specifications and Special Tools
Group 0341 - Housings and Covers
Group 0350 - Gears, Shafts, Bearings and SECTION 11 - PARKING-EMERGENCY BRAKES
Power Shift Clutch Group 1111 - Active Elements
Group 0360 - Hydraulic System Group 1115 - Controls Linkage
Group 0370 - Clutch Disconnect and Controls Group 1199 - Specifications and Special Tools
Group 0399 - Specifications and Special Tools
SECTION 15 - EQUIPMENT ATTACHING
SECTION 4 - ENGINE Group 1511 - Drawbar
Group 0400 - Removal and Installation Group 1599 - Specifications and Special Tools
Group 0422 - Starting Motor and Fastenings
Group 0499 - Specifications and Special Tools Continued on next page

All information, illustrations and specifications contained in this technical manual


are based on the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.

Copyright@ 1987
DEERE & COMPANY
Moline, Illinois
All Rights Reserved

Previous Editions
Copyright@ 1983 Deere & Company
Copyright@ 1980 Deere & Company
Copyright@ 1979 Deere & Company
Litho in U.S.A. Copyright@ 1978 Deere & Company
Section and Group Contents JD670-A and JD672-A Motor Graders
1-2 TM- 1188 (Dee-87)

SECTION 16 - ELECTRICAL SYSTEMS SECTION 20 - SAFETY, CONVENIENCE AND


Group 1671 - Batteries, Support and Cables MISCELLANEOUS
Group 1672 - Alternator, Regulator and Group 2002 - Mirror
Charging System Wiring Group 2003 _ Fire Extinguisher
Group 1673 - Lighting System Group 2004 - Horn
Group 1674 - Wiring Harness and Switches Group 2006 - Cigar Lighter
Group 1675 - System Controls
Group 1676 - Instruments and Indicators SECTION 21 - MAIN HYDRAULIC SYSTEM
Group 1699 - Specifications and Special Tools Group 2160 - Hydraulic System
Group 2199 - Specifications and Special Tools
SECTION 17 - FRAME, CHASSIS OR SUPPORTING
STRUCTURE SECTION 34 - GRADING DEVICE
Group 1740 - Frame Installation Group 3401 - Blade
Group 1746 - Frame Bottom Guards Group 3415 - Controls Linkage
Group 1747 - Bumpers, Vehicle Group 3440 - Frames
Group 1799 - Specifications and Special Tools Group 3450 - Circle Gear Box
Group 3460 - Hydraulic System
SECTION 18 - OPERATORS STATION Group 3499 - Specifications and Special Tools
Group 1810 - Operator Enclosure
Group 1821 - Seat and Seat Belt SECTION 42 - GROUND CONDITIONING TOOL
Group 1822 - Steps and Handholds Group 4201 - Blades, Teeth, Shanks, Etc.
Group 1830 - Heating and Air Conditioning Group 4215 - Controls Linkage
Group 1899 - Specifications and Special Tools Group 4240 - Frames
Group 4260 - Hydraulic System
SECTION 19 - SHEET METAL AND STYLING Group 4299 - Specifications and Special Tools
Group 1910 - Hood or Engine Enclosure
Group 1913 - Miscellaneous Shields
Group 1921 - Grille and Grille Housing

Litho in U.S.A.
JD670-A and JD672-A Motor Graders General Information I
TM- 1188 (Jul- 79) Introduction and Safetv Information H-1

Group II
INTRODUCTION AND SAFETY INFORMATION
INTRODUCTION

Use FOS Manuals for Reference Use Technical Manuals for Aciual Service

This technical manual is part of a twin concept of


This technical manual was written for you - an
service:
experienced service technician. Keep it in a permanent
The two kinds of manuals work as a team to give you
binder in the shop where it is handy. Read it when you
both the general background and technical details of
need to know correct service procedures or specifica-
shop service.
tions.
lFOS Manuals - For Reference
Fundamentals of Service (FOS) Manuals cover Some features of this manual:
basic theory of operation, fundamentals of trouble-
shooting, general maintenance, and basic types of Inside front cover - “Table of Contents”.
failure and their causes. FOS Manuals are for training
new personnel and for reference by experienced ser- Section I - General specifications and services.
vice technicians.
When a service technician should refer to a Sections 1 through 46 - Removal, repair, testing
FOS Manual for more information, A FOS (components removed), installation, and adjust-
symbol like the one at the left is used in the ment.
El o technical manual.
Section 90 - Detailed explanation of system
lTechnical Manuals - For Actual Service operation, diagnosis, visual inspection, testing,
Technical manuals are concise service guides for and adjustments.
specific machines. Technical manuals are on-the-job
guides containing only the vital information needed by Specifications are listed and illustrated at the end
an experienced service technician. of each section.

Litho in U.S.A.
I General Information JD670-A and JD672-A Motor Graders
II-2 Introduction and Safety lnforma tion TM- 1188 (Jul- 79)

MAINTENANCE WITHOUT ACCIDENT


WORK SAFELY

!?‘27999N

A This safety symbol is used for important safety


messages. When you see this symbol, follow
the safety message to avoid personal injury.

EVERY EMPLOYER HAS A l'27502N

SAFETY PROGRAM. KNOW


WHAT IT IS! BE ALERT!

Plan ahead-work safely-know


how to use a first-aid kit and a fire
extinguisher-and where to get
assistance.

Maintenance Area
Make sure the maintenance area has enough ven-
tilation.

Keep the maintenance area CLEAN AND DRY. Oily


and wet floors are slippery. Greasy rags are a fire
hazard. Wet spots are dangerous when working with
electrical equipment.
See your shop supervisor for specific instructions on
a job, and the safety equipment required.
Keep starting aids in a cool, well-ventilated place,
For instance, you may need: Hard hat, safety shoes, out of reach of unauthorized personnel.
safety goggles, heavy gloves, reflector vest, ear pro-
tectors, respirator.

Litho in U.S.A.
I..
JD670-A and JD672-A Motor Graders General Information I
TM- 1188 (Jul- 79) Introduction and Safety Information II-3

MAINTENANCE WITHOUT ACCIDENT


AVOID FIRE HAZARDS- UNDER ALL MAINTENANCE
CONDITIONS-
Fuel Is Dangerous!
Do not work on the equipment unless you are ap-
proved to do so. Then be sure you know the safe and

a
correct procedure.
Never work on equipment while it is being operated.

T38238N Q w

Do not smoke while putting fuel in the fuel tank.

Do not smoke while working with material that will


start on fire easily.

Stop the engine before filling the fuel tank.

If the engine is hot, use care when putting fuel in the When the engine is running, avoid working on
fuel tank. equipment.

Do not use gasoline or diesel fuel for cleaning parts. If you must work on the machine with the engine
Use solvents that will not start on fire. running, ALWAYS USE TWO service technicians. One
must be at the controls. The other must be within sight
Battery Gas Is Highly Flammable! of the operator.

When charging batteries, be sure there is enough


KEEP HANDS AWAY FROM
ventilation.
MOVING PARTS
Put a support under all raised equipment.

Never work under a raised blade, ripper, or scarifier.


Lower all equipment to the ground.
If the machine is on a slope, use blocks to hold it in
place.

Do not lift heavy parts by yourself. Use hoisting


equipment for this.

Do not check the battery charge by putting metal TAKE CARE! WATCH OUT FOR OTHER
objects across the posts. PEOPLE IN THE AREA
Do not let sparks or open flame near batteries. When drilling, grinding, or hammering metal, wear
safety glasses.
Do not smoke near battery.

Flame Is Not a Flashlight!


NEVER USE OPEN FLAME ARdUND THE MA-
CHINE.

KNOW WHERE FIRE EXTINGUISHERS ARE


KEPT!

Litho in U.S.A.
I General lnforma tion JD670-A and JD672-A Motor Graders
H-4 Introduction and Safety information TM- I 188 (Jul-79)

BE CAREFUL DURING SERVICE KNOW EQUIPMENT IS READY!


AND REPAIR
Check all guards, shields, and safety bars. Every
one must be in place and tight.

CHECK IT OUT!
GUARDS
SHIELDS
SAFETY BARS
ROLL-OVER PROTECTIVE STRUCTURES
SEAT BELTS, ETC.

T38242N

Keep ALL equipment free of dirt and oil.

Clean oil, grease, mud, ice or snow from the opera-


tor’s station, steps and hand rails.

T38243N
When getting the engine ready for storage, re-
member that inhibitor changes easily into gas and is Carefully inspect all systems for leaks.
dangerous. After adding the inhibitor, seal and tape
openings. When you are not using the inhibitor, keep
the can tightly closed.
@@
Do not remove the radiator cap unless you can hold
your hand on the radiator tank. First, loosen the cap
slowly to the stop. Then release all pressure in the
cooling system before removing the cap.
T45794

Check the exhaust system regularly for leaks.


Use a piece of cardboard or wood, rather than
Release hydraulic pressure before working on the hands, to search for suspected leaks.
hydraulic system. Stop the engine. Lower all equip-
ment to the ground. Move the control levers until the Escaping fluid under pressure can penetrate the
equipment does not move. skin.

When checking hydraulic pressure, be sure to use If injured by escaping fluid, see a doctor at once.
the correct test gauge.

Before working on the fuel system, close the fuel


shutoff valve.

Before working on the electrical system, or making a


major overhaul, disconnect the batteries.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders General Information I
TM- 1188 (Jul- 79) General Specifications 111-l

Group III
GENERAL SPECIFICATIONS
(Specifications and design subject to change without notice. Wherever applicable, specifications are in accordance
with ICED and SAE Standards. Except where otherwise noted, these specifications are based on a unit equipped

q
with 13.00-24, 12 ply rating, tubeless tires, 12 ft. (3.66 m) moldboard, and standard equipment. Weights include
lubricants, coolants, full fuel tank and 175 lb. (79 kg) operator.)

Power Travel Speeds (2300 engine rpm, no tire slip):


(at 2300 engine rpm): SAE DIN
Gross . . _. . . . . . 135 hp (100.7 kW) Shifl Lever Position Forward Reverse
Net _._............. 125hp(93.2kW) 126.7 PS mph km/h mph km/h

1 2.3 3.6 2.8 4.5


Net engine flywheel power is for an engine equipped 2 3.2 5.1 3.9 6.3
with fan, air cleaner, water pump, lubricating oil pump, 3 4.8 7.8 5.9 9.5
fuel pump, alternator, and muffler. The gross engine 4 6.3 10.1 7.6 12.3
5 8.2 13.2
power is without fan. Flywheel power ratings are under
6 10.5 17.0
SAE standard conditions of 500 ft. altitude and 85°F 7 14.1 22.8
temperature, and DIN 70 020 conditions (non-correct- 8 23.9 38.4
ed). No derating is required up to 10,000 ft. (3000 m)
altitude. Differential Lock. . . Foot-operated, hydraulically
actuated
Engine: John Deere turbocharged diesel, vertical 6-
cylinder, valve-in-head, 4-stroke cycle. Front Drive: (JD672-A only)
Bore and stroke.. . . . _. 4.19x5 in. (106.5~127 mm) Hydrostatic motor in each wheel controlled through a
Piston displacement . . . . 414 cu. in. (6784 cm3) flow divider to provide optimum traction. Free-wheeling
Compression ratio . . . . . . . . . . . . . . . 16.2 to 1 in gears 5 through 8. Switch controlled for two modes
Maximum torque @ 1300 rpm . .372 lb.-ft. (504 Nm) of operation.
(51.4 kg/m)
NACC or AMA (U.S. Tax) horsepower . . . . . . . .42.1 Pump.... .5.43 cu. in. (89 cm3) variable displacement
Main bearings ....... .. ..... .......... . 7 pump driving a 2.03 cu. in. (33 cm3) reversible motor in
Lubrication . . . . . . Pressure system w/full-flow filter each wheel.
Cooling Pressurized, w/thermostat and fixed bypass
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..Suction
Air cleaner w/restriction indicator. . . . . . . . _. . . Dry
Electrical system . . . . . . . . . . . 24 volt w/alternator
Batteries (2) 12 volt. . Reserve capacity: 180 minutes

Transmission. . . Direct drive full Power Shift with


planetary gear reductions. Foot inching pedal.

Litho in U.S.A.
I General Information ;lD670-A and JD672-A Motor Graders
Ill-2 General Specifications TM- 1188 (Jul- 79)

Rear Drive. . . Inboard planetary final drives with heat- Blade Lifting Mechanism:
treated, split-ted steel torque shafts. Oscillating welded Control. ~ . Dual-lever, hydraulic w/float position
construction tandems; nodular cast sprockets driving 2
in. (51 mm) pitch roller chain in oil bath. Lift Arms: Nodular cast
Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Front Axle: Fabricated steel box-frame with steel Control . . . . . . . . . Hydraulic, foot operated
spindles
Total oscillation.. . . . . . . . . . . . . . . . .30 deg. Circle: Fabricated steel angle construction
Wheel lean range (either direction) . . . . .20 deg. Circle diameter . . . . . . . . . .4 ft. 10 in. (1.47 m)
Rotation . .. .. .... . . . .360 deg.
Steering: Drive. . . Hydraulic motor and worm gear w/positive
Front. Full hydraulic power system. Steering capa- position lock
bilities without power Sideshift, right and left . . . . 31.2 in. (792 mm)
Rear. . Hydraulically articulated frame steering (25
deg. left or right) Drawbar.. . Welded box section, 3.5x7x0.5 in.
Minimum turning radius (89x178x13 mm) wall w/ball and
(JD670-A) ... ..... ... ~. .22 ft. (6.7 m) socket draft connection
Minimum turning radius
(JD672-A) . . . . . . . . .22 ft. 6 in. (6.86 m) Frame:
Rear main frame. . Welded box sectioni;from articula-
Brakes: tion joint to main frame arch
Service. . . Foot-operated, hydraulically-actuated, wet- Width, minimum . . . . . . . . . . . 9.25 in. (235 mm)
disk, effective on 4 tandem wheels Height, minimum . . . . . . . 14.65 in. (372 mm)
Parking . . . Foot-operated, mechanical, dry-disk, Thickness, sides. . . . . . . . . . . 0.63 in. (16 mm)
effective on 4 tandem wheels top and bottom (min.). . 0.75 in. (19 mm)
Hydraulic System: Closed-center Weight per ft. (m), minimum . . . 110 lb. (164 kg/m)
Pressure controlled variable-displacement pump. . .35 Minimum vertical section modulus. . 125 inches cubed
gpm (132 L/min) @ 2300 engine rpm (2050 cm cubed)
Front main frame. . Welded box section from main
Blade: frame arch to front hood
Length .. . . . . . _ . _ 12 ft. (3.66 m) Width . . . . . . . . . _. ... . . 10 in. (254 mm)
Height.. .... .... . . . . . . .24 in. (610 mm) Height, minimum . . . . . . . . . . . 13 in. (330 mm)
Thickness. , . .. . _. . . . . . . . . . 0.88 in. (22 m) Thickness, minimum . . . . . . . . . 0.50 in. (13 mm)
Weight per ft. (m), minimum 110 lb. (164 kg/m)
Blade Range: Minimum vertical section modulus _ 109 inches cubed
Lift above ground.. .. 1 ft. 4.10 in. (409 mm) (1786 cm cubed)
Blade side shift:
Right or left . . . . .. . 2 ft. 2.9 in. (683 mm) Capacities: U.S. Imp. Liters
Shoulder reach outside wheels: Fuel tank . . .. ... .60 gal. 50.0 gal. 227
Right or left.. . _. _. . _. . . . . . . .7 ft. (2.13 m) Cooling system.. . .. 7 gal. 5.8 gal. 26.5
Pitch at ground line. . . . . . . 44 deg. forward Engine lubrication, including
10 deg. back filter.. . . . . . . . . . . .20 qt. 16.7 qt. 18.9
Transmission case.. . . . .14 gal. 12 gal. 53
Transmission and hydraulic
system . . . . . . . . . .28 gal. 23.3 gal. 106
(JD670-A)
Transmission and hydraulic
system . . . . . . . . . .38 gal. 32 gal. 144
(JD672-A)
Tandem housings (each) . . 4 gal. 3.3 gal. 15.1
Worm gearbox . . . . . . . . 3 qt. 2.5 qt. 2.8

Litho in U.S.A.
JD670-A and JD672-A Motor Graders General lnforma tion I
TM- 1188 (Jul- 79) General Specifications III-3

Additional Standard Equipment: Dimensions:


Transistorized voltage Gauges: Ground
Tire Wheel Tread Width Clearance
regulator Water temperature
Size Front Rear Front Rear (Front Axle)
Lights (2 white front Transmission
w/stop and tail light) temperature 13.00-24 76.60 in. 79.61 in. 7 ft. 10 in. 7 ft. 10 in. 1 ft. 10 in.
Work lights (2 front and 2 Transmission lube (1.94 m) (2.02 m) (2.34 m) (2.34 m) (559 mm)
rear floods) pressure
14.00-24 76.60 in. 79.61 in. 8 ft. 8 ft. 1 ft. 10.5 in.

q
Turn signals Transmission pressure
(1.94 m) (2.02 m) (2.44 m) (2.44 m) (571 mm)
Horn Engine oil pressure
Deluxe suspension seat Fuel 17.5-25 79.36 in. 82.37 in. 8 ft. 6 in. 8 ft. 6 in. 1 ft. 11.2 in.
Mechanical hour meter Indicators: (2.01 m) (2.09 m) (2.59 m) (2.59 m) (589 mm)
Cold weather starting aid All-wheel drive charge
Precleaner pressure (JD672-A) Height to top of steering wheel. . 7 ft. 4.4 in. (2.25 m)
Engine side shields Air filter
ROPS cab w/seat belt Transmission filter Scarifier (Special Equipment):
Front and rear windshield All-wheel drive filter V-type for 4 ft. (1.22 m) cut with 3 manual pitch
wipers (JD672-A) positions and hydraulic float
Floor mat Number of teeth (9 possible) . . . . ... .. 5
Lift above ground. . . . . . . . 1 ft. 10 in. (559 mm)
Penetration . . . . . 12 in. (305 mm)
Shank size.. .... 1.25x4 in. (31.7x102 mm)
JD670-A
S$;ghqperating On Front On Rear Ripper (Special Equipment): 8 ft. (2.44 m) cut width,
Wheels Wheels Total
parallelogram linkage, 2 manual shank
Standard equipment 7728 lb. 18,252 lb. 25,980 lb.
(3 505 kg) (8 279 kg)
vertical positions
(11 784 kg)
Standard equipment 8828 lb. 18,252 lb. 27,080 lb. Number of shank pockets ... .. . . . . 5
and scarifier (4 004 kg) (8 279 kg) (12 283 kg) Number of shanks . . . ... ... . ... . 3
Standard equipment, 8031 lb. 21,549 lb. 29,580 lb. Lift above ground.. . 1 ft. 2.5 in. (368 mm)
scarifier and ripper (3 643 kg) (9 775 kg) (13 418 kg) Penetration . . ..... . . .l ft. 2 in. (356 mm)
JD672-A Shank size.. .. .2x5 in. (51x127 mm)
SAE Operating On Front On Rear Lift above ground (shanks in upper
Weight Wheels Wheels Total position). . . . . . . . . . . . . . . 1 ft. 11.5 in.
Standard equipment 8568 lb. 18,507 lb. 27,075 lb. (597 mm)
(3 886 kg) (8 395 kg) (12 281 kg)
Standard equipment 9668 lb. 18,507 lb. 28,175 lb. Special Equipment:
and scarifier . (4 385 kg) (8 395 kg) (12 780 kg) Scarifier Overlay end bits
Standard equipment. 8871 lb. 21,804 lb. 30,675 lb. Transmission bottom
Heavy-duty scarifier
scarifier and ripper (4 024 kg) (9 890 kg) (13 914 kg)
Below-cab blade lights guard
Bench seat Heavy-duty bottom
Tires :
Cab heater (40,000 BTU) guard w/drawbar
13.00-24, 8 or 12 ply rating; 8 in. rim
Cab heater (19,000 BTU) Rear-mounted ripper
14.00-24, 10 or 12 ply rating; 8 or 10 in. rim
Cab defroster fan w/drawbar hitch
17.525, 12 ply rating; 14 in. rim
Air conditioning w/50 amp Drawbar hitch
heavy-duty alternator Tool box
Roof-mounted heater Articulation indicator
(w/air conditioner only) Engine disconnect
Outside rear view mirrors Reverse warning system
ROPS canopy w/seat belt Sound-baffled engine
Coolant heater side shields
2 ft. (610 mm) moldboard 3 in. seat belt
extensions, right or left Heavy-duty cutting edge
13 ft. (3.96 m) and 14 ft. Automatic blade control
(4.27 m) moldboards

Litho in U.S.A.
I General information JD670-A and JD672-A Motor Graders
111-4 General Specifications TM- 1188 (Jul- 79)

DIMENSIONS

A
t
LO ft. 6
c3.20 m)

8 ft. 9.3 in.

27 ft. 3.2 in. (8.31 m) I


I
c
Lb29 ft. 2.6 in. (8.90 m)

31 ft. 8.2 in. (9.66 m) c

NOTE: Dimensions for the JD672-A are the same as those shown above. When a motor grader has air
conditioning, the height is 70 ft. 7 in. (3.23 m).

Litho in U.S.A.
JD670-A and JD672-A Motor Graders General Information I
TM- 1188 (Jul-79) Redelivery, Delivery, and After-Sale Services IV-1

Group IV
PREDELIVERY, DELIVERY, AND
AFTER&ALE SERVICES
TEMPORARY GRADER STORAGE Check air conditioner controls.

q
NOTE: Air temperature must be 60°F (16°C) or
After receiving your grader from the factory and
higher.
before putting the machine into temporary storage,
perform the following checks.

1. Check the battery electrolyte level. Charge the


battery, if necessary.

2. Check the level of the coolant in the radiator. The


coolant must be 4 in. (102 mm) below the top of the
filler neck.

3. Fill the fuel tank.

4. Check the crankcase oil level. Oil must be be-


tween marks on the dipstick after the engine has been
stopped for 10 minutes.

5. Relieve hydraulic pressure by lowering the blade,


stopping the engine and operating the hydraulic control
levers until no equipment moves.

PREDELIVERY SERVICE A-Louvers D-Cooling Control Knob


B-Recirculating Air Control E-Blower Control Knob
The service technician must carefully check and
C-Heat Control Knob
service the machine before the dealer delivers it to the
customer. When the customer receives a machine that Fig. I-Air Conditioner Controls
is correctly prepared, the customer is well-satisfied.
For these reasons, correct predelivery service is very 1 - Turn key switch ON. Operate the blower control
important to the dealer and the customer. knob (E) in all positions. Check the fan speeds and air
volume from the louvers (A).
Use the following check list when getting a unit 2 - Turn the key and blower switches ON. Turn the
ready for delivery to the customer. cooling control knob (D) clockwise toward maximum
cooling. Listen for the click from the compressor clutch.
1. Cab Equipment
Check the operation of doors, windows, seat belts,
horn, defroster fan, dome light, wipers, heater, etc.

Fig. P-Heater Valve

Litho in U.S.A.
I General Information JD670-A and JD672-A Motor Graders
IV-2 Predelivery, Delivery, and After-Sale Services TM- 1188 (Jul-79)

3 - Turn the heater valve (Fig. 2) clockwise to C - Weight adjustment tube - Sit on the seat. Turn
closed position. knob B until the yellow pointer inside the tube is flush
4 - Turn the blower control knob clockwise to high with tube.
speed. Turn the cooling control knob clockwise to D - Forward and rearward adjustment lever - tvlove
maximum cooling. Run the engine at approximately the lever outward to the left (L.H.). Move the seat
2000 rpm. forward or rearward to the desired position. Release
5 - After ten minutes check sight glass for bubbles. the lever.
The sight glass is on the receiver-dryer in the engine
compartment next to the compressor.
NOTE: Bubbles may be seen immediately after the
compressor cycles ON. If bubbles are seen under any
other condition, see Section 90, Group 9031.
6 - Check the temperature of air from louvers. Hold
a thermometer in louver until you get the lowest read-
ing.
When air temperature is above 80°F (27”C), the
temperature of air from louvers must be 25”-30°F
(14”-17%) lower.
When air temperature is below 80°F (27”(Z), the
temperature of air from louvers must be less than 50°F
(10%).
7 - When the unit does not operate correctly, see
Section 90, Group 9031.
Fig. 4 - Cab Seat Controls
Cab equipment checked Yes No
A - Backrest tilt knob - Lift the knob to tilt the
bottom of the backrest forward.
2. Seat
B - Lower the knob to tilt the top of the backrest
Check operation of seat controls. forward.
C - Backrest knob - Raise the knob for a soft
backrest. Lower the knob for a firm backrest.
D - Armrest button - Hold the button in. Move the
armrest up or down to the desired position. Release
the button. The armrest will latch in four different
positions.

fig. 3-Controls for Cab Seat and


Seat without Cab

A - Height adjustment lever - Push down the lever.


Move the seat to the desired position. Release
the lever. F@ 5-Adjustment for Seat without Cab

B - Weight adjustment knob - Turn the knob Adjust backrest tilt as follows:
clockwise for a firm ride. Turn the knob coun- 1 - Loosen two cap screws on each side.
terclockwise for a soft ride. Use the flip-out 2 - Move the backrest to the desired position.
handle to crank the knob. 3 - Tighten the cap screws.

Seat controls checked Yes No

Litho in U.S.A.
JD670-A and JD672-A Motor Graders General Information
TM- 1188 (Mar-80) Predelivery, Delivery, and After-Sale Services

3. Transmission Shifting
Check the operation of the grader in all gears.

A-Frame Steer B-Frame Steer


Left (L.H.) Right (R.H.)

Fig. 7-Frame Steering Lever

Move either lever to aid turning. The frame will


articulate 25 degrees left (L.H.) or right (R.H.).

A-Direction Selector Lever B-Transmission Shift Lever

Fig. d-Transmission Shifting Levers

A - Direction Selector Lever: Push lever ahead to F


to move grader forward. Pull lever back to R to move
grader in reverse. This can be done without using the
inching pedal.

When the transmission is in 5th gear or higher, Fig. d-Rear Steer Indicator
reverse is locked out.
The rear steer indicator shows whether the rear of
A smoother F to R or R to F shift can be made by the grader is in line with the front or pivoted to the left
stopping the grader and slowly engaging the inching (L.H.) or right (R.H.)
pedal or by reducing engine speed.

NOTE: Parking brake must be released before the


direction selector lever can be moved out of neutral.

B - Transmissiqn Shift Lever: Shift this lever when


the grader is stopped or moving. Shift one gear at a
time.

NOTE: When transmission shift lever is in reverse


(R), rear warning alarm will sound at intervals.

Transmission shifting checked Yes No

4. Control Levers
A-Lower Left (L.H.) End of Blade
Check the operation of all control levers. B-Raise Left (L.H.) End of Blade
C-Lower Right (R.H.) End of Blade
D-Raise Right (R.H.) End of Blade

Fig. g-Blade Lifi Levers

Move one lever at a time or both levers together.


Litho in U.S.A.
General Information JD670-A and JD672-A Motor Graders
Predelivery, Delivery, and After-Sale Services TM- 1188 (Mar-80)

A-Wheel Lean Left (L.H.) B-Wheel Lean Right (R.H.) A-Circle Side-Shift B-Circle Side-Shift
Left (L.H.) ’ Right (R.H.)
Fig. IO-Wheel Lean Lever
fig. 72-Circle Side-Shift Lever
Lean wheels toward turn to make a sharper turn.

A-Rotate Circle C-Blade Side-Shii


A-Lower Scarifier C-Pitch Blade Clockwise Left (L.H.)
E-Raise Scarifier Forward B-Rotate Circle D-Blade Side-Shift
D-Pitch Blade Counterclockwise Right (R.H.)
Rearward

Fig. 11 -Scarifier Lever and Fig. 13-Circle Rotation Lever and Blade
Blade Pitch Lever Side-Shift Lever

Scarifier Lever: Push the lever forward until it locks IMPORTANT: Be sure blade does not contact
I
in float position. Pull the lever back to release it from tires or main frame during rotation.
float.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders General Information
TM- I 188 (Jul- 79) Predelivery, Delivery, and After-Sale Services

Fig. 14-Hand Throttle A-Engage Pedal B-Disengage Handle

Use the hand throttle to operate at constant speed. Fig. 17-Parking Brake
Control levers checked Yes No
Push down the parking brake. When the pedal uses
5. Control Pedals over 3/4 total travel to fully engage the brake, change
the adjustment. See page I-IV-26.

To release the parking brake, pull handle B, while


holding down pedal A to take the load off the latch.

Fig. 15-Accelerator Pedal

Push down the pedal to increase speed quickly.


When you release the pedal, speed will go back to the
hand throttle setting.

A- -Differential Engage B-Differential Disengage


Pedal Pedal

Fig. 18-Differential Lock Pedals

Check the operation of the differential lock. Engage


the lock and attempt to turn the steering wheel. If the
lock is working correctly, steering resistance must be
felt.

Fig. 16-Decelerator

Push down the pedal to decrease speed quickly.


When you release the pedal, speed will go back to the
hand throttle setting.

Litho in U.S.A.
I General Information JD670-A and JD672-A Motor Graders
IV-6 Predelivery, Delivery, and After-Sale Services TM- 1188 (Jul-79)

To check the adjustment of the inching pedal, stop


the grader. Push down the pedal all the way. When the
grader moves ahead strongly, the pedal needs adjust-
ment. See page I-IV-27.
Control pedals checked Yes No

6. Gauges
Check the operation of all gauges.

DFn LIGHT

Fig. 19-Brake Pedals

Check the brake system for leaks or wrong opera-


tion.

Put the grader in gear. Push down the brake pedal.


Moderate pedal force must hold grader in place.

If pedal force does not hold the grader in place,


pedal feels spongy or bottoms out, repair is needed, or
air must be removed from the system.

Fig. al-Engine Oil Pressure Gauge

Normal operating range is shown by the green zone


(25-80 psi [1.7-5.5 bar]).

If the indicator hand goes into the red-orange zone,


stop the grader. Check the engine oil level. If the oil
level is not low, check for restrictions in the oil lines or
wrong viscosity oil.

BLACK

A-Disengaged B-Engaged

Fig. 204nching Pedal

Use the inching pedal for precise control of the


grader when hitching equipment to the grader or when
you need a slow, smooth start.
X0859
Push down the pedal (A) to disengage the clutch.
Release the pedal (B) to engage the clutch. Fig. 22-Engine Coolant Temperature Gauge

The light green zone shows the normal operating


IMPORTANT: Do not “ride” the inching pedal.
temperatures, 160-224°F (71-107°C).
Do not use this pedal for normal transmission
shifting. Do not push down the pedal for an emer- IMPORTANT: If the indicator hand goes into the
gency stop unless the engine is running. RED-ORANGE ZONE, stop the engine and find the
cause.

Litho in U.S.A.

..
JD670-A and JD672-A Motor Graders General Information I
TM- 7 188 (Mar-80) Redelivery, Delivery, and After-Sale Services IV-7

LIGHT
LIGHT GREEN GREEN
1
I I-RED-ORANGE
RED RED
ORANGE

q
Y39318
T39316

Fig. 23-Transmission Oil Temperature Gauge Fig. 25-Transmission Oil Pressure Gauge

The light green zone shows the normal operating During normal operations, the indicator hand must
range, IOO-222°F (38-l 05°C). be in the light green zone. If the indicator hand is in the
right (R.H.) red-orange zone, there is too much pres-
If the indicator hand goes into the red-orange zone,
sure in the transmission. If the indicator hand is in the
operate in a lower gear. If the hand remains in the red
left (L.H.) red-orange zone, there is low pressure. If the
zone, check the transmission oil level and the oil cooler
hand is in either red-orange zone, stop the grader and
for plugging.
find the cause.
If these possible solutions do not fewer the oil tem-
LIGHT
perature, do not operate the grader. GREEN

IMPORTANT: Do not operate under load when /

transmission temperature is in red-orange zone of


gauge.

GREEN

RED

T39319

Fig. 26-Transmission Lube Pressure Gauge

When the engine is idling, throttle pulled completely


back, the gauge must show in the striped zone. When
161271N
operating under. constant heavy loads, the gauge must
Fig. 24-Hydrostatic Charge Pressure Gauge (JD672-A) show in the light green zone.

Normal operating range is in the light green zone.


When the indicator hand goes into the red-orange
zone, stop the grader. Find the cause.

Litho in U.S.A.
I General Information JD670-A and JD672-A Motor Graders
IV-8 Predelivery, Delivery, and After-Sale Services TM- 1188 (Mar-80)

DO NOT operate the grader when the needle is in


the red-orange zone. If needle goes into this zone, stop
the grader. Check the transmission filter. If the filter is
not clogged and the needle is still in the red-orange
zone, see your John Deere dealer.

NOTE: Transmission lube pressure will vary with


engine speed and oil temperature.

q
Gauges checked Yes No

7. Switches

Fig. Z&Starting Aid Button

Remove the starting aid can from the engine. Push


the starting aid button. Listen for the solenoid click.
Install the starting aid can.

Fig. 27-Hydraulic Front Wheel Drive Switches (JD672-A)

A - Front Wheel Drive ON: Operate in 1st to 4th


gear, forward and reverse.

B - Front Wheel Drive OFF.


A-Lower Ripper B-Raise Ripper
C - Front Wheel Action NORMAL: Front wheel
drive engages only when rear wheels slip. Front Fig. 294iipper Switch
wheels turn slightly slower than rear wheels.
Switches checked Yes No

D - Front Wheel Action AGGRESSIVE: Front


wheels turn slightly faster than rear wheels. For use in
difficult conditions, on side slopes, and in wet or slip-
pery spots.

IMPORTANT: Switch OFF(B) the hydraulic front


wheel drive system before charging batteries or
using booster batteries or welding on the grader.

Check the hydraulic front wheel drive on a hard, dry


surface, forward and reverse. Turn the hydraulic front
wheel drive ON (A). Put the aggressiveness switch in
the NORMAL (C) position. Then put the aggressive-
ness switch to AGGRESSIVE (D). The surge must be
noticeable.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders General Information I
TM- 1188 (Jul- 79) Predelivery, Delivery, and After-Sale Services IV-9

8. Indicator Lights 9. Lights


Check the operation of all lights, switches, and turn
signal lever.

Fig. 30-Indicator Lights

A - Hydraulic Filter Restriction Indicator Light


(JD672-A only): The light is on when the hy-
draulic front wheel drive pump return filter is
plugged. May be on short time when oil is cold.

B - Brake Pressure Indicator Light: The light is on


when brake pressure falls below 1250 psi (88 A-Left (L.H.) Turn Signal indicator Light
bar). May be on a short time until pressure B-Right (R.H.) Turn Signal indicator Light
C-Work Lights Switch
builds.
D-Driving Lights Switch
E-Turn Signal Lever
C - High Beam Indicator Light: The light is on when
driving lights are on high beam. ,Fig. 31-Light Switches and indicator Lights

D - Transmission Filter Restriction indicator Light: Move the turn signal lever to the desired position.
The light is on when the transmission filter is
plugged. Will be on until oil is warm. Move the lever to neutral after a turn.

E - Locking Pin Indicator Light: The light is on Four amber lights flash as warning lights.
when the locking pin is not fully engaged.

F - Alternator Indicator Light: The light is on when


the alternator is not charging.

Yes No FLASHING WARNING


Indicator lights checked
LIGHTS

T39362

Fig. 32-Turn Signal Label

Litho in U.S.A.
I General Information JD670-A and JD672-A Motor Graders
IV-10 Predelivery, Delivery, and After-Sale Services TM- 1188 (Jut- 79)

10. Steering
Start the engine. Operate the steering wheel.
Steering must be free and easy when the engine is
running.

Steering checked Yes No

11. Lift Arm Locking Pin


Check the operation of the lift arm locking pin,
locking pin valve plunger, and locking pin indicator
light.

A-Left (L.H.) Turn C-Work Lights


Signal Light D-Driving Lights
B-Right (R.H.) Turn
Signal Light

Fig. 33-Front Lights

A-Lift Arm

Fig. 36-Lift Arm

A-Turn Signal Lights C-Working Lights


B-Brake Lights, Taillights,
and Turn Signal Lights

Fig. 3#-Rear Lights

B-Lift Arm Locking Pin

Fig. 37-Lift Arm Locking Pin

Fig. 35-Dimmer Switch

Lights and switches checked Yes No

Litho in U.S.A.
JD670-A and JD672-A Motor Graders General information I
TM- 1188 (Jul- 79) Predelivery, Delivery, and After-Sale Services IV-1 1

Describe any malfunctions:

q
C-Lift Arm Locking Pin Valve Plunger
Fig. 38-Lift Arm Locking Pin Valve Plunger

When the locking pin valve plunger (C, Fig. 38) is 12. Accumulator Action
pushed down, the locking pin (B, Fig. 37) retracts from Check the accumulator reserve capacity as follows:
the hole in the crossbar connected to the lift arm (A,
Fig. 36). “Rock” the lift arms slightly (using the lift Start the engine. Run it approximately one minute.
cylinders) to take the load off the locking pin. The Stop the engine. Push down the brake pedals five
indicator light on the instrument panel must be on. times at five second intervals. If the brakes do not work
When the locking pin valve plunger is released, the after this, the accumulator needs repair.
locking pin must go back into the hole in the crossbar
connected to the lift arm. The indicator light must go off Accumulator checked Yes No
when the pin is in the hole.
Visually check the pin in the hole when the light is 13. Batteries
out. Also check if the locking pin valve plunger travels
Check the electrolyte level of the batteries. If distilled
freely.
water is not available, use clean soft water. Do not use
When the blade lift arm is in the horizontal position
hard water. Remove dirt from the top of the batteries
(locking pin in the center hole), the pointer on the lift
with a damp cloth. Put petroleum jelly on terminals.
arm must be in line with the center positioning hole in
the indicator plate.
IMPORTANT: Never add water to the batteries in
freezing weather unless the engine will be run 2 or
3 hours.

Check battery connections.

Punch date code on batteries.

Batteries checked Yes No

Fig. 39-Lift Arm Pointer

If adjustment is needed, loosen the fasteners hold-


ing the pointer. Move the pointer to the desired posi-
tion. Tighten the fasteners.
Indicator plate adjustment required Yes No
Locking pin working Yes No
Light functioning Yes No

Litho in U.S.A.
-
I General Information JD670-A and JD672-A Motor Graders
IV-12 Predelivery, Delivery, and After-Sale Services TM- 1188 (Jul- 79)

14. Air Intake System

fig. 40-Pre-Cleaner

Check and clean the pre-cleaner bowl.

Fig, 42-Air Intake Hose Clamps

Check clamps on hoses from the air cleaner to the


turbocharger tube and from the air intake manifold to
the turbocharger tube. Tighten hose clamps if neces-
sary. Inspect hoses for cracks.

Air intake system checked Yes No

15. Radiator

A-Air Cleaner Housing D-Primary Element


B-Wing Nut for Safety E-Wing Nut for Cover
Element F-Air Cleaner Cover
C-Safety Element
Fig. 43-Removing Radiator Cap

A
Fig. 4l-Air Cleaner
CAUTION: Do not remove the radiator filler
cap unless you can hold your hand on the
Check the air cleaner restriction indicator on the
radiator tank. First, loosen the cap slowly to the
instrument panel. If the indicator shows red, check and
stop. Then release all pressure in the cooling sys-
clean both primary and safety elements. install new
tem before removing the cap.
elements, if necessary.

Check the level of the coolant in the radiator. Cool-


ant must be 4 in. (102 mm) below the top of the filler
neck. Use clean water for warm weather. Use a solu-
tion of 50% clean water and 50% permanent antifreeze
(ethylene glycol with approved rust inhibitor) for cold
weather.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders General information I
TM- 1188 (Jul- 79) Predelivery, Delivery, and After-Sale Services IV-13

Check the cooling system for loose connections and


leaks. Remove trash from the radiator.

Coo/ant level checked Yes No

16. Transmission-Hydraulic System


Oil Level

A-Dipstick B-Filler Cap

fig. &-Crankcase Oil Level

NOTE: There is 2 quarts (1.9 L) difference between


Fig. 44-Transmission-Hydraulic System
the bottom mark and the top mark on the dipstick.
Filler Cap and Dipstick
Crankcase oil level checked Yes No
Oil added us. w
To check the transmission-hydraulic system oil
level, fully insert the dipstick in the dipstick tube.
18. Fuel System
Before starting the engine, check the oil level. If the
oil level is at or near the upper mark, there is enough oil
in the system to permit starting the engine. If oil level is
low, add oil specified on page l-V-2. Install the dipstick.

NOTE: Do not add oil above the top mark on the


dipstick.

Transmission-hydraulic oil level checked Yes No


Transmission-hydraulic oil added -----qts. (L)

17. Crankcase Oil Level


Check crankcase oil level when the machine is on
level ground and the engine is off. If oil level is at or
below the bottom mark on the dipstick, add oil specified
140227N
on page l-V-2 to bring oil level to between marks on
dipstick. Do not operate the engine when the oil level is Fig. 46-Fuel Level Gauge
below the bottom mark.
Fill the fuel tank with correct fuel.

Check the operation of the fuel gauge.

The fuel gauge shows the amount of fuel in the


fuel tank.

Litho in U.S.A.
I General Information JD670-A and JD672-A Motor Graders
IV-14 Predelivery, Delivery, and After-Sale Services TM- 1 I88 (Jul- 79)

Remove air from the fuel system after the fuel filter is
drained or removed, or after the fuel tank is drained.

1 - Loosen the bleed screw.

2 - Pump the primer lever until fuel without bubbles


flows from the bleed screw.

3 - Tighten the bleed screw.

4 - Leave the primer lever in the down position.

NOTE: When primer lever does not pump fuel and


A-Fuel Tank Sump C-Plastic H&e no resistance is felt at the top of the lever stroke, turn
B-Drain Cock the engine slightly with the starter to change the fuel
pump cam position.
Fig. 47-Fuel Tank Sump

Open the fuel tank drain cock. Drain the liquid for Fuel system checked Yes No
several seconds. Close the drain cock.
19. Belt Tension
Check belt tension.

A-Fuel Filter B-Drain Screw

Fig. 48-Fuel Filter


Fig. 50-Strand Tension Gauge
Check the fuel filter for sediment. Open the drain
screw for several seconds. Drain liquid. Tighten the Checking Tension
drain screw. Strand Tension Gauge. Both belts must have 90 lb.
Remove air from the fuel system. (400 N) (41 kg) strand tension. Check the front belt
only.

Immediately after stopping the engine (run the en-


gine 5 minutes or more), check the belt tension. If
tension is less than 50 lb. (223 N) (23 kg), wait ten
minutes. Then change tension to 90 lb. (400 N) (41 kg).

Fig, 49-Removing Air from the Fuel System

bitho in U.S.A.
JD670-A and JD672-A Motor Graders General Information I
TM- 1188 (Jul- 79) Predelivery, Delivery, and After-Sale Services IV-15

Tighten the compressor belt to 90 lb. (400 N) (41


kg).

To change tension, loosen cap screws B and C.


Apply outward force to the compressor. Tighten cap
screws B and C.

Alternator-fan be/t tension

q
checked Yes No
Compressor belt tension checked Yes No

20. Tandem Drive Oil Level

Fig. N-Tension Tester

Tension tester: A 24 lb. (107 N) (11 kg) force halfway


between the pulleys must move the belt l/2 in. (13
mm).

A-inspection Plates B-Oil Level Plug

Fig. M-Tandem Drive Oil level

Fig. 5%Adjusting Belt Tension


1 - Park the grader on a level surface.
Tension Adjustment: Loosen the cap screws (A).
2- Check the oil level in each tandem.
IMPORTANT: Apply pressure ONLY to the front
alternator housing (B).
3- Remove the oil level plug (B). Oil must be level
Tighten the cap screws. with the oil level plug hole.

4- If not, remove one of the inspection plates and


add oil specified on page l-V-2.

5- Install the inspection plate and oil level plug.

Tandem drives oil level checked Yes No


Oil added -- qts. &I

A-Compressor Belt C-Rear Mounting Cap


B-Adjusting Strap Cap Screw Screw

Fig. 53-Compressor Belt

Litho in U.S.A.
I General Information JO670-A and JD672-A Motor Graders
IV-16 Redelivery, Delivery, and After-Sale Services TM- 7 788 (Jul- 79)

21. Engine Speeds 23. Grease Fittings


Warm up the engine. Remove the hour meter. Fas- The grease fittings were lubricated before the grader
ten a tachometer in the hour meter drive plug hole to left the factory. However, to insure customer satisfac-
check engine rpm. tion, check each lubrication point shown on the follow-
ing pages. Lubricate with several strokes of John
No-load, fast idle speed must be 2475 rpm. Slow Deere Multi-Purpose Grease or equivalent, if neces-
idle must be 900 rpm: sary.

If engine rpm need adjustment, see page I-IV-38.


P
Engine speeds checked Yes No

22. Circle Drive Gearbox Oil Level

>,,,,e*^s.. ‘,,X
.tolTd-l.,,. Al Fig. 56-Scariiier (1 point)

A-Oil Level Plug B-Filler Plug Lubrication required Yes No

Fig. 55-Circle Drive Gearbox

1 - Park the grader on level ground.

2 - Lower the blade to the ground.

3 - Remove the oil level plug (A). Oil must be level


with the hole.

4 - When oil is needed, remove the filler plug (B).


Add oil specified on page l-V-2.

5 - install the filler plug and the oil level plug.

Circle drive gearbox oil level checked Yes No


Oil added 9fs. 04

Fig. 57-Heavy Duty Scarifier (9 points)

Lubrication required Yes No

Lifho in U.S.A.
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JD670-A and JD672-A Motor Graders General Information I
TM- 1188 (Jul- 79) Predelivery, Delivery, and After-Sale Services IV-17

Fig. 67-Lift Arm Locking Pin Housing (1 point)


q
Lubrication required Yes No

Fig. 58-Blade Tilt Cylinder (2 points)

lubrication required Yes No

Fig. 59-Draft Ball Pivot (1 point) Fig. 62-Tandem Pivot - Right (R.H.) Side
(2 points)
Lubrication required Yes No
Lubrication required Yes No

fig. 60-Ripper (10 points)


Fig. 63-Steering Yoke and Cylinder (7 points)
Lubrication required Yes No
Lubrication required Yes No

Litho in U.S.A.
I General Information JD670-A and JD672-A Motor Graders
IV-18 Predelivery, Delivery, and After-Sale Services TM- 1188 (Jul- 79)

Fig. 64-Front Axle (2 points) Fig. 67-Front Ax/e and Wheel Lean Pivots - Left (L.H.)
Side Shown (11 points total)
Lubrication required Yes No
Lubrication required Yes No

Fig. 68-Frame Steering Cylinder - Left (L.H.) Side Show


(2 points total)

Lubrication required Yes

Fjg. 65-Frame Pivots (2 points)

Lubrication required Yes No

Fig. 69-Ball Joints and Trunnions (10 points)

Lubrication required Yes No


Fig. 66-Tie Rod Connector - Left (L.H.) Side Shown
(4 points total)

Lubrication required Yes No

Litho in USA
JD670-A and JD672-A Motor Graders General Information I
TM- 1188 (Jul- 79) Predelivery, Delivery, and After-Sale Services IV-19

Tire Ply Type inflation Pressure-psi (bar)


Size Rating

13.00-24 a G-2 30 (2.07)


13.00-24 12 G-2 35 (2.41)
14.00-24 10 G-2 30 (2.07)
14.00-24 12 G-2 35 (2.41)
17.5 -25 12 L-2 25 &72j*

*For sloping and ditching, inflate to 45 psi (2.8 bar).


q
NOTE: Be sure that tire inflation pressures are
equal for all six tires.
Fig. 70-Circle Supports (4 points total)
For maintenance work on established highways,
Lubrication required Yes No inflation pressure can be increased up to 50% if de-
sired.

Tire pressure checked Yes No

25. Wheel Retaining Cap Screws

Fig. 71-Lift Arm Pivots and Stub Shaft-


Right (R.H.) Side Shown (6 points total)

Lubrication required Yes No Fig. 7%Front Wheel Retaining Cap Screws -


JD672-A only
24. Tires
Check the air pressure in all tires with an accurate Tighten to 130 lb-ft (177 Nm) (18 kg-m).
gauge having 1 psi (0.07 bar) graduations.

When more pressure is needed, use a pressure


regulating valve with a tire valve system locking air
chuck.

When adding air to the tire, stand to the front or rear


of the grader.

Litho in U.S.A.
I General Information JD670-A and JD672-A Motor Graders
IV-20 Predeliverv, Deliverv, and After-Sale Services TM- 1188 (Jul- 79)

27. Fluid Leakage


Check the following systems for leakage. Check for
broken hoses, broken lines, and loose or worn con-
nections.

A. Cooling system checked Yes No


6. Hydraulic system checked Yes No
C. Transmission system checked Yes No
D. Fuel system checked Yes No

28. Final Check


Clean the whole unit. Make the unit LOOK like a new
machine. Touch up any chipped paint. Wash the ma-
Fig. 73-Wheel Retaining Cap Screws chine thoroughly. Deliver to the customer a machine
anyone would be proud to own.
Tighten all wheel retaining cap screws on the
JD670-A and rear wheel cap screws on the JD672-A to
300 lb-ft (407 Nm) (42 kg-m).

NOTE: Tighten these cap screws after every wheel


change. Check again after 50 hours.

Wheel cap screws tightened Yes No

26. Accessible Hardware Torque Values


Check all accessible hardware. See the chart on
page I-IV-51 for torque values.

I Accessible hardware tightened Yes No

Litho in U.S.A.
JD670-A and JD672-A Motor Graders General information I
TM- I 188 (Jui- 79) Predeliverv. Deliverv. and After-Sale Services IV-21

DELIVERY SERVICE AFTER-SALE INSPECTION


Proper delivery should be an important part of a The purchaser of a new John Deere motor grader is
dealer’s program. entitled to a free inspection at a mutually agreeable
time within the warranty period after the equipment has
The dealer should take time, at the owner’s conve- been “run in,” usually after 50 to 100 hours of opera-
nience, to show the owner how to operate and service tion. The terms of this after-sale inspection are outlined
the new machine. on the customer’s John Deere Delivery Receipt.

Using the operator’s manual as a guide, the dealer This inspection is to make sure that the customer is
should be sure the owner understands these points: receiving satisfactory performance from the motor
grader. At the same time, the inspection should reveal
1. The importance of safety. whether or not the motor grader is being operated,
2. The importance of lubrication and periodic ser- lubricated and serviced properly.
vices.
3. The importance of the break-in period. If the recommended after-sale service inspection is
4. Controls and instruments. followed, the dealer can eliminate a needless volume
5. How to start and stop the engine. of service work by preventing minor irregularities from
6. All functions of the hydraulic system. developing into serious problems later on. This will
promote strong dealer-customer relations and present
After explaining and demonstrating the above fea- the dealer an opportunity to answer questions that may
tures, have the owner sign the Delivery Receipt and have arisen during the first few days of operation.
give the owner the operator’s manual.
During this inspection service, the dealer has the
opportunity to promote the possible sale of other new
equipment.

Check operation of all controls and instruments for


freedom of movement and correct operation.

Litho in U.S.A.
I General Information JD670-A and JD672-A Motor Graders
IV-22 Predelivery, Delivery, and After-Sale Services TM- 1188 (Jul- 79)

1. Cab Equipment 2. Seat


Check the operation of doors, windows, seat belt, Check the operation of the seat controls.
horn, defroster fan, dome light, wipers, heater, air-
conditioner, etc.

Check the air conditioner filters. Clean as neces-


sary.

Fig. 76-Controls for Cab Seat and


Seat without Cab

Fig. 74-Recirculating Filter A- Height adjustment lever - Push down the lever.
Move the seat to the desired position. Release
Recirculating filter: Remove the cover and element. the lever.
Wash the filter in warm, soapy water. Rinse and dry it.
B - Weight adjustment knob - Turn the knob
clockwise for firm ride. Turn it counterclockwise
for a soft ride. Use the flip-out handle to crank
the knob.

C- Weight adjustment tube - Sit on the seat. Turn


knob B until the yellow pointer inside the tube is
flush with the tube.

D- Forward and rearward adjustment lever - Move


the lever outward to the left (L.H.). Move the
seat forward or rearward to the desired posi-
tion. Release the lever.

Fig. 75-Outside Air Filter

Outside air filter: Remove two screws. Remove the


cover (A). Remove the filter element (B).

Clean the element by tapping it on a fiat surface with


dirty side down, by blowing low pressure compressed
air under 30 psi (2.1 bar) through the element opposite
to normal air flow, or by washing the element in warm,
soapy water. Rinse and dry it.

Cab equipment checked Yes No

Fig. 77-Cab Seat Contrcls

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JD670-A and JD672-A Motor Graders General Information I
TM- 1188 (Mar-80) Predelivery, Delivery, and After-Sale Services IV-23

A - Backrest tilt knob - Raise the knob to move the 3. Transmission Shifting
bottom of the backrest forward.
Check the operation of the grader in all gears.

B - Lower knob to move the top of the backrest


forward.

C - Backrest knob - Raise the knob for a soft


backrest. Lower the knob for a firm backrest.

D - Armrest button - Hold the button in. Move the


armrest up or down to the desired position.
Release the button. The armrest will latch in
four different positions.

A-Direction Selector Lever B-Transmission Shift Lever

Fig. 79-Transmission Shifting Levers

1161076
A - Direction Selector Lever: Push lever ahead to F
to move grader forward. Pull lever back to R to move
Fig. 78-Adjustment for Seat without Cab grader in reverse. This can be done without using the
inching pedal.
Adjust backrest tilt as follows:
When the transmission is in 5th gear or higher,
1 - Loosen two cap screws on each side. reverse is locked out.

2 - Move the backrest to the desired position. A smoother F to R or R to F shift can be made by
stopping the grader and slowly engaging the inching
3 - Tighten the cap screws. pedal or by reducing engine speed.

Seat co&o/s checked Yes No


NOTE: Parking brake must be released before the
direction selector lever can be moved out of neutral.

B - Transmission Shift Lever: Shift this lever when


the grader is stopped or moving. Shift one gear at a
time.

NOTE: When transmission shift lever is in reverse


(R), rear warning alarm will sound at intervals.

Transmission shifting checked Yes No

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I General lnforma tion JD670-A and JD672-A Motor Graders
IV-24 Predelivery, Delivery, and After-Sale Services TM- 1188 (Mar-80)

4. Control Levers
Check the operation of all control levers.

A-Lower Left (L.H.) End of Blade


B-Raise Left (L.H.) End of Blade
C-Lower Right (R.H.) End of Blade
D-Raise Right (R.H.) End of Blade
A-Frame Steer Left (L.H.) B-Frame Steer Right (R.H.)
Fig. 83-Blade Lift Levers
Fig, 80-Frame Steering Levers
Move one lever at a time or both levers together.
Move either lever to aid turning. The frame will
articulate 25 degrees left (L.H.) or right (R.H.)

Fig. 81 -Rear Steer Indicator


A-Wheel Lean Left (L.H.) B-Wheel Lean Right (R.H.)
The rear steer indicator shows whether the rear of
the grader is in line with the front or pivoted to the left Fig. 84-Wheel Lean Lever

(L.H.) or right (R.H.).


Lean the wheels toward the turn to make a sharper
turn.

A-Circle Side-Shift B-Circle Side-Shift


Left (L.H.) Right (R.H.)

Fig. 82-Circle Side-Shift Lever

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JD670-A and JD672-A Motor Graders General Information
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q
A-Lower Scarifier C-Pitch Blade Forward Fig. 87-Hand Throttle
B-Raise Scarifier D-Pitch Blade Rearward

Fig. 85-Scarifier Lever and Blade Pitch Lever Use the hand throttle to operate at constant speed.
Control levers checked Yes No
Scarifier Lever: Push the lever forward until it locks
in float position. Pull the lever back to release it from 5. Control Pedals
float.

fig. 88-Accelerator Pedal


A-Rotate Circle C-Blade Side-Shift
Clockwise Left (L.H.) Push down the pedal to increase speed quickly.
B-Rotate Circle D-Blade Side-Shift When you release the pedal, speed will go back to the
Counterclockwise Right (R-H.) hand throttle setting.

Fig. 86-Circle Rotation Lever and


Blade Side-Shift Lever

IMPORTANT: Be sure the blade does not con-


tact the tires or main frame during rotation.

Fig. 89-Decelerator

Push down the pedal to decrease speed quickly.


When you release the pedal, speed will go back to the
hand throttle setting.
-.

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IV-26 Predelivery, Delivery, and After-Sale Services TM- 1188 (Mar-80)

4 - Turn the yoke, at caliper, until the holes in the


yoke are in alignment with the outside hole (J)
in the caliper lever. Install pin in yoke (I).

5 - Engage the parking brake. Brake must be tight


when the locking paw1 (K) reaches the first or
second notch on the pedal ratchet when 70 lb.
(311 N) (32 kg) force is applied to brake pedal.

6 - Lubricate linkage. Release brake. Pedal should


return to top slot in dash. Brake disk should
rotate freely.

A-Engage Pedal B-Disengage Handle

Fig. g&Parking Brake

To release the parking brake, pull handle B, while


holding down pedal A to take the load off the latch.
Push down the parking brake. When the pedal uses
over 3/4 total travel to fully engage the brake, change
the adjustment as follows:

A-Differential Engage B-Differentiaf Disengage


Pedal Pedal

Fig. 9247ifferential Lock Pedals

Check the operation of the differential lock. Engage


the lock and attempt to turn the steering wheel. If the
lock is working correctly, steering resistance will be felt.

Fig, 9 1-Ad@ ting Parking Brake

1 - Remove pin from yoke (I). Turn cap screw (A) in


the transmission cover under caliper (B), until
the bottom friction pad (C) just touches the
bottom of the brake disk (D).
2 - Turn lock nut (E) on top of the caliper lever (F)
until the top friction pad (G) just touches the Fig. 93-Brake Pedals
brake disk (D).
3 - When the parking brake pedal (H) is in full Check the brake system for leaks or wrong opera-
raised position and the caliper lever (F) is in tion.
center position, turn the brake cable end yoke
(1). Put the grader in gear. Push down the brake pedal.
Moderate pedal force must hold the grader in place.

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JD670~A and JD672-A Motor Graders General Information I
TM-1 188 (Dee-87) Predelivety, Delivery and After-Sale Services IV-27

If pedal force does not hold the grader in place, Use the inching pedal for precise control of the
pedal feels spongy or bottoms out, repair is needed, grader when you hitch equipment to the grader or
or air must be removed from the system. Also remove when you need a slow, smooth start.
air from the brake system if the pedal jumps back
when pushed down. Push down the pedal (A) to disengage the clutch.
Release the pedal (B) to engage the clutch.

IMPORTANT: Do not “ride” the inching pedal. Do


not use this pedal for normal transmission shifting.
Do not push down the pedal for an emergency stop
unless the engine is running.

To check the adjustment of the inching pedal, stop


the grader. Push down the pedal all the way. When
the grader moves ahead strongly, the pedal needs
Fig. 94-Brake Bleed Screw
adjustment as follows:

The brake bleed screws are on both sides of the


transmission housing, forward of the axle and on the
top, near the differential housing casting.

Loosen lock nuts. Open bleed screws one full


turn. Tighten lock nuts. Push both brake pedals and
hold to release hydraulic pressure from accumulator.
Release brake pedals. Start engine and run at slow
idle. Push pedals down and hold a minimum of two
minutes.

Still holding pedals down, loosen lock nuts and


tighten bleed screws. Tighten lock nuts. Release the
brake pedals. Each pedal must feel solid. If not,
repeat the procedure.

If the braking action is poor or erratic after removing


air from the brakes, check the accumulator reserve
capacity.

l-Return Spring 4-Control Lever


2-Valve Operating Arm B-Cable Yoke
3-Valve Operating Rod
Yoke

Fig. O&Clutch Pedal Valve Adjustment

Remove the return spring (1, Fig. 96) from the


control lever (4). Disconnect the cable yoke (5). Turn
both the valve operating arm and the control lever
counterclockwise until they hit the stops.

When the operating arm and the control lever are


A-Disengaged B--Engaged
against the stops, turn the yoke (3) on the operating
Fig. 95-Inching Pedal
rod so that the hole in the yoke is in line with the hole
in the control lever. Then turn the yoke l/2 turn
counterclockwise to make the rod longer.

Litho in U.S.A.
I General Information JD670-A and JD672-A Motor Graders
IV-28 Predelivery, Delivery, and After-Sale Services TM- 1188 (Jul- 79)

Install the clutch cable yoke (5). Turn the yoke so LIGHT GREEN
--I
that when the control lever (4) is turned counterclock-
:ANw
wise against the stop, the bottom side of the clutch
pedal clears the floor plate.

Install the return spring (1).

IMPORTANT: Make sure that the cable yoke (5)


is pinned to the lever extension. Put the yoke of the
valve operating arm (2) in the upper hole.

Be sure to tighten nuts against the yokes.

Control pedals checked Yes No


Clutch pedal adjusted Yes No
T39318 -
Brakes bled Yes No
Parking brake adjusted Yes No
Fig. 98-Transmission Oil Temperature Gauge
6. Gauges
The light green zone shows the normal operating
Check operation of all gauges. range, lOO-222°F (38-105°C).
If the indicator hand goes into the red zone, operate
RED in a lower gear. If the hand remains in the red zone,
ORANG
check the transmission oil level and the oil cooler for
plugging.
If these possible solutions do not lower the oil tem-
perature, do not operate the grader.
IMPORTANT: Do not operate under load when
transmission temperature is in red-orange zone of
gauge.
LIGHT
GREEN

I
RED C RED
ORANGE

Fig. 97-Engine Oil Pressure Gauge

Normal operating range is shown by the green zone


(25-80 psi [1.7-5.5 bar]).

If the indicator hand goes into the red-orange zone,


stop the grader. Check the engine oil level. If the oil
level is not low, check for restrictions in the oil lines or
wrong viscosity oil.
539316

Fig. 99-Transmission Oil Pressure Gauge

During normal operations, the indicator hand must


be in the light green zone. If the indicator hand is in the
right (R.H.) red-orange zone, there is too much pres-
sure in the transmission. If the indicator hand is in the
left (L.H.) red-orange zone, there is low pressure. If the
hand is in either red-orange zone, stop the grader and
find the cause.

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JD670-A and JD672-A Motor Graders General information I
TM- 1788 (Mar-80) Predeliverv, Delivery, and After-Sale Services IV-29

LIGHT RED- GREEN


STRIPED GREEN
ZONE
/ /

RED-
P61271N
T39319
fig. 102-Hydrostatic Charge Pressure Gauge (JD672-A)
Fig. loo-Transmission Lube Pressure Gauge
Normal operating range is in the light green zone.
When the engine is idling, throttle pulled completely When the indicator hand goes into the red-orange
back, the gauge must show in striped zone. When zone, stop the grader. Find the cause.
operating under constant heavy loads, the gauge must
show in the light green zone. Gauges checked Yes No

DO NOT operate the grader when the needle is in 7. Switches


the red-orange zone. If the needle goes into this zone,
stop the grader. Check the transmission filter. If the
filter is not clogged and the needle is still in the red-
orange zone, see your John Deere dealer.

NOTE: Transmission lube pressure will vary with


engine speed and oil temperature.

LIGt'T GREEN
BLACK

RED-
ORANGE

A-Lower Ripper B-Raise Ripper

Fig. 703~Ripper Switch

\
T508.59

Fig. lOl-Engine Coolant Temperature ‘Gauge

The light green zone shows the normal operating


temperatures, 160-224°F (71-l 07°C).

IMPORTANT: If the indicator hand goes into the


RED-ORANGE ZONE, stop the engine and find the
cause.

Litho in U.S.A.
I Genera.1 Information JD670-A and JD672-A Motor Graders
IV-30 Predelivery, Delivery, and After-Sale Services . TM- 1188 (Mar-80)

Check the hydraulic front wheel drive on a hard, dry


surface, forward and reverse. Turn the hydraulic front
wheel drive ON (A). Put the aggressiveness switch in
the NORMAL (C) position. Then put the aggressive-
ness switch to AGGRESSIVE (D). The surge must be
noticeable.

Switches checked Yes No

8. Indicator Lights

Fig. 104-Starting Aid Button

Remove the starting aid can from the engine. Push


the starting aid button. Listen for the solenoid click.
Install the starting aid can.

Fig. 106~Indicator Lights

A - Hydraulic Filter Restriction indicator Light


(JD672-A only): The light is on when the hy-
draulic front wheel drive pump return filter is
plugged. May be on a short time when oil is
cold.

Fig. YO5-Hydraulic Front Wheel Drive Switches (JD672-A) B - Brake Pressure Indicator Light: The light is on
when brake pressure falls below 1250 psi (88
A - Front Wheel Drive ON: Operate in 1st to 4th bar). May be on a short time until pressure
gear, forward and reverse. builds.

B - Front Wheel Drive OFF. C - High Beam Indicator Light: The light is on when
the driving lights are on high beam.
C - Front Wheel Action NORMAL: Front wheel
drive engages only when rear wheels slip. Front D - Transmission Filter Restriction Indicator Light:
wheels turn slightly slower than rear wheels. The light is on when the transmission filter is
plugged. Will be on until the oil is warm.
D - Front Wheel Action AGGRESSIVE: Front
wheels turn slightly faster than rear wheels. For use in E - Locking Pin Indicator Light: The light is on
difficult conditions, on side slopes, and in wet or slip- when the locking pin is not fully engaged.
pery spots.
F -’ Alternator Indicator Light: The light is on when
IMPORTANT: Switch OFF(B) the hydraulic front the alternator is not charging.
wheel drive system before charging batteries or
using booster batteries or welding on the grader. Indica’tor lights checked Yes No

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JD670-A and JD672-A Motor Graders General Information I
TM- 1188 (Jul- 79) Predelivery, Delivery, and After-Sale Services IV-31

9. Lights
Check the operation of all lights, switches, and turn
signal lever.

A-Left (L.H.) Turn C-Work Lights


Signal Light D-Driving Lights
B-Right (R.H.) Turn
Signal Light

A-Left (L.H.) Turn Signal Indicator Light Fig. 109-Front Lights


B-Right (R.H.) Turn Signal Indicator Light
C-Work Lights Switch
D-Driving Lights Switch
E-Turn Signal Lever

fig. 107-Light Switches and Indicator Lights

Move the turn signal lever to the desired position.

Move the lever to neutral after completing a turn.

Four amber lights flash as warning lights.

A-Turn Signal Lights C-Work Lights


B-Brake Lights, Taillights,
and Turn Signal Lights
/ FLASHING WARNING Fig. 1 IO-Rear Lights

T39382

Fig. 108-Turn Signal Label

Fig. 7 7 I -Dimmer Switch

Lights and switches checked Yes No

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I General Information JD670-A and JD672-A Motor Graders
IV-32 Predelivery, Delivery, and After-Sale Services TM- 1188 (Jul- 79)

10. Steering
Start the engine and operate the steering wheel.
Steering must be free and easy when the engine is
running.

Steering checked Yes No

11. Lift Arm Locking Pin

- Check the operation of the lift arm locking pin,


locking pin valve plunger, and locking pin indicator
light. C-Lift Arm Locking Pin Valve Plunger
Fig. 114-Lift Arm Locking Pin Valve Plunger

When the locking pin valve plunger (C, Fig. 114) is


pushed down, the locking pin (B, Fig. 113) retracts
from the hole in the crossbar connected to the lift arm
(A, Fig. 112). “Rock” the lift arms slightly (using the lift
cylinders) to take the load off the locking pin. The
indicator light on the instrument panel will be on.
When the locking pin valve plunger is released, the
locking pin must go back into the hole in the crossbar
connected to the lift arm. The indicator light must go off
when the pin is in the hole.
Visually check the pin in the hole when the light is
out. Also check if the locking pin valve plunger travels
freely.
When the blade lift arm is in the horizontal position
(locking pin in the center hole), the pointer on the lift
arm must be in line with the center positioning hole in
the indicator plate.

A-Lift Arm

Fig. 7 72-Lift Arm

Fig. 715-Lift Arm Pointer

B-Lifl Arm Locking Pin If adjustment is needed, loosen the fasteners hold-
ing the pointer. Move the pointer to the desired posi-
Fig. 113-Locking Pin
tion. Tighten the fasteners.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders General Information
TM- 1188 (Jul-79) Predelivery, Delivery, and After-Sale Services

Indicator p/ate adjustmenf required Yes No


Locking pin working Yes No
Light functioning Yes No

Describe any malfunctions:

12. Check Accumulator Action


Check the accumulator reserve capacity as follows:

Startthe engine. Run it one minute. Stop the engine.


Apply brakes five times at five second intervals. If
brakes will not operate in five applications or less, the
accumulator is not working correctly.
Accumulator checked Yes No

13. Batteries A-Air Cleaner Housing D-Primary Element


Check the electrolyte level of the batteries. If distilled B-Wing Nut for Safety E-Wing Nut for Cover
Element F-Air Cleaner Cover
water is not available, use clean soft water. Do not use C-Safety Element
hard water. Remove dirt from the top of the batteries
with a damp cloth. Put petroleum jelly on terminals. Fig. 117-Air Cleaner

IMPORTANT: Never add water to the batteries in Check the air cleaner restriction indicator on the
freezing weather unless the engine will be run 2 or instrument panel. If the red signal can be fully seen,
3 hours. check and clean both the primary and safety elements.
Install new elements, if necessary.
Check battery connections.
Batteries checked Yes No

14. Air Intake System


Check and clean the pre-cleaner bowl.

Fig. 116-Pre-Cleaner
Fig. 1 la-Air intake Hose Clamps

Check clamps on hoses from the air cleaner to the


turbocharger tube and from the air intake manifold to
the turbocharger tube. Tighten hose clamps if neces-
sary. Inspect hoses for cracks.
Air intake system checked Yes No

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iv-34 Predelivery, Delivery, and After-Sale Services TM- 1188 (Jul-79)

15. Radiator ,’d

A
_,
CAUTION: Do not remove the radiator filler
cap unless you can hold your hand on the
radiator tank. First, loosen the cap slowly to the
stop. Then release all pressure in the cooling sys-
tem before removing the cap.

A-Cap Screw B-Filter Cover

Fig. 120-Transmission Oil Filter

Fig. 119~Removing Radiator Cap

Check the coolant level. Keep coolant 4 inches (102


mm) below the top of the filler neck. Use clean water
for warm weather. Use a solution of 50% clean water
and 50% permanent antifreeze (ethylene glycol with
approved rust inhibitor) for cold weather.
T61467

Check the cooling system for loose connections and


A-Cap Screw C-Filter Element
leaks. Remove trash from the radiator. B-Filter Cover D-Packing

Coolant level checked Yes No Fig. 121-Transmission Oil Filter

16. Transmission-Hydraulic System 1 - Remove the cap screw (A) and filter cover (B)
Oil Level and Filter together, along with all parts shown.
2- Discard the element (C) and packing (D).
NOTE: Before checking the oil level, find out if the 3- Clean the inside of the the filter cover.
customer has changed the transmission filter (first 50 4- Install a new element and a new packing in the
hours service). cover.
5- Install the cover.
If the filter has been changed, write the information
below:

Approximate hours at change

If not, change as follows:

Fig. 122-Transmission-Hydraulic System


Filler Cap and Dipsfick

Litho in U.S.A.
JD670-A and JD672-A Motor Graders General Information
TM- 1188 (Jul- 79) Predelivery, Delivery, and After-Sale Services

Check the transmission oil level before starting the


engine. Oil level must be at or near the upper mark on
the dipstick.

If the engine has been running and the transmission


oil is warm, allow 10 minutes for oil to drain down
before checking.

Add oil specified on page i-V-2 if needed.

IMPORTANT: Do not overfill.

Transmission-hydraulic oil /eve/ checked Yes No


Transmission-hydraulic oil added qts. (6 B-Drain Screw
A-Fuel Filter
Transmission filter changed Yes No
Fig. 125Fuel Filter
17. Fuel System
Check the fuel filter for sediment. Open the drain
screw for several seconds. Drain liquid. Tighten the
drain screw.

Remove air from the fuel system.

P40227N

Fig. 123-Fuel Level Gauge

Add a small amount of fuel to the fuel tank.

Check the action of the fuel gauge.


Fig. 126~Bleeding Fuel System

Remove air from the fuel system after the fuel filter is
drained or removed, or after the fuel tank is drained.

1 - Loosen the bleed screw.


2- Pump the primer lever until fuel without bubbles
flows from bleed screws.
3 - Tighten the bleed screw.
4- Leave primer lever in the down position.

NOTE: When the primer lever does not pump fuel


and no resistance is felt at the top of the lever stroke,
turn the engine slightly with the starter to change the
A-Fuel Tank Sump C-Plastic Hose
B-Drain Cock
fuel pump cam position.

Fig. 124-Fuel Tank Sump Fuel system checked Yes No

Open the fuel tank drain cock. Drain liquid for sev-
eral seconds. Close the drain cock.

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IV-36 Predelivery, Delivery, and After-Sale Services TM- 1188 (Jut-79)

18. Engine Crankcase Oil and Filter


Elements

NOTE: Check with the customer if oil and filters


have been changed before doing this service.

Normal order of service is as follows:

Oil and filter change - after first 100 hours


m - every 200 hours thereafter

If changed, write the information below.

Approximate hours at change

If not, change as follows: fig. 128-Crankcase Oil Filters

1 - To remove the filters, turn them counterclockwise.

2 - Put a thin film of oil on the gasket of the new filters.

3 - Install new filters. Turn the filter clockwise by hand


until the gasket touches the mounting surface.

4 - Tighten an -additional l/2 to 3/4 turn. Fill the


crankcase with oil specified on page l-V-2.
Crankcase capacity is 20 qt. (19 L) including filter.

IMPORTANT: Before starting the grader after a


filter change, crank the engine for 20 seconds with
the hand throttle in stop position.

5 -‘Start the engine. Check for leaks around filters.


Tighten again if necessary. Do not overtighten.

Fig. 12?‘-Engine Crankcase Drain Plug 6 - Stop the engine. Check the crankcase oil level.

1 - Run the engine to heat the oil.

2 - Drain the oil from the engine crankcase.

3 - While the crankcase is draining, install new filters


as follows:

A-Dipstick B-Filler Cap

Fig. 129-Crankcase Oil Level

Litho in U.S.A.
JD670-A and JD672-A Motor Graders General Information I
TM- 1188 (Jul-79) Predelivery, Delivery, and After-Sale Services IV-37

Check the crankcase oil level when the machine is


on level ground and the engine off. If oil level is at or
below the bottom mark on the dipstick, add oil specified
on page l-V-2 to bring oil level to between marks on
dipstick. Do not operate engine when the oil level is
below the bottom mark.

NOTE: There is 2 quarts (1.9 L) difference between


the bottom mark and the top mark on the dipstick.

Filter changed Yes No


Crankcase oil level checked Yes No
Oil added - (8s. (L/

Fig. 131-Tension Tester


19. Belt Tension
Check and adjust belt tension. / Tension tester: A 24 lb. (107 N) (11 kg) force halfway
between the pulleys must move the belt l/2 in. (13
mm).

Fig. 130-Tension Gauge

Immediately after stopping the engine (run the en- Fig. 132-Adjusting Belt Tension
gine 5 minutes or more), check the belt tension. If
tension is less than 50 lb. (223 N) (23 kg), wait ten Tension Adjustment: Loosen the cap screws (A).
minutes. Then change tension to 90 lb. (400 N) (41 kg). IMPORTANT: Apply pressure ONLY to the front
alternator housing (B).
Tighten the cap screws.

A-Compressor Belt B-Adjusting Strap Cap Screw


C-Rear Mounting Cap Screw

Fig. 133-Compressor Bell

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IV-38 Predelivery, Delivery, and After-Sale Services TM- 1188 fJul- 791

Tighten the compressor belt to 90 lb (400 N) (41 kg). 21. Engine Speeds
Check the engine speeds. Make adjustments if
To change tension, loosen cap screws B and C.
necessary.
Apply outward force to compressor. Tighten cap
screws B and C.
NOTE: The engine must be at operating tempera-
Alternator - fan belt tension checked Yes No
ture for the following adjustments.
Compressor be/t tension checked Yes No

q
20. Tandem Drive Oil Level

l-Fast Idle Stop Screw 3-Throttle Lever


2-90~ Idle Stop Screw 4-Yoke

Fig. 135~Injection Pump /d/e Adjustment

A-Inspection Plates B-Oil Level Plug


Disconnect the yoke (4, Fig. 135) connecting the
Fig. 134-Tandem Drive Oil Level throttle cable to the pump throttle lever.

1 - Park the grader on a level surface. Run the engine. Turn the pump throttle lever (3, Fig.
135) until the fast idle stop screw contacts its stop.
2 - Check the oil level in each tandem. Engine speed must be 2450 to 2500 rpm. If not, turn
the fast idle stop screw (1, Fig. 135) to make the
3 - Remove the oil level plug (B). Oil must be level adjustment.
with the oil level plug hole.
Move the injection pump throttle lever to the left
4 - If not, remove one of the inspection plates and add (L.H.). If the engine rpm remains the same as the lever
oil specified on page i-V-2. is moved, the engine is running at slow idle. If the
engine is not running at a slow idle speed of 875 to 925
5 - Install the inspection plate and oil level plug. rpm, turn the slow idle stop screw (2, Fig. 135) to make
the adjustment.
Tandem drives oil level checked Yes No
Oil added - 9ts. (L) Connect the throttle cable yoke to the pump throttle
lever.

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JD670-A and JD672-A Motor Graders General Information I
TM- I 188 (Jul-79) Predelivery, Delivery, and After-Sale Services IV-39

Accelerator-Decelerator Pedal Adjustments Speed Control Lever Adjustment

Remove the right shield (bolted to the front of the Remove the right (R.H.) control console cover for
right [R.H.] footrest) for access to the accelerator-de- access to the speed control lever linkage.
celerator pedal linkage.

l-Speed Control Rod 4-Fast Idle Stop Screw


l-Accelerator Pedal 4-Control Rod a--Speed Control Lever 5-Throttle Stop
2-Decelerator Pedal 5-Stop Screw (Decelerator) 3-Friction Spring B-Yoke (Top Shown)
3-Yoke (Bottom Shown) B-Control Cable Yoke
Fig, 137~Speed Control Linkage
fig. 136-Pedal Linkage
Disconnect the speed control rod (1, Fig. 137) from
Turn the yokes (3 and 6, Fig. 136) on the control rod the speed control lever (2, Fig. 137). Turn the speed
(4, Fig. 136) to make the decelerator pedal parallel to control lever friction spring (3, Fig. 137) until 8 Ibs.
the footrest. Turn the decelerator stop screw (5, Fig. (35.5 N) (3.6 kg) pull at the end of the speed control
136) until it contacts the bottom of the decelerator lever is needed to move the lever.
pedal.
Connect the speed control rod to the speed control
When the decelerator pedal is in the parallel posi- lever.
tion, turn the control cable yoke (6, Fig. 136) until the
engine runs at slow idle speed. Turn the fast idle stop screw (4, Fig. 137) until the
engine runs at fast idle.
NOTE: Do not make the decelerator pedal adjust-
ment so that the engine can be shut off by pedal action. Move the throttle stop (5, Fig. 137) so that the speed
control lever contacts the rear surface of the stop at
Check to be sure that fast idle can be run by the slow idle. Move the stop in the other direction so that
accelerator pedal. Pedal adjustments for fast idle nor- the speed control lever must be moved to the right
mally are not needed because of the override area in (R.H.) to clear the throttle stop. This must move the
the linkage. speed control lever to the rear to the engine shut-off
position.

Inspect the linkage for correct operation.

Engine speeds checked Yes No

Litho in U.S.A.
General Information JD670-A and JD672-A Motor Graders
Predelivery, Delivery, and After-Sale Services TM- 1188 (Jul- 79)

22. Circle Drive Gearbox Oil Level

A-Oil Level Plug B-Filler Plug

fig. 138-Circle Drive Gearbox


Fig. 139-Scarifier (1 point)

1 - Park the grader on level ground. Lubrication required Yes No

2 - Lower the blade to the ground.

3 - Remove the oil level plug (A). Oil must be level


with the hole.

4 - When needed, remove filler plug (B) and add oil


specified on page l-V-2.

5 - Install the filler plug and the oil level plug.

Circle drive gearbox oil level checked Yes No


Oil added -9t.s. (L)

23. Grease Fittings


Check each lubrication point shown on the following
pages. Lubricate with several strokes of John Deere
Multi-Purpose Grease or equivalent, if necessary.

Fig. 140-Heavy Duty Scarifier (9 points)

Lubrication required Yes No

Litho in U.S.A.
JD670-A and JD672-A Motor Graders General information I
TM- 1188 (Jul- 79) Predelivery, Delivery, and After-Sale Services IV-41

Fig. 144-Lift Arm Locking Pin Housing (1 point)

Lubrication required Yes No

Fig. 14 1-Blade Tilt Cylinder (2 points)

Lubrication required Yes No

Fig. 142-Draft Ball Pivot (1 point) Fig. 145-Tandem Pivot - Right (R.H.) Side

Lubrication required Yes No Lubrication required Yes No

Fig. 143~Ripper (10 points) Fig. 146Steering Yoke and Cylinder (7 points)

Lubrication required Yes No Lubrication required Yes No

Litho in U.S.A.
I General Information JD670-A and JD672-A Motor Graders
IV-42 Predelivery, Delivery, and After-Sale Services TM- 1188 (Jul- 79)

fig. 147~Front Axle (2 points) Fig. 150-Front Axle and Wheel Lean Pivots - Left (L. H.) Side Shown
(17 points total)
Lubrication required Yes No
Lubrication required Yes No

Fig. 151-Frame Steering Cylinder - Left (L.H.) Side Shown


(2 points total)

Lubrication required Yes No

Fig. l48-Frame Pivots (2 points)

Lubrication reuuired Yes No

Fig. 152~Ball Joints and Trunnions (10 points)

Lubrication reouired Yes No


Fig. 149-Tie Rod Connector - Left (L.H.) Side Shown
(4 points total)

Lubrication required Yes No

Litho in U.S.A.
JD670-A and JD672-A Motor Graders General lnforma tion I
TM- 1188 (Mar-80) Predelivery, Delivery, and After-Sale Services IV-43

Tire Ply Type Inflation Pressure-psi (bar)


Size Rating

13.00-24 8 G-2 30 (2.07)


13.00-24 12 G-2 35 (2.41)
14.00-24 10 G-2 30 (2.07)
14.00-24 12 G-2 35 (2.41)
17.5 -25 12 L-2 25 (1.72)*

*For sloping and ditching, inflate to 45 psi (2.8 bar). q


NOTE: Be sure that tire inflation pressures are
equal for all six tires.
Fig. 153-Circle Supports (4 points total)
NOTE: When adding a new rear tire, inflate rear
Lubrication required Yes No tires so the rolling radius of all tires is the same.

For maintenance work on established highways in-


flation, pressure can be increased up to 50% if desired.

Tire pressure checked Yes No

25. Cylinder Ball and Socket Assemblies

Fig. 154-Lift Arm Pivots and Stub Shaft-


Right (R.H.) Side Shown (6 points total)

Lubrication required Yes No

24. Tires
Fig. 755-Cylinder Ball and Sockets
Check the air pressure in all tires with an accurate
gauge having 1 psi (0.07 bar) graduations. Check the play of the sockets shown. Lower the
blade to the ground. Move the cylinder wittiout load.
When more pressure is needed, use a pressure The ball must be free to move. When play is more than
regulating valve with a tire valve system locking air 0.030 in. (0.76 mm), change the adjustment as follows.
chuck.

When adding air to the tire, stand to the front or rear


of the grader.

Litho in U.S.A.
General Information JD670-A and JD672-A Motor Graders
Predelivery, Delivery, and After-Sale Services TM- 1188 (Mar-80)

Tighten the retainer cap screws to 445 lb (603 N.m)


(61 kg-m).

Moldboard retainer checked Yes No


Number of shims removed

27. Circle Adjustment


Check the clearance between the front and rear
circle supports and the circle.

Preliminary Procedure:
T606.52 1. Raise the blade.
2. Rotate the blade so it makes a 90” angle with the
A-Cap Screw C-Shim main frame.
B-Cap D-Cylinder
E-Ball
Vertical Clearance
Fig. 156-Ball and Socket Assembly

Remove the cap screws (A) and cap (B). Use shims
(C) as needed.

NOTE: The ball must turn freely in the socket.

Ball and socket assemblies checked Yes No

26. Moldboard Retainers


Check the amount of play between the moldboard
retainers and the moldboard. Rest the blade lightly on
the ground. Raise and lower the blade slightly. The T70432

blade must slide easily without being too loose. Fig. 158-Front Circle Support Clearance

T70436

A-Retainer B-Shims Fig. 159-Rear Circle Support Clearance

Fig. 157-Blade Side-Shift Guides Measure distance (A) between front supports (B)
and circle (C) and between rear supports (D) and wear
When adjustment is needed, remove the retainer pads (E). If the minimum distance at these four points
(A). Add or take away shims (B). is more than one shim (F) thickness (0.036 in. lo.9 mm1
or 0.06 in. L1.5 mm] shim), remove shims to make the
distance less than one shim. Remove the same
number of shims from each support.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders General lnforma tion I
TM- 1188 (Mar-80) Predelivery, Delivery, and After-Sale Services IV-45

To change front support clearance, loosen bolts (G). Front support contact surfaces must contact the
Remove shims. Tighten bolts to 607 lb-ft. (908 Nmm). circle ring uniformly. Gap at the end of either support
should not be more than 0.030 in. (0.76 mm). If the gap
To adjust rear circle clearance, remove washers is too large, move the front support(s).
from two end bolts (H) from each rear support. Install
nuts flush with end of bolts. Remove three center bolts
(H) from each support.

CAUTION: Be sure rear support is always


a supported.

Remove shims. Leave ten bolts loose to adjust


horizontal clearance.

Horizontal Clearance
T70435

Fig. 161 -Circle Gear Clearance

Measure the horizontal clearance between contact


surfaces of rear circle supports and circle ring. The
sum of the clearances should be 0.03 in. (0.70 mm) to
0.060 in. (1.52 mm) total when the clearances of the
right (R.H.) and left (L.H.) rear supports are added.

Check clearance (L) between tip of drive pinion (M)


and root of circle gear (N) at three blade positions:
Blade perpendicular to main frame and approximately
45 degrees to left (L.H.) and right (R.H.) of main frame.
Clearance should measure from 0.120 to 0.320 in. (3.0
to 8.1 mm).

Cover the top and bottom surfaces of circle gear and


inside of circle contact surface with a thin, uniform
coating of grease.
Fig. 160-Adjusting Horizontal Clearance
Turn the circle one revolution in each direction. The
To change clearance (I), loosen bolts (H) slightly. circle should turn freely. If the circle binds, check the
Loosen jack screws (J). Turn each jack screw on both horizontal and vertical clearance. Also find the sup-
supports the same number of turns until the rear sup- port(s) that is binding.
ports (D) are against the circle. Tighten the jack screws
until the front supports (B) are against the circle. If the horizontal clearance is too small, add enough
shims under the support causing the binding to let the
Turn each jack screw counterclockwise l/4 turn. circle turn freely.
Tighten the lock nuts.

Push rear supports against jack screws. Tighten


bolts (H) to 445 lb-ft (603 N.m).

Litho in U.S.A.
I General Information JD670-A and JD672-A Motor Graders
IV-46 Predelivery, Delivery, and After-Sale Services TM- 1188 (Mar-80)

NOTE: The circle must not be turned more than one Remove the cap screws (A) and ball retainer (B).
revolution unless other hydraulic controls are operated. Use shims (C) as needed. The ball must turn freely by
Do not turn the circle more than two turns in one hand pressure.
direction without stopping. Stop for 30 seconds before
turning the circle again in the same direction. The circle Pivot checked Yes No
can be turned in the opposite direction immediately. Number of shims removed

W
Circle adjustments required Yes No
29. Hydraulic System Cycle Times
If yes, explain Check the following cycle times at fast idle when the
oil is at normal operating temperature. Troubleshoot
the system if times are not close to those shown.

Seconds

Blade Lift Cylinders


Extend 12 in. (305 mm) 2.3- 3.3
Retract 12 in. (305 mm) 3.2- 4.2

Circle Side Shift


Extend 7.5 9.5
Retract 11.5-l 3.5
28. Draft Ball Pivot
Check the amount of play in the draft ball pivot. Blade Side Shift
Right and Left 8.0-l 1.O

Blade Pitch
Extend l.O- 2.0
Retract l.O- 2.0

Circle Rotate - 180”


Right and Left 23-32

Wheel Lean (Not adjustable)


Right and Left 2.8- 3.8

Fig. 162-Draft Ball and


Rear Steer (Lock to Lock)
Pivot
Right and Left 4.5- 7.5
Lower the blade to the ground. Move the grader
forward and back a little. When play in the pivot joint is NOTE: If the grader has a ripper, the control valve is
more than l-1/2 times the shim thickness, change the on the transfer drive gearbox.
adjustment as follows.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders General Information
TM- 1188 (Jul- 79) Predelivery, Delivery, and After-Sale Services

A-Ripper C-Adjusting Screw for Raising


B-Rear Bumper Ripper
D-Adjusting Screw for
Lowering Ripper

Fig. 763~Ripper Valve

Two poppet valves control the speed of ripper hy-


draulic functions.
l--Test Port P-Pressure Regulating
Valve Shims
Turn the adjusting screw clockwise to make the
function slower. Fig. 164-Pump Pressure Test foinf and
Pressure Regulating Valve Shims
Turn screw counterclockwise to make the function
faster. If necessary, change pressure by adding or remov-
ing shims (2, Fig. 164) under the spring of the pressure
IMPORTANT: Do not turn the screw out beyond regulating valve.
flush with the end of the special plug.
Push down the clutch pedal. The pressure must go
Hydraulic cycle times checked Yes No to zero.

30. Transmission Clutch Pressure


Slowly release the clutch pedal. The pressure must
Run the engine at fast idle until the transmission oil rise at a smooth rate until the pedal is approximately 1
temperature is approximately 150°F (65°C). inch (25 mm) from the top. At this point the pressure
should be about 80 psi (6 bar). Any further movement
Stop the engine. Remove the transmission pressure of the pedal must cause the pressure to go up to
gauge elbow from the pressure port in the clutch pedal approximately pump pressure.
valve. Install a 0 to 300 psi (0 to 21 bar) gauge in the
pressure port. If the pressure does not drop to zero when the clutch
pedal is down (see note below), the clutch pedal link-
Start the engine. Measure the pressure at an engine ages are out of adjustment or bent, or there is too much
speed of 1900 rpm. Pressure must be 165 to 185 psi leakage past the valve. This can also take place if the
(11.5 to 13 bar). pressure does not go up smoothly as the pedal is
released. The clutch pedal valve controls oil flow to Cl
and C2. Too much leakage of the spool can cause low
clutch engagement pressure. Clutches and brakes can
slip as a result.

NOTE: On a 0 fo 300 psi (0 to 21 bar) gauge the


pressure may appear to go to zero, but you may still
have 8 to 70 psi (0.6 to 0.7 bar) on the clutches.

Litho in U.S.A.
I General lnforma tion JD670-A and JD672-A Motor Graders
IV-48 Predelivery, Delivery, and After-Sale Services TM- 1188 (Jul- 79)

To check for this remaining pressure, use a 0 to 30 Remove the cap (4) from the tee (3) at the junction of
psi (0 to 2 bar) gauge in place of the larger gauge. the differential lock tube (5) and the hydraulic hose (2)
in the main frame pivot area.
IMPORTANT: To test with the 30 psi (2 bar)
gauge, the following precaution MUST BE taken. Connect a 0 to 1000 psi (0 to 69 bar) pressure gauge
to the tee.
The clutch pedal must be fully down when the
engine is started. The pedal must be held down Start and run the unit until transmission temperature

II during the test.

If you do not hold the clutch pedal down, you will


is 150°F (65°C). Run the engine at 2375 rpm. Engage
the differential lock valve. Check the reading on the
pressure gauge.
destroy the pressure gauge.
If the reading is not 635 2 25 psi (44 L- 1.7 bar) add
Transmission clutch pressure or remove shims.
checked Yes No
Describe any malfunction:
NOTE: One shim will change the pressure setting
by approximately 31 psi (2.1 bar).

Differential lock valve


checked Yes No
Number of shims added/
removed
31. Differential Lock Valve
Pressure Test 32. Cap. Screw Torque

Stop the engine. Release hydraulic pressure by Check the following cap screw torque values:
applying the brakes and turning the steering wheel
when the engine is off.

DIFFERENTIAL

Fig. 166-Tandem Housing


T4813111’

l-Differential Lock Function Tube Tandem housing-to-pivot housing cap screws.


P-Hydraulic Hose Tighten to 300 ft-lb (407 Nm) (41 kg-m). Only the
3-Swivel Nut Run Tee bottom 5 cap screws on each side need checking. If
4-Cap they are loose, check all cap screws.
5-Differential Lock Tube
Tandem housing-to-pivot
fig. 165-Differential Lock Valve Pressure
housing cap screws
Check Port
tightened Yes No

Litho in U.S.A.
JD670-A and JD672-A Motor Graders General Information
TM- 1188 (Mar-80) Predelivery, Delivery, and After-Sale Services

Fig. 167-Lower Articulation Pivot

Lower articulation pivot pin bolts (2 total). Tighten to


170 lb-ft (230 N.m).

Lower articulation pivot


pin bolts tightened Yes No

A-Engine Frame to Final Drive Housing Cap Screws


B-Engine Frame to Differential Housing Cap Screws

Fig. 169-Engine Frame Cap Screws

Engine-frame-to-differential-housing
cap screws tightened Yes No

Fig. 168-Front Axle Pin Retainer

Front axle pin retainer cap screws (4 total). Tighten


to 170 lb-ft (230 N.m) (23 kg-m).

Pin retainer cap screws tightened Yes No

Engine-frame-to-final-drive-housing cap screws.


(See Fig. 169.) Tighten to 670 lb-ft (908 Nsm) (93
kg-m) (4 bolts total).

Engine frame to final drive housing Fig. 170-Front Wheel Retaining Cap Screws -
cap screws tightened Yes No JD672-A only

Engine-frame-to-differential-housing cap screws. Tighten to 130 lb-ft (177 N.m) (18 kg-m).
(See Fig. 169). Tighten to 445 lb-ft (603 N-m) (62
kg-m) (6 bolts). Front wheel retaining cap screws
tightened Yes No

NOTE: If a torque multiplier tool is available, use it


to tighten these cap screws.

Litho in U.S.A.
General Information JD670-A and JD672-A Motor Graders
Predeliverv. Delivery, and After-Sale Services TM- 1188 (Mar-80)

Cab (or canopy)-to-front-cab-support cap screws:


Tighten to 300 lb-ft (407 Nem) (41 kg-m).

Cab (or canopy)-to-front


cab support cap screws Yes No

Front circle support nuts: Tighten to 670 lb-ft (908


Nam) (98 kg-m).

Front circle support nuts tightened Yes No

Lower blade retainer cap screws: Tighten to 300 lb-ft


(407 Nem) (41 kg-m).

Fig. 171 -Wheel RetainingCap Screws Lower blade retainer cap


screws tightened Yes No
Tighten all wheel retaining cap screws on the
JD670-A and rear wheel cap screws on the JD672-A to Upper blade retainer cap screws: Tighten to 445 lb-ft
300 lb-ft (407 Nam) (42 kg-m). (603 Nam) (61 kg-m).

NOTE: Tighten after every wheel change and check Upper blade retainer cap
screws tightened Yes No
after 50 hours.
Cab (or canopy)-to-main frame cap screws: Tighten
Wheel cap screws tightened Yes No
to 300 lb-ft (407 N.m) (41 kg-m). Stake nuts to cap
screws.
Rear circle support nuts: Tighten to 445 lb-ft (603
Nem) (61 kg-m). Cab (or canopy)-to-main frame
cap screws tightened Yes No
Rear circle support nuts tightened Yes No

Litho in U.S.A.
JD670-A and JD672-A Motor Graders General information I
TM- 1188 (Mar-go) Predelivery, Delivery, and After-Sale Services IV-51

33. Accessible Hardware Torque Values


Check all accessible bolts and nuts for correct tight- 3-Dash Head: tempered steel high-strength bolts
ness. If hardware is loose, tighten it to the correct and cap screws.
torque.
6-Dash Head: tempered steel extra high-strength
The table below gives correct torque values for bolts and cap screws.
various bolts and cap screws. Tighten all hardware to

q
standard torque unless a different torque is specified. Machine bolts and cap screws 7/8-inch (22 mm)
and larger are sometimes formed hot rather than cold,
Most hardware used is high-strength (note dashes which accounts for lower torque.
on hex. heads). The types of bolts and cap screws are
identified by head markings as follows: A// accessible hardware torqued Yes No

Plain Head: regular machine bolts and cap screws.

RECOMMENDED TORQUE - COARSE AND FINE THREADS

D F

0 'L
0\\\5,

0 0 0
B

-: 7\-
\/

BOLT PLAIN THREE SIX


IIAMETER HEAD DASHES DASHES

LB-FT Nm Kg-m LB-FT Nm Kg-m LB-FT Nm Kg-m

l/4 NOT USED NOT USED NOT USED 10 14 1 14 19 2

5116 NOT USED NOT USED NOT USED 20 27 3 30 41 .4

3/a NOT USED NOT USED NOT USED 35 47 5 50 68 7

7116 35 47 5 55 75 8 a0 108 11

112 55 75 8 a5 115 12 120 163 17

906 75 102 10 130 176 18 175 237 24

5/a 105 142 15 170 230 24 240 325 33

314 185 251 26 300 407 42 425 576 59

718 160 217 22 445 603 62 685 929 95

1 250 339 35 670 908 93 1030 1396 142

l-l/a 330 447 46 910 1234 126 1460 1979 202

l-1/4 480 651 66 1250 1695 173 2060 2793 285


1X.77"

Fig. 1?4-Torque Chart

Litho in U.S.A.
I General Information JD670-A and JD672-A Motor Graders
IV-52 Predelivery, Delivery, and After-Sale Services TM- 1188 (Mar-80)

34. Toe-In
Check the toe-in of the front wheels. Park the grader
on a level surface.

Use the blade or scarifier hydraulics to lift the front


wheels off the ground. Block the front axle.

Fig. 177-Measuring Toe-In

Measure the distance (E) from center to center of tie


rod pins. Measure the distance (F) from center to
center of tie rod pins. The measurement between the
two dimensions must be within 0.10 in. (2.5 mm).
Fig. 775-Checking JD670-A Toe-in Measure the distance (G) and (H) from the floor to
the center of the axle. Record measurement of each
JD670-A - Turn wheels to align the steering cylinder side.
pin (A) with the oscillation pin (B).
Use a piece of chalk and draw a horizontal line (I) on
the backside of each tire at the “G” and “H” height.
Draw a vertical line (J) through the horizontal line at the
approximate center of each tire.

Measure and record the distance (K) between the


tire center lines at the “G” and “H” axle height.

Fig. 176-Checking JD672-A Toe-In

JD672-A - Draw a line through the center of plate (C)


and through the center of bell crank (D).
Turn the wheels to align these two lines. Fig. 178-Measuring Toe-In

Now rotate the tires toward the front of the unit so


the horizontal lines (I) on the tires are again at the “G”
and “H” height.

Measure and record the distance (L) between the


tire center lines at the “G” and “H” axle height.

Distance “L” must be 0.0 to 0.50 in. (0.0 to 13 mm)


less than distance “K”.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders General Information I
TM- 1188 (Mar-go) Predelivery, Delivery, and After-Sale Services IV-53

If adjustment is needed, follow the procedure below. 35. Fluid Leakage


Check the following systems for leakage. Check for
broken hoses, broken lines, and loose or worn con-
nections.

A. Cooling system checked Yes No


6. Hydraulic system checked Yes No

q
C. Transmission system checked Yes No
D. Fuel system checked Yes No

Fig. 179-Adjusting Toe-In

Loosen tie rod nuts (M). Turn each tie rod the same
number of turns until toe-in is correct. Tighten the nuts
to 330 lb-ft (447 N.m) (46 kg-m).

Litho in U.S.A.
General lnforma tion JD670-A and JD672-A Motor Graders
Predelivery, Delivery, and After-Sale Services TM- 1188 (Mar-80)

MEMORANDA

Litho in U.S.A.
JD670-A and JD672-A Motor Graders General Information I
TM- 1188 (Jul- 79) Lubrication V-l

Group V
LUBRICATION
GENERAL INFORMATION
Below are copies of the periodic service charts which are on the motor grader right (R.H.) engine side shield.

q
Read the current JD670-A and JD672-A Motor Grader Operator’s Manual for more information on service.

Use the operator’s manual and periodic service charts when working on the motor grader. Tell your customer to
thoroughly read the operator’s manual before attempting to service or operate the motor grader.

Fig. l-Periodic Service Chart

Fig. BHydraulic Front Wheel Drive Periodic Service Chart

Litho in U.S.A.
I General Information JD670-A and JD672-A Motor Graders
V-2 Lubrication TM- 1188 (Jul- 79)

LUBRICANTS TRANSMISSION-HYDRAULIC OILS AND


HYDRAULIC FRONT WHEEL DRIVE
Use only lubricants specified on this page. Apply
WHEEL MOTORS
them at intervals and according to instructions shown
on periodic service chart. Above -15°F (-26°C) use John Deere HY-GARD@
Transmission and Hydraulic Oil (J20A) or an equiva-
ENGINE LUBRICATING OILS lent.

Use HY-GARD Winter Grade Oil (J2OB) when tem-


perature is below - 15°F (-26°C).

Continued use of HY-GARD Winter Grade Oil


(J20B) at temperatures above 32°F (0°C) may result in
X3377N
increased transmission and hydraulic component wear
and shorter life.

Use John Deere TORQ-GARD SUPREME@ Engine TANDEM DRIVES


Oil in the engine crankcase.
Use John Deere HY-GARD Transmission and Hy-
Oils other than TORQ-GARD SUPREME must con- draulic Oil (J20A) or an equivalent.
form to one of the following specifications:
CIRCLE DRIVE GEARBOX
SINGLE VISCOSITY OILS
Use SAE EP90 oil.

API Service CD/SD


GREASES
MIL-L-2104C
Series 3 Use John Deere Multi-Purpose Grease or equiva-
lent for all grease fittings and front wheel bearings.
MULTI-VISCOSITY OILS
STORING LUBRICANTS
API Service CC/SD
MIL-L-46152 Use clean containers to handle all lubricants. Store
them in an area protected from dust, moisture, and
Depending on average temperature, use oil as fol- other contamination.
lows.

Other Oils
John Deere
Air TORQ-GARD Single Vis- Multi-Vis-
Temperature SUPREME Oil cosity Oil cosity Oil

Above SAE 30 SAE 30 Not recom-


32°F (0°C) mended

-10°F to SAE low-20 SAE 1OW SAE low-30


32°F (-23°C to 0%)

Below SAE 5W-20 SAE 5W SAE 5W-20


-10°F (-23°C)

When SAE 5W-20 or SAE 5W oils are used, ma-


chines can use more oil. Check oil level regularly.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Wheels 1
TM- 1188 (J&78) Powered Wheels and Fastenings 011 o-1

Section 01
WHEELS
CONTENTS OF THIS SECTION

Page Page
GROUP 0110 - POWERED WHEELS AND GROUP 0120 - NON-POWERED WHEELS
FASTENINGS AND FASTENINGS

q
General Information ................... 011 o-3 General Information .. . ... . 0120-l
Removal ............................. 011 o-3 Removal . . . . . . . . . . .._................ 0120-l
Repair ............................... 011 o-3 Repair . . . . .._._........_......._.... 0120-l
Installation. ........................... 011 o-4 Installation . .. . ... 0120-2
Checking Tire Pressure ................ 011 o-4 Checking Tire Pressure . .. .. 0120-2

GROUP 0199 - SPECIFICATIONS AND


SPECIAL TOOLS
Specifications and Torque Values . 0199-I

Litho in U.S.A.
1 Wheels JD670-A and JD672-A Motor Graders
0110-2 Powered Wheels and Fastenings TM- 1188 (Jul-78)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Wheels 1
TM- 7 188 (Jul- 78) Powered Wheels and Fastenings 011 o-3

Group 0110
POWERED WHEELS AND FASTENINGS
GENERAL INFORMATION REPAIR

A
The four tandem wheels are identical to non-pow-
CAUTION: Failure to follow proper proce-
ered front wheels. Powered front wheels are not in-
dures when mounting a tire on a wheel or
terchangeable with the tandem or non-powered
rim, can produce an explosion which may result in
wheels due to the larger bolt pattern.
serious bodily injury. DO NOT attempt to mount a
tire unless you have the proper equipment and
REMOVAL
experience to perform the job safely. Have it done
Shut machine off and lower equipment to ground. by your John Deere dealer or a qualified tire repair
Turn steering wheel back and forth to relieve pressure service.
in the steering system. Pump brake pedal to discharge
the brake accumulator. Operate hydraulic controls to Detailed tire mounting instructions, including
relieve pressure in the hydraulic system. las necessary safety precautions, are contained
in John Deere Fundamentals of Service
Loosen cap screws (7, Fig. 1) before jacking wheel cl Q (FOS) Manual 55, TIRES AND TRACKS,
off ground. which is available from your John Deere dealer.

Place a hydraulic floor jack of at least &ton (44 500 NOTE: Refer to John Deere Off-The-Road Tire
N) (4 500 kg) capacity under tandem housing or front Maintenance Manual for dismounting and mounting
axle and raise wheel off ground. tires.

Securely block tandem housing or front axle. Refer to Fig. 1 during disassembly and assembly.

Position a wheel hook, forklift or platform jack of at


least l-ton (8 900 N) (900 kg) capacity to tire. Remove
cap screws (7) and washers (6). Pull wheel assembly
away from wheel axle.

T58032N
l-Valve Stem 3-Side Ring 5-Lock Ring T-Cap Screw (14 used)
?-Wheel 4-O-Ring GWasher (14 used) (Rear) (16 used) (Front)
(Rear Wheels Only)

Fig. I-Wheel Assembly (R.H. Wheel Shown)

Litho in U.S.A.
1 Wheels JD670-A and JD672-A Motor Graders
011 o-4 Powered Wheels and Fastenings TM- 1188 (Jul- 78)

Inspect all parts for worn or bent condition. Replace CHECKING TIRE PRESSURE
parts as needed.
Check air pressure in all tires with an accurate
gauge having 1 psi (0.07 bar) (0.07 kg/cm2) gradua-
Make sure all parts are clean and free from rust or
tions.
grease before assembly.

When inflation is required, use a pressure regulating


Cap screws (7, Fig. 1) and tapped holes in wheel
valve with a tire valve stem locking air chuck.
axles must be clean and dry to achieve correct wheel
torque. Use solvent and air to remove oil.
Stand to front or rear of grader when filling tire.

To prevent slipping of the wheel under load, the Tire Inflation Pressure
Ply
inside and outside of wheel (2) and washers (6) must Size Rating
be free of rust, oil, grease, dirt or other foreign material
before installation. 13.00-24 8 30 psi (2.07 bar) (2.11 kg/cm2)
13.00-24 12 35 psi (2.41 bar) (2.46 kg/cmz)
INSTALLATION 14.00-24 10 30 psi (2.07 bar) (2.11 kg/cm2)
14.00-24 12 35 psi (2.41 bar) (2.46 kg/cm2)
Position wheel to wheel axle and securely tighten
17.5 -25 12 “25 psi (1.72 bar) (1.76 kg/cm2)
cap screws (7, Fig. 1).
*For sloping and ditching, inflate to 40 psi (2.8 bar)
Lower unit to ground.
(2.81 kg/c&).

Tighten tandem wheel cap screws to 300 lb-ft (407


NOTE: Be sure that tire inflation pressures are
Nm) (41 kg-m).
equal for all six tires.

Tighten powered front wheel cap screws to 130 lb-ft


NOTE: When adding a new powered wheel tire
(175 Nm) (18 kg-m).
inflate tires so the rolling radius of all tires is the same.

IMPORTANT: ff a power wrench is used, be sure


For maintenance work on established highways in-
that the cap screws are properly engaged to pre-
flation pressure can be increased up to 50% if desired.
vent stripping. Run the wrench slowly to prevent
galling of the threads.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Wheels 1
TM- 1188 (J&78) Non-Powered Wheels and Fastenings 0120-l

Group 0120
NON-POWERED WHEELS AND FASTENINGS
GENERAL INFORMATION REPAIR

A
Non-powered front wheels are identical to the four
CAUTION: Failure to follow proper proce-
tandem wheels.
dures when mounting a tire on a wheel or
rim, can produce an explosion which may result in
REMOVAL
serious bodily injury. DO NOT attempt to mount a
Shut machine off and lower equipment to ground. tire unless you have the proper equipment and
Turn steering wheel back and forth to relieve pressure experience to perform the job safely. Have it done 0
in the steering system. Pump brake pedal to discharge by your John Deere dealer or a qualified tire repair
the brake accumulator. Operate hydraulic controls to service.
relieve pressure in the hydraulic system.
Detailed tire mounting instructions, including
Loosen cap screws (7, Fig. 1) before jacking wheel ms necessary safety precautions, are contained
off ground. in John Deere Fundamentals of Service
cl Q (FOS) Manual 55, TIRES AND TRACKS,
Place a hydraulic floor jack of at least 5-ton (44 500 which is available from your John Deere dealer.
N) (4 500 kg) capacity under front axle and raise wheel
off ground. NOTE: Refer to John Deere Off-The-Road Tire
Maintenance Manual for dismounting and mounting
Securely block front axle. tires.

Position a wheel hook, forklift or platform jack of at Refer to Fig. 1 during disassembly and assembly.
least 1-ton (8 900 N) (900 kg) capacity to tire. Remove
cap screws (7) and washers (6). Pull wheel assembly
away from wheel hub.

T58032N

l-Valve Stem 3-Side Ring 5-Lock Ring 7-Cap Screw (14 used)
P-Wheel 4-O-Ring GWasher (14 used)

7ig. l-Front Wheel Assembly (R. H. Wheel Shown)

Litho in U.S.A.
1 Wheels JD670-A and JD672-A Motor Graders
0120-2 Non-Powered Wheels and Fastenings TM- 1188 (Jul- 78)

Inspect all parts for worn or bent condition. Replace Checking Tire Pressure
parts as needed.
Check air pressure in all tires with an accurate
gauge having 1 psi (0.07 bar) (0.07 kg/cm*) gradua-
Make sure all parts are clean and free from rust or
tions.
grease before assembly.

When inflation is required, use a pressure regulating


Cap screws (7, Fig. 1) and tapped holes in wheel
valve with a tire valve stem locking air chuck.
hubs must be clean and dry to achieve correct wheel
torque. Use solvent and air to remove oil.
Stand to front or rear of grader when filling tire.

To prevent slipping of the wheel under load, the Tire Inflation Pressure
MY Type
inside and outside of wheel (2) and washers (6) must Size Rating
u be free of rust, oil, grease, dirt or other foreign material
before installation 13.00-24 8 30 psi (2.07 bar)(2.11 kg/cmz)
13.00-24 12 G-2 35 psi (2.41 bar)(2.46 kg/cm*)
14.00-24 10 G-2 30 psi (2.07 bar) (2.11kg/cm*)
INSTALLATION 14.00-24 12 G-2 35 psi (2.41 bar) (2.46kg/cm*)
17.5 -25 12 L-2 *25 psi (1.72 bar) (1.76kg/cm*)
Position wheel to wheel hub and securely tighten
cap screws (7, Fig. 1).
*For sloping and ditching, inflate to 40 psi (2.8 bar)
(2.8 1 kg/cm2).
bower unit to ground.
NOTE: Be sure that tire inflation pressures are
Tighten cap screws to 300 lb-ft (407 Nm) (41 kg-m).
equal for all six tires.
IMPORTANT: if a power wrench is used, be sure
NOTE: When adding a new powered wheel tire,
that the cap screws are properly engaged to pre-
inflate tires so the rolling radius of all tires is the same.
vent stripping. Run the wrench slowly to prevent
galling of the threads.
For maintenance work on established highways in-
flation pressure can be increased up to 50% if desired.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Wheels 1
TM- 1188 (Jul-78) Specifications and Special Tools 0199-l

Group 0199
SPECIFICATIONS AND SPECIAL TOOLS
POWERED WHEELS AND FASTENINGS
SPECIFICATIONS AND TORQUE VALUES

1 - Powered tandem wheel cap screws . 300 lb-ft


;407 Nm)
(41 kg-m)

Fig. I-Wheel Retaining Cap Screw

l- Powered front wheel cap screws.. . . 130 lb-ft


(175 Nm)
(18 kg-m)

Fig. PFront Wheel Retaining Cap Screw

Litho in U.S.A.
1 Wheels JD670-A and JD672-A Motor Graders
0199-2 Specifications and Special Tools TM- 1188 (J&78)

NON-POWERED WHEELS AND FASTENINGS


SPECIFICATIONS A,ND TO RQUE VALUES
1 - Wheel+ l-wheel hub cap screws .. 300 lb-ft
'(407 Nm)
(41 kg-m)

fig. 3-Wheel Retaining Cap Screw

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Dee-87) Drive Axle Housina and SuDDort 0201-l

Section 2
AXLES AND SUSPENSION SYSTEM
CONTENTS OF THIS SECTION

Page Page
GROUP 0201 - DRIVE AXLE HOUSING GROUP 0210 - DIFFERENTIAL OR BEVEL
AND SUPPORT DRIVE-Continued
General Information ................... 0201-3 Adjustments
Removal Cone Point Adjustment ............ 0210-I 1
Wheel Axle Housing ................. 0201-4 Pinion Shaft Adjustment ........... 021 O-l 2
Tandem Housing ................... 0201-5 Differential Preload ............... 021 O-l 3
Tandem Pivot Housing ............... 0201-6 Differential Backlash .............. 021 O-l 3
Final Drive Housing ................. 0201-6 Tooth Bearing Pattern ............. 0210-13
Repair Differential Lock Valve
Pivot Housing ..................... 0201-7 General Information .............. 021 O-14
Wheel Axle and Tandem Housing ...... 0201-8 Removal ....................... 021 O-l 4
Installation Repair
Pivot Housing ..................... 0201-9 Disassembly .................. 021 O-l 5
Wheel Axle and Tandem Housing ..... 0201-11 Inspection .................... 021 O-l 6
Final Drive Housing Assembly .................... 021 O-l 6
Removal ........................ 0201-l 3 Installation ..................... 021 O-l 6
Repair .......................... 0201-I 4
Installation ....................... 0201-I 5 GROUP 0230 - NON-POWERED WHEEL AXLES
Powered Axle Assembly General Information ................. 0230-I
General Information ................ 0201-16 Removal ......................... 0230-I
Removal ........................ 0201-I 6 Repair
Repair Disassembly ..................... 0230-2
Disassembly .................... 0201-I 7 Assembly ....................... 0230-4
Assembly ...................... 0201-18 Installation ........................ 0230-5
Installation ....................... 0201-I 8
GROUP 0250 - AXLE SHAFTS, BEARINGS AND
GROUP 0210 - DIFFERENTIAL OR BEVEL REDUCTION GEARS
DRIVE General Information ................. 0250-l
General Information ................. 021 O-l Drive Chain
Differential Assembly Removal ........................ 0250-2
Removal ........................ 021 O-l Repair ......................... 0250-3
Repair Installation ...................... 0250-3
Disassembly ................... 021 O-3 Wheel Axle Assemblies
Cleaning, Handling and Removal ........................ 0250-4
Inspecting ................... 021 O-4 Repair
Assembly ..................... 021 O-6 Disassembly ................... 0250-4
Installation ...................... 021 O-7 Assembly ..................... 0250-5
Differential Pinion Shaft Installation ...................... 0250-6
Removal ........................ 021 O-8 Final Drive Assembly
Repair Removal ........................ 0250-7
Disassembly ................... 021 O-8 Repair
Assembly ..................... 021 O-9 Disassembly ................... 0250-7
Installation ..................... 021 O-l 0 Assembly ..................... 0250-8
Installation ...................... 0250-9
Cleaning, Handling and Inspecting .... 0250-9

Contents continued on next page

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Gra\ders
0201-2 Drive Axle Housing and Support TM- 1188 (Dee-87)

CONTENTS OF THIS SECTION-Continued

Page Page

GROUP 0250 - AXLE SHAFTS, BEARINGS GROUP 0260 - HYDRAULIC SYSTEM


AND REDUCTION GEARS- Wheel Motor and Oil Manifold
Continued Removal ........................ 0260-l
(JD672-A) Front Wheel Drive Assembly Repair
General Information .............. 0250-10 Disassembly ................... 0260-2
Removal ....................... 0250-l 1 Inspection ..................... 0260-7
Repair Assembly ..................... 0260-l 3
First Planet Pinion Carrier Assembly Motor Shaft End Plan Adjustment . . 0260-17
Disassembly ................ 0250-14 Installation ..................... 0260-l 8
Assembly ................... 0250-15 Motor Housing
Second Planet Pinion and Housing Removal ....................... 0260-l 9
Assembly Repair ........................ 0260-20
Disassembly (Early Units) ....... 0250-l 6 Installation ..................... 0260-21
Assembly (Early Units) ......... 0250-16 Front Wheel Case Relief Valve
Disassembly (Later Units) ....... 0250-l 8 Repair ........................ 0260-22
Assembly (Later Units) ......... 0250-l 8
Brake Backing Plate Assembly GROUP 0299 - SPECIFICATIONS AND
Disassembly ................ 0250-20 SPECIAL TOOLS
Assembly ................... 0250-21 Specifications and Torque Values
Planet Brake Piston Housing Drive Axle Housing and Support ...... 0299-l
Disassembly ................ 0250-22 Differential or Bevel Drive ........... 0299-3
Assembly ................... 0250-22 Non-Powered Wheel Axles .......... 0299-8
Wheel Hub Assembly Axle Shafts, Bearings and Reduction
Disassembly ................ 0250-23 Gears ........................ 0299-9
Assembly ................... 0250-23 Hydraulic System ................ 0299-15
Installation and Adjustment ....... 0250-24 Special Tools
Wheel Bearing Adjustment ...... 0250-24 Axle Shafts, Bearings and Reduction
Gears ....................... 0299-l 8

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Jul-78) Drive Axle Housing and Support 0201-3

Group 0201
DRIVE AXLE HOUSING AND SUPPORT
GENERAL INFORMATION

PllOiON

l-Tandem Pivot Housing 3-Tandem Housing 5-Rear Wheel Axle Housing


2-Final Drive Housing 4-Front Wheel Axle Housing

Fig. l-Right Hand Tandem Assembly

The final drive system is composed of a final drive Components may be removed as follows:
housing, tandem pivot housing, tandem housing and
two wheel axle housings. 1. Front wheel axle housing (4, Fig. 1) or rear wheel
axle housing (5) separately.
The final drive housing contains an axle mounted on
two tapered roller bearings, and the planetary reduc- 2. Tandem housing (3) after wheel axle housings
tion gear system. The tandem pivot housing allows the are removed.
rear wheels to remain on the ground when traveling
over uneven terrain. 3. Tandem housing and wheel axle housings as a
unit.
The tandem housing contains the two drive chains
and provides a mounting surface for the wheel axle 4. Tandem pivot housing (1) after tandem housing
housings. The wheel axle housings contain the wheel and wheel axle housings are removed.
axle which is mounted on two tapered roller bearings.
5. Final drive housing (2) after tandem pivot hous-
Components of the final drive system may be ser- ing, tandem housing, and wheel axle housings are
viced individually, in component grouping, or may be removed.
removed as a unit to service the service brake active
elements or the differential assembly. 6. Pivot housing and final drive housing after tan-
dem housing and wheel axle housings are removed.

7. Wheel axle housings, tandem housing, pivot


housing and final drive housing as a unit.

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0201-4 Drive Axle Housing and Support TM- 1188 (J&78)

WHEEL AXLE HOUSINGS, TANDEM HOUSING,


PIVOT HOUSING AND FINAL DRIVE HOUSING
REMOVAL Raise and block the rear of the motor grader so the
tandem drive wheels on the side you are servicing are
Wheel Axle Housing clear of the ground.

NOTE: It is not always necessary for the tandem


Refer to Group 0110 and remove wheels from hubs.
drive chains to be disconnected when servicing com-
ponents of the final drive sysfem.
Remove plug and drain oil from the tandem housing.
NOTE: Approximately 5 gal. (19 L) of oil will be
The tandem drive chains are not required to be
drained.
broken when:
Attach a 3/4 inch eyebolt (1, Fig. 2) to the top of the
1. Removing wheel axle housing assemblies (3,
wheel axle housing (3) in tapped hole provided on
Fig. 2) from tandem housing (4).
outer flange. Remove cap screws securing wheel axle
housing to tandem housing (4) and with the aid of a
2. Removing tandem housing (with or without wheel
hoist remove wheel axle housing far enough to permit it
axle housings) from pivot housing, providing the
to move toward the center of the tandem drive housing.
double sprocket is retained with the tandem
housing by sliding it from the splined tandem
drive shaft.

To remove the double sprocket from the tandem


drive shaft, remove the round inspection plate with step
from the outboard center of the tandem housing. Re-
move the two cap screws securing the retaining plate
and double sprocket to the tandem drive shaft. The
double sprocket and drive chains may now be removed
with the tandem housing.

The tandem drive chains must be disconnected


when:

1. Replacing the double sprocket.

2. Removing the tandem housing with the double


sprocket remaining on the tandem drive shaft.

To disconnect the tandem drive chains, refer to page * $. $ L- ,; < ,.: y

_CI Y”“.%.

0250-2.
l-3/4” Eyebolt 3-Wheel Axle Housing
Disconnect battery ground strap. %-Drive Chain and “Tandem Housing
Sprocket

Fig. P-Removing Wheel Ax/e Housings

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (J&78) Drive Axle Housing and Support 02014

Reach into the tandem housing through top assem-


bly hole and lift the drive chain off the wheel axle
sprocket (2, Fig. 3).

Remove wheel axle housing (1) from tandem hous-


ing. NOTE: identify the front wheel ax/e housing from
the rear wheel axle housing after they’re removed from
tandem housing. This is important when reinstalling.

Refer to Group 0250 for disassembly of wheel axle


housings.

Tandem Housing

A CAUTION: Be sure that motor grader is


blocked securely under engine frame and
transmission.

Remove double sprocket or disconnect drive chains


as outlined earlier in this Group.

Attach chains to the tandem housing (3, Fig. 4) and


l-Wheel Axle Housing P-Wheel Axle Sprocket
an overhead hoist. Remove the cap screws (1) secur-
ing the tandem housing to the tandem pivot housing F&. 3-Removing Wheel Ax/e Housing
(2). Remove the tandem housing.

l-Cap Screw (21 used) 2-Tandem Pivot Housing 3-Tandem Housing

Fig. 4-Removing Tandem Housing With Wheel Axle Housings Removed

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0201-6 Drive Axle Housing and Support TM- 1188 (J&78)

Tandem Pivot Housing

NOTE: If the double sprocket is attached to the


tandem drive shaft, it must be removed before the
tandem pivot housing can be removed.

Remove the two cap screws (5, Fig. 5) securing the


sprocket retainer (6) and double sprocket (4) to the
tandem drive shaft. Remove double sprocket.

Remove pivot retainer cap screws (2). Remove pivot


retainer (3) and shim pack.

Remove thrust washers and pivot housing (1).

R Final Drive Housing

A CAUTION: Be sure that motor grader is


blocked securely under engine frame and
transmission.

Drain oil from transmission case. I-Tandem Pivot Housing 6-Sprocket Retainer
2-Gap Screw (12 used) 7-Frame Steer Cylinder
3-Pivot Retainer 8-Final Drive Housing
Remove frame steer cylinder (7, Fig. 5) from final
4-Double Sprocket g-Cap Screw/Nut (2 used)
drive housing. 5-Gap Screw (2 used) lO-Cap Screw (18 used)

Remove cap screws and hex nuts (9) securing final Fig. 5-Tandem Pivof Housing and
drive housing (8) to engine frame. NOTE: Drive hollow Final Drive Housing

dowel, in rear mounting hole, up through engine frame.

Remove cap screws (10) securing drive housing to


transmission case.

Remove final drive housing.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Dee-87) Drive Axle Housing and Support 0201-7

REPAIR

Pivot Housing

16 6

T60438N

l-Gasket 7-O-Ring 12-Shim (use as required)


2-Hollow Dowel (2 used) 8-Special Cap Screw (2 used) 13-Pivot Retainer
3-Dowel Pin (3 used) O-Grease Fitting 14-Special Cap Screw
4-Final Drive Housing lo--Tandem Pivot Housing (12 used)
5-Cap Screw (16 used) 1 l-Tandem Pivot Bushing 15-O-Ring
I-Thrust Washer (6 used) 16--Pipe Plug

Fig. 6-Pivot Housing Assembly

All parts must be cleaned to permit effective Inspect all parts for excessive wear, cracks or
inspection. Steam cleaned parts should be oiled other damage. Replace as needed.
immediately after drying.
Apply multi-purpose grease to O-rings (7 and 15,
Fig. 6) before installing.

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0201-8 Drive Axle Housing and Support TM- 1188 (J&78)

Wheel Axle and Tandem Housing

T60439B

l--Cap Screw (44 used) E-Drain Plug 15-Gasket (4 used)


P-Round Inspection Plate (3 used) g-D-Ring (2 used) 1Chain Cover (3 used)
3-Gasket (3 used) ltl-Front Wheel Axle Housing 17-Pipe Plug
Cl-Top Inspection Plate (2 used) 11-Special Cap Screw (32 used) 18-Rear Wheel Axle Housing
5-Gasket (2 used) 12-Gap Screw (2 used) 19--Cover with Breather
6-Tandem Housing 13-Washer (2 used) PO-Air Vent
7-Washer 14-Step

Fig. 7-Tandem Housing and Wheel Axle Housings

Refer to Group 0250 and remove wheel axles from Parts should be dried with compressed air. Steam
wheel axle housings. cleaned parts should be oiled immediately after drying.

All parts must be clean to permit effective inspection. Inspect all parts for excessive wear, cracks or other
damage. Replace as needed.
All metallic parts should be cleaned thoroughly with
volatile mineral spirits, or by the steam-cleaning meth- Refer to Group 0250 and install wheel axles in wheel
od. Do not use a caustic soda solution for steam axle housings.
cleaning.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM-l 188 (Dee-87) Drive Axle Housing and Support 0201-9

INSTALLATION

Pivot Housing

16 6

1 -Gasket 7-O-Ring 12-Shim (use as required)


2-Hollow Dowel (2 used) I-Special Cap Screw (21 used) 13-Pivot Retainer
3-Dowel Pin (3 used) g--Grease Fitting 14-Special Cap Screw (12 used)
4-Final Drive Housing Assembly lo-Tandem Pivot Housing 15-O-Ring
J-Cap Screw (16 used) 11-Tandem Pivot Bushing 16-Pipe Fitting
B-Thrust Washer (6 used)

Fig. 8-installing Tandem Pivot Housing

Install O-ring (7, Fig. 8) on final drive housing.

Place three thrust washers (6) on final drive housing


using grease to hold thrust washers in place.

Install tandem pivot bushing (11) on final drive


housing.

Install tandem pivot housing (10) to final drive


housing so that area with closely spaced holes on
pivot is at the bottom of the final drive housing.

Place other three thrust washers on tandem pivot


housing using grease to hold thrust washers in place.

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0201-10 Drive Axle Housing and Support TM- 1 I88 (J&78)

Select shim pack (12, Fig. 8) to provide 0.002 rt


0.002 in. (0.05 2 0.05 mm) clearance between thrust
washer and pivot retainer (13). Tighten retainer cap
screws (14) to 300 lb-ft (407 Nm) (42 kg-m).

The pivot housing should rotate on final drive hous-


ing when a torque of 1000 lb-ft (1 356 Nm) (138 kg-m)
maximum is applied. This torque can be attained by
using a prybar against cap screws placed in flange of
pivot housing.

Install grease fitting (9) into pivot housing on same


side as the clevis feature on final drive housing. Install
pipe plug (16) into opposite side of pivot housing.

Lubricate pivot housing with John Deere Multi-Pur-


pose Grease or an equivalent.

Install O-ring (15) on tandem pivot housing.

Install double sprocket (1, Fig. 9) with long hub at


sprocket, toward sprocket retainer (2).

Install sprocket retainer and tighten cap screws (3)


to 170 lb-ft (230 Nm) (24 kg-m).

l-Double Sprocket 3-Cap Screw


2-Sprocket Retainer (2 used)

Fig. 9-Installing Double Sprocket

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Jul- 79) Drive Axle Housing and Support 0201-11

Wheel Axle and Tandem Housing

TE0439N

l-Cap Screw (44 used) E-Drain Plug 15-Gasket (4 used)


2-Round Inspection Plate (3 used) g-O-Ring (2 used) 16-Chain Cover (3 used)
3-Gasket (3 used) lo--front Wheel Axle Housing 17-Pipe Plug
~-TOP Inspection Plate (2 used) ll-Special Cap Screw (32 used) ll-Rear Wheel Axle Housing
Casket (2 used) 12-Special Cap Screw (2 used) 19-Cover with Breather
6-Tandem Housing 13-Washer (2 used) 20-Breather I
7-Washer 14-Step

Fig. 1O-Installing Tandem and Wheel Axle Housings

Install tandem housing (6, Fig. 10). Tighten pivot housing to tandem housing cap screws
(1, Fig. 4) to 300 lb-ft (407 Nm) (42 kg-m).
NOTE: If double sprocket was left in tandem hous-
ing, it should be raised by using the fop inspection install sprocket retainer and tighten cap screws to
ho/es and sfarted onto the splined tandem drive shaft 170 lb-ft (230 Nm) (24 kg-m).
as the tandem housing is placed on the tandem pivot.
Install O-rings (9, Fig. 10) on front and rear wheel
When installing tandem housing, index tandem axle housings.
pivots so that pivot lube fitting points to the front of
motor grader. Care should be taken so that O-ring is
lubricated and not damaged when installing tandem
housing to pivot housing.

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0201-12 Drive Axle Housing and Support TM- 1188 (Jul- 79)

Install drive chains in tandem housing.

Place drive chain onto sprocket (2, Fig. 11).

NOTE: Position rear drive chain on inside of double


sprocket and front drive chain on outside of double
sprocket.

Refer to Group 0250-3 to connect the tandem drive


chains.

Secure wheel axle housings to tandem housing with


special cap screws (11, Fig. 10) and tighten.

For right-hand tandem housing, install chain as-


sembly cover (16) with breather (20) on front (drain ’
plug end) inboard side of tandem housing.

For left-hand tandem housing, install chain assem-


bly cover with breather on rear (drain plug end) inboard
side of housing.
I-3/4-Inch Eyebolt 3-Wheel Axle Housing
2-Drive Chain and 4-Tandem Housing Install inspection plates (2 and 4) to tandem hous-
Sprocket ing.
fig. 7 I-lnstatl Wheel Axle Housings
Refer to Group 0110 and install wheels and lower
IMPORTANT: Install wheel axle housings with grader to the ground.
eyebolt hole (1, Fig. 11) to top of tandem housing.
Outer wheel axle bearing lubrication depends upon Fill tandem housing with recommended oil to the oil
proper wheel axle housing installation. level plug (17, Fig. 10). (See Section I, Group V for the
type of oil used).
Position wheel axle housings (10 and 18, Fig. 10) up
to tandem housing (6). Make sure to position wheel Fill transmission with recommended oil to dipstick
axle housings, as when they were removed, in their level. (See Section I, Group V).
proper location before installing.

NOTE: for the right-hand tandem housing, install


the front wheel axle assembly in the same end as the
drain plug.

For the left-hand tandem housing, install the rear


wheel axle assembly in the same end as the drain plug.

Care should be taken so that O-ring is lubricated


and not damaged when installing wheel axle housings
to tandem housings.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (J&78) Drive Axle Housing and Support 0201-l 3

FINAL DRIVE HOUSING


REMOVAL

Fig. 12-Removing Tandem Assembly

Disconnect battery ground strap. Refer to Group 0110 and remove wheels from hubs.

NOTE: Wheels may be left on tandem housing as-


A CAUTION: Raise and block the rear of en-
gine frame and transmission so the tandem
sembly depending upon shop facilities.

wheels on the side you are servicing are clear of Remove plug and drain oil from tandem housing.
the ground. NOTE: Approximately 5 gal. (19 L) of oil will be
drained.
Drain oil from transmission case.

Remove round inspection plate with step from out-


board side of tandem housing.

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0201-14 Drive Axle Housing and Support TM- 1188 (J&78)

Remove cap screws (21, Fig. 13) securing double Remove pivot retainer cap screws (14, Fig. 13)
sprocket (19) to drive shaft and remove sprocket re- securing pivot housing to final drive housing. Remove
tainer (20). pivot housing assembly.

NOTE: This allows the tandem housing to be re- Remove cap screws (5) securing final drive housing
moved without disconnecting drive chains. (4) to transmission case. Remove final drive assembly
from transmission case.
Attach chains to the tandem housing and an over-
head hoist. NOTE: An alternate method of removing the final
drive housing when servicing the brakes, differential
Remove cap screws (8) securing tandem pivot assembly or transmission case, is to attach the chains
housing (10) to tandem housing. as shown in Figure 12.

Swing tandem housing with wheel axle housings Remove cap screws (5, Fig. 13) securing final drive

El
away from final drive and pivot housing.

NOTE: It is not necessary to remove tandem pivot


housing (4) to transmission case and swing final drive
housing, pivot housing, tandem housing and wheel
axle housings away as an assembly.
unless it requires service.

REPAIR

15
T60440N

l-Bearing Cup (2 used) a-Cap Screw (21 used) l--Ring


2-Gil Seal 9-Grease Fitting M-Pipe Plug
3-Gasket l&Tandem Pivot Housing 17-Dowel Pin (3 used)
4-Final Drive Housing with Gear 1 l-Bushing l&Tandem Drive Shaft
6-Gap Screw (16 used) 12-Shim (as required) 19-Double Sprocket
CThrust Washer (6 used) 13-Pivot Retainer PO-Sprocket Retainer
7-CRing 14-Gap Screw (12 used) Pi-Cap Screw (2 used)

Fig. 13-Final Drive Housing and Pivot Housing

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Dee-871 Drive Axle Housing and Suoport 0201-15

Refer to Group 0250 and remove tandem drive INSTALLATION


shaft and planetary system from final drive housing.
Install final drive housing to transmission case and
tighten cap screws (5, Fig. 13) to 170 lb-ft (230 Nm)
All parts must be cleaned to permit effective
(24 kg-m).
inspection.
Install O-ring (15) on tandem pivot housing (10).
All metallic parts should be cleaned thoroughly
Care should be taken so that O-ring on tandem pivot
with volatile mineral spirits, or by the steam-cleaning
is lubricated and not damaged when tandem housing
method. Do not use a caustic soda solution for
is installed on tandem pivot.
steam cleaning.
Install tandem housing.
Parts should be dried with compressed air. Steam
cleaned parts should be oiled immediately after
NOTE: When installing tandem housing, index
drying.
tandem pivot so that pivot lube fitting points to the
front of the motor grader.
Inspect all parts for excessive wear, cracks or
other damage. Replace as needed.
Align double sprocket (19, Fig. 13) with chains in
tandem housing and tandem drive shaft in final drive
Clean final drive housing mounting brackets of
housing. Slide double sprocket on tandem drive shaft
grease, paint, weld splatter and weld.
while positioning tandem housing.

If final drive gear is worn or damaged, the final


Install sprocket retainer (20) and tighten sprocket
drive gear and final drive housing (4, Fig. 13) must be
retainer cap screws (21) to 170 lb-ft (230 Nm) (24
replaced as a unit.
kg-m).

Lubricate O-rings (7 and 15) with John Deere


Apply thread lock and sealer (medium strength) to
Multi-Purpose Grease or an equivalent before
the first five threads of the pivot housing-to-tandem
installing.
housing cap screws (8, Fig. 13). Install cap screws
and tighten to 300 lb-ft (407 Nm) (42 kg-m).
Refer to Group 0250 and install tandem drive shaft,
bearings and planet pinion carrier assembly.
Install round inspection plate with step to outboard
side of tandem housing.
NOTE: Do not install drive sprocket (19, Fig. 13) or
sprocket retainer (20).
Refer to Group 0110 and install wheels. Lower
power unit to ground.
Install tandem pivot assembly as described on
page 2-0201-g of this group.
Fill tandem housing with recommended oil to the
oil level plug (17, Fig. 10). (See Section 1, Group V for
Install dowel pins (17). Strike end of dowel pins
the type of oil used).
with hammer to seat firmly. Hand check dowel pins
for tightness.
Fill transmission with recommended oil to dipstick
level. (See Section 1, Group V).
NOTE: All dowel pins must be installed correctly to
insure proper brake operation.

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0201-16 Drive Axle Housing and Support TM- 1188 (Jul- 79)

POWERED AXLE ASSEMBLY


GENERAL INFORMATION
The front axle consists of a welded frame which
provides mountings for steering, wheel lean, axle
oscillation and front wheel drive assembly.

All linkage and cylinders are mounted with no con-


nections to the main frame except for hydraulic lines.

The front axle features 20” wheel lean and 15” axle
oscillation.

q REMOVAL
Refer to Group 0110 and remove front wheels.

Refer to Group 0260 and remove motor housing with


front drive wheel as an assembly.

Relieve hydraulic pressure in steering and wheel


lean cylinders. Disconnect hydraulic lines from steering l-Cap Screw (4 used) 3-Scarifier Cylinder
cylinders and lean cylinders. Cap and plug all hydraulic 2-Front Axle Pivot Pin
hoses and lines to keep dirt or other foreign material
fig. 14-Removing Front Axle
from entering the hydraulic system.

Remove cap screws (1, Fig. 14) from front axle pivot
NOTE: Block wheel lean assemblies to prevent ro-
pin (2). Use two of the cap screws and install in thread
tation when hydraulic lines are disconnected.
holes of front axle pivot pin, Use cap screws as jack
screws to remove pin.
Support axle assembly with moveable floor jacks
under each side.
Lower front axle to the ground.
Disconnect scarifier cylinder (3, Fig. 14) from rod
end for added clearance (if so equipped).

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axle and Suspension System 2
TM- 1188 (Jul-78) Drive Axle Housino and SupRort 0201-17

REPAIR

Disassembly
Refer to Group 0960 to remove and repair steering
cylinder and lean cylinder.

Remove cap screws (1, Fig. 15) and drive out wheel
lean link pin (2) from right and left-hand yoke (9).
Remove wheel lean link (3).

Remove cap screw (4) and drive out wheel lean


cylinder pin (5).

Remove cap screw (7) and drive out wheel lean pin
(8).

Remove right and left-hand yoke from front axle.

Inspect all parts for cracks, wear or other damage.

Inspect pivot pins for worn or bent conditions.

Inspect bushings located in wheel lean link, front


axle and right and left-hand yoke.

l-Cap Screw (2 used) 5-Wheel Lean Cylinder


Replace parts as necessary. 2-Wheel Lean Link Pin
Pin (2 used) 6-Wheel Lean Cylinder
3-Wheel Lean Link 7-Gap Screw (2 used)
4-Gap Screw &-Wheel Lean Pin
(2 used)
9-L.H. Yoke

Fig. ldWhee/ Lean Link and Yoke Assembly

Litho in U.S.A.
2 Axle and Suspension System JD670-A and JD672-A Motor Graders
0201-18 Drive Axle Housing and Support TM- 1188 (J&78)

Assembly
Press bushings (1, 13, 18 and 20, Fig. 16) flush with
their counterbore.

Install right and left-hand yokes (2) to front axle (19).

Install wheel lean pin (22) and secure with cap screw
(9) and nut (23).

Position wheel lean link (14) to the left and right yoke
and install wheel lean link pins (12). Secure with cap
screws (11) and nuts (3).

q
Refer to Group 0960 and install wheel lean cylinder. 2’1 ‘23 IP60444N

Secure with pins (4 and 22).


l-Yoke Pin Bushing 12-Wheel Lean Link
(4 used) Pin (2 used)
Refer to Group 0960 and install steering cylinder. 2-Right Yoke (Not Shown) 13-Bushing (2 used)
Left Yoke lAWheel Lean Link
Refer to Group 0920 and install bellcrank with tie 3-Special Nut (5 used) 1Crease Fiiing, Straight
cl-Wheel Lean Cylinder (2 used)
rods.
Pin 1GSteering Cylinder Pin
!&Grease Fitting, Straight 17-Gap Screw
INSTALLATION (2 used) l&Bushing
9-Gap Screw (2 used) 19-Front Axle
Position front axle assembly on two movable floor 7-Lock Washer (2 used) 20-Bushing (2 used)
jacks. 8-Washer (2 used) 21-Grease Fitting, 90
9-Gap Screw (2 used) (5 used)
Raise front axle in position with main frame and 1 O-Wheel Lean Cylinder 22-Wheel Lean Pin
Pin (2 used)
install front axle pin (2, Fig. 14). Secure front axle
Ii-Cap Screw (3 used) 23-Special Nut (2 used)
pin-to-main frame with cap screws (1). Torque cap 24-Gap Screw
screws to 170 lb-ft (230 Nm) (24 kg-m).
Fig. 16-Front Axle Assembly
Connect scarifier cylinder (if so equipped).
Refer to Group 0260 and install front wheel drive
Connect hydraulic lines to steering cylinders and with housing.
wheel lean cylinders.
Refer to Group 0110 and install front wheels.
Connect hydraulic front wheel drive lines to lines on
main frame. Refer to Group 0920 for toe-in adjustment.

‘IMPORTANT: See the component location Grease all fittings before operation.
drawing in Group 9016 for correct hose routing.
Check hose clearances in all extreme positions to
eliminate hose and wiring damage.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Mar-80) Differential or Bevel Drive 021 o-1

Group 0210
DIFFERENTIAL OR BEVEL DRIVE
GENERAL INFORMATION
The differential is located in the forward portion of
the one-piece transmission and differential case.

The differential is equipped with a lock. The drive


axles can be locked together to rotate at the same
speed. The differential control pedal, located in the
center of the operator’s platform, actuates a control
valve which provides a convenient means of releasing
the drive axles so that they will rotate at different
speeds for turns.

DIFFERENTIAL ASSEMBLY
REMOVAL

IMPORTANT: If the external differential pres-


sure line is removed, care must be taken to keep
bulkhead fitting from turning. If the fitting is not
held while removing the outside flare nut, the fit-
ting may turn and twist off the internal line.
l-Right (R.H.) Bearing Quill 5-Right (R.H.) Differential
Refer to Group 0201 and remove both final drive a--Spiral Bevel Pinion Housing with Spiral Bevel
housings and tandem assemblies. C&Left (L.H.) Bearing Quill Gear
4-Differential Lock 6-Left (L.H.) Differential
Oil Line Housing
Refer to Group 0341 and remove transmission as-
sem bly. Fig. l-Differential Assembly

Remove the differential housing cover and parking


Remove right (R.H.) and left (L.H.) bearing quill
brake assembly.
being sure to keep bearing quill shims with their re-
spective quills.
Remove oil line (4, Fig. 1) from transmission case to
left (L.H.) bearing quill (3). Remove the differential lock
Remove differential assembly from the transmission
line connector from the left (L.H.) bearing quill.
case.

Place a chain around the differential housing, and


raise the differential assembly enough to relieve weight
on the quill bearings (1 and 3).

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0210-2 Differential or Bevel Drive TM- 1188 (Dee-87)

REPAIR

T6771AI
l-Cap Screw (12 used) 15-Backing Plate 28-Sealing Ring (2 used)
2-Right (R.H.) Bearing Quill 1 B-Piston 29-Cap Screw (8 used)
3-Nut (2 used) 17-Outer O-Ring 30-Bearing Cone
4-Bearing Cup ll-Inner O-Ring 31-Bearing Cup
S-Bearing Cone 19-Right (R.H.) Differential 32-Snap Ring (4 used)
B-Cap Screw (12 used) Housing with Spiral Bevel Gear 33-Washer (4 used)
7-Shim (as required) PO-Thrust Washer (2 used) 34-Roller Bearing
8-Spring Pin (3 used) 21-Bevel Lock Gear 35-Washer
g--Housing Cover 22-Thrust Washer 36-Old Assembly
lo--Spring (3 used) 23-Bevel Pinion Shatt 37-New Assembly
1 l-Bushing 24-Bevel Pinion 38-Assembly (3 used) (SNOO5421-
12-O-Ring (2 used) 25-Bevel Gear 39-Hub
13-Drive Disk (4 used) 26-Lelt (L.H.) Bearing Quill 40-Washer
14-Separator Plate (3 used) 27-Lett (L.H.) Differential Housing 41-Bolt

Fig. P-Differential Assembly With Lock

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Dee-87) Differential or Bevel Drive 0210-3

Disassembly Remove the bevel lock gear (21, Fig. 2) with thrust
washer (22).
Pull bearing cones (5 and 30, Fig. 2) from each
side of differential.
Remove bevel pinion (24) and bevel pinion shafts
(23).
Remove sealing rings (28) from diffferential housing.
Inspect sealing rings for wear or damage. Replace
If equipped, remove roller bearings (34) and snap
as necessary.
ring (32).

Remove cap screws (6) securing differential


Inspect roller bearings in each pinion for wear.
housing cover (9) to differential housing with spiral
bevel gear and remove housing cover.
NOTE: If any roller bearing is found defective,
replace bearings as an entire set.
Be careful not to lose the three small springs (10)
mounted on spring pins (8) located in the cover.
Remove bevel gear (25) with thrust washer.

Remove the separator plates (14) drive disks (13)


Remove bearing cups (4 and 31) from the differential
and backing plate (15).
bearing quills (2 and 26).

Remove piston (16) from differential housing (19).


Refer to page 0210-4 for cleaning, handling and
inspecting the differential parts.
If necessary, apply compressed air at the oil
pressure inlet holes in the housing to lift piston.
Installing New Ring Gear

A CAUTION: Piston can be forced out of bore


suddenly and cause bodily injury. Apply
IMPORTANT: If the spiral bevel gear is no longer
serviceable and must be replaced, it will be neces-
compressed air slowly until piston can be removed sary to replace the spiral bevel pinion shaft also as
from bore. these parts are furnished only as matched sets.

Remove outer and inner O-ring (17 and 18) and If any of the cap screws (19, Fig. 3) are to be
inspect for damage. Replace as necessary. replaced, it is necessary to heat cap screws to
350°F (177°C) to loosen the epoxy.
Remove cap screws (29) securing the left-hand
differential housing to right-hand differential housing Clean and degrease cap screw threads and threads
with spiral bevel gear and separate the housings. in gear with lacquer thinner, chloroethane or an
equivalent.
Remove bushing (11) from ring gear side of dif-
ferential housing. Inspect O-rings (12) and replace if NOTE: Do not use petroleum base solvents such
necessary. as gasoline or diesel fuel as they will leave a residue
that adversely affects epoxy.

Apply epoxy adhesive 3M2158 or an equivalent to


lower 3/4-inch of threads. Cross tighten cap screws
to 85 lb-ft (115 N-m) (12 kg-m).

Refer to page 0210-10 to replace spiral bevel


pinion shaft.

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0210-4 Differential or Bevel Drive TM- 1188 (Jun-83)

Cleaning, Handling and Inspecting NOTE: Never spin dry bearings with compressed air.
Do not rotate bearings while they are not lubricated.
Parts which have close operating tolerances must be
handled carefully to prevent nicking, scratching, or dent-
Inspect bearings for roughness of rotation. Replace a
ing. The slightest damage to these parts can result in
bearing if its rotation is still rough after cleaning and
erratic operation and possible malfunction of the differ-
oiling.
ential. These parts must be carefully handled and pro-
tected during removal, cleaning, inspection, and installa-
Inspect bearings for scored, pitted, scratched,
tion.
cracked or chipped races, and for indication of exces-
sive wear of rollers or balls. If one of these defects is
All parts must be clean to permit effective inspection.
found, replace the bearing.
During assembly, it is very important that no dirt or
foreign matter enters the differential. Even minute parti-
Inspect the defective bearing’s housing and shaft for
cles can cause the malfunction of close-fitting parts.

q
grooved, burred, or galled conditions that indicate the
bearing has been turning in its housing or on its shaft. If
All metallic parts of the differential (except bearings)
the damage cannot be repaired with crocus cloth, re-
should be cleaned thoroughly with volatile mineral spir-
place the defective part.
its, or by the steam-cleaning method. Do not use a caus-
tic soda solution for steam cleaning. Gum and varnish
Inspect gears for scuffed, nicked, burred, or broken
deposits should be removed by allowing the parts to
teeth. If the defect cannot be removed with a soft honing
soak in varnish remover.
stone, replace the gear.

Parts should be dried with compressed air; steam-


Inspect gear teeth for wear that may have destroyed
cleaned parts should be oiled immediately after drying.
the original tooth shape. If this condition is found, re-
place the gear.
Clean oil passages by working a piece of soft wire
back and forth through the passages and flushing with
Coat face of differential gears with the same type of
spirits. Dry the passages with compressed air.
oil that will be used in the transmission case before
installing.
After cleaning, examine the parts and especially the
oil passages to make certain they are entirely clean.
Inspect differential housings, covers and bearing
Reclean them if necessary.
quills for cracks or other damage. Replace housing, cov-
er or quills if necessary.
Bearings that have been in service should be thor-
oughly washed in volatile mineral spirits.
Inspect sealing ring contact areas in the left-hand
bearing quill for wear and scoring. Replace quill if neces-
If the bearings are particularly dirty or filled with hard-
sary.
ened grease, soak them in the spirits before trying to
clean them.
Inspect drive disks for worn conditions. Replace
when grooved surfaces of disks are completely worn
Before inspection, oil the bearings with the same type
smooth.
of oil that will be used in the transmission case.

l-Bearing Cone 12-Bevel Lock Plate 22-Left (L.H.) Differential


2-Cap Screw (12 used) 13-Bevel Pinion (4 used) Housing
3-Spring Pin (3 used) 14-Thrust Washer (4 used) 23-Cap Screw (8 used)
4-Housing Cover lli-Bevel Gear 24-Sealing Ring (2 used)
5-Spring (3 used) 16-Piston *25-Bevel Pinion Shaft (2 used)
B-Bushing 17-Outer O-Ring 26-Bearing Cone
7-O-Ring (2 used) 18-Inner O-Ring ‘27-Washer (4 used)
8-Drive Disk (4 used) Is-Cap Screw (12 used) ‘28-Roller Bearing (104 used)
g--Separator Plate (3 used) 20-Washers (12 used) *29-Washer (4 used)
lo--Backing Plate 21-Right (R.H.) Differential l30-Snap Ring (4 used)
11-Thrust Washer (2 used) Housing ‘New Assembly

Legend for Fig. 3

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 IJun-83) Differential or Bevel Drive 0210-5

Fig. 3-Assembling Differential with Lock (New Assembly Shown)

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0210-6 Differential or Bevel Drive TM- 1188 (Jun-83)

Assembly (Old Assembly) Install O-rings (7) on bushing (6):lnstall bushing as-
sembly in right-hand differential housing (21). Coat O-
Install thrust washer (11, Fig. 3) and bevel gear (15) in
rings with oil before installing.
left (L.H.) differential housing (22).

Install right (R.H.) differential housing on left (L.H.)


Assemble by locking the two bevel pinion shafts (25)
differential housing (22) and secure with cap screws
together.
(23). Tighten cap screws to 85 lb-ft (115 Nmm)(12 kg-m).

Install one bevel pinion (13) on each end of shaft.


Install bevel lock gear (12, Fig. 3) on top of bevel
Place one thrust washer (14) with dish side of washer,
pinion. Place thrust washer (11) inside of bevel lock
toward bevel pinion.
gear.

Install bevel pinion and shaft assembly in the left (L.H.)


Apply John Deere Multi-Purpose Grease or an equiv-
differential housing (22) in mesh with the bevel gear.
alent on inner and outer O-rings (17 and 18) and install
Make sure this assembly is placed in the four half-moon
O-rings in right-hand differential housing.
slots of the differential housing.

Before installing piston (16) coat the chamfered ends


Assembly (New Assembly)
of piston in oil.
Install thrust washer (11, Fig. 3) and bevel gear (15) in
left (L.H.) differential housing (22). Install piston in differential housing. NOTE; Use care
when installing piston in differential housing so O-rings
Install snap ring (30) and washer (29) on bevel pinion are not damaged.
shafts (25).
Install the backing plate (10) on piston.
Install roller bearings (28) in bevel pinion (13), using
petroleum jelly to hold bearings in place. Start with a drive disk (8) and alternately install three
separator plates (9) and four drive disks. Be sure that
Install one bevel pinion on each end of shaft. Place the separator plates are installed with the tangs in the
washer (27) and one thrust washer (14) (with dish side of same position. This will allow the piston return springs to
washer toward bevel pinion) on pinion shafts. contact the clutch backing plate when the differential is
assembled.
Assemble bevel pinion shafts (25) together.
Drive spring pins (3) in differential housing cover (4)
Install bevel pinion and shaft assembly in the left (L.H.) until spring, pins are flush with outside of cover.
differential housing (22) in mesh with the bevel gear.
Make sure this assembly is placed in the four half-moon Install springs (5) over the spring pins.
slots of the differential housing.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Mar-so) Differential or Bevel Drive 021 o-7

Install differential housing cover (4, Fig. 3) on dif- Immerse entire differential assembly in the same
ferential housing and secure with cap screws (2). Make type of oil used in the transmission before installing.
sure springs (5) do not fall out of place. Tighten cap
screws to 85 lb-ft (115 N.m) (12 kg-m). Lower the differential assembly (1, Fig. 4) in the
correct position in the case and install right and left-
Install two sealing rings (24) in differential housing hand bearing quills (2 and 3) with their respective shim
sealing grooves. NOTE: DO NOT overstretch sealing packs. NOTE: Position the left (L.H.) bearing quill so
rings when installing and make sure sealing rings are that the differential lock line connector port is in the 1 I
securely locked. o’clock position.

Drive or press bearing cones (1 and 26) on each end Tighten bearing quills-to-transmission case cap
of differential assembly until cones bottom at their screws securely. NOTE: Cap screws do not need to be
shoulders. tightened at this time until bearing preload and back-
lash adjustments are made.
Install bearing cups in right and left-hand bearing
quill until cups bottom out. Install differential lock line connector (4) in left (L.H.)
bearing quill. Tighten connector to 30 lb-ft (41 Nem) (4
INSTALLATION kg-m).

Install oil line (5) from transmission case to connec-


tor. Secure the connector while tightening differential
lock inner oil line.

If the spiral bevel gear and bevel pinion shaft were


replaced, proceed with cone point adjustment on page
0210-l 1. If they were not replaced, proceed with
bearing preload and backlash adjustment on page
0210-13.

Install the differential cover with parking brake as-


sembly to transmission case only after all the adjust-
ments are made.

Refer to Group 0341 and install transmission as-


sembly.

Refer to Group 0201 and install final drive housing


and tandem assemblies.

l-Differential Assembly 4-Connector


2-Right (R.H.) Bearing Quill 5-Differential Lock
3-Left (L.H.) Bearing Quill Oil Line

Fig. 4-installing Differential

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0210-8 Differential or Bevel Drive TM- 1188 (Dee-87)

DIFFERENTIAL PINION SHAFT Remove special nut (1, Fig. 5) from differential
bevel pinion shaft (2).
REMOVAL
Remove bevel pinion shaft from its housing.
Refer to Group 0201 and remove both final drive
housings and tandem assemblies.
Bearing cone (10, Fig. 6) shims (8) spacers (5 and
7), and gear (6) will be free for removal.
Refer to Group 0341 and remove transmission
assembly.
REPAIR
Refer to Group 0350 and remove clutch pack and Disassembly
brake housing assembly. Refer to page 0210-l and
remove differential assembly.

l-Differential Bevel B-Gear


Pinion Shatt T-Spacer
P-Bearing Cone 6-Shims (as required)
3-Bearing Cup g-Bearing Cup
4-Shims (as required) lo-Bearing Cone
S-Spacer W-Special Nut
l-Special Nut 3-Bearing Cone
a--Differential Bevel Pinion ShaR Fig.-B-Differential Bevel Pinion Shaft Assembly

fig 5-Removing Differential Bevel Pinion Shaft


Press bearing (2, Fig. 6) from differential bevel
pinion shaft (1).

Remove bearing cups (3 and 9) from transmission.

NOTE: Shims (4) are located behind bearing cup


(3) so be careful not to damage shims when removing
bearing cup. Keep respective shim pack with bearing
cup.

Refer to page 0210-4 for cleaning, handling and


inspecting these parts. Replace parts as necessary.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Jul-78) Differential or Bevel Drive 021 o-9

Assembly Before installing bearing cup (3, Fig. 6) refer to page


021 O-1 1 and proceed with the Cone Point Adjustment
IMPORTANT: If the differential bevel pinion shaft
to determine amount of shims (4) used. NOTE: If any of
is no longer serviceable and must be replaced, it
the following parts; bearing cup (3), bearing cone (2) or
will be necessary to replace the spiral bevel gear
differential bevel pinion shaft (1) was replaced, this
with housing also. These parts are furnished only
adjustment would also be required.
as matched sets.
Place the determined amount of shims (4) after the
Press bearing cone (2, Fig. 6) on differential bevel
cone point adjustment is made behind bearing cup (3).
pinion shaft (1) tight against its shoulder.
Use a suitable driver and install bearing cup with
Use a suitable driver and install bearing cup (9) in
shims in transmission case.
transmission case.

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0210-10 Differential or Bevel Drive TM- I 188 (Jun-83)

INSTALLATION

l-Differential Bevel 4-Shims (use as required) 8-Shims (use as required)


Pinion Shaft 5-Spacer g-Bearing Cup
Z-Bearing Cone g--Gear lo-Bearing Cone
3-Bearing Cup 7-Spacer 11 -Special Nut

Fig. 7-kW/ing Differential Bevel Pinion Shaft

Install the differential bevel pinion shaft (1, Fig. 7) with Install spacer (7, Fig. 7) with raised neck toward
bearing cone (2) as an assembly. threaded end of pinion shaft.

Install spacer (5) on pinion shaft. Refer to page 021 O-12 and proceed with the Pinion
Shaft Adjustment before installing shims (8) and bearing
Install gear (6) on pinion shaft splines. Align teeth on cone.
gear with teeth on reduction gear.
After the correct adjustment is made, stake special
nut (11) to shaft two places.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (J&78) Differential or Bevel Drive 021 o-1 1

ADJUSTMENTS
When installing new parts (transmission case, spiral
bevel gear and pinion shaft set, bearing cones, bearing
cups or differential quills) or when installing the dif-
ferential assembly in the transmission case, the fol-
lowing adjustments are necessary:

1. Cone point adjustment


2. Pinion shaft adjustment
3. Differential preload
4. Differential backlash
5. Tooth bearing pattern

Cone Point Adjustment


Cone point adjustment is obtained by controlling the
shim pack (4, Fig. 8) between the pinion shaft bearing
cup (3) and the transmission case.

To determine the shim pack to be placed behind the


differential quill bearing cup, the following dimensions T60462N
are required.
l-Dimension on Face of 3-Bearing Cup
1 - On the face of the spiral bevel pinion (1) is an Spiral Bevel Pinion 4-Shim Pack
P-Bearing Mean Overall 5-Amount of Shims
etched dimension. Add the etched dimension to 1.8125
Width Required
in. (46.038 mm) which is the bearing mean overall
width (2). Fig. b-Cone Point Adjustment

2 - Add the total dimension from the above step to EXAMPLE:


0.0015 in. (0.038 mm) to allow for increase in length
when cup is pressed into the case. 8.2725 in. (210.122 mm) = dimension on bevel pinion
shaft
3 - To determine the amount of shims (5) to be + 1.8125 in. (46.038 mm) = bearing mean over-all
placed between the bearing cup (3) and the backing width
shoulder in the case, subtract the dimension as deter- + 0.0015 in. (0.038 mm)
mined in Step 2 from 10.143 (257.63 mm) (case mean
= 10.0865 in. (256.197 mm)
bore depth).
10.143 in. (257.63 mm) = case mean bore depth
- 10.0865in. (256.197 mm)
= 0.0565 in. ( 1.435 mm) = amount of shim pack be-
tween bearing cup and
backing shoulder in the
case.

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0210-12 Differential or Bevel Drive TM- 1188 (J&78)

Pinion Shaft Adjustment


Refer to page 021 O-l 0 and install differential bevel
pinion shaft with enough shims to provide end play.

Press bearing cone (1, Fig. 9) onto bevel pinion


shaft.

IMPORTANT: Bearing cone must be pressed on


and the differential bevel pinion shaft (3) pressed
out when making this adjustment. Driving the
bearing cone on gets debris in the case and driving
the differential bevel pinion shaft out may damage
the bearing cone and bearing cup.

NOTE: Cut a piece of angle iron to be bolted across


the rear of case. The angle iron will support a porta-
power while pressing bearing cone on or differential
bevel pinion shaft out.

Adjust the differential drive and bevel pinion bearing


to give 17 to 27 lb-in. (1.9 to 3.1 Nm) (0.20 to 0.31
l--Bearing Cone 2-Special Nut
kg-m) rolling torque with the lock nut tightened to 400 3-Bevel Pinion Shaft
lb-ft (542 Nm) (55 kg-m) torque. NOTE: Disconnect the
shifter collar on reduction shaft so bevel pinion shaft Fig. g-Pinion Shaft Adjustment
can free wheel before making this adjustment. Adjust
by means of the front bearing cone shims (8, Fig. 7).
After correct adjustment is made, stake lock nut to
shaft in two places.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Dee-87) Differential or Bevel Drive 0210-13

Differential Preload Tooth Bearing Pattern


With backlash between the spiral bevel gear and Check the tooth bearing pattern (Fig. 11) of the
the bevel pinion, check the end play with a dial differential spiral bevel gear (2) with the bevel pinion
indicator. If necessary, add shims under bearing (1). End of the tooth pattern (3) must be located 0.35
quills until a measureable amount of end play is + 0.59 - 0.12 in. (9 + 15 - 3 mm) from toe end of
obtained. Then set the differential bearings with 0.002 pinion. (This is for new parts only.) Adjust shim pack
to 0.005 in. (0.05 to 0.13 mm) preload which should to correct the tooth pattern if required.
give 5 to 10 lb-in. (0.6 to 1.1 N-m) (0.06 to 0.12 kg-m)
drag torque on differential.

NOTE: This drag torque is the differential between


drag torque with preload and drag torque with end
play.

Differential Backlash
With preload established, mount the dial indicator
as shown in Figure 10, to check the backlash between
the spiral bevel gear and the bevel pinion. Then by
moving shims from one side of the differential to the
other, set the backlash between the bevel pinion and
spiral bevel gear at 0.007 to 0.015 in. (0.19 to 0.39
mm).

To increase backlash, move shims from left to


T63729N
right; to decrease backlash, move shims from right to
left when viewed from the bevel pinion input bore. l-Differential Spiral 4--0.35 + 0.59 - 0.12 in.
Bevel Pinion (9 + 15 - 3 mm)
P-Spiral Bevel Gear 5-1.50 f 0.31 in.
With bearing preload and backlash properly
3-Tooth Bearing Pattern (38 f 8 mm)
adjusted, tighten the differential bearing quill to trans-
mission case cap screws to 85 lb-ft. (115 N.m) (12
Fig. 11 -Tooth Bearing Pattern
kg-m).

Fig. lo-checking Backlash

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
021 o-1 4 Differential or Bevel Drive TM- 1188 (Mar-80)

DIFFERENTIAL LOCK VALVE


GENERAL INFORMATION REMOVAL

A CAUTION: f&aping fluid under pressure


can have sufficient force to penetrate the
skin, causing serious personal injury. Before dis-
connecting lines, be sure to relieve all pressure.
Before applying pressure to system, be sure all
connections are tight and that lines, pipes and
hoses are not damaged. Fluid escaping from a very
small hole can be almost invisible. Use a piece of
cardboard or wood, rather than hands, to search
for suspected leaks.

If injured by escaping fluid, see a doctor at once.


Serious infection or reaction can develop if proper
medical treatment is not administered immediate-
ly.

NOTE: Before removing the differential lock valve,


relieve pressure in hydraulic system by actuating the
steering valve and brake valve with the engine
stopped.

Remove cover from left-hand side of control con-


Fig. 1247ifferential Lock Valve
sole.
The differential lock valve (Fig. 12) is located in the
Disconnect and mark the hoses and lines on the
operator’s station below the steering valve. When en-
valve. Cap hoses and lines to prevent dirt from entering
gaged, this valve directs pressure oil to lock the dif-
hydraulic system.
ferentials for better traction.

Remove valve from unit.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 lJui-78) Differential or Bevel Drive 0210-15

REPAIR

15969ON PI -23

l-Headed Pin 9-O-Ring (2 used) 17-Elbow 24-O-Ring


P-Cotter Pin 16-Cap Screw 16-Valve 26-Plunger
3-Elbow 1 l-Lock Washer (2 used) 19-Shim (as required) 26-Valve Spring
4-O-Ring 12-Nut 26-Plunger Spring 27-Retaining Ring
6-Spring 13-Return Spring 21-Link (2 used) 28-Pin
6-Ball U-O-Ring 22-Retaining Ring (2 used) 29-Valve Housing
-/-Roller Bearing 16-PI ug 23-Headed Pin (2 used) 36-Pedal
&Connector 1g--Cap Screw

fig. 73-Differential Lock Valve Assembly

Refer to Fig. 13 when disassembling and assem- Disconnect pedal from lock valve housing and re-
bling the differential lock valve. move pedal and plunger assembly. Note the number of
shims (19, Fig. 13).
Disassem blv
Remove control valve and spring from the lower end
Remove inlet connector (3, Fig. :3), spring (5), ball
of the differential lock valve housing.
(6), and roller bearing (7) from the inlet port.

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0210-16 Differential or Bevel Drive TM- 1188 (J&78)

Inspection Assembly
Inspect all parts for wear or damage. Check for free Replace all O-rings, and coat O-rings, housing bore,
movement of control valve and plunger in valve hous- valves and valve parts in oil before assembly.
ing. Also check for contaminants which may be caus-
ing blockage in lines and ports. Install valve (18, Fig. 13) and spring in housing.
Drilled passage in control valve must be toward the
Compare the dimension of the parts removed with bottom of the housing.
the following new part dimensions to help determine if
repair is necessary. Place the same number of shims as were removed
in the plunger bore and assemble springs (20 and 26)
I.D. of housing bore and plunger (25).
(plunger end) . . .. . . 0.5610 to 0.5630 in.
(14.25 to 14.30 mm) Connect pedal and pedal linkage to the housing and
(control valve end) . . . . . il.4995 to 0.5005 in: plunger. Pedal stop pin (28) must be installed so

El (12.69 to 12.71 mm) retaining ring groove is flush with outside of housing.

O.D. of plunger. .. ... . . 0.5550 to 0.5590 in. Install roller bearing (7), steel ball (6), and check
(14.10 to 14.20 mm) valve spring (5).

O.D. of control valve .. 0.4978 to 0.4984 in. After assembly, cap all fittings until assembly is
(12.6 to 12.7 mm) mounted on unit.

Check Valve Spring (5, Fig. 13) INSTALLATION


Free length . . . . . . .. . . . . . . . .0.62 in.
Position differential lock valve assembly and install
(15.7 mm)
attaching hardware.
Length compressed at 4.0 to
5.0 oz. (1.1 to 1.4 N) (114 to 142 g) . . .0.38 in.
Connect hydraulic lines to fittings on valve.
(9.7 mm)

Test and adjust valve as explained in Group 9025.


Return Spring (13, Fig. 13)
Free length . . . . . . . . . . .. ... . . .2.56 in.
Install cover on left-hand side of control console.
(65 mm)
Length compressed at 9.5 to
115Ib.(42to51 N)(4to5kg) . . . . . . . . . 1.31 in.
(33.3 mm)

Plunger Spring (20, Fig. 13)


Free length . . . . . . . . . . . . . . . . . . . . . . .2.18 in.
(55.4 mm)
Length compressed at 25 to 31 lb.
(111 to 138 N) (11.3 to 13.9 kg) . . . . . . 1.80 in.
(45.7 mm)

Valve Spring (26, Fig. 13)


Free length . . . . . _. . . . . . . . . . . . . . . . .2.28 in.
(57.9 mm)
Length compressed at 103 to 125 lb.
(458 to 556 N) (46.7 to 56.7 kg) . . . . . . . . 1.92 in.
(48.8 mm)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (J&78) Non-Powered Wheel Axles 0230-l

Group 0230
NON-POWERED WHEEL AXLES
GENERAL INFORMATION Refer to Group 0920 and disconnect tie rods from
spindles.
The front axle consists of a welded frame which
provides mountings for steering, wheel lean and axle
Remove plugs (1, Fig. 1) and cap screws (2) from
oscillation.
bottom and top of spindles.
All linkage and cylinders are mounted with no con-
Install a slide hammer or an equivalent in tapped
nections to the main frame except for hydraulic lines.
hole of spindle pin (3) and remove spindle pin.
The front axle features 20” wheel lean and 15” axle
Remove front wheel hub with spindle (5) as an
oscillation.
assembly from wheel lean yokes (4).

REMOVAL
Refer to Group 0120 and remove front wheels.

Relieve hydraulic pressure in steering and wheel


lean cylinders. Disconnect hydraulic lines from steering
cylinders and wheel lean cylinders. Cap and plug all
hydraulic hoses and lines to keep dirt or other foreign
material from entering the hydraulic system.

NOTE: Block wheel lean assemblies to prevent ro-


tation when hydraulic lines are disconnected.

l-Cap Screw (4 used) 3-Scarifier Cylinder


2-Front Axle Pivot Pin

Fig. 2-Removing Front Ax/e

Support axle assembly with movable floor jacks


under each side.

Disconnect scarifier cylinder (3, Fig. 2) from rod end


for added clearance (if so equipped).

Remove cap screws (1) from front axle pivot pin (2).
Use two of the cap screws and install in thread holes of
front axle pivot pin. Use cap screws as jack screws to
remove pin.
c,~:““,“:T
, ,,>...>
Lower front axle to the ground.
l-Plug (4 used) 4-L. H. Wheel Lean Yoke
2-Cap Screw (4 used) 5-Front Wheel Hub with
3-Spindle Pin (4 used) Spindle

Fig. l-Removing Front Wheel Hub with Spindle

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0230-2 Non-Powered Wheel Axles TM- 1188 (J&78)

REPAIR

Disassembly
Refer to Group 0960 to remove and repair steering
cylinder and wheel lean cylinder.

Remove cap screws (1, Fig. 3) and drive out wheel


lean link pin (2) from right and left-hand wheel lean
yoke (9). Remove wheel lean link (3).

Remove cap screw (4) and drive out wheel lean


cylinder pin (5).

Remove cap screw (7) and drive out wheel lean pin
(8).

Remove right and left-hand wheel lean yoke from


front axle.

Inspect all parts for cracks, wear or other damage.

inspect pivot pins for worn or bent conditions.

Inspect bushings located in wheel lean link, front


axle and right and left-hand wheel lean yoke.
l-Cap Screw (2 used) E-Wheel Lean Cylinder
2-Wheel Lean Link Pin
Replace parts as necessary. Pin (2 used) 8-Wheel Lean Cylinder
3-Wheel Lean Link 7-Gap Screw (2 used)
4-Cap Screw 8-Wheel Lean Pin
(2 used)
9-L. H. Wheel Lean Yoke

Fig. 3-Wheel Lean Link and Yoke Assembly

Litho in U.S.A.
J/3670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (J&78) Non-Powered Wheel Axles 0230-3

T58349F

l-Cap Screw (6 used) 7-Retainer Washer (2 used) 134X Seal (2 used)


a--Lock Washer (6 used) 8-Bearing Cone (2 used) 14-Oil Seal Cup (2 used)
3-Gap Hub (2 used) Q-Front Wheel Hub (2 used) 15--Dust Shield
4-Cotter Pin (2 used) lo-Bearing Cup (2 used) M-Cap Screw (4 used)
6-Slotted Nut (2 used) ll-Bearing Cone (2 used) 17-Special Nut (4 used)
6-Hub Cap Gasket (2 used) la-Bearing Cup (2 used)

Fig. 4-Front Wheel Hub Assembly

Remove cap screws (1, Fig. 4) securing hub (3) to Parts should be dried with compressed air. Steam-
front wheel hub (9). cleaned parts should be oiled immediately after drying.

Remove cotter pin (4) and slotted nut (5) securing Bearings that have been in service should be
front wheel hub to spindle. thoroughly washed in volatile mineral spirits.

Remove front wheel hub assembly with dust shield If the bearings are particularly dirty or filled with
(15) from spindle. hardened grease, soak them in the spirits before trying
to clean them.
Remove bearing cups (10 and 12) and oil seal cup
(14) from front wheel hub. Inspect bearings for roughness of rotation. Replace
a bearing if its rotation is still rough after cleaning and
Remove bearing cone (11) from spindle. oiling.

Remove oil seal (13) from spindle. Inspect bearings for scored, pitted, scratched,
cracked or chipped races, and for indication of exces-
All parts must be clean to permit effective inspection. sive wear of rollers or balls. If one of these defects is
found, replace the bearing.
All metalic parts (except bearings) should be
cleaned thoroughly with volatile mineral spirits, or by Inspect all parts for excessive wear, cracks or other
the steam-cleaning method. Do not use a caustic soda damage. Replace as needed.
solution for steam cleaning.

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0230-4 Non-Powered Wheel Axles TM- 1188 (J&78)

Assembly
Pack lips of oil seal (1, Fig. 5) with John Deere
Multi-Purpose Grease or an equivalent and install onto
spindle (3) with metal face side toward spindle ears.

Drive bearing cups (5 and 6) in front wheel hub (3).

Install oil seal cup (7) in front wheel hub.

Pack bearing cones (2 and 9) with John Deere


Multi-Purpose Grease or an equivalent before install-
ing.

Install bearing cone (2) on spindle until bearing cone


bottoms out.

Position dust shield (8) on spindle and install front


wheel hub assembly.
TE0469N
Install bearing cone (9) and secure with retainer
washer (10) and slotted nut (11).
l-Oil Seal 8-Bearing Cone
2-Bearing Cone 1 O-Retainer Washer
Rotate front wheel hub while tightening slotted nut to 3-Spindle ll-Slotted Nut
70 lb-ft (95 Nm) (10 kg-m). NOTE: Nut threads must be 4-Front Wheel Hub 12-Cotter Pin
lubricated. !&Bearing Cup 13-Hub Cap Gasket
GBearing Cup M-Cap Hub
7-Oil Seal Cup l!&Cap Screw (3 used)
If dust shield interferes with wheel hub when hub is I--Dust Shield
rotated, grinding may be required on shield to eliminate
interference points. Fig. 5-Assembling Front Wheel Hub

Back off nut to first locking position and install cotter


pin (12).

NOTE: No measurable end play is allowed on the


front wheel hub.

Fill hub cap (14) with John Deere Multi-Purpose


Grease or an equivalent before installing.

Position hub cap with hub cap gasket (13) to front


wheel hub and secure with cap screws (15).

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM-1188 (Jul-79) Non-Powered Wheel Axles 0230-5

INSTALLATION
Position front axle assembly on two moveable floor
jacks.

Raise front axle in position with main frame and


install front axle pin (2, Fig. 2). Secure front axle
pin-to-main frame with cap screws (1). Tighten cap
screws to 170 lb-ft (230 Nm) (24 kg-m).

Connect scarifier cylinder (if so equipped).

Connect hydraulic lines to steering cylinders and


wheel lean cylinders.
l’60445N

l-Spindle Pin Bushing 12-Wheel Lean Link Pin


(4 used) (2 used)
Z-l?. H. Wheel Lean Id-Bushing (2 used)
Yoke 14-Wheel Lean Link
L. H. - (Not Shown) 15-Grease Fitting,
J-Special Nut (5 used) Straight (2 used)
4-Wheel Lean Cylinder 16-Steering Cylinder Pin
Pin 17-Cap Screw
5-Grease Fitting, 18-Bushing
Straight (6 used) 1g-Front Axle
B-Cap Screw (2 used) 20-Bushing (2 used)
7-Lock Washer (2 used) 21-Grease Fitting, 90”
8-Washer (2 used) (5 used)
g--Cap Screw (2 used) 22-Wheel Lean Pin
lO-Wheel Lean Cylinder (2 used)
Pin 23-Special Nut (2 used)
Ii-Cap Screw (3 used) 24-Cap Screw

Fig. b-Front Axle Assembly

Press bushings (1, 13, 18 and 20, Fig. 6) flush with


their counterbore.

Install right and left-hand wheel lean yokes (2) to l-Front Wheel Hub 4-Dust Shield (2 used)
front axle (19). with Spindle 5-Cap Screw (4 used)
2-Thrust Washer 6-Plug (4 used)
Install wheel lean pin (22) and secure with cap screw (2 used) 7-Wheel Lean Yoke
3-Spindle Pin (4 used) (2 used)
(9) and nut (23).
Fig. 7-/nsta//ing Front Wheel Hub
Refer to Group 0960 and install wheel lean cylinder. with Spindle
Secure with pins (4 and 22).

Position wheel lean link (14) to the left and right


wheel lean yoke and install wheel lean link pins (12).
Secure with cap screws (11) and nuts (3).

Refer to Group 0960 and install steering cylinder.

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0230-6 Non-Powered Wheel Axles TM- 1188 (Jul- 79)

Install front wheel hub with spindle (1, Fig. 7) as an


assembly to wheel lean yoke (7).

Install a thrust washer (2) between top of spindle


and wheel lean yoke.

Install spindle pins (3) aligning hole in pin with


spindle. Position dust shield in place and secure with
cap screws (5) and nuts.

Install plugs (6) and tighten.

Refer to Group 0920 and connect tie rods to spin-


dles.

Refer to Group 0120 and install front wheels.

Grease all fittings before operation.

Refer to Group 0920 for toe-in adjustment. Fig. &Location of Tapped Hole

Tire Chain Clearance on Front Wheel Drive Turn the wheels as far as possible in each direction
Units until the steering stop comes in contact with the cap
screws. Determine the length of cap screws which will
If tire chains are installed on the front wheels, dam- provide the adequate clearance.
age can occur to the hydraulic plumbing when tires are
turned in their extreme steering positions while the unit IMPORTANT: The tire chains must be snugly
is in motion. fastened and in good repair to insure good perfor-
mance and safety, and minimize the possibility of
Perform the following adjustment to maintain an damage.
adequate tire chain clearance:

Located in the rear side of the left (L.H.) and right


(PH.) wheel lean yoke is a IQ”-13 UNC tapped hole
(Fig. 8). Install a cap screw, with washers if required, in
both the tapped holes. Length of cap screws are not
important at this time.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (J&78) Axle Shafts, Bearings and Reduction Gears 0250-l

Group 0250
AXLE SHAFTS, BEARINGS, AND REDUCTION GEARS
GENERAL INFORMATION

3 K r-7
2
\ ,J
IF-I
/ I
Kii
I \WT
6

T61222N

l-Tandem Housing CTandem Drive Shaft g-Drive Sprocket


2-Pivot Housing GDriven Sprocket 10-Rear Wheel Axle Housing
3-01 Seal 7-Oil Seal 1 l-Wheel Axle
4-Final Drive Housing B--Chain

Fig. l-Final Drive System

The final drive housing (4, Fig. 1) contains a tandem Components of the final drive system may be ser-
drive shaft (5) mounted on tapered roller bearings and viced as follows:
a planetary reduction gear system.
1. Wheel axles, drive chains and sprockets may be
Power from the drive sprocket (9) on the tandem serviced without separating the tandem housing (1,
drive shaft is transmitted through chains (8) in the Fig. 1) from the final drive housing (4).
tandem housing to the driven sprockets (6). The driven
sprockets are splined to the axles (11). 2. To service the tandem drive shaft and planetary
system, refer to Group 0201 and remove tandem
All internal components, including the bearings, housing and final drive housing.
sprockets and chains are splashed-lubricated by the
lubricant in the tandem housing.

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0250-2 Axle Shafts, Bearings and Reduction Gear TM- 1188 (J&78)

DRIVE CHAIN

I-
2

f9 /=A’
ii
3--b* ’
5
/ /
/ /
t /
4 .’
*I
$!9@
/
/
/
/ t
1

l-Tandem Drive Chain 4-Connecting Link S-Wheel Axle Sprocket


2-Cotter Pin (2 used) 5-Tandem Drive Sprocket 7-2-Jaw Puller
3-Roller Link

Fig. P-Removing Chain Assembly

REMOVAL Raise and securely block under side of tandem


housing until the wheels clear the ground.
The tandem drive chains (1, Fig. 2) should be in-
spected when the top inspection covers are removed.
Roll tandem drive chain until cotter pin (2, Fig. 2)
Chain replacement should be made when slack in the
appear at tandem side cover.
chain exceeds 3 inches (76 mm).
Remove the cotter pins from the connecting link (4).
To check the chain slack, measure the distance from
the top of the tandem housing, at the inspection hole,
Position a 2-jaw puller or an equivalent to the con-
to the chain, with the chain slack. Then measure
netting link and drive out connecting link. Alternately
between the same points with the chain tight. If the
re-position 2-jaw puller to each side of link until con-
difference between the measurements exceeds 3
netting link is free for removal.
inches (76 mm), replace the chain.

Remove drive chain(s) from tandem housing.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Jul- 79) Axle Shafts, Bearings and Reduction Gears 0250-3

REPAIR Position connection ends of chain near tandem side


cover and tie ends with wire. Tighten wire until the
Clean tandem chain thoroughly to permit effective
connecting link (4, Fig. 2) can be installed.
1 inspection.

Press roller link (3) on connector link.


If chain is worn beyond the slack test on page
0250-2, replace entire chain assembly.
NOTE: The roller link must be a press fit on the
connector link pins. Replace roller link if otherwise.
Coat tandem chain assembly with oil before install-
ing.
Secure chain connection with cotter pins (2). Face
cotter pins away from each other.
INSTALLATION
Install tandem chain (1, Fig. 2) in tandem housing. Remove blocking from tandem housing and lower
Guide chain around the tandem drive sprocket (5) and unit.
wheel axle sprocket (6). NOTE: A piece of rope or wire
tied to the end of chain could be an aid when installing Install tandem housing covers.
chain on sprockets.

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0250-4 Axle Shafts, Bearings and Reduction Gears TM- 1188 (Jul- 79)

WHEEL AXLE ASSEMBLIES

T60473N

l-Cotter Pin GBearing Cone lO-Oil Seal


2-Slotted Hex Nut 7-Bearing Cup 1 l-Wear Sleeve
3-Sprocket Retainer 8-Bearing Cup 12-Wheel Axle
AWheel Axle Sprocket g-Bearing Cone U-Wheel Axle Housing
5-Thrust Washer

Fig. 3-Wheel Axle Assembly

REMOVAL REPAIR
Raise and securely block under tandem housing Disassembly
until wheels clear the ground.
Remove cotter pin (1, Fig. 3) and slotted hex nut (2)
from wheel axle (12).
Refer to Group 0110 and remove wheels.
Remove sprocket retainer (3) and wheel axle
Refer to Group 0201 and remove wheel axle as-
sprocket (4) from wheel axle.
semblies from tandem housing.
Press wheel axle (12) from wheel axle housing
being careful not to damage oil seal (10). Bearing cone
(6) will be free for removal.

Remove bearing cone (9) and oil seal (10) from


wheel axle.

Drive bearing cups (7 and 8) from wheel axle hous-


ing.

Refer to page 0250-9 for cleaning, handling and


inspecting parts.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Dee-87) Axle Shafts, Bearings and Reduction Gears 0250-5

Assembly

T6255AC -H-

(Front Wheel Axle Housing) (Rear Wheel Ax/e Housing)

l-Cotter Pin 6-Bearing Cone lo--Wear Sleeve


2-Slotted Hex Nut 7-Searing Cup 1 l-Oil Seal
3-Sprocket Retainer S-Bearing Cup 12-Wheel Axle
4-Wheel Axle Sprocket g-Bearing Cone l3-Wheel Axle Housing
B-Thrust Washer

Fig. 4-Assembling Wheel Axle

NOTE: The 0.75 in. (19 mm) wide wear sleeve (70,
Fig. 4) cannot be used with a new oil seal. Replace
with a new 0.83 in. (21 mm) wide sleeve.

Coat seal (11, Fig. 4) with multi-purpose grease.


Install wear sleeve (10) in seal with outer chamfered
end to the spring side of seal.

Apply a thin coat of thread lock and sealer (medium


strength) to axle surface (1, Fig. 4A).

Place wear sleeve and seal assembly on axle


shaft with spring side of seal towards the small end
of the axle shaft. Fig. 4A-Wheel Axle

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0250-6 Axle Shafts. Bearings and Reduction Gears TM- 1188 (Dee-871

install JT38058 spacer plates (1, Fig. 4C) between


axle flange and oil seal. Plates can be held together
with rubber bands at the cutout corners.

Lower axle housing assembly onto axle, being


careful to center seal and wear sleeve assembly.

l-Bearing Cone 4-Sprocket Retainer


2-JT38031 Driver 5-Hex Nut
3-Wheel Axle Sprocket

Fig. 4B-Installing Outer Bearing Cone

Fig. 4D-Assembling Wheel Axle


install outer bearing cone (1, Fig. 4B), JT38031
driver (2) sprocket (3) sprocket retainer (4) and nut
(5) on axle. NOTE: Install front sprocket with part number
toward wheel axle flange. Install rear sprocket with
Tighten nut to press wear sleeve and bearing cone the,part number away from the wheel flange.
on axle shaft. Loosen nut and turn JT38031 driver
l/2 turn. Tighten nut again to assure the bearing is Install bearing cone (6, Fig. 4) thrust washer (5)
tight against shaft shoulder. Remove nut, retainer, sprocket (4), sprocket retainer (3), and nut (2).
sprocket, and driver.
Tighten nut (2) until clearance between axle
Install bearing cups (7 and 8, Fig. 4) in axle housing housing (13) and JT38058 spacer plate is 0.065 in.
(1.65 mm), or axle end play is removed, whichever
(13).
comes first. Loosen nut (2) to remove JT38058 plates.

To adjust bearing preload, measure rolling drag


torque without bearing preload. Tighten nut (2) to
provide 10 to 25 lb-in (1.1 to 2.8 N.m) (0.12 to 0.29
kg-m) of rolling drag torque more than the rolling
drag torque without bearing preload. Install cotter pin
(1).

INSTALLATION
l-JT38058 l-Wear Sleeve and
Spacer Plates Oil Seal Assembly Refer to Group 0201 and install wheel axle
assemblies to tandem housing.
Fig. 4C-Installing Oil Seal and Wear Sleeve
Refer to Group 0110 and install wheels.

Remove blocking from tandem housing and lower


unit to the ground.
Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Mar-80) Axle Shafts, Bearings and Reduction Gears 0250-7

FINAL DRIVE ASSEMBLY

l-Snap Ring 7-Thrust Washer id--Roller Bearing (75 used)


2-Snap Ring Retainer E-Snap Ring 14-Special Washer
3-Bearing Cone (2 used) Q-Planet Pinion Carrier 16-Cap Screw
4-Bearing Cup (2 used) 18-Planet Pinion Shaft 16-Lock Plate
!i-Tandem Drive Shaft 1 l-Thrust Washer 17-Sun Pinion
6-Oil Seal 12-Planet Pinion (3 used) I-Snap Ring
I Q-Final Drive Shaft

Fig. 5-Final Drive and Planetary SyStem

REMOVAL REPAIR
Refer to Group 0110 and remove wheels. Disassembly I
Pull sun pinion (17, Fig. 5), brake disk and final drive I
Refer to Group 0201 and remove tandem housing,
shaft (19) from differential drive coupling.
tandem pivot and final drive housing from motor
grader.
Remove lock plate (16) and cap screw (15). Lift
planet pinion carrier assembly from axle housing.

Each planet pinion shaft (10) can be removed as


snap ring (8) is expanded to clear groove in planet
carrier (9).

Press tandem drive shaft (5) and bearing cone (3)


toward outside of housing.

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2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0250-8 Axle Shafts, Bearings and Reduction Gears TM-l 188 (Dee-87)

Remove bearing cups (4, Fig. 5) and oil seal (6)


from final drive housing.

Remove other bearing cone (3) and snap ring


retainer (2) from tandem drive shaft.

Refer to page 0250-9 for cleaning, handling and


inspecting parts.

Assembly
Replace entire set of roller bearings (13, Fig. 6) if
any are found to be defective or lost.

Coat bores of planet pinions (12) with John Deere


Multipurpose-Type Grease or an equivalent to retain
roller bearings (13).

Mount planet pinion (12) and roller bearings (13) in


carrier (9). Place thrust washers (11) on each side of
planet pinions and insert shafts (10) far enough to
secure roller bearing (13) in position. Install snap
ring (8).

Press bearing cups (4) into final drive housing,


tight against shoulder with 10,000 Ibs. (4536 kg).

Install oil seal (6) in final drive housing with seal


lips facing planetary carrier. l--Snap Ring g--Planet Pinion Carrier
l--Snap Ring Retainer lo--Planet Pinion Shaft
3-Searing Cone (2 used) 11-Thrust Washer
Install snap ring (1) on tandem drive shaft. Install
4-Searing Cup (2 used) 12-Planet Pinion (3 used)
snap ring retainer (2) with counterbore toward the 5-Tandem Drive Shaft 13-Roller Searing
snap ring. 6-011 Seal (75 used)
T-Thrust Washer 14-Special Washer
Heat bearing cones (3) for not more than two B-Snap Ring 15-Cap Screw
16-Lock Plate
hours in a suitable oil bath or hot air oven not
exceeding 300°F (149V).
Fig. d-Assembling Final Drive

A CAUTION: Oil fumes or oil can ignite above


380°F (193OC). Use a thermometer and do Install planet pinion carrier assembly (9, Fig. 6) on
tandem drive shaft and secure with special washer
not exceed 360°F (182OC). Do not allow a flame or
heating element to be in direct contact with the oil. (14) and cap screw (15).
Heat the oil in a well-ventilated area. Plan a safe
handling procedure to avoid burns. Adjust bearings by’first measuring the drag torque
with planet carrier assembled in place, but with end
Drive bearing cone on tandem drive shaft tight play in bearings. Tighten the planet pinion carrier
against the snap ring retainer. cap screw to give a drag torque of 15 to 35 lb-in (1.7
to 4.0 N-m) (0.17 to 0.40 kg-m) greater than that
Install tandem drive shaft assembly in final drive measured with end play.
housing and install the other bearing cone.
Install lock plate (16, Fig. 6) on cap screw.

NOTE: Put multi-purpose grease on both sides of


lock plate. Tighten cap screw a maximum of eight
degrees when installing lock plate. Do not loosen
cap screw.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Jul- 79) Axle Shafts, Bearings and Reduction Gears 0250-g

1 Install sun pinion (17, Fig. 5) brake disk and final Bearings that have been in service should be
drive shaft (19) into differential drive coupling. thoroughly washed in volatile mineral spirits.

INSTALLATION If the bearings are particularly dirty or filled with


hardened grease, soak them in the spirits before trying
Refer to Group 0201 and install final drive and pivot
to clean them.
housing to motor grader. Refer to the same group and
install tandem housing assembly.
Before inspection, oil the bearings with the same
type of oil that will be used in the final drives.
Refer to Group 0110 and install wheels.
NOTE: Never spin dry bearings with compressed
CLEANING, HANDLING AND air. Do not rotate bearings while they are not lubrica t-
INSPECTING ed.
Parts which have close operating tolerances must
be handled carefully to prevent nicking, scratching, or Inspect bearings for roughness of rotation. Replace
denting. The slightest damage to these parts can result a bearing if its rotation is still rough after cleaning and
in erratic operation and possible malfunction of the final oiling.
drives. These parts should be carefully handled and
protected during removal, cleaning, inspection, and Inspect bearings for scored, pitted, scratched,
installation. cracked or chipped races, and for indication of exces-
sive wear of rollers or balls. If one of these defects is
All parts must be clean to permit effective inspection. found, replace the bearing.
During assembly, it is very important that no dirt or
foreign matter enters the final drives. Even minute Inspect the defective bearing’s housing and shaft for
particles can cause the malfunction of close-fitting grooved, burred, or galled conditions that indicate the
parts. bearing has been turning in its housing or on its shaft. If
the damage cannot be repaired with crocus cloth,
All metallic parts of the final drives (except bearings) replace the defective part.
should be cleaned thoroughly with volatile mineral
spirits, or by the steam-cleaning method. Do not use a Inspect lip-type oil seals for cuts and hardness.
caustic soda solution for steam cleaning. Gum and Replace the oil seal if these defects are found.
varnish deposits should be removed by allowing the
parts to soak in varnish remover. When replacing lip-type oil seals, make sure the lip
of each oil seal is toward the oil to be sealed (toward
Parts should be dried with compressed air; steam- the inside of the unit). Use a nonhardening sealing
cleaned parts should be oiled immediately after drying. compound on the outside of the seal to help prevent oil
leaks. Coat the inside of the seal with high temperature
Clean oil passages by working a piece of soft wire grease (AT30408 or equivalent) to protect the seal
back and forth through the passages and flushing with during shaft installation and to provide lubrication dur-
spirits. Dry the passages with compressed air. ing initial operation.

After cleaning, examine the parts and especially the Inspect gears or sprockets for scuffed, nicked,
oil passages to make certain they are entirely clean. burred, or broken teeth. If the defect cannot be re-
Reclean them if necessary. moved with a soft honing stone, replace the gear.

Inspect gear or sprocket for wear that may have


destroyed the original tooth shape. If this condition is
found, replace the gear.

Litho in U.S.A.
2 Axles and Suspen_ion System JD670-A and JD672-A Motor Graders
0250-10 Axle Shafts, Bearings and Reduction Gears TM- 1188 (Jun-83)

02

l-Area of Early Units 4-Revised Seal with Spacer in


2--Revised Area in Later Units Later Units
3-Seal Area in Early Units %--Revised Seal without Spacer
in Later Units
Fig. 7-Front Wheel Drive Assembly

ritho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Jul-78) Axle Shafts, Bearings and Reduction Gears 0250-I 1

On the JD672-A Motor Grader an outboard double Rotate planetary housing until drain plug (1, Fig. 8)
planetary drive is attached to the front axles which will is located at bottom. Remove plug and drain the oil.
provide additional traction when required.
Remove cap screws (2) securing cover (3) to plan-
Power to the planetary drives is provided by a hy- etary housing and remove the cover.
draulic motor located in the motor housing.

REMOVAL
NOTE: Parts which make up the front wheel drive
can be removed separately while mounted on the front
axle.

IMPORTANT: When removing the hydraulic


parts that make up the front wheel drive, keep the
surrounding area clean. Either steam clean or use
diesel fuel to clean the area. Cleanliness is very
important on the unit. Cap and plug all hydraulic
lines and hoses to keep foreign material from en-
tering the hydraulic system.

Refer to Group 0110 and remove wheel from wheel


hub.

l-First Planet P-First Planet Pinion


Sun Pinion Carrier Assembly

Fig. 9-Firsf Planet Pinion Carrier Assembly

Remove first planet sun pinion (1, Fig. 9) and first


planet pinion carrier assembly (2).

l-Drain Plug 3-Cover


2-Cap Screw (8 used)

Fig. b-planetary Cover

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2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0250-l 2 Axle Shafts. Bearinqs and Reduction Gears TM- 1188 (Jul-78)

Remove the second planet sun pinion (1, Fig. 10).

Remove cap screws (2) securing the planetary


housing (3) to wheel hub (4). Hoist planetary housing
from hub.

CAUTION: Lifting planetary housing with-


A out an aid of a hoist could cause personal
body injury.

l-Cap Screw (24 used) 3-Second Planet


2-Planet Brake Sacking Ring Gear
Plate

Fig. 7 l-Removing Planet Brake Backing


Plate Assembly

Remove cap screws (1, Fig. 11) securing planet


brake backing plate (2) to brake piston housing. NOTE:
Loosen cap screws in an alternate sequence because
l-Second Planet Sun 3-Planetary Housing the brake backing plate is spring applied.
Pinion 4-Wheel Hub
2-Gap Screw (16 used)
Remove planet brake backing plate, second planet
ring gear (3), brake facings and planet brake pressure
Fig. 1O-Removing Planetary Housing
plate as an assembly.

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JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (J&78) Axle Shafts, Bearings and Reduction Gears 0250-l 3

l-Special Screw 2-Planet Brake Piston l-Wheel Hub J-Motor Housing


(10 used) Housing 2-Outer Bearing Cone

Fig. l2-Removing Planet Brake Piston Housing Fig. 13-Removing Wheel Hub

Remove special screws (1, Fig. 12) securing planet Grab outer edge of wheel hub (1, Fig. 13) and pivot
brake piston housing (2) to wheel hub. Remove planet against housing to remove outer bearing cone (2) from
brake piston housing. motor housing (3).

IMPORTANT: The word “UP” stamped on the Remove hub and inner bearing.
planet brake piston housing identifies correct po-
sition of planet brake piston housing when re-in-
stalling.

NOTE: Be careful not to lose O-ring between piston


housing and motor housing.

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2 Axles and Suspension System JD670-A and JD672-A Motor ,Graders
0250-14 Axle Shafts, Bearings and Reduction Gears TM- 1188 (Jun-83)

REPAIR
First Planet Pinion Carrier Assembly
Disassembly

l-Dowel Pin At Shaft 2-Snap Ring

Fig. 15-Removing First Planet Pinions


Fig. 14-Removing Oil Seal From Motor Housing

To remove oil seal (Fig. 14) from motor housing, pry To remove first planet pinions, insert a drift at dowel
behind seal on opposite sides. Be careful not to score pin closest to the break in snap ring (2, Fig. 15). Push
motor housing surfaces. snap ring out of groove and remove snap ring. Remove
dowels (1) which hold pinion shafts in place.

Remove pinion shafts and disassemble planet pinion


assemblies.

Inspect roller bearings (4, Fig. 16) in each pinion for


wear. NOTE: If any roller bearing is found defective,
replace bearings as an entire set.

Check first planet pinion carrier (1) and first planet


pinions (3) for breaks or chips.

inspect first planet pinion shafts (5) for worn or bent


conditions.
l-Spacer 3-Motor Housing
P-Seal Replace parts as necessary.
Fig. 14A-Remove Spacer

On units with two-piece oil seal, remove spacer (1,


Fig. 14A) if used.

NOTE: On /a ter units, motor housing is machined with


a shoulder for seal. These units do not require a spacer.
See Figure 7.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Jul- 79) Axle Shafts, Bearings and Reduction Gears 0250-l 5

l-First Planet Pinion Carrier 4-Roller Searing (17 used) S-Dowel Pin
2-Thrust Washer (2 used) !5-First Planet Pinion Shaft 7-Snap Ring
3-First Planet Pinion

Fig. lb-First Planet Pinion Carrier Assembly

Assembly
Thoroughly clean all parts before assembling.

Apply John Deere Multi-Purpose Grease or an


equivalent to roller bearings (4, Fig. 16) and assemble
roller bearings in first planet pinions (3).

Install first planet pinion shafts (5) in planet pinions.


Place thrust washer (2) on each side of pinion assem-
bly.

Align hole in first pinion shafts with holes in first


planet pinion carrier and install dowel pin (6).

Install snap ring (Fig. 17) securing planet pinion


assemblies.

Fig. 17-Installing Snap Ring

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2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0250-I 6 Axle Shafts, Bearings and Reduction Gears TM- 1188 (Jul- 79)

Second Planet Pinion and Housing


Assembly
Disassembly (Early Units)

l-Second Planet Pinion 3-Steel Ball (2 used)


2-Second Planet Pinion 4-Roller Bearing
Shaft (22 used)
5-Thrust Washer (2 used)

Fig. 19-Second Planet Pinion Assembly

Inspect roller bearings (4, Fig. 19) in each pinion for


wear. NOTE: If any roller bearing is found defective,
replace as an entire set.

l-Planetary Housing 3-Planet Pinion Retainer Check second planet pinion (1) and planetary
2-Cap Screw (6 used) 4-Second Planet Pinion housing for breaks or chips.
Shaft (3 used)
inspect second planet pinion shaft (2) for worn or
Fig. l&Removing Planet Pinion Retainer
bent conditions.

Remove cap screws (2, Fig. 18) securing planet


Replace parts as necessary.
pinion retainer (3) to planetary housing (1).

Assembly (Early Units) I


Pry under planet pinion retainer to remove the re-
I tainer. NOTE: Tap on second planet pinion shafts (4) Thoroughly clean all parts before assembling.
while removing retainer to keep planet pinion assem-
blies in planetary housing. Apply John Deere Multi-Purpose Grease or an
equivalent to bearing rollers (4, Fig. 19) and assemble
Pull each planet pinion assembly from planetary bearing rollers in second planet pinion (1).
housing for disassembly.
Install second planet pinion shafts (2) in planet pin-
NOTE: Be careful not to lose shaft retainer balls (3, ions. Place thrust washers (5) on each side of pinion
Fig. 79). assembly.

Apply grease to steel balls (3) and install in holes of


shafts. Make sure thrust washers are installed first.

If care is taken the balls will hold the pinion assembly


together during installation. Index ball with the retainer
seat in shaft bores. Install assembly into planetary
housing.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Jul- 79) Axle Shafts, Bearings and Reduction Gears 0250-17

I-Dowel Pin (3 used) 3-Slots in Planetary l-Planet Pinion Retainer 2-Cap Screw (6 used)
2-Second Planet Pinion Housing
Assembly Fig. PI-/n.sta// Planet Pinion Retainer

Fig 20-installing Second Planet Pinion Assemblies Install planet pinion retainer (1, Fig. 21) over dowel
pins and pinion shafts. NOTE: Make sure steel balls
Tap on pinion shafts to secure pinion assemblies in are installed in pinion shafts before installing planet
planetary housing. pinion retainer.

When replacing dowel pins (1, Fig. 20), drive dowel Secure planet pinion retainer with cap screws (2)
pins in planetary housing until pins bottom out. and special flat washers. Tighten cap screws to 50 lb-ft 1
(68 Nm) (7 kg-m).

NOTE: For repair on the later version of the second


planet pinion and housing, turn to the next page.

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_-
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0250-18 Axle Shafts, Bearings and Reduction Gears TM- 1188 (Jul-79)

Disassembly (Later Units)

l-Second Planet Pinion 3-Roller Pin


l--Second Planet Pinion 4-Roller Bearing (22 used)
Shaft 6-Thrust Washer (2 used)

Fig. 23-Second Planet Pinion Assembly

Inspect roller bearings (4, Fig. 23) in each pinion for


wear. NOTE: If any roller bearing is found defective,
replace as an entire set.
l-Planetary Housing 4-Planet Pinion Retainer
2-Roller Pin (3 used) 6-Cap Screw (6 used)
3-Pipe Plug (3 used) GSecond Planet Pinion Check second planet pinion (1) and planetary
Shaft (3 used) housing for breaks or chips.

Fig. 22-Removing Planet Pinion Retainer


Inspect second planet pinion shaft (2) for worn or
bent conditions.
Remove the three pipe plugs (3, Fig. 22) from the
planet pinion retainer (4). Inspect roller pin (3) for bent conditions. The pin
must pass freely through the planet pinion shafts.
insert a drift in small hole (see large arrow) from
inside of the planet pinion retainer and remove roller Replace parts as necessary.
pin (2).
Assembly (Later Units)
Pry under planet pinion retainer to remove the re-
tainer. NOTE: Tap on second planet pinion shafts (6) Thoroughly clean all parts before assembling.
while removing retainer to keep planet pinion assem-
blies in planetary housing. Apply John Deere Multi-Purpose Grease or an
equivalent to bearing rollers (4, Fig. 23) and assemble
Pull each planet pinion assembly from planetary bearing rollers in second planet pinion (1).
housing for disassembly.
Install second planet pinion shafts (2) in planet pin-
ions. Place thrust washers (5) on each side of pinion
assembly. NOTE: The hole inplanetpinionshafts must
be at the top of the pinion assemblies.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Jul-79) Axle Shafts, Bearings and Reduction Gears 0250-l 9

l--Dowel Pin (3 used) 3--Second Planet Pinion l-Planet Pinion Retainer 3-Pipe Plug (3 used)
2-Second Planet Pinion Shaft (3 used) 2-Roller Pin (3 used) 4-Cap Screw (6 used)
Assembly
Fig. 25-Installing Planet Pinion Retainer
fig. 24installing Second Planet Pinion Assemblies
Install planet pinion retainer (1, Fig. 25) over dowel
Use care in handling the second planet pinion as- pins and pinion shafts.
sembly (2, Fig. 24) so roller bearings do not fall out.
Install each assembly into the planetary housing. Align holes in pinion shafts and planet pinion re-
tainer and install the roller pins (2). NOTE: Roller pin
Tap on pinion shafts (3) to secure pinion assemblies must pass freely through the retainer and shafts.
in planetary housing. Index shafts, so hole, points
toward the center of the planetary housing. Secure the roller pins with pipe plugs (3). Tighten the
pipe plugs with 7 to 8 lb-ft (10 to 11 Nm) (1 to 1.1
When replacing dowel pins (l), drive dowel pins in kg-m).
planetary housing until pins bottom out.
Secure planet pinion retainer with cap screws (4)
and special flat washers. Tighten cap screws to 85 lb-ft
(115 Nm) (12 kg-m).

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2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0250-20 Axle Shafts, Bearings and Reduction Gears TM- 1188 (Jul- 79)

Brake Backing Plate Assembly


Disassembly

l-Planet Brake Backing Plate 3-Second Planet Ring Gear 6-Spring (6 used)
2-Facing (2 used) 4-Planet Brake Pressure Plate

I Fig. 26-Brake Backing Plate Assembly

Disassemble brake backing plate assembly into inspect facings (2, Fig. 26) for wear or breaks. 1
parts as shown in Fig. 26. Replace when grooves are not visible or facing is
broken or chipped.
Inspect second planet ring gear (3, Fig. 26). Its side
surfaces should be free of chips and scoring since it is Check return springs (5) for proper strength and
also used as a brake for gear reduction. appearance. Springs should be 1.69 in. (43 mm) long
at 70 to 86 lbs. (312 to 383 N) (31 to 38 kg) load. Free
Inspect planet brake backing plate (1) and planet length should be 1.89 in. (48 mm).
brake pressure plate (4) for wear or scoring.

bitho in U.S.A.
JD670-A and JD672-A Motor Graders Ax/es and Suspension System 2
TM- 1188 (Jul- 79) Axle Shafts, Bearings and Reduction Gears 0250-21

Assembly

l-Spring (6 used) 3-Facing l-Facing 2-Planet Brake Pressure Plate


2-Planet Brake Backing cl-Second Planet
Plate Ring Gear Fig. 28-Installing Planet Brake Pressure Plate

I Fig, 274nstalling Second Planet Ring Gear


Install other facing (1, Fig. 28) on second planet ring
gear.
Thoroughly clean all parts before assembly.
install planet brake pressure plate (2) with counter-
1 Install springs (1, Fig. 27) in planet brake backing
bores on tabs, toward springs.
plate (2).

Install facing (3) and second planet ring gear (4) in


planet brake backing plate.

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2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0250-22 Axle Shafts, Bearings and Reduction Gears TM- 1188 (Jul- 79) ’

Planet Brake Piston Housing Inspect backup rings (2, Fig. 30) and O-rings (3) for 1
damage.
Disassembly

Inspect planet brake piston (1) for chips or scoring.

Inspect planet brake piston housing (4) for chips,


cracks, or other damage.

Replace parts as necessary.

Fig. 29-Removing Planet Brake Pistons

Remove planet brake pistons (Fig. 29) from brake


housing by inserting a 5/16 inch eye bolt or cap screw
in threaded hole in end of piston. Pull piston out of its
bore.

l-Plug 2-O-Ring

Fig. 3 1-Inspeciing O-Ring

Remove plug (1, Fig. 31) and O-ring (2) from back of
planet brake piston housing. Insert a piece of wire into
oil passage to clean dirt or other foreign matter from
passage.
.,>,.)
,_l cI\n-1s..
\rrri.‘i*l.l
Assembly
l-Planet Brake Piston 3-O-Ring (12 used)
(12 used) 4-Planet Brake Piston Thoroughly clean all parts before assembling.
2-Backup Ring Housing
(12 used) Install plug (1, Fig. 31) and tighten. Apply John I
Deere Multi-Purpose Grease or an equivalent to O-ring
I Fig. 30-Planet Brake Piston Assembly
(2) and install on back of planet brake piston housing.

Position backup ring (2, Fig. 30) in front of O-ring (3) 1


and install in piston bores. Make sure they seat in their
grooves.

Install planet brake pistons (1) in bores of planet


brake piston housing (4). NOTE: Pistons may be in-
terchanged in other piston bores. When installing the
last brake piston, loosen plug (I, Fig. 31). This way you
defeat the “vacuum effect”.

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JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 7 188 (Jun-83) Axle Shafts, Bearings and Reduction Gears 0250-23

Wheel Hub Assembly Inspect wheel hub for cracks or other damage. Re-
place wheel hub if necessary.
DisassemSbly
Inspect bearing cups and motor housing for grooved,
burred, or galled conditions that indicate the bearings
have been turning in its cups or on the motor housing. If
the damage cannot be repaired with crocus cloth, re-
place the defective part.

Assembly
Thoroughly clean all parts before assembling.

If the wheel hub and/or bearing cups were re-


placed, see Wheel Bearing Adjustment on page
0250-24 to determine the correct amount of shims to
be used.

Place the determined amount of shims against the


outer bearing cup shoulder and install outer and in-
ner bearing cups.

T91.837

l-Wheel Hub 3-Shims (as required)


2-Bearing Cup 4-Oil Seal Cup
(2 used) (401794- 1

fig. 32-Wheel Hub Assembly

On units with serial numbers from (40 1794- )>


remove oil seal cup (4, Fig. 32).

Drive bearing cups (2, Fig. 32) from wheel hub (1).
NOTE: Shims are located behind outside bearing cup so
be careful not to damage shims when removing bearing
cup.

Keep respective shim pack (3) with bearing cup.

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2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0250-24 Axle Shafts, Bearings and Reduction Gears TM- 1188 (Jul- 79)

INSTALLATION AND ADJUSTMENT

l-Motor Housing 3-Inner Bearing Cone l-Wheel Hub 4-Washers (4 used)


2-Dowel Pin (2 used) 2-Outer Bearing Cone 5-Weight
3-Strap Iron (2 used)
Fig. 33-Installing Dowel Pins
Fig. 34-Measuring For Shim Replacement
When replacing dowel pins (2, Fig. 33) drive pins in
motor housing (1) until pins bottom out. 5. Tighten both strap bolts so washers are lightly
held.
Wheel Bearing Adjustment
6. Bolt a 3-lb. (14 N) (1.36 kg) weight (5, Fig. 34) at
I 1. install inner bearing cone (3, Fig. 33) over motor
the 2 o’clock position on the outer edge of the front
housing.
wheel hub.

NOTE: Do not install oil seal until after bearing


7. Release the weight from its 2 o’clock position.
adjustment.
Slightly tighten only one cap screw until weight fails to
turn wheel hub.
1 2. Install front wheel hub (1, Fig. 34) and outer
bearing cone (2).
8. Mark the cap screw and back off l/2 turn.

3. Bolt two pieces of strap iron (3) approximately 6


9. Release the weight again from its 2 o’clock posi-
in. (150 mm) long, to the front of the motor housing.
tion. Slightly tighten second cap screw until weight fails
to move the hub.
4. Place a washer (4) under each strap end so they
contact the edge of the bearing. Washers should not
10. Retighten the first cap screw the same amount it
contact motor housing.
was backed off.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Jul- 79) Axle Shafts, Bearirw and Reduction Gears 0250-25

Wheel Bearing Adjustment-Continued

A-End Play E-Preload

I Fig. 35-Using Feeler Gauge to Measure


End Play or Preload
60509N
Il. Lay a straightedge across motor housing and
A-Additional Shims Required l-Strap Iron
outer bearing. Use a feeler gauge to measure between
B-Deduction of Shims Required 2-Motor Housing
straightedge and outer bearing to determine end play
1 (A) or preload (B, Fig. 35). Fig. 36-Adjusting Fronf Bearings

12. Vary the number of shims behind the outer


bearing cup in the front wheel hub until the bearing is
adjusted to 0.004 in. preload to 0.004 in. end play (0.10
mm preload to 0.10 mm end play) (Fig. 36).

13. Remove hub and bearings to install oil seal.

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0250-26 Axle Shafts, Bearings and Reduction Gears TM- I 188 (Jun-83)

Installation-Continued To install two-piece oil seal, put SILASTIC@ 732 RTV ’


Adhesive/Sealant or an equivalent on the inner surface
of seal. Install seal (2, Fig. 37A) on motor housing (3)
with spring load side facing inner bearing cone. Push
seal tight against housing. Fill seal lips with multi-pur-
pose grease.

Put SILASTIC 732 RTV Adhesive/Sealant or an


equivalent on outer surface of oil seal cup. Press oil seal
cup (4, Fig. 32) tight against wheel hub. Put multipur-
pose grease on inner surface of cup.

Install inner bearing cone.

Install wheel hub (1, Fig. 38) over inner bearing cone
and using the bearing as a guide, slide hub in until outer
bearing cone (2) can be installed.

Fig. 374nstaU One-Piece Oil Seal Slide wheel hub assembly carefully next to seal. Use
To install one-piece oil seal, coat oil seal (Fig. 37) with care not to tilt wheel hub damaging the motor housing.
clean oil and install oil seal with the small holes in the
seal, facing the inner bearing cone.

Make up a simple driver to install the seal, or if a seal


driver is not used, use a brass drift to drive the seal flush
to 0.010 inch (0.25 mm) below shoulder on motor hous-
ing. The inner bearing cone (3, Fig. 33) can also be used
to install the seal, but be sure to clean the bearing thor-
oughly before reusing. Refer to page 0250-9 for clean-
ing and inspecting bearings.

T60488NY

l-Wheel Hub 3-Motor Housing


2-Outer Bearing Cone
T91591
Fig. 384nstahg Wheel Hub
l-Spacer 3-Motor Housing
2-Seal SILASTIC is a trademark of Dow Corning Corp. 1

Fig. 37A-install Two-Piece Oil Sea/

Install spacer (1, Fig. 37A) if motor housing does not


have a machined shoulder for seal. See Figure 7.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Jun-83) Axle Shafts, Bearings and Reduction Gears 0250-27

T60486NY TKJ484

l-Special Screw P-Planet Brake Piston l-Planet Brake Backing P-Cap Screw (24 used)
(10 used) Housing Plate Assembly 3-O-Ring

Fig. 39hstall Planet Brake Piston Housing Fig. 40-installing Planet Brake Backing
Plate Assembly
install planet brake piston housing (2, Fig. 39) on
wheel motor houing. IMPORTANT: Be sure “UP” Position the planet brake backing plate assembly (1,
marked on housing is at top and make sure small O- Fig. 40) to planet brake piston housing. Make sure brake
ring is installed in oil port on back of brake piston pressure plate and springs are installed.
housing.
Secure backing plate assembly with cap screws (2).
Secure planet brake piston housing with special Tighten cap screws to 35 lb-ft (47 N.m) (5 kg-m).
screws (1). Tighten F-grade cap screws to 100 lb-ft (136
N.m) (14 kg-m). Tighten G-grade cap screws to 120 lb-ft Apply John Deere Multi-Purpose Grease or an equiv-
I (163 N.m) (17 ka-m). alent on O-ring (3) and install on wheel hub.

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0250-28 Axle Shafts, Bearings and Reduction Gears TM- 1188 (Jun-83)

1 -Planetary Housing 3-Second Planet Sun


2-Wheel Hub Pinion T60512h11

1-Firat Planet Pinion l-First Planet Sun Pinion


Fig. 4 l-hstalling PlanetaryHousing Carrier Assembly 3-Gasket

Hoist planetary housing (1, Fig. 41) in position with Fig. 42-Installing First Planet Pinion Carrier Assembly
wheel hub. Align second planet pinions with second ring
gear. Be careful not to damage O-ring.

Secure planetary housing-to-wheel hub with cap


screws. Tighten cap screws to 35 lb-t? (47 N.m) (5 kg-
ml.
Install second planet sun pinion (3) in planetary hous-
ing.

Install first planet pinion carrier assembly (1, Fig. 42)


and align first planet pinions to first planet ring gear.
Install first planet sun pinion (2).

Apply John Deere Permatex Form-A-Gasket or


equivalent to gasket (3) and install on planetary housing.

Install cover (1, Fig. 43) and secure with cap screws
(2) and washers. Tighten cap screws to 50 lb-ft (69 N.m)
(7 kg-m).

Rotate planetary housing until plug (3) is in the top


position. Fill planetary housing with approximately 3 gal.
(11 L) of recommended oil. (See Section 1, Group V for
the type of oil used.
l-Cover 3-Plug
NOTE: Run grader with front wheel drive activated l-Cap Screw (8 used)
for a period of time and then check transmission oillevel.
Fig. 43-Installing Planetary Cover
Drain or fill transmission to proper dipstick level.

Refer to Group 0110 and install wheel to wheel hub.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Dee-87) Hydraulic System 0260-l

Group 0260
HYDRAULIC SYSTEM
WHEEL MOTOR AND OIL MANIFOLD
REMOVAL
To remove left wheel motor and oil manifold, steer
front wheels to the full right. To remove right wheel
motor and oil manifold, steer front wheels to the full
left.

A-Sensor B-Cable Support Bracket

fig. lA-L. H. Wheel (Later Units)

Drain oil from planetary housing by removing plug


(Fig. 2).

l-Motor Housing 3-Front Sensor


2-Oil Manifold

Fig, 1 -L. H. Wheel (Early Units)

Fig. P-Planetary Housing Plug

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0260-2 Hydraulic System TM- 1188 (Dee-87)

IMPORTANT: Front and rear sensors are sensitive.


Caution should be exercised at all times to insure
that the sensor and lead wiring are not damaged.

IMPORTANT: Sensor and wiring to sensor are


serviced as one part. If wire breaks, it will be neces-
sary to also replace sensor. During removal and
installation, be sure to turn wire with sensor. Also, it
is important not to disconnect protective hose from
cover.

To remove front sensor on early units, carefully


disconnect harness (5, Fig.3) at frame. Remove sensor
cover (3). Loosen jam nut. Unscrew sensor turning
harness with cover to prevent twisting of the sensor
wire.

To remove front sensor on later units, remove


cover at front of equipment frame. Disconnect front
sensor connector. Remove tie bands and clamps
along sensor wire. Remove cap screws holding cable
support (B, Fig. 3A) and cable clamp to remove
support. Loosen locking nut on sensor. Unscrew
sensor and wiring harness to remove.

REPAIR

l-Brake Pressure Hose 3-Front Sensor Cover Disassembly


P-Cap Screw (6 used) 4--Tie Rod
IMPORTANT: When performing internal service on
S-Harness Connection
the motor, keep the work bench, tools, and equip-
ment clean. Cleanliness is very, important on this
fig. 3-Left Wheel Oil Manifold (Early Units)
unit.

Use only diesel fuel to clean parts. Solvents are


damaging to the internal components. Dry with clean
compressed air (do not exceed 30 psi [2 bar]
[kg/cm*]).

On early units, if the front sensor is attached to the


manifold, remove the front cap screw retaining the
sensor cover to obtain the maximum clearance when
removing the manifold.

Remove the six oil manifold cap screws (2).

A-Sensor B-Cable Support Bracket


IMPORTANT: Behind the oil manifold are a valve
plate and a bearing plate which have lapped
Fig. 3A-Left Wheel Oil Manifold (Later Units)
surfaces. DO NOT allow the two parts to drop when
removing oil manifold.
Jack up and block the front axle on the appropriate
c
side.
With one hand under oil manifold to hold the valve
plate and bearing plate, remove the oil manifold from
Disconnect tie rod (4, Fig. 3) and swing out of the
the dowels.
way.
IMPORTANT: Separately wrap the valve plate and
Remove brake hose (1).
bearing plate in lint free paper towels and set out of
the way.
Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0260-4 Hydraulic System TM- 1188 (Jul-78)

l-Knife Puller 2-Tape

Fig. 6-Wrapping Puller

IMPORTANT: Wrap the knife type bearing puller


(1, Fig. 6) with tape (2) so there is a cushion
between the metal surface of the puller and that of
the lapped surface of the motor cylinder block.

Attach bearing puller as shown in Fig. 7. Pull bear-


ing.

Fig. 7-Pulling Bearing

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (J&78) Hydraulic Sys tern 0260-3

l-Oil Manifold 3-Bearing Cup


P-Valve Plate

Fig, 4-Oil Manifold

Remove valve plate (2, Fig. 4) from oil manifold (1)


by lifting with a wood dowel only at the retaining pin
l-Bearing Plate 3-Sensor Plate
groove. 2-Dowel Pin Groove 4-Gap Screw

IMPORTANT: If anyplace but the retaining pin Fig. 5-Bearing Plafe Removal
groove is used as a pry point, the lapped surface (L. H. Wheel)

may be damaged.
Carefully pull motor approximately 0.25 in. (6.4 mm),
Remove bearing plate (1, Fig. 5) by prying only at then rotate motor assembly 180” while removing it from
the dowel pin groove (2) with a wood dowel. the wheel to clear the wheel lean yoke.

Separately wrap the valve plate and bearing plate in


lint free paper towels. Set them away from the working
area.

Remove bearing plate pilot ring (17, Fig. 9).

Remove cap screw (4, Fig. 5) and sensor plate (3)


(L. H. Wheel Only).

IMPORTANT: The slipper side of the swashplate


and the bearing plate side of the cylinder block are
lapped surfaces. Be very careful not to damage
this part or allow metal to metal contact of these
surfaces.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM-1 188 (J&78) Hydraulic Sys tern 0260-5

Insert a bolt (1, Fig. 8) with a large washer (2)


through the I.D. of the cylinder block.

NOTE: Make sure washer (2) is not too large that it


contacts retaining ring (3).

Place another large washer and a nut at the splined


end of the cylinder block.

Tighten nut to compress the spring (3, Fig. 9).

Remove retaining ring.

IMPORTANT: Do not pry on the I.D. of the cylin-


der block to remove ring. A burr created on this I.D.
will cause leakage between the bearing plate and
cylinder block.

l-Bolt 2-Washer 3-Retaining Ring

Fig. &Removing Cylinder Block Parts

Remove spring guide (16, Fig. 9) from shaft.

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0260-6 Hvdraulic Svstem TM- 1188 (J&78)

l-Retaining Ring 7-Large Bearing 12-Spring (6 used)


P-Spring Retainer 6-Swashpiate 13-Cylinder Block
3-Spring Q-Bail Guide W-Dowel Pin
4-Spring Seat 1O-Piston Retainer 16-Bearing Plate
6-Small Bearing 11-Piston Assembly (9 used) 16Spring Guide
6-Shaft 17-Bearing Plate Pilot

fig. O-Motor Assembly

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Jul- 79) Hydraulic Sys tern 0260-7

Inspection The balance land (1, Fig. 10) balances the 5000 psi
(345 bar) (352 kg/cm2) system pressure, against the
Wash all parts in diesel fuel and dry thoroughly. Coat case pressure. Scoring of both lands (4) and (5) would
all Darts with clean oil. indicate fine contamination over a long period of time.
Deep scoring of one land would indicate the presence
IMPORTANT: Be very careful when handling of large contaminants in the system.
these parts during washing, drying and inspection.
Keep parts separated from each other by wrapping Bearing plates may be encountered where the bal-
the parts in lint free paper towels. ance land (1) appears good, but the outer foot (2, Fig.
10) is scored. This condition could arise from either a
NOTE: To dry parts after washing in diesel fuel, lack of lubrication or from a lubricant breakdown. This
shake off excess liquid and blow dry with clean com- condition would not indicate the presence of con-
pressed air. DO NOT dry with rags or paper towels. taminants in the system.

Inspect all surfaces for excessive wear, nicks, NOTE: Failure of a bearing plate can be caused by
scratches, or scoring. any one or a combination of the following:

Refer to Fig. 10 to familiarize yourself with the 1. Cavitation (caused by air in the system oil).
various parts of a valve or bearing plate.
2. Contamination (from either within the system or
from outside the system).

3. Water (indicated when oil in the reservoir is


white, milky, or light yellow in color and bearing plate is
discolored).

TE0383N

l-Balance Land 4-Outer Land


2-Outer Foot 5-Inner Land
3-Kidney

Fig. 70-Parts of a Valve or Bearing f/ate

NOTE: Replace bearing plate, valve plate or ball


guide if a scratch or groove can be detected with a lead
pencil.

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0260-8 Hydraulic System TM- 1 I88 (Jul- 79)

Examples of Scored
Bearing Plates and Valve Plates

Fig. 12-Example of Deeply Scored Searing Plate

This bearing plate (Fig. 12) shows deep scoring only


Fig. 7 l-Example of Scored Searing P/ate through the area on the balance land between the
kidneys. This deep scoring indicates solid particles of
This bearing plate (Fig. 11) shows complete inter- contamination within the system.
face (bearing plate to valve plate) scoring due to fine
abrasive contamination (dust or dirt) suspended in the
hydraulic fluid. This example (Fig. 11) could also indi-
cate early stages of water contamination. When water
is present in the system, the oil in the reservoir is white,
milky, or light yellow in color.

NOTE: Replace bearing plate, valve plate, or ball


guide if a scratch or groove can be detected with a
fingernail or lead pencil.

Fig. 73-Example of Scored Valve Plate

This valve plate (Fig. 13) shows scoring between


valve plate kidney, indicating solid particle contamina-
tion within the system, such as brass particles.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Mar-80) Hydraulic Sys tern 0260-9

Examples of Eroded Bearing Plates

Fig. 15-Example of Eroded Area


in Bearing Plate Kidney
Fig. 14-Example of Eroded Areas on a Baaring Plate
This bearing plate (Fig. 15) shows erosion in the
This bearing plate (Fig. 14) shows eroded areas on bearing plate kidney. This erosion is characteristic of
the balance land. This erosion is characteristic of ca- cavitation. See Fig. 14 for another example.
vitation. Cavitation is usually caused by air in the
system. This can be caused by loose hose or incorrect
line connections or by a hole in the suction hose. See
Fig. 15 for another example.

NOTE: Erosion that can not be felt but seen on the


cylinder block side of the bearing p/ate and the lapped
surface of the cylinder block can cause excessive
leakage.

Lifho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0260-l 0 Hydraulic System TM- 1188 (Mar-80)

Examples of Smeared Bearing Plates

!EO398N

l-Bearing Plate t-cylinder Block


l-Block Lift (Block Tilt)

Fig. 17-Block Lift (Block Tilt)

Block lift (2, Fig. 17) sometimes referred to as block


tilt, occurs when the cylinder block (3) and the bearing
plate (1) separate, which is caused by overspeeding
l-Outer Foot
due to incorrect plumbing.
2-Balance Land

Fig. Id-Example of Smearing on a Bearing Plate

This bearing plate (Fig. 16) shows smearing of the


outer edge of the outer foot (1) and of the inner edge of
the balance land (2). This smeared condition indicates
that cylinder block lift or block tilt has occurred or
system contamination is present.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (J&78) Hydraulic Sys tern 0260-11

F@. lb-Example of Smearing of Balance Land Fig. 79-Example of Partial Smearing of


on a Searing P/ate Balance Land on a Bearing Plate

This bearing plate (Fig. 18) shows smearing on most This bearing plate (Fig. 19) unlike (Fig. 18), shows
of the balance land due to water contamination. This partial smearing at the outer edges of the balance land,
plate shows the dull yellow or gold coloration and the due to water contamination. This plate also shows the
darker oxidation tarnish characteristic of water con- dull yellow or gold coloration and the darker oxidation
tamination. When water is present in the system, the oil tarnish characteristic of water contamination.
in the reservoir is white, milky, or light yellow in color.
NOTE: Fig. 18 shows more advanced deterioration
NOTE: The dark (tarnished) areas are exposed to by smearing than does Fig. 19.
case pressure, where the dull yellow or gold area is the
balance land and is exposed to high pressure.

The smearing at the outer edge of the balance land


occurs because this area is in contact with the valve
plate and is not receiving the lubrication of the system
high pressure fluid.

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0260-12 Hydraulic System TM- 1188 (J&78)

Piston and Piston Slipper Damage Replace pistons if pieces of filler are missing from
the ends of the pistons.
Inspect piston slippers for scoring across their bal-
ante lands. The balance land is the second land in
Check for piston to piston slipper play. Play of more
from the outside edge. Scoring, to some degree, may
than 0.005 in. (0.13 mm) is excessive. Replace piston
be seen across the inner lands. When inspecting slip-
assembly. Excessive slipper play results from cavita-
pers, also check to be certain the oil hole in each
tion caused by incorrect plumbing.
slipper is open.

Replace if steel particles are imbedded in the slipper


faces or a path is eroded through the balance land.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Jul- 79) Hydraulic System 0260-l 3

Assembly
IMPORTANT: Be very careful when handling
these parts during washing, drying and inspection.

NOTE: To dry parts after washing in diesel fuel,


shake off excess liquid and blow dry with clean com-
pressed air. DO NOT dry with rags or paper towels.

NOTE: Be certain to install new O-rings when as-


sembling motor.

Have a can of clean oil and a container of petroleum


jelly available. Apply a light coat of oil to each compo-
nent’s surface prior to assembly.
l-Retaining Ring lo--Piston Retainer
IMPORTANT: Use only JD bearings ordered by 2-Spring Retainer 1 l-Piston Assembly
specific part number as they are selected for close 3-Spring (9 used)
tolerances. Bearing manufacturer’s numbers may 4-Spring Seat 12-Spring (6 used)
6-Small Bearing IJ-Cylinder Block
be the same but not matched to the necessary
GShaft M-Dowel Pin
close tolerances. 1!5-Bearing Plate
7-Large Bearing
8-Swashplate 16-Spring Guide
If swashplate anchor dowel pin in motor housing g--Ball Guide 17-Bearing Plate Pilot
needs to be replaced it will be necessary to remove the
Fig. ZO-Motor Assembly
wheel, planetary housing assembly, and brake piston
housing. Refer to Group 0250. Press out old pin. Press
in new pin until inner end of pin protrudes 0.17 in. (4.32
mm) into housing bore.

Protect the face of the cylinder block when installing


parts into the block. Install spring seat (4, Fig. 20) bevel
side first into cylinder block.

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0260-14 Hvdraulic Svstem TM- 1188 (Jul- 79)

Install spring (3, Fig. 20), spring retainer (2), and Lubricate piston assemblies (11, Fig. 20) and piston
retaining ring (1) by using the same “bolt and washer retainer (10). Place piston retainer on ball guide with
press” method to seat the retaining ring as for removal beveled side toward the cylinder block. Install pistons
of the ring. alternately into the cylinder block.

Remove bolt press tool. Place swashplate (8, Fig. 20) on shaft (6).

Install springs (12, Fig. 20) in cylinder block. Lubricate the lapped surface of the swashplate.
Gently install cylinder block assembly onto shaft while
Place ball guide (1, Fig. 21) onto cylinder block (4). aligning the missing tooth on the shaft with that in the
Align missing tooth (2) on the ball guide with the narrow ball guide.
valley (3) in the spline of the cylinder block.
Install spring guide (16) onto shaft.

Lubricate small bearing (5). Carefully press small


bearing onto shaft.

Install dowel pin (14, Fig. 20) into cylinder block.

Install wheel motor into motor housing with the thick


side of the swashplate forward to clear the wheel lean
yoke. After the motor is in the housing rotate it 180” so
the thick side of the swashplate (both wheels) is clo-
sest to the steering arm.

Make sure the groove in the swashplate drops over


the dowel pin in the motor housing.

NOTE: The swashplate has a groove for a dowel


pin on both the thick and thin side. The groove on the
thick side is longer. This is the groove in which the
housing dowel pin must be located.

NOTE: Incorrect installation of the motors will make


l-Ball Guide 3-Narrow Valley the motors turn backwards.
P-Missing Tooth 4-Cylinder Block

F/g. PI-Alignment of Ball Guide and


Cylinder Block

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM-l 188 (J&78) Hvdraulic Svstem 0260-15

Install sensor plate (3, Fig. 22) and cap screw (4).

Install bearing plate pilot (17, Fig. 20) in cylinder


block.

Lubricate bearing plate. Install bearing plate (1, Fig.


22) onto cylinder block aligning dowel pin groove (2)
over dowel pin (14, Fig. 20).

l-Bearing Plate 3-Sensor Plate


2-Dowel Pin Groove 4-Cap Screw

Fig. 2243earing Plate /nsia//ation


(L. H. Wheel)

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2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0260-l 6 Hydraulic System TM- 1188 (J&78)

Lubricate valve plate (2, Fig. 23) and install onto the
oil manifold aligning dowel pin and groove.

P60402N
l-Oil Manifold 3-Bearing Cup
2-Valve Plate
l-Cap Screw (6 used) 6-Packing
2-Plug (2 used) g-Bearing Cup
Fig. 23-Oil Manifold
3-O-Ring (2 used) lO-Shim (as required)
4-Manifold 11-Shim (as required)
Replace all Q-rings and packings. 6-Dowel Pin (2 used) la-Packing (2 used)
6-O-Rlng 13-O-Ring (2 used)
Install new packing (8, Fig. 24) in motor housing 7-Dowel Pin 14-Plug (2 used)

packing groove.
Fig. 24-Oil Manifold

Carefully install oil manifold with valve plate and new


O-rings onto the motor housing. The dowels in the
motor housing will help guide the oil manifold while
holding onto the valve plate.

IMPORTANT: Do not allow valve plate and


bearing plate to shift or drop when installing oil
manifold.

Tighten cap screws (1, Fig. 24) to 35 lb-ft (47 Nm) (5


kg-m).

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Jul-79) Hydraulic Sys tern 0260-17

Motor Shaft Endplay Adjustment


NOTE: This adjustment can be performed with the
wheel assembly on or off the unit.

Turn front wheels as far as possible in one direction


to gain clearance to the oil manifold (3, Fig. 25).

Drain oil from the drain plug in the planetary hous-


ing.
Remove front cover, the first planet pinion carrier
assembly and the first planet pinion shaft.

Proceed with the motor shaft adjustment as follows:


1. Install a 3/8 x 3.75 in. (95 mm) - 12 UNC cap
screw (2, Fig. 25) with a 24H1300 washer (1)
(25/64x 2 in. [51 mm], 0.194 in. 15 mm1 thick)
into the splined end of the motor shaft.

2. Tap the head of the cap screw to seat the bearing


assembly into the inboard bearing cup.

3. Set up a linear dial indicator on the motor hous-


ing. Remove center plug from rear of oil manifold
or refer to page 0260-2 in removing the front
sensor assembly. This depends on which wheel
assembly is being adjusted.

4. Install the stylus of the indicator on end of motor


shaft. (See large arrow, Fig. 26).

5. Tighten the cap screw (2) to approximately 60


lb-in. (6.75 Nm) to overcome the spring bias in
the motor assembly and seat the shaft assembly
into the outboard bearing cup. NOTE: Perform
this step with a small torque wrench to feel the
bearing seat.
6. Note the motor shaft end play indicated on the
dial indicator.
Correct end play is 0.006 to 0.012 in. (0.152 to 0.305 l-24H1300 Washer 3-Oil Manifold
mm). Adjust by adding or removing shims (10 and 11, a--Cap Screw

Fig. 24) behind the oil manifold bearing cup (9).


Fig. 25-Motor Shaft End Play Adjustment

Install all parts that were removed for this adjust-


ment.

Fill planetary housing with approximately 3 gal. (11


L) of the recommended oil. (See Section I, Group V for
the type of oil used).
NOTE: Run grader with front wheel drive activated
for a period of time and then check transmission oil
level. Drain or fill transmission to proper dipstick level.

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0260-18 Hvdraulic Svstem TM- 1188 (Dee-87)

INSTALLATION IMPORTANT: Improper routing of hoses to the


wheel motor will result in hose and wire damage.
Connect brake hose (1, Fig. 26). Brake hose fitting
Upon start-up, cycle front axle to all extreme posi-
should be rotated clockwise toward the motor housing
tions; check and adjust hose and wiring clearances
as much as possible.
with wheel hub and rim so hoses have a minimum
clearance of 0.75 in. (19.1 mm).
Turn motor until a sensor plate tooth is centered
on the thread sensor hole in the manifold.

IMPORTANT: The front sensor and wiring to sensor


are serviced as one part. if wire breaks, it will be
necessary to also replace sensor. During installation,
be sure to turn wire with sensor. Also, it is important
not to disconnect protective hose from cover.

To reinstall front sensor on early units, install jam


nut with nylon insert toward wheel. Turn harness
with cover while screwing in sensor to prevent
twisting of the sensor wire.

Turn sensor and wire in until it contacts sensor


plate. Rotate sensor counterclockwise 270 degrees
and tighten jam nut to 10 to 12 lb-ft (14 to 16 N-m).

Reinstall cover gasket and cover and connect


harness.

To install front sensor on later units, install locking


nut and adjust all the way towards wire end of
sensor. Turn wiring harness and cover while screwing
sensor into manifold until it contacts sensor plate or
locking nut contacts manifold.

If locking nut contacts the manifold first, remove


l-Brake Pressure Hose 4-Tie Rod
nut and grind to reduce thickness. Reinstall nut and
P-Cap Screw (6 used) B-Harness Connection
turn sensor in until it contacts sensor plate. 3-Front Sensor Cover

IMPORTANT: Overtightening the lock nut will Fig. 26-Brake Hose and Front Sensor
cause sensor damage. Installation (L. H. Wheel)

Turn sensor out three quarters of a turn (270


degrees). Hold sensor and tighten lock nut to 11 lb-ft
(15 N.m) (1.5 kg-m).

Install cable support bracket (B, Fig. 8A) and cable


clamp. Route wire to front of equipment frame and
attach connector. Install clamps and tie bands around
wire. Install cover to equipment frame.

Connect tie rod.

Fill planetary housing with proper oil (see Section


I, Group V for the correct type of oil). A-Sensor B-Bracket

IMPORTANT: Do not start engine at this time. Fig. 26A-Front Sensor Installation
Refer to the Start-Up procedure in Group 9016.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Jul- 79) Hydraulic System 0260-19

MOTOR HOUSING

REMOVAL Disconnect hoses and lines (1, 4 and 9, Fig. 27),


from motor housing.
Jack up and block the front axle on the appropriate
side.
Disconnect brake supply hose (6) from oil manifold.

Remove front wheel. Refer to Group 01 IO.


Remove appropriate hose clamps; disconnect har-
ness (7) at frame connection (5). Protect wiring con-
NOTE: If motor housing is damaged it will also be
nectors from dirt and damage.
necessary to remove the planetary assembly. Refer to
Group 0250.
Disconnect tie rod at motor housing.

IMPORTANT: Before completely removing motor


housing pivot pins (a), attach an overhead hoist to
the motor housing.

Remove four cap screws from each pivot pin (3).


Use two of the cap screws (2) to pull the pivot pins from
the motor housing by inserting them into the pivot pin
blind holes. Turn cap screw equally to pull pivot pins
from motor housing.

Remove motor housing from unit.

l-Motor Drain Hose B--Brake Pressure Hose


2-Cap Screw (8 used) T-Wiring Harness
3-Pivot Pin (2 used) 8-Remove Tie Rod Here
4-Forward Pressure Line 9-Revyse Pressure Line
5-Wiring Harness Frame IO-Motor Housing
Connection

Fig. 27-Motor Housing

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0260-20 Hydraulic Sys tern TM- 1188 (Jun-83)

REPAIR
Replace quad rings (6, Fig. 28) and backup rings (5).

Inspect bushing (11). If replacement is necessary


press new bushing into housing flush to 0.010 in. (0.25
mm) below edge of bore with grease hole aligned.

l-Thrust Washer (2 used) E&Backup Ring (4 used) 8-O-Ring (2 used)


2-Wheel Lean Yoke 8-O-Ring (4 used) g--Motor Housing
3-Pivot Pin (2 used) 7-Tube (2 used) lo-Grease Fitting (2 used)
4-Cap Screw (8 used) ll-Bushing (2 used)

fig. 28-Motor Housing Assembly


(1. H. Shown)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Jut- 79) Hydraulic System 0260-21

INSTALLATION Install front wheel. Refer to Group 0110.

Install motor housing in wheel lean yoke. Be sure to


IMPORTANT: Do not start engine at this time.
install a thrust washer between each end of the motor
Refer to Start-Up procedure in Group 9016.
housing and the wheel lean yoke.

Install tubes (7, Fig. 28) and pivot pins (3).

Install hose retaining brackets. Install cap screws


and tighten to 35 lb-ft (47 Nm) (5 kg-m).

Connect tie rod.

Connect forward and reverse pressure lines.

Connect brake pressure hose to oil manifold with


fitting pointing rearward and as close to the motor
housing as possible.

Connect motor drain hose to motor housing with


fitting pointing rearward and toward wheel.

Connect wiring harness.

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0260-22 Hydraulic System TM- 1188 (Jul- 79)

FRONT WHEEL CASE RELIEF VALVE

l-O-Ring %-Spring
2-Relief Valve 6-Retainer
3-Valve Body 74tetaining Ring
4-O-Ring

Fig. 30-Case Relief Valve Disassembled

Inspect spring (5) for the following specifications:


Free length . . . . . . . . . . . . . . . . . . .2.37 in.
(60.2 mm)
Test length . . . . . . . . . . . . . . . . . . 1.13 in.
(28.7 mm)
when compressed with 22.5 L 2.3 lb.
(100.1 2 10.2 N) (10.2 ? 1 kg)

I Fig. 29-Case Relief Valve


Inspect seating area of relief valve (2) and valve
body (3) for nicks, scratches or embedded material.
I Remove case relief valve (Fig. 29) from front wheel
motor housing. Replace O-rings.

I Remove retaining ring (7, Fig. 30) from case relief Assemble case relief valve and hold together with
valve to disassemble parts. retaining ring.

Install case relief valve in motor housing.

Replace any oil lost with recommended oil. Use plug


in planetary housing to replenish oil.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Jul-78) Specifications and Special Tools 0299-l

Group 0299
SPECIFICATIONS AND SPECIAL TOOLS
DRIVE AXLE HOUSING AND SUPPORT
SPECIFICATIONS AND TORQUE VALUES

1 - Final drive housing-to-


transmission case cap screws . . . _ . . 170 lb-ft
(230 Nm) (24 kg-m)

2 - Pivot retainer-to-final
drive housing cap screws . . . . . . . . . . . 300 lb-ft
(407 Nm) (42 kg-m)

3 - Sprocket retainer-to-final drive


shaft cap screws . . . . . . . . . . . . . . . . . 170 lb-ft
(230 Nm) (24 kg-m)

F/g. l-final Drive and Pivot Housing Retainer

1 - Shim pack clearance between


thrust washer and pivot retainer
to.. . . . . . . . . . . . . . . . . . . . . . . 0.‘002 + 0.002 in.
(0.05 + 0.05 mm)

-
T60514N -Ii3
Fig. P-Shim Pack Measurement

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0299-2 Specifications and Special Tools TM- 1188 (Dee-87)

DRIVE AXLE HOUSING AND SUPPORT


SPECIFICATIONS AND TORQUE VALUES-Continued

l- Pivot housing-to-tandem
housing cap screw . . . . .

Fig. 3-Pivot Housing

1 - Front axle pin-to-main


frame cap screws . . . . . .

Fig. 4-Front Ax/e Pin

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Jul-78) Specifications and Special Tools 0299-3

DIFFERENTIAL OR BEVEL DRIVE


SPECIFICATIONS AND TORQUE VALUES
1 - Differential housing cover-to-
Ft. H. differential housing cap
screws . . .. ........ . . . 85 lb-ft
(115 Nm) (12 kg-m)

2- Differential ring gear-to-right


hand differential housing cap
3

P
-27 3-
screws . . . . . . . . . . . . . . . 170 lb-ft

L. H. differential housing-to-
R. H. differential housing cap
(230 Nm) (24 kg-m)

screws . . . . . . . . . . _. . . . . . . . . 85 lb-ft
(115 Nm) (12 kg-m)
IT12231

Fig. 5-Differential Housing

1 - Differential lock line connector-to


L. H. bearing quill . . . . . . . . . . . . . . . 30 lb-ft
(41 Nm) (4 kg-m)

Fig. B-Lock Line Connector

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0299-4 Specificafions and Special Tools TM- 1188 (J&78)

DIFFERENTIAL OR BEVEL DRIVE


SPECIFICATIONS AND TORQUE VALUE&Continued

1 - Pinion shaft special nut


torqued to . . . . . . . . . . . . . . 400 lb-ft
(542 Nm) (55 kg-m)

with a rolling torque of . . . . . . . . . .17 to 27 lb-in.


(1.9 to 3.1 Nm) (0.20 to 0.31 kg-m)

NOTE: Refer to paQe 02.1O-1 1 for cone point ad-


justment. Refer to page OZlO- 12 for adjusting the spiral
bevel pinion rolling torque.

Fig. 7-Pinion Shaft Adjustment

1 - Differential bearing quill-to-differential


case cap screws . . . . . . . . . . . . . . . . . . . 85 lb-ft
(115 Nm) (12 kg-m)

2 - Differential bearing preload . . 0.002 to 0.005 in.


(0.05 to 0.13 mm)

NOTE: Refer to page 0270- 13, for adjusting dif-


ferential preload.

Fjg, d-Differential Bearing Quill Preload

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Mar-80) Specifications and Special Tools 02994

DIFFERENTIAL OR BEVEL DRIVE


SPECIFICATIONS AND TORQUE VALUES-Continued
1 - Backlash between ring gear and pinion
shaft . . . . . . . . . . . . . . . . 0.007 to 0.015 in.
(0.19 to 0.39 mm)

Fig. 9-Differential Back/ash

1 - Tooth pattern located from end of pinion


shaft . . . . . . . . . . . . . . . .0.35 + 0.59 - 0.12 in.
(9 + 15 - 3 mm)

2 - Tooth pattern . . . . . . . . . . . . . .1.50 + 0.31 in.


(38 + 8 mm)

Fig. IO-Tooth Pattern

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0299-6 Specifications and Special Tools TM- 1188 (Ma:-80)

DIFFERENTIAL OR BEVEL DRIVE


SPECIFICATIONS AND TORQUE VALUES-Continued

1 - I.D. of housing bore . . . . ~ 0.5610 to 0.5630 in.


(plunger end) (14.25 to 14.30 mm)

2 - I.D. of housing bore . . . . . . 0.4995 to 0.5005 in.


(control valve end) (12.69 to 12.71 mm)

Fig. 1l-Differential Lock Valve Musing Bore

1 - O.D. of plunger . . . . . . . . 0.5550 to 0.5590 in.


(14.1 to 14.2 mm)

l’27857

Fig. 12-Differential Lock Valve Plunger

1 - O.D. of control valve. . . . 0.4978 to 0.4984 in.


(12.6 to 12.7 mm)

T27858

Fig. 13-Differential Lock Valve Control Valve

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (J&78) Specifications and Special Tools 0299-7

DIFFERENTIAL OR BEVEL DRIVE


SPECIFICATIONS AND TORQUE VALUES-Continued
1 - Check valve spring free length. . . . . . .0.62 in.
(15.7 mm)

2 - Check valve spring test length . . . . 0.38 inches


(9.7 mm) when compressed with 4.0 to 5.0
oz. (1.1 to 1.4 N) (114 to 142 g) of force.

3 - Return spring free length. .. 2.56 inches


(65.0 mm)

4 - Return spring test length . . . . . . . 1.31 inches


(33.3 mm) when compressed with 9.5 to 11.5 Ibs
(42 to 51 N) (4 to 5 kg) of force.
T42474N

5 - Plunger spring (smallest)


Fig. 74-Differential Lock Valve Springs free length . . . .‘. . . . 2.18 inches
(55.4 mm)

Plunger spring (smallest)


test length . ... . ..... . . 1.80 inches
,(45.7 mm) when compressed with 25 to 31 Ibs
(111 to 138 N) (11.3 to 13.9 kg) of force.

Plunger spring (largest)


free length.. . . . . . . .... 2.28 inches
(57.9 mm)

Plunger spring (largest)


test length . . . . . . ... . .. 1.92 inches
(48.8 mm) when compressed with 103 to 125 Ibs
(458 to 556 N) (46.7 to 56.7 kg) of force.

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0299-8 Specifications and Special Tools TM- 1188 (J&78)

NON-POWERED WHEEL AXLES


SPECIFICATIONS AND TORQUE VALUES

1 - Front axle hub-to-spindle


nut*. . . . . . . . . . . . . . . . . . . . . . . . . . . 70 lb-ft
(95 Nm) (10 kg-m)

*Nut threads must be lubricated.

T41022N

Fig. 15-Front Axle Hub

Front axle pin-to-main


frame cap screws . . . . . .

Fig. l&Front Axle Pin

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Jul- 79) Specifications and Special Tools 0299-g

AXLE SHAFTS, BEARINGS AND REDUCTION GEARS


SPECIFICATIONS AND TORQUE VALUES

1 - Chain replacement should be


made when slack exceeds .. . .3 in.
(76 mm)

T60517N

Fig. 17-Tandem Drive Chains

1 - Oil seal stand out from


wheel axle housing . .. . ..... .0.06 in.
\ Id 2 - Wheel axle drag torque
(1.5 mm)

r-l
T37819N
I I
A. Measure drag torque without bearing preload.
B. Nominal drag torque . . . .10 to 25 lb-in.
(1.1 to 2.8 Nm) (0.12 to 0.29 kg-m)
C. Tighten slotted hex. nut to give a drag torque
equal to the sum of steps A and B.

Fig. IS-Wheel Axle and Bearings

1 - Tandem drive shaft drag torque


A. Measure drag torque with end play in bearings
(3).

B: Nominal drag torque . . . . .15 to 35 lb-in.


(1.7 to 4.0 Nm) (0.17 to 0.40 kg-m)

C. Tighten the planet pinion carrier retaining


screw (2) to give a drag torque equal to the
sum of steps A and B.

Fig. 19-Tandem Drive Shaft and Planetary System

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0299-10 Specifications and Special Tools TM- 1188 (Jul- 79)

AXLE SHAFTS, BEARINGS AND REDUCTION GEARS


SPECIFICATIONS AND TORQUE VALUES-Cbntinued

1 - Planet pinion retainer-to-


planetary housing cap screws . . . . . 50 lb-ft
(68 Nm) (7 kg-m)

I Fig, ZO-Planet Pinion Retainer (Early Units)

1 - Roller pin retaining pipe


plugs to . . . . . . . :. . . . . . . . . . . . . i to 8 lb-ft
(10 to 11 Nm) (1 to 1.1 kg-m)

2- Planet pinion retainer-to-


planetary housing cap screws . . . . . . 85 lb4
(115 Nm) (12 kg-m)

Fig. PI-Pressure Pinion Retainer (Later Units)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 ‘(Jul- 79) Specifications and Special Tools 0299-11

AXLE SHAFTS, BEARINGS AND REDUCTION GEARS


SPECIFICATIONS AND TORQUE VALUES-Continued

1 - Return spring test length . . . .. 1.69 in.


(43 mm) with 70 to 80 Ibs
(312 to 383 N) (31 to 38 kg)
force applied.

2 - Return spring free length . . . . ... . . 1.89 in.


(48 mm)

T38675N

I Fig. 22-Pressure Plate Return Spring

1 - Wheel hub bearings adjusted


to. . . . .0.004 in. preload to 0.004 in. end play
(0.10 mm preload to 0.10 mm end play)

NOTE: Refer to page 0250-24 when making this


adjustment.

Fig. 23-End Play or Preload on Wheel


Hub Bearings

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0299-12 Specifications and Special Tools TM- 1188 (Jun-83)

AXLE SHAFTS, BEARINGS AND REDUCTION GEARS


SPECIFICATIONS AND TORQUE VALUES-Continued

Motor housing oil seal flush to 0.010 in. (0.25 mm)


below shoulder on motor housing.

Fig. 24-Motor Housing Oil Seal

1 - Planet brake ! piston housing-to-motor


housing cap screws . . , . . . . . . . . . . . . . 100 lb-ft
(136 Nam) (14 kg-m)

Fig. 25-Planet Brake Piston Housing

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Jul- 79) Specifications and Special Tools 0299-13

AXLE SHAFTS, BEARINGS AND REDUCTION GEARS


SPECIFICATIONS AND TORQUE VALUES-Continued

1 - Planet brake backing plate-to-


wheel hub cap screws . . . . . . . . 35 lb-ft
(47 Nm) (5 kg-m)

Fig. 26-Planet Brake Backing Plate

1 - Planetary housing-to-wheel hub


cap screws .. . . . . .... . 35 lb-ft
(47 Nm) (5 kg-m)

Fig. 27-Planetary Housing

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0299-14 Specifications and Special Tools TM- 1188 (Jul- 79)

AXLE SHAFTS, BEARINGS AND REDUCTION GEARS


SPECIFICATIONS AND TORQUE VALUES-Continued
1 - Planetary cover-to-planetary
housing cap screws . . . . . . 50 lb-ft

Fig. 28-PlanetaryCover

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Jul- 79) Specifications and Special Tools 0299-15

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES

1 - Swashplate anchor dowel pin


protrusion length . .’ . . 0.17 in. (4.32 mm)

Fig. 29-Swashplate Anchor Dowel Pin

Oil manifold cap screws.

Fig. 30-Oil Manifold Cap Screws

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0299-I 6 Specifications and Special Tools TM- 1188 (Dee-87)

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

Motor shaft endplay . . , . . . , . , . 0.006 to 0.012 in.


(0.152 to 0.305 mm)

NOTE: See page 0260- 17 for this adjustment.

Fig. 314otor Shaft Endplay

Front sensor - Turn sensor in until it


contacts sensor plate. Rotate sensor
270’ counterclockwise.
Tighten jam nut , , . . . , . . . , , . . . . . 10 to 12 lb-ft
(14 to 16 N-m)

Fig. 32-Front Sensor (Early Units)

Fig. 32A-Front Sensor (Later Units)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Axles and Suspension System 2
TM- 1188 (Jul- 79) Specifications and Special Tools 0299-17

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE YALUES-Continued

1 - Press bushing into housing flush to


0.10 in. (0.25 mm) below edge of bore
with grease holes aligned.

2 - Cap screw torque . . ... . . 35 lb-ft


(47 Nm) (5 kg-m)

Fig. 33-Motor Housing

1 - Case relief valve spring:


Free length.. . . . _.2.37 in. (60.2 mm)

ep
Test length . . . .1.13 in. (28.7 mm)
when compressed with 22.5 i 2.3 lb.
(100.1 2 10.2 N) (10.2 i 1 kg)

Fig. 34-Case Relief Valve

Litho in U.S.A.
2 Axles and Suspension System JD670-A and JD672-A Motor Graders
0299-18 Specifications and Special Tools TM- 1188 (Dee-87)

AXLE SHAFTS, BEARINGS AND REDUCTION GEARS


SPECIAL TOOLS

Essential Tools

Tool Tool Number Use

*JT38031 Driver - To install wear sleeve and


bearing cone on axle.
--__------- --

B c

----e-w--- I::

T6240AB
A-9.50 in. (241.3 mm) C4.50 in. (101.6 mm)
B-3.826 in. (95.25 mm)

Material: 4.00 in. Extra Heavy Black Pipe

Fig. 35-Driver

*JT38058 Spacer plates - To install tandem


axle seal in housing.

hUT
T6240At
A-l.00 in. (25.4 mm) C-4.80 in. (122 mm)
B-O.50 in. (12.7 mm) D-8.00 in. (203 mm)

Material: 3/16 in. (4.57 mm) Steel Plate

Fig. 36-Spacer Plates

*Make in dealer shop.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Mar-80) Controls 0315-l

Section 3
TRANSMISSION
CONTENTS OF THIS SECTION
Page Page

GROUP 0315 - CONTROLS GROUP 0350 - GEARS, SHAFTS,


Clutch Valve Linkage BEARINGS AND POWER
Removal ............................ 0315-3 SHIFT CLUTCH-Continued
Repair .............................. 0315-3 Repair
installation. .......................... 0315-4 Cleaning and Inspection . . . . . . . . . 0350-4
Adjustment .......................... 0315-4 Low and High-Range Drive Shafts . . . 0350-5
Direction Selector Lever and Linkage Clutch Pack Assembly. . . . . . . . . . 0350-5
Removal ............................ 0315-5 Planetary Pack Assembly . . . . . , . . . . . 0350-l 1
Repair.. ............................ 0315-5 Tow Disconnect and Reduction
Installation. .......................... 0315-5 Gear Shaft . . . . . . . . . . . . 0350-22
Adjustment ....................... .-. 0315-6 installation
Shift Lever and Linkage Planetary Pack . . . . . . . _. . . . 0350-24
Removal ............................ 0315-7 Reduction Gear Shaft and Tow
Repair .............................. 0315-7 Disconnect . . . . . . _. . . . . . . 0350-24
Installation. .......................... 0315-8 Reduction Gear Shaft Bearing Preload
Adjustment .......................... 0315-8 Adjustment. . . . . . . . . ... .. 0350-25
Transmission Clutch Pack. . . . . . . . . 0350-25
GROUP 0341 - HOUSINGS AND COVERS
Transmission Clutch Housing GROUP 0360 - HYDRAULIC SYSTEM
General Information .................. 0341-l Transmission Oil Pump
Removal ............................ 0341-l General Information . . . . . .. . 0360-l
Repair .............................. 0341-2 Removal . . . . .._................. 0360-l
Installation. .......................... 0341-3 Repair .. . .. .... . .. ..... 0360-l
Transmission Case and Covers Installation. . ... .... . .. .. 0360-3
General Information .................. 0341-4 Transmission Control Valve Assembly
Removal ............................ 0341-4 General Information . . . . ... ._ 0360-3
Repair .............................. 0341-4 Removal . . . . . . . . . . . . .._.......... 0360-3
Installation. .......................... 0341-7 Repair . . . . . . . . _. . . ... ... 0360-4
Transmission Control Valve . . . _. 0360-4
GROUP 0350 - GEARS, SHAFTS, Shift Valve Housing . . . . . _ . . . 0360-6
BEARINGS AND Installation. . ... ..... ... . .. 0360-6
POWER SHIFT CLUTCH Transmission Oil Pressure Regulating
General Information .................... 0350-l Valve
Removal General Information . .. _ .... 0360-7
Transmission Clutch Pack. ............ 0350-2 Removal . . . . . . . . . . . . . _ . . 0360-7
Low- and High-Range Drive Shafts Repair . . . . . . . . . . . . . . . . . . . . . 0360-7
and Planetary Pack ................ 0350-2 Installation . . . . . . . . . . . . . . . . 0360-8
Reduction Gear Shaft and Adjustment . . . ... . .,...... 0360-8
Tow Disconnect ................... 0350-3
Contents continued on next page

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor’ Graders
0315-2 Controls TM- 1188 (Mar-80)

CONTENTS OF THIS SECTION-Continued


Page Page
GROUP 0360 _ HYDRAULIC SYSTEM-Continued GROUP 0370 - CLUTCH DISCONNECT
Transmission Clutch Valve AND CONTROLS
General information .................. 0360-9 Clutch Linkage
Removal ............................ 0360-9 General Information ................ . 0370-l
Repair .............................. 0360-9 Removal .......................... 0370-2
Installation. .......................... 0360-l 1 Repair ............................ 0370-2
Adjustment ......................... 0360-l 1 Installation. ........................ 0370-2
Forward-Reverse Modulator Adjustment ........................ 0370-3
General Information ................. 0360-l 1 Clutch Shaft and Carrier Assembly
Removal ........................... 0360-l 2 Removal .......................... ,. 0370-3
Repair ............................. 0360-l 2 Repair ............................ 0370-3
Installation. ......................... 0360-l 2 Installation. ........................ 0370-3
Transmission Oil Filter Assembly Clutch Elements
General Information ................. 0360-l 3 General Information ................ 0370-4
Removal ........................... 0360-l 3 Removal .......................... 0370-4
Repair ............................. 0360-l 3 Repair ............................ . 0370-5
Installation .......................... 0360-13 Installation. ........................ . 0370-6
Transmission Filter Restriction Switch
General Information ................. 0360-l 4 GROUP 0399 - SPECIFICATIONS AND
Removal ........................... 0360-l 4 SPECIAL TOOLS
Repair ............................. 0360-l 4 Specifications and Torque Values
Installation .......................... 0360-l 4 Housings and Covers.. . . . . . . . . . . . . . . 0399-l
Gears, Shafts, Bearings and
Power Shift Clutch . . . . . . . . . . . . . . . . 0399-2
Hydraulic System . . . . . . . . . . . . . . . . . 0399-8
Clutch Disconnect and Controls . . . . . b399-15
Special Tools
Gears, Shafts, Bearings and
Power Shift Clutch . . _ . . . . . . . . . . 0399-l 6
Hydraulic System . . . . . . . . . . . . . . . . . . 0399-l 6
Clutch Disconnect and Controls ... 0399-l 7

Litbo in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Mar-80) Controls 0315-3

Group 0315
CONTROLS
CLUTCH VALVE LINKAGE
REMOVAL REPAIR

I-Nut (2 used) 14-Cotter Pin (2 used)


2-Clutch Pedal Pivot l&Cap Screw
Pin Support 16-Clamp (2 used)
3-Cap Screw (2 used) 17-Boot
4-Washer (2 used) 16-Cable Spacer
6-Cap Screw (3 used) 1 g--Pin
6-Washer (2 used) tO--Yoke
7-Bushing (2 used) 21-Nut
8-Clutch Pedal 22-Clutch Cable
g--Pin Support Clamp Bracket
lo--Cap Screw 23-Lock Washer (2 used)
1 l-Spacer 24-Cap Screw (2 used)
12-Clamp 2!5-Seal
13-Pin 26-Clutch Cable

l-Clutch Cable J-Clutch Pedal


Fig. P-Clutch Valve Linkage ( -08636)
2-Cap Screw (3 used)

Fig. I-Clutch Pedal Valve and Clutch Cable Inspect bushing (7, Fig. 2 or 10, Fig. 3) for wear or
damage. Replace as necessary.
Remove panel from left-hand side of control con-
sole. inspect clutch cable (26 or 22) for bends or kinks.
Replace if defective.
Disconnect control cable (1, Fig. 1).

Remove cap screws (5 and 10, Fig. 2 or 4 and 18,


Fig. 3).

Slide out clutch pedal pivot pin support (2 or 5) and


clutch pedal (8 or 11).

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0315-4 Controls TM- 1188 (Mar-80)

INSTALLATION
Secure cable (26, Fig. 2 or 22, Fig. 3) to bracket (22
or 23) with clamp (15 or 17) and cap screws (16 or 18).

Secure yoke (20) to clutch valve lever extension with


pin (19) and cotter pin (14).

Secure cable (26 or 22) to clutch pedal pivot pin


support (2 or 5). Be sure to install cable spacer (18 or
15) between pivot pin support and cable.

Position clutch pedal (8 or 11) on pin support (9).

Secure pivot pin support to pin support (9) with cap


screws (5 or 4).
l-Nut (4 used) 14-Clevis
P-Washer 16-Strap (2 used)
I-Nut %-Nut Secure cable to pedal with pin (13 or 12) and cotter
4-Cap Screw (2 used) 17-Clamp (2 used) pin.
6-Clutch Pedal Pivot la--Cap Screw (4 used)
Pin Support 1g--Pin ADJUSTMENT
B-Pipe Spacer 20-Yoke
7-Cap Screw Pl-Nut Depress the clutch pedal (8, Fig. 2 or 11, Fig. 3) until
E-Cap Screw (2 used) 22-Clutch Cable a heavy spring resistance is felt. Release the pedal.
g--Pin Support 23-Clutch Cable
Adjust the clutch cable yoke (20) so the height between
1 ’IO-Bushing (2 used) Clamp Bracket
I I-Clutch Pedal 24-Lock Washer (2 used) the clutch pedal and brake pedal is within 0.25 in. (6
I l-Pin 26-Cap Screw (2 used) mm).
13-Cotter Pin (2 used)
Turn the unit in both directions to make sure the
Fig. 3-Clutch Valve Linkage (08637- )
cable is not binding or stressed.

If a high-pressure washer was used in the clutch


:able area before S.N. 08637, the following procedure
should be followed to remove any moisture that may
have been forced into the cable to prevent possible
freeze-up problems in cold climates.

Loosen cables at both ends and remove seals.


Attach a dry compressed air line to transmission end.
B!ow dry air through cable to completely purge all
moisture. Do not add lubricant, since the cable’s origi-
nal special lubricant will be damaged. Reinstall cable,
making sure all seals are replaced tightly.

NOTE: If a new clutch cable kit is installed, the


above procedure will not be necessary.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Mar-80) Controls 0315-S

Remove L.H. control console cover.


DIRECTION SELECTOR
LEVER AND LINKAGE To remove cable (21, Fig. 4), remove cap screws
REMOVAL (14, Fig. 5) cotter pin (12) and pin (20).

To remove lever (1, Fig. 4), disconnect ball joint (20)


and remove retaining ring (2).

To remove arm (9), remove nut (17) and disconnect


link (6) and rod (3).

REPAIR
Inspect cable for wear, damage and binding.

Inspect pivot points for wear.

Inspect all parts for wear and damage and replace


as necessary.

Use John Deere Never-Seez or an equivalent on all


pivot point areas. I

INSTALLATION
Install nut (4, Fig. 5) on rod (7). Install ball joint (6) on 1
rod (7) so as to have 0.67 in. (17 mm) thread engage-
ment. Lock ball joint with nut (4).

Install nut (27) on rod (7). Install yoke (26) so that


distance between yoke pin cross hole and stud on ball
joint (6) is 8.56 in. (217.5 mm). Do not lock yoke in
l-Direction Selector 1 l-Yoke
position until final adjustment is made.
Lever 12-Pin
2--Retaining Ring 13-Retaining Ring
3-Rod 14-Nut install jam nut and yoke on link (6, Fig. 4). Adjust 1
cl--Retaining Ring 16-Eccentric yoke so that distance between center of washer on link
6-Pin 16-Washer (6) and yoke pin cross hole is 3.31 in. (84 mm). Do not
B-Link With Yoke 17-Nut
lock yoke in position until final adjustment is made.
7-Interlock Cam 18-Clamp
I-Cotter Pin 1O-Cap Screw
g--Arm 20-Ball Joint Install cable (18, Fig. 5) and secure with clamps (15
IO-Jam Nut 21-Cable and 31).

Fig. #-Direction Selector Lever


Set direction lever on transmission control valve in
the neutral (center detent) position. Adjust yoke (19) on
cable (18) so that when it is connected to the direction
lever on the control valve the distance between the
center of the hook on the other end of the cable and the
center of the mounting clamp (15) is 5.32 in. (135 mm).

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0315-6 Controls TM-7 788 (Dee-87)

CLAMP PLATE

I - 418
VALVE ARM

i"61624N

l-Cap Screw (2 used) g-Washer 1 ‘I-Washer 25-Pin


2-Nut (2 used) lQ-Bushing 18-Cable 26-Yoke
3-Knob 11-Arm 1 g--Yoke 27-Nut
4-Nut 12-Cotter Pin 20-Pin 28-Bushing
5-Washer 13-Cotter Pin 21-Lock Washer 29-Direction Selector
6-Ball Joint 14-Cap Screw (2 used) PP--Retaining Ring Lever
7--Rod 15-Clamp 23-Eccentric ( -509129) 30-Nut ( -509129)
8-Lock Nut 16-Nut Screw (509130. 1 Nut (509130- 1
24-Retaining Ring Washer (2 used) (509130. 1
Sl-Clamp (2 used)

Fig, 5-Direction Selector Linkage

Install direction selector lever (29, Fig. 5) and ADJUSTMENT


secure with retaining ring (22).
Apply parking brake.
Install eccentric ( -509129) or screw
(509130- ) (23) into arm (11) and secure with Rotate eccentric (23, Fig. 5) until it moves interlock
nut (30). cam to the point where the tab welded to the cam
contacts the parking brake pedal. Tighten eccentric
Install washer (17), interlock cam, arm (1 l), washer lock nut ( -509129) (30) or nut and washer
(9) and lock nut (8) in that order. (509130- )

Install rod (7). Secure ball joint (6) to direction Adjust length of link (6, Fig. 4) so that pin (5) just
selector lever (29) and yoke (26) to arm (11). Pin (25) bottoms in slot in the rod brackets.
must be installed with retaining ring (24) to the
outside. Release parking brake.

Install link (6, Fig. 3). Secure yoke to rod (3) and Adjust direction selector lever stop screws (1, Fig.
washer to interlock cam (7). 5) so that a slight override of forward and reverse
detents is possible.
Connect cable (21) to arm (9).
Tighten all lock nuts after adjustments are made.

Operate the rear steer control lever to turn the unit


in both directions to make sure the cable is not
binding or stressed.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Mar-so) Controls 0315-7

SHIFT LEVER AND LINKAGE

f+
I
19

l-Nut (2 used) g--Yoke 11 -Cotter Pin 16-Cap Screw


2-Lock Washer (2 used) 7-Cotter Pin 12--Retaining Ring 17-Nut
3-Clamp (2 used) 8-Pin 13-Knob 18-Nut
4-Cap Screw (2 used) g--Cap Screw 14-Bushing 1 g--Clamp
6-Nut IO-Shift Cable 15-Shift Lever

Fig. B-Shift Lever and Linkage

REMOVAL Remove R.H. control console cover.

Remove shift lever (2, Fig. 7) by disconnecting cable 1


(5) and removing retaining ring (1).

Remove cable (5) by removing clamps (4, Fig. 7 and 1


3, Fig. 6) and pin (8).

REPAIR
Inspect cable for wear, damage and binding and
replace if necessary.

Inspect bushing (14, Fig. 6) for wear.


l-Retaining Ring 4-Clamp
2-Shift Lever 5-Cable Inspect all parts for damage and replace as neces-
3-Cap Screw sary.

Fig. 7-Shift Lever


Use John Deere Never-Seez or an equivalent on all
pivot point areas.

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0315-a Controls TM- 1188 (Mar-80)

INSTALLATION ADJUSTMENT
install shift lever (15, Fig. 6) on pivot pin and secure Move the shift arm on the transmission control valve
with retaining ring (12). to neutral. To find neutral, rotate shift arm counter-
clockwise against the stop, then rotate arm clockwise
Secure cable (10) to machine with clamps (3 and to the first detent position.
19).
Move shift lever (15, Fig. 6) to the neutral position.
Connect cable (10) to shift lever (15) and secure
with cotter pin (11). Adjust yoke (6) so pin (8) will align with hole in shift
arm.
Connect yoke (6) to valve arm with pin (8) and cotter
pin (7). Adjust shift lever stop screws (9 and 16) so that a
slight override of the neutral and eighth speed detents
Install R.H. control console cover. is possible.

Operate the rear steer control lever to turn the unit in


both directions to make sure the cable is not binding or
stressed.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Jwl-78) Housings and Covers 0341-l

Group 0341
HOUSINGS AND COVERS
TRANSMISSION CLUTCH HOUSING
GENERAL INFORMATION Remove transfer drive housing lube line from clutch
housing.
The transmission clutch housing, located at the rear
of the power unit, contains the transmission oil pump
Remove lube pressure gauge tube from connector
and clutch pack assembly.
at clutch housing.

The transmission clutch housing bolts directly to the


Disconnect pump charge line from clutch oil pres-
rear of the transmission case.
sure regulating valve and remove from unit.

REMOVAL Attach a sling around clutch housing and attach to


Refer to Section 42 and remove rear mounted ripper an overhead hoist.
and rear valve (if so equipped).
Make sure all lines and hoses to clutch housing are
Drain lubricant from transmission. disconnected.

Refer to Group 0400 and remove engine. Remove cap screws securing clutch housing to
transmission case and remove clutch housing from
Refer to Group 0841 and remove transfer drive transmission case.
housing.
NOTE: There are two internal cap screws securing
NOTE: When disconnecting hydraulic front wheel the transmission clutch housing to the transmission
drive oil lines, take care so that contamination does not case. The clutch pack must be removed before these
enter system. Plug or cap all fittings. two cap screws can be removed.

NOTE: The engine and transfer drive housing can


be removed as a unit.

Remove cap screws securing transmission oil pump


and clutch pack assembly to clutch housing. Remove
oil pump and clutch pack assembly.

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0341-2 Housings and Covers TM- 1188 (Jul- 78)

REPAIR

l-Gasket 5-Dowel Pin (2 used) g-O-Ring (3 used)


2-O-Ring (2 used) 6-O-Ring - lO-Dowel Pin
3-Clutch Housing 7-Plug (Lube Oil Pressure 11-Pin
d--Special Cap Screw (2 used) Check 12-O-Ring
8-Gap Screw (8 used) 13-Plug

Fig. l-Clutch Housing

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Jul- 79) Housings and Covers 0341-3

Refer to Group 0360 and remove transmission Replace all O-rings.


clutch and pressure regulating valve.
Lubricate O-rings with oil before installation.
I
All parts must be clean to permit effective inspection.
Press dowel pins (5, Fig. 1) to bottom of bores in
All metallic parts of the transmission clutch housing clutch housing flange.
should be cleaned thoroughly with volatile mineral
spirits, or by the steam-cleaning method. Do not use a Refer to Group 0360 and secure transmission clutch
caustic soda solution for steam cleaning. Gum and valve and transmission pressure regulating valve to
varnish deposits should be removed by allowing the clutch housing.
parts to soak in varnish remover.
INSTALLATION
Parts should be dried with compressed air. Steam-
Position a new gasket to the transmission clutch
cleaned parts should be oiled immediately after drying.
housing.

Clean oil passages by working a piece of soft wire


Install O-rings (2 and 9, Fig.
- 1).
back and forth through the passages and flushing with
spirits. Dry the passages with compressed air.
Align the transmission clutch housing with the
transmission case and push housings together.
After cleaning, examine the parts and especially the
oil passages to make certain they are entirely clean.
Tighten internal clutch housing-to-transmission
Reclean them, if necessary.
case cap screws (4, Fig. 1) to 170 lb-ft (230 Nm) (24
kg-m).
Check clutch housing (3, Fig. 1) for cracks and other
possible damage.
Tighten clutch housing-to-transmission case cap
screws (8) to 300 lb-ft (407 Nm) (41 kg-m).
Replace all defective parts as necessary.
Install support housing and secure with snap ring.

Install high and low-range drive shafts.

Install a new gasket on the transmission oil pump


manifold and install clutch packs. Tighten cap screw to
35 lb-ft (47 Nm) (5 kg-m).

Connect hydraulic lines and electrical wires.

Refer to Group 0841 and install the transfer drive


housing.

Refer to Group 0400 and install the engine.

Fill the transmission case with recommended oil, at


filler cap, to dipstick level. (See Section I, Group V for
the type of oil used.)

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0341-4 Housings and Covers TM- 1188 (Jul- 79)

TRANSMISSIQN CASE AND COVERS


GENERAL lNFORMATlON REMOVAL
The transmission case, located below the engine in Refer to Group 0400 and remove the engine.
the power unit, consists of two compartments. The
forward compartment contains the differential assem- Refer to Group 0841 and remove the transfer drive
bly and the rearward compartment contains the plane- housing.
tary pack.
NOTE: When disconnecting hydraulic front wheel
The transmission mounts to the engine frame and drive oil lines, take care so that contamination does not
supports the engine and final drive systems. The enter system. Plug or cap all fittings.
transmission clutch housing bolts directly to the rear of
the transmission case. Attach a hoist to the transmission case and clutch
housing.

Refer to Group 0201 and remove the final drive


housing and tandem housing as a unit.

Remove cap screws attaching front of transmission


case to engine frame and remove transmission.

REPAIR

T59893F

l-Special Cap Screw (4 used) &O-Ring (2 used) 11 -Rear Cover


2-Cap Screw (7 used) ‘I-Nut (9 used) 1 P-Gasket
3-Lock Washer (8 used) I-Lock Washer (21 used) 13-Front Cover
4-Nut Q-Special Washer (15 used) 14-Gasket
5-Dipstick lO-Cap Screw (12 used)

Fig. 2-Transmission Case Top Covers

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Jun-83) Housings and Covers 0341-5

Remove transmission clutch housing as described Clean oil passages by working a piece of soft wire
previously in this group. back and forth through the passages and flushing with
spirits. Dry the passages with compressed air.
Refer to Group 0360 and remove transmission con-
trol valve and forward and reverse modulator. After cleaning, examine the parts and especially the
oil passages to make certain they are entirely clean.
Remove transmission rear cover (11, Fig. 2). Reclean them, if necessary.

Remove brake caliper from front cover and brake disk For units (002356- ), install retainer screws
from brake support on front cover. (31, Fig. 3) through teardrop holes on right side of trans-
mission case (5). Fasten with cover (32) and nut (33).
Remove parking brake shaft assembly from trans-
mission front cover. Check transmission case (5, Fig. 3) and covers (11
and 13, Fig. 2) for cracks and other possible damage.
Remove transmission front cover (13).
Replace parts as needed.
Refer to Group 0210 and remove differential assem-
bly. Install steel balls (18, Fig. 3) O-rings (13), and brake
bleed valve screw (16) and jam nuts (17).
Refer to Group 0350 and remove planetary pack and
reduction gear shaft. Press clutch housing to transmission case dowel pins
(10) into transmission case until they project 1.06 in.
All parts must be clean to permit effective inspection. (26.9 mm) from base of transmission case (5).

All metallic parts of the transmission case should be Coat stud and pipe plug threads with Dow Corning
cleaned thoroughly with volatile mineral spirits, or by the Silastic 732 RTV (Black) or an equivalent before assem-
steam-cleaning method. Do not use a caustic soda solu- bly.
tion for steam cleaning. Gum and varnish deposits
should be removed by allowing the parts to soak in Coat outside of plug (24) with Dow Corning Silastic
varnish remover. 732 RTV (Black) or an equivalent before installing.

Parts should be dried with compressed air. Steam- install plug (24) 5/8 inch (16 mm) below outside sur-
cleaned parts should be oiled immediately after drying. face of transmission case, measured from flat surface of
plug with flange of plug facing outward.

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0341-6 Housings and Covers TM- 1188 (Jun-83)

/20
0
T91503

l-Retainer, Storage Bore 12-O-Ring (2 used) 24-Plug


2-Dowel Pin (2 used) 13-O-Ring (4 used) 25-Lock Washer (6 used)
3-Special Pipe Plug (4 used) 14-Plug 26-Cap Screw (4 used)
4-Dowel Pin (2 used) IS-Pipe Plug (2 used) 27-Nut (2 used)
B-Transmission Case ( -002355) Is-Brake Bleed Valve Screw (2 used) 26-Rear Cover
Transmission Case (002356- ) 17-Jam Nut (2 used) 29-Gasket
B-Stud (3 used) 16-Steel Ball (2 used) 30-Stud (2 used)
7-Stud 19-Dowel Pin (4 used) 31--Retainer Screw (2 used - Right
6-Dowel Pin (2 used) 20-Plug (2 used) Side Only) (002356- )
g-O-Ring (2 used) 21-Drain Plug 32-Cover (2 used - Right Side Only)
lo-Dowel Pin (2 used) 22-Special Washer (002356- )
11 -O-Ring (3 used) 23-O-Ring 33-Nut (2 used - Right Side Only)
(002356- )
Fig. 3-Transmission Case 34-Funnel (002356- )

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (J&78) Housings and Covers 0341-7

Refer to Group 0210 and install differential assem- INSTALLATION


bly.
Hoist transmission into engine frame and install cap
screws.
Refer to Group 0350 and install reduction gear shaft
and planetary pack.
Refer to Group 0201 and secure the final drive
assembly to transmission case.
Install transmission front cover.
Connect hydraulic lines, wires and control linkages.
Refer to Group 1111 and install parking brake shaft
assembly.
Refer to Group 0841 and install the transfer drive
housing.
Install brake caliper and brake disk to front cover.
Refer to Group 0400 and install the engine.
Install transmission rear cover.

Refer to Group 0360 and install transmission control


valve.

Assemble transmission clutch housing to transmis-


sion case as described in this group.

Lifho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0341-8 Housincp and Covers TM- 1188 (Jut-78)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Jul-78) Gears, Shafts, Bearings and Power Shift Clutch 0350-l

Group 0350
GEARS, SHAFTS, BEARINGS AND
POWER SHIFT CLUTCH
GENERAL INFORMATION

7
b
24 2
22

T41056N

l-Spiral Bevel Pinion +Transmission Clutch Housing 18-Support Housing


2-Disconnect Shifter Collar l&-C2 Clutch Pack 19-Transmission Case
3-Reduction Gear Shaft Ii-Cl Clutch Pack 28--81 Brake Pack
Bearing Retainer 12-Oil Pump Housing 21--82 Brake Pack
4-Disconnect Shifter Yoke 13-Clutch Oil Pump 22--83 Brake Pack
5-Reduction Gear 14-Clutch Drive Shaft 23-B4 Brake Pack
8-Reduction Gear Shaft 15-Clutch Manifold 24-Gear
7-C3 Clutch Pack E-Clutch Separator Plate
8-Transmission Case Rear Cover 17-Clutch Backing Plate

fig. 1-Power Shift Transmission

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0350-2 Gears, Shafts, Bearings and Power Shift Clutch TM- 1188 (J&78)

The John Deere Power Shift Transmission provides The transmission consists of a clutch pack located in
eight forward and four reverse speeds. Speed ranges the clutch housing and a planetary pack located in the
are controlled by the speed selector lever. Shifting transmission case.
on-the-go and under load is accomplished by two
compound planetary pinion sets which are controlled /A tow disconnect lever can be engaged to discon-
by three clutches and four brakes. These are hydrauli- nect the transmission from the differential for towing
tally actuated by pressure oil from the transmission oil the grader and for transmission control pressure
pump. checks.

REMOVAL
NOTE: Careful determination of the transmission Low- and High-Range Drive Shafts
component to be serviced is required in order that on/y and Planetary Pack
the necessary grader components need be removed
Refer to Group 0841 and remove the transfer drive
for servicing.
housing.

Transmission Clutch Pack


Refer to Group 0400 and remove the engine.
Refer to Group 0841 and remove the transfer drive
housing. Remove the transmission oil pump and clutch pack
assembly from the transmission clutch housing.
NOTE: When disconnecting hydraulic front wheel
drive oil lines, take careso that contamination does not To remove the low- and high-range drive shafts, pull
enter system. Plug or cap all fittings. shafts from their mounted position in the transmission
clutch housing.
Remove cap screws securing the transmission
pump to the transmission clutch housing. Remove snap ring and pull support housing (18, Fig.
1) from the clutch housing.
The transmission oil pump and clutch pack are
removed from the transmission clutch housing as a unit Remove transmission case rear cover, front cover
(Fig. 2). and parking brake assembly.

Remove reduction gear shaft bearing retainer from


inside differential compartment.

Use a long brass drift to reach through bore in


planetary pack from the rear. Drive reduction gear
shaft forward enough to free planetary pack.

l-Clutch Separator Plate 3-42 Clutch Pack


2-Clutch Backing Plate 4-Cl Clutch Pack

Fig. PTransmission Oil Pump and Clutch Pack

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Jul- 79) Gears, Shafts, Bearings and Power Shift Clutch 0350-3

Remove cap screws securing planetary pack to Reduction Gear Shaft and
transmission case. Tow Disconnect
Refer to Group 0400 and remove engine.

Remove transmission case top covers.

Remove reduction gear shaft bearing retainer from


inside differential compartment.

Remove reduction gear shaft from transmission


case.

Remove disconnect shifter lever (16, Fig. 42) from


shaft (9).

Remove disconnect shifter stop (14).

Remove retainer (7) and pull shaft (9) from trans-


mission case.

Remove left hand shifter yoke shaft (12).


Fig. 3-Removing Planetary Pack
Hold yoke (10) forward and lift reduction gear out of
Install two eye bolts or lifting eyes to remove the transmission case.
planetary pack. The B3 housing has two 9/16 inch
c Remove yoke (lo), disconnect shifter collar (12),
tapped holes for this purpose.
Fig. 41), rear bearing cone (14) and cup (15).

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0350-4 Gears, Shafts, Bearings and Power Shift Clutch TM- I 188 (Jul- 79)

REPAIR
Cleaning and Inspection NOTE: Never spin dry bearings with compressed 1
air. Do not rotate bearings while they are not lubricat-
Parts which have close operating tolerances must
ed.
be handled carefully to prevent nicking, scratching, or
Inspect bearings for roughness of rotation. Replace
denting. The slightest damage to these parts can result
a bearing if its rotation is still rough after cleaning and
in erratic operation and possible malfunction of the
oiling.
transmission. These parts should be carefully handled
and protected during removal, cleaning, inspection,
Inspect bearings for scored, pitted, scratched,
and installation.
cracked or chipped races, and for indication of exces-
sive wear of rollers or balls. If one of these defects is
All parts must be clean to permit effective inspection.
found, replace the bearing.
During assembly, it is very important that no dirt or
foreign matter enters the transmission, Even minute
Inspect the defective bearing’s housing and shaft for
particles can cause the malfunction of close-fitting
grooved, burred, or galled conditions that indicate the
parts.
bearing has been turning in its housing or on its shaft. If
the damage cannot be repaired with crocus cloth,
All metallic parts of the transmission (except bear-
replace the defective part.
ings) should be cleaned thoroughly with volatile min-
eral spirits, or by the steam-cleaning method. Do not
Inspect lip-type oil seals for cuts and hardness.
use a caustic soda solution for steam cleaning. Gum
Replace the oil seals if these defects are found.
and varnish deposits should be removed by allowing
the parts to soak in varnish remover.
When replacing lip-type oil seals, make sure the lip
of each oil seal is toward the oil to be sealed (toward
Parts should be dried with compressed air. Steam-
the inside of the unit). Use a nonhardening sealing
cleaned parts should be oiled immediately after drying.
compound on the outside of the seal to help prevent oil
leaks. Coat the inside of the seal with high temperature
Clean oil passages by working a piece of soft wire
grease (AT30408 or equivalent) to protect the seal
back and forth through the passages and flushing with
during shaft installation and to provide lubrication dur-
spirits. Dry the passages with compressed air.
ing initial operation.

After cleaning, examine the parts and especially the


Inspect gears for scuffed, nicked, burred, or broken
oil passages to make certain they are entirely clean.
teeth. If the defect cannot be removed with a soft
Reclean them, if necessary.
honing stone, replace the gear.

Bearings that have’ been in service should be


Inspect gear teeth for wear that may have destroyed
thoroughly washed in volatile mineral spirits.
the original tooth shape. If this condition is found,
replace the gear.
If the bearings are particularly dirty or filled with
hardened grease, soak them in the spirits before trying
Inspect the thrust faces of gears for scores,
to clean them.
scratches, and burrs. Remove such defects with a soft
honing stone.
Before inspection, oil the bearings with the same
type of oil that will be used in the transmission.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Dee-87) Gears, Shafts, Bearings and Power Shift Clutch 0350-5

Low- and High-Range Drive Shafts Clutch Pack Assembly

l-Snap Ring 5-High-Range Drive


P-Clutch Support Shaft W$” :>““I.y
-,J,b‘CL/,.

Housing 6-Bushing
3-Spring Pin 7-Thrust Washer l-Cap Screw 3-Cl Clutch Drum
4-Low-Range Drive 6-Snap Ring 2-C2 Clutch Drum 4-Clutch Manifold and
Shaft ( -005298) 9-Support Sleeve Pump Assembly
Low-Range Drive
Shaft (005299- ) Fig.5-Clutch Pack Assembly

Fig.4-Low- and High-Range Drive Shafts For easy disassembly and assembly of clutch pack
position clutch shaft through a hole in work bench or
Refer to Figure 4 during disassembly and assembly in a suitable stand.
of drive shafts.
Remove cap screws (1, Fig. 5) holding clutch
Slide low-range drive shaft (4, Fig. 4) from high- drums together.
range drive shaft (5).
Remove C2 clutch drum (2) from Cl drum (3).
Remove clutch support housing (2) from clutch
housing. Remove clutch plates (11, Fig. 6) and disks (12),
clutch hub (10) and clutch separator plate from Cl
Inspect and replace parts as needed. clutch drum (3, Fig. 5).

Press bushing (6) into high-range drive shaft (5) Remove snap ring from clutch drive shaft and
0.400 in. (0.0157 mm) below end of shaft. remove Cl clutch drum.

I. D. of new bushing is 1.327-l .329 in. (33.71-33.76


mm).

Install clutch support housing (2) with spring pin


(3) into clutch housing so that spring pin fits into cast
notch of clutch housing. Spring pin must fit inside
end gap of snap ring (1).

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0350.6 Gears, Shafts, Bearings and Power Shift Clutch TM-1 188 (Dee-87)

8
6

,i-

T61630N

I-Cap Screw (6 used) S-Outer Seal g--Snap Ring


2-C2 Clutch Drum S-High-Range Clutch Piston lo--High-Range Clutch Hub
L-Bushing I-Clutch Plston Return Spring ( -005296) 1 l-Clutch Drive Plate
4-tnner Seal Disk Spring (6 used) (005299- ) (1 flat and 5 wavy used)
S-Spring Retainer ( -005296) 12-Clutch Drive Disk (6 used)

Fig. &Transmission C2 Clutch Pack

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM-1 188 (Dee-87) Gears, Shafts, Bearings and Power Shift Clutch 0350-7

10

l--Clutch Separator Plate ( -005298) 8-Snap Ring 11-Inner Seal


Clutch Separator Plate (005299- 1 ‘I-Spring Retainer ( -005298) ll-Snap Ring (2 used)
a--Dowel Pins (2 used) ( -005298) 8-Clutch Piston Return Spring ( -005298) 13-Cl Clutch Drum
3-Clutch Drive Plate (1 flat and 4 wavy used) Disk Spring (8 used) (005299- ) 14-Bushing
4-Clutch Drive Disk (5 used) g-Low-Range Clutch Piston 15-Clutch Drive Shatt
5-Low-Range Clutch Hub lo-Outer Seal

Fig. 7-Transmission CI Clutch Pack

Use a JDT-24 spring compressor (1, Fig. 8) to


depress clutch piston return spring in Cl and C2
clutch drum until snap ring (2) can be removed.

Remove clutch pistons (6, Fig. 6 and 9, Fig. 7) from


the Cl and C2 clutch drums.

l-JDT-24 Spring P-Snap Ring


Compressor 3-Clutch Drum

Fig. B-Spring Compressor Tool

Litho in U.S.A.
3 TfXLSmiSSiOn JD670-A and JD672-A Motor Graders
8350-a Gears, Shafts, Bearings and Power Shift Clutch TM- 1188 (J&78)

l-Sealing Ring 2-Ring Grooves


(3 used) 3-Oil Manifold

3 Fig. 9-Sealing Ring Location


l--Cl Clutch Drum 3-Polished Surface
m
2-Seal Ring
Turn sealing rings (1, Fig. 9) in their grooves and
check for freedom. If they are stuck, check for con- Fig. IO-C.2 Clutch Drum
tamination or a bad manifold.
Inspect the sealing ring pattern (3, Fig. 10) in the Cl
Remove the rings and inspect for wear. The sides of clutch drum (1).
the ring opposite the pressure side should be smooth
and polished. The polished area should cover all but There should be three smooth, even polished sur-
the extreme outer edge of the ring. faces with a full 360 degrees of contact. Skips in the
pattern indicate a defective clutch drum or sealing
If a thin wear line is present, look for the edge of the rings.
housing rolled over into the ring groove or burrs holding
the sealing ring away from the side of the groove. If the ring pattern is worn into the clutch drum, the
sealing rings are sticking in the ring grooves.
Improper seating of the rings will cause high leak-
age. Inspect the clutch drum for scratches, nicks or
porosity across the sealing ring pattern as this will
increase leakage.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM-1 188 (Dee-87) Gears. Shafts, Bearings and Power Shift Clutch 0350-g

1 -Bushing ( -005298) 13-Bushing


Needle Bearing (005299- ) i4-Gasket
P-Clutch Drive Shaft ( -005298) 15-Steel Ball (2 used)
Clutch Drive Shaft (005299- ) 1 B-Cap Screw
3-Snap Ring (2 used) 17-011 Pump Housing
4-Thrust Washer 18-Cap Screw
5-Ball Bearing 1 O-Cap Screw (2 used)
g--Snap Ring 20-011 Pump Drive
7-Bushing Gear
l-Puller 3-Bushing 8-Sealing Ring (3 used) 21-Cap Screw (3 used)
g--Gasket 22-011 Pump Internal
2-C2 Clutch Drum
1 O-Snap Ring Gear
1 l-Cap screw (8 used) 23-Packing
Fig. 11 -C2 Clutch Drum Bushing 12-Clutch Manifold 24-Oil Pump Body

Inspect the bushing (3, Fig. 11) and replace if Fig. 1BClutch Drive Shaft and Oil Pump
necessary.

Press bushing (3) 0.06 in. (1.5 mm) below rear


surface of C2 clutch drum.

Remove snap ring (10, Fig. 12) and pull clutch


drive shaft (2) from the manifold (12).

NOTE: If clutch manifold (12) is removed from oil


pump housing (17), be careful not to lose steel balls
(15).

Remove snap ring (6) ball bearing (5) and thrust


washer (4) from clutch drive shaft (2). Inspect parts
and replace as required.

Inspect bushing ( -005298) (1, Fig. 12) or needle


bearing (005299- ) and (2, Fig. 13) for wear and
scoring.

Press bushing ( -005298) (1, Fig. 12) or needle


bearing (005299- ) flush with edge of bushing
!I'536288
bore.
l-05 Manifold l-Bushing

Fig. 1%Bushing Location

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0350-10 Gears, Shafts, Bearings and Power Shift Clutch TM- 1188 (Dee-87)

Lubricate all parts with the same type of oil used in Install the three sealing rings (1, Fig. 9) in their
the transmission before assembling clutch pack. proper location on clutch oil manifold. Make sure
tangs are interlocked.
Install the thrust washer (4, Fig. 12) ball bearing
(5), and snap ring (6) on the clutch drive shaft (2). Install snap ring (3, Fig. 12) in the groove nearest
the manifold.
Install drive shaft (2) and secure with snap ring
(10). Apply petroleum jelly or an equivalent on sealing
_- rings before installing Cl clutch drum.

Position Cl clutch drum (2, Fig. 15) on clutch oil


manifold assembly. Be careful not to damage sealing
rings on clutch oil manifold.

i ,,sj,\
“jj&?j<” ,,:,, .I

l-Clutch Piston G-inner Seal


2-Outer Seal

Fig. 14-Clutch Piston Seals

Thoroughly clean and install new inner and outer


piston seals (2 and 3, Fig. 14). Make sure the lip of !rS363S?.7’-v ,;., 1

the inner seal (3) is in the down position when l--Snap Ring 2-Cl Clutch Drum
installed on clutch drums.
Fig. 15-Installing the Cl Clutch
Clutch Drum
Coat inner and outer clutch piston seals and inside
and outside surfaces of clutch pistons with oil before Install snap ring (1).
assembly.

Install clutch pistons in Cl and C2 clutch drum.


Protect clutch piston inner seals with suitable thin
sleeve when installing.

Install clutch piston return springs and spring


retainers ( -005298) or disk springs (005299- ).
Use a spring compressor to compress springs and
install snap rings (Fig. 8).

bitho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Dee-87) Gears, Shafts, Bearings and Power Shift Clutch 0350-I 1

Planetary Pack Assembly


Protect assembly from dirt contamination at all
times.

Use the exploded view (Fig. 18) to identify parts


and as a reference for disassembly.

l-C2 Clutch Hub 4-Cl Clutch Drum


2-Drive Disk 5-Drive Plate
3-Separator Plate

Fig. 76-C/&h Plates and Disks

Inspect Cl and C2 clutch plates and


signs of excessive heat and warping. If evident,
l-C3 Clutch Housing 4--83 Brake Housing
install new plates and disks. a--Cap Screw (5 used) 5--82 Brake Housing
3--84 Brake Housing 6-Bl Brake Housing
IMPORTANT: Clutch drive plates with wavy configu-
ration have a notched tang and a punch mark on Fig. 17-Planetary Pack
one side. For smooth transmission engagement,
punch marked side of wavy plates must be installed Place planetary pack on work bench with B-l
alternately in pack. housing down. Remove five hex. bolts (2, Fig. 17)
securing brake housings together.
Place low-range clutch hub in Cl clutch drum
with flat side up. Starting with the flat clutch drive Lift B-4 housing off while applying finger pressure
plate against the piston, alternately install five clutch to separator plate next to piston to keep piston from
drive disks and four wavy clutch drive plates. Install dropping out of bore. Remove plates, disks and
the wavy plates in pack so punch marked side is springs.
installed alternately, marked side up, marked side
down, marked side up, etc. Lift C-3 clutch housing out of pack.

Place high-range clutch hub in the C2 clutch drum Remove B3 housing, plates, disks, springs and B3
with the flat side up. Starting with the flat clutch drive ring gear.
plate against the piston, alternately install six clutch
drive disks and five wavy clutch drive plates. Install Remove B2 housing, plates, disks and spring,s
the wavy plates in pack so punch marked side is from brake backing plate.
installed alternately, marked side up, marked side
down, marked side up, etc. After removing 82 brake housing, the planetary
carrier assembly (14, Fig. 18) can be removed from
Position clutch separator plate (3, Fig. 16) with Bl brake housing. Bl and 82 ring gears will come
dowel pins to C2 clutch drum. with the planetary unit.

Pick up assembled C2 clutch drum and position to


Cl clutch drum assembly.

Install six long cap screws and tighten to 20 lb-ft


(27 N.m) (3 kg-m).

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0350-l 2 Gears, Shafts, Bearings and Power Shift Clutch TM- 1188 (J&78)

‘A

lW633N

1 -Cap Screw 7A-Bushing (rear) 9 -Spring (8 used in 83)


2 -B4 Brake Piston Housing and 7B-C3 Clutch Piston Housing 10 -B3 Ring Gear
Piston Assembly 7C-Bushing (front) 11 -Fourth Planet Sun Pinion
2A-B4 Brake Piston Housing 7D-Housing Sealing Ring 12 -B2 Brake Piston Housing and
28-64 Housing Seat 7E-Piston Sealing Ring Piston Assembly
2CB4 Piston Seal 7F-C3 Clutch Piston 12A-B2 Brake Piston Housing
2D-B4 Brake Piston 7G-Piston Return Spring 12B-82 Housing Seal
3 -Brake Piston Return Plate 7H--Spring Retainer 12CB2 Piston Seal
(4 used) 71 -Snap Ring 12D--82 Brake Piston
4 -Spring (8 used in 81, 82 and 84) 7J -C3 Clutch Hub 13 -Planetary Brake Backing Plate
5 -Brake Disk 7K-C3 Clutch Plate (5 used) 14 -Planet Pinion Carrier Assembly
(2 used in 84) 7L-C3 Clutch Disk (5 used) (see Fig. 25)
(3 used in Bl and 82) 7M-C3 Clutch Drum 15 -Bl Brake Piston Housing and
(5 used in B3) 8 -B3 Brake Piston Housing and Piston Assembly
6 -Brake Plate Piston Assembly 15A-Bl Brake Piston Housing
(1 used in 84) SA-B3 Brake Piston Housing 15B-81 Housing Seal
(2 used in Bl and 82) SB--83 Housing Seal 1X-Bl Brake Piston Seal
(4 used in B3) SC-B3 Piston Seal 15D-Bl Brake Piston
7 -C3 Clutch SD-Brake Piston
SE-B3 Housing Bushing

Fig. Id-Planetary Pack Components

Remove brake backing plate by prying off of dowel Inspect all brake separator plates and brake disks
pins in B, housing. for cracks, unusual grooving, broken teeth on disks, or
warping.
Remove B, disks, plates and springs.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Jul- 79) Gears, Shafts, Bearings and Power Shift Clutch 0350-13

l-Brake Housing 3-Inner Seal l-B3 Brake Housing P-Bushing


2-Brake Piston 4-Outer Seal
Fig. 2OBushing Locaiion
Fig. 194nner and Outer Seals
Inspect bushings (2, Fig. 20) in B3 brake housing.
Remove brake pistons from housings. I.D. of new bushing is 3.7562 inches (95.407 mm). If
bushing requires replacement, align notches in bush-
Inspect brake housings for possible cracks. Check ing with notches in housing when installing.
ring gear for damage.
Check piston return springs for proper strength. Bl,
Remove all brake housing and piston seals. Inspect B2 and 84 return spring free length should be approx-
the housing piston bores for sharp edges and remove imately 0.83 in. (21.1 mm). With 23.5 to 28.5 Ibs (105 to
with emery paper or a fine file. Thoroughly clean the 127 N) (11 to 13 kg) compressive force, length should
housings and install new inner and outer piston seals be 0.625 in. (15.88 mm).
(3 and 4, Fig. 19). Make sure the lips of inner and outer
seals are in the down position when installed in brake B3 piston return springs have an approximate free
housings and pistons. length of 1.54 in. (39.1 mm). With a compressive load
of 23.4 to 28.6 Ibs (104 to 127 N) (11 to 13 kg), length
Coat planet brake piston seals and their mating should be 1.12 in. (28.5 mm).
surfaces with the same type of oil used in the trans-
mission before assembly. Protect seals with suitable
thin sleeve during assembly.

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0350-14 Gears, Shafts, Bearings and Power Shift Clutch TM- 1188 (Jul- 79)

l-Piston Housing 6-Rear Bushing


2-Ball 7-Dowel Pin
3-Plug 6-Clutch Piston
4-Inner Seal g-Outer Seal
!5-Front Bushing

Fig. 22-C3 Piston Housing

l-C3 Clutch Housing 3-Front Bushing Inspect bushings (5 and 6, Fig. 22) in the C3 clutch
2-Rear Bushing 4-Cap Screw (6 used) piston housing. I.D. of front bushing is 1.9425 to 1.9445
inch (49.340 to 49.390 mm) and I.D. of rear bushing is
Fig. 21 -C3 Clutch Assembly
2.128 to 2.130 inches (54.05 to 54.10 mm). Install front
bushing (5) 0.19 inch (4.8 mm) deep. Rear bushing
Disassemble the C3 clutch housing (1, Fig. 21) by
must be installed with the large chamfer on inside
removing six cap screws (4) securing unit together.
diameter facing the outside.

Use a JDT-24 spring compressor to depress clutch


If dowel pin (7, Fig. 22) is replaced, press into piston
piston return spring (7G, Fig. 18) in C3 piston housing
housing (1) until 0.39 in. (10 mm) remains exposed.
until snap ring (71) can be removed.

Inspect C3 clutch plates and disk for signs of ex-


Check piston return spring (7G) for proper strength.
cessive heat and warping. If evident, install new plates
Free length is 2.70 inches (68.5 mm). With 275 +- 27
and disks.
Ibs. (1223 or 122 N) (125 +- 12 kg) compressive load,
length should be 1.12 inches (28.5 mm)
Coat inner and outer clutch piston seals and inside
and outside surfaces of clutch pistons with oil before
Remove clutch piston from C3 piston housing.
assembly.
Thoroughly clean and install new inner and outer pis-
ton seals. Make sure the lip of inner seal is in down
Install the clutch piston in C3 clutch drum. Protect
position when installed on housing.
clutch piston inner seal with suitable thin sleeve when
installing.
Make sure C3 air bleed ball (2, Fig. 22) is free to
move. Clean passage if required.

Plug (3) is to protrude 0.03 in. (0.8 mm) from bottom


of piston bore.

Plug (3) must retain ball (2) when a 5 lb. (23 N) (2 kg)
force is applied to ball from the opposite side.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (J&78) Gears, Shafts, Bearings and Power Shift Clutch 0350-l 5

l-Clutch Hub 3-Plates and Disks


2-Clutch Drum

Fig. 23-C3 Clutch Assembly

Install clutch piston return spring and spring retainer.


Use a JDT-24 spring compressor to compress spring
l-B1 Ring Gear 4-Front Cover
and install snap ring.
2-Front Retainer 5-Cap Screw (3 used)
I-Bushing GCap Screw (3 used)
Place clutch hub (1, Fig. 23) in C3 clutch drum (2).
Starting with the clutch drive plate, alternately install Fig. 24-Planet Pinion Carrier Front Cover
five clutch drive plates and five clutch drive disks (3) in
the Cl clutch drum. Remove cap screws securing retainer (2, Fig. 24)
and front cover to planetary carrier and remove re-
Position the C3 clutch piston housing on the C3 tainer. Lift front cover (4) from carrier and disassemble
clutch drum and secure with cap screws. Tighten cap front gears. Plate may have to be pried off dowel pins.
screws to 20 lb-ft (27 Nm) (3 kg-m). BE CAREFUL not to lose the bearing rollers (8, Fig.
25). There are 62 in each planet pinion gear.

Examine planet pinion shafts (5) for wear. Replace if


necessary. Check sun and planet pinion gears for
chips or unusual wear. Replace if necessary.

Turn carrier onto opposite end. Remove retaining


cap screws and disassemble this part of carrier as-
sembly in the same manner as the other end. Inspect
bearing rollers, shafts and pinions. Replace if neces-
sary.

Inspect B2 and B3 sun pinion thrust washers for


wear and damage. Replace sun pinions if necessary.

Inspect bushing (3, Fig. 24) in planet pinion carrier


front cover. I.D. of bushing is 2.366 to 2.368 inches
(60.10 to 60.15 mm).

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0350-16 Gears, Shafts, Bearings and Power Shift Clutch TM- 1188 (Jul-78)

&g$- 30
IT61
634N

l-Thrust Washer ll--83 Sun Pinion with Thrust Washer 21-Cl Sun Pinion (B2)
2-Cap Screw (3 used) 12-Fourth Planet Pinion (3 used) 22-C2 Sun Pinion (Bl)
3-Rear Retainer 13-Steel Ball (9 used) 23--81 Ring Gear
4-Rear End Plate 14-Hollow Bowel (3 used) 24-Bushing
E-Shaft (6 used) 16-Bowel Pin (3 used) 26-Front End Plate
B-Thrust Washer (16 used) 16Planet Pinion Carrier 26-Front Retainer
7-Third Planet Pinion (3 used) 17--82 Ring Gear 27-Cap Screw (3 used)
I-Roller Bearing (372 used) 18-Roller Bearing (144 used) 28-Washer (3 used)
B-Spacer (6 used) 19-Spacer (3 used) 29-Gap Screw (6 used)
l&B4 Sun Pinion 26-First and Second Planet Pinion 36-Washer (6 used)
(3 used) 31-Shaft (3 used)

Fig. 25-Planet Pinion Carrier Paris

Press bushing (24, Fig. 25) in end plate flush to 0.02


inch (0.5 mm) below the face of end plate (25) with
notched end of bushing toward the bottom of bore in
the end plate.

When assembling planetary, position planet pinion


carrier (16) front side up, on work bench.

Apply grease to steel ball (1, Fig. 26) and place ball
in recessed hole of planet pinion shaft (2).

IMPORTANT: Do not place bail in lubricating


holes (3) on shaft.

Press shaft with ball into planet pinion carrier (4)


until shaft bottoms out.

Inspect first and second planet pinion shafts (2) to


insure oil lube holes will face front end plate (25, Fig.
25). T53573:i_v

l-Steel Bail (3 used) 3-Lube Hole


2-1st and 2nd Planet Q-Planet Pinion
Pinion Shaft (3 used) Carrier

Fig. 26-hstahg Planef Pinion Shafts

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1 I88 (Jui- 79) Gears, Shafts, Bearings and Power Shift Clutch 0350-17

1-1st and 2nd 3-Bearing Roller


Planet Pinion (144 used)
2-Spacer 4-Thrust Washer
l-B2 Ring Gear 4-Bl and 82 Planet
(3 used) (6 used)
P-Timing Marks Pinions
3--82 Sun Pinion j-Thrust Washer
Fig. 27-Planet Pinion Assembly
(6 used)

Install thrust washer (4, Fig. 27) onto planet pinion FQ. 28-Timing Planetary
shaft.
Install B2 ring gear (1, Fig. 28) with protruding side
Apply petroleum jelly or equivalent into bore of first installed down.
and second planet pinion (1).
Align first and second planet pinions (4) with timing
Install spacer (2) into center of planet pinion. marks (2) corresponding to timing marks on B2 ring
gear.
Place bearing rollers (3) in planet pinion bore, mak-
ing sure 24 bearing rollers are used on each side of Install B2 sun pinion (3) with two notched areas on
spacer. the top of pinion in the up position.

Slide planet pinion assembly on pinion shaft. Install Bi sun pinion (2, Fig. 29) with relieved side up
and Bl ring gear (1) with protruding side of ring gear
Coat planet pinion bearing rollers with oil. installed up.
I
Install another thrust washer (4) onto shaft. Position front cover (4, Fig. 24) over planet pinion
shafts. Install front retainer (2) and install cap screws
(5). Tighten cap screws to 35 lb-ft (47 Nm) (5 kg-m).

Install cap screws (6) and tighten to 8 lb-ft (11 Nm)


(1 kg-m).

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0350-18 Gears, Shafts, Bearings and Power Shift Clutch TM- 1188 (Jul- 79)

l-B1 Ring Gear 2--81 Sun Pinion

Fig. 294nsfalling B7 Gears

Turn assembly over and install third planet pinions,


thrust washers and shafts (Fig. 30). Be sure steel balls
are installed to prevent shafts from turning in carrier.
The third planet sun pinion is installed with the thrust
washer facing the carrier (Fig. 30).

Install fourth planet pinions with shafts and balls, l-Third Planet Pinions 3-Thrust Washer
and fourth planet sun pinion. 2-Third Planet Sun 4-Thrust Washer
Pinion L&-Pinion Shaft
Coat planet pinion bearing rollers with oil after pin-
Fig. 30-Installing Third Planet Sun Pinion
ions are installed.

Install rear cover and retainer and tighten cap


screws (5, Fig. 31) to 30 lb-ft (41 Nm) (4 kg-m) torque.

Tighten cap screws (4) to 8 lb-ft (11 Nm) (1 kgm).

Install thrust washer (1) and B4 sun pinion.

l-Thrust Washer 4-Cap Screw (3 used)


P-Rear Cover 5--Cap Screw (3 used)
3-64 Sun Pinion E---Rear Retainer

Fig. 31-/nsfalling Thrusf Washer

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (J&78) Gears, Shafts, Bearings and Power Shift Clutch 0350-l 9

l-Brake Piston 3-Guide Screws l-Guide Screw 3-Brake Disk (5 used)


2-Piston Return Plate 4--81 Brake Housing a--Dowel Pin 4-Plate (4 used)

Fig. 32-Assembling Bl Brake F@ 34-Installing Bl Plates and Disks

Place the Bl brake housing (4, Fig. 32) on a work Alternately install three brake disks (3, Fig. 34) and
bench with the piston (1) installed. install piston return two plates (4) starting with a disk.
plate (2) and guide screws (3).
Install dowel pins (2) in the untapped holes. Install
the eight piston return springs.

Fig. 33-Carrier Assembly Installed l-B2 Piston Housing 4-Separator Plate


2-Piston Return Plate (2 used)
Place planetary carrier assembly in Bl brake hous- 3-Backing Plate 5-Brake Disk (3 used)

ing.
Fig. 35-Installing 82 Brake Assembly

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0350-20 Gears, Shafts, Bearings, and Power Shift Clutch TM- 1188 (Jul- 78)

fig. 36-83 Ring Gear Installed l-Bushing 3-Piston Return Plate


2-B3 Piston Housing

Install backing plate (3, Fig. 35) between Bl and 82


Fig. 37-83 Piston Housing Installed
housing making sure the oil passages are aligned
correctly. Bl cannot be pressurized if plate is installed
Install 83 brake piston housing (2, Fig. 37) on B2
incorrectly.
housing.

After backing plate is installed, alternately install


Install the C3 clutch housing (3, Fig. 38) aligning
three brake disks (5) and two separator plates (4) on
splines with sun pinion in planet carrier.
B2 ring gear. Install 8 small springs over guide pins and
dowels.
Install brake disk, a separator plate and another
brake disk to C3 clutch housing. Insert 8 springs over
NOTE: Take precaution when placing brake hous-
dowels and guide screws.
ings onto assembly to avoid brake piston slipping out of
housing far enough to dislodge seals on brake piston.

Position the brake piston return plate against piston


and hold plate against piston while installing brake
housings on assembly (see Fig. 35).

Install the B3 ring gear (Fig. 36).

Alternately install five brake disks and four separator


plates on B3 ring gear. Install 8 large springs over
guide pins and dowels.

l-Piston Return Plate 3-C3 Clutch Housing


2--84 Brake Housing 4-Brake Disk (2 used)
S-Separator Plate

Fig. 38-C3 Clutch installed

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (J&78) Gears, Shafts, Bearings and Power Shift Clutch 0350-21

Fig. 40-Testing Planetary Pack

Test the assembled planetary pack with com-


pressed air (Fig. 40). Use 50 to 80 psi (3 to 6 bar) (4 to
6 kg/cm2) air pressure at each of the piston housing
inlet passages. As air pressure is applied to each
l-C3 Clutch Housing 4--83 Brake Housing passage, the corresponding brake should be activated.
2-Gap Screw (5 used) S-B2 Brake Housing Air leakage indicates defective seals.
3--84 Brake Housing G--B1 Brake Housing

Fig. 39-Planetary Pack

Install 84 brake housing on B3 housing and install


the five planetary cap screws (2, Fig. 39). Tighten cap
screws to 35 lb-ft (7 Nm) (5 kg-m).

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0350-22 Gears, Shafts, Bearings and Power Shift Clutch TM- 1188 (Dee-87)

Tow Disconnect and Reduction Gear Shaft

l-Cap Screw (2 used) a-Bearing Cone 16-Bearing Cup with Ring


2-Cap Screw O-Bushing ( -005298) 16-90’ Adjustable Elbow (2 used)
3-Roller Bearing Oil Seal (005299- ) 17-O-Ring (2 used)
4-Steel Ball lo-Reduction Gear Shaft ( -005298) la-C3 Clutch Oil Line
S-Sealing Ring Reduction Gear Shatt with 19-Reduction Gear Shaft
6-Shim (as required) Spring Pin (005299- ) Bearing Retainer
7-Bearing Cup 1 l-Sealing Ring (2 used) 20-Baffle
l2-Disconnect Shifter Collar
la-Reduction Gear
14-Bearing Cone

Fig. 41-Reduction G&r Shaft

See page 0350-4 for information on cleaning and I.D. of new bushing is 0.7525 to 0.7535 in. (19.114
inspecting gears and bearings. to 19.139 mm).

Inspect sealing rings (5 and 11, Fig. 41) for wear, Replace parts as necessary.
scoring and damage.

Inspect splines on collar (12), gear (13) and shaft


(10) for wear and damage.

Inspect bushing in the rear of reduction shaft for


scoring and wear ( -005298).

To install spring pin, press flush into reduction


shaft rear bearing lube hole (005299- ).

To install oil seal, press into transmission reduction


gear shaft 2 k 0.5 in. below end of shaft with sealing
lips facing inward (005299- ).

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Jul- 79) Gears, Shafts, Bearings and Power Shift Clutch 0350-23

T66803N

l-Latch 7-Retainer 13--Shifter Yoke Shoe (2 used)


P-Spring Pin &O-Ring 14-Disconnect Shifter stop
3-Spring Pin g-Right-Hand Shifter Yoke Shaft 1 !&Spring
4-Cap Screw (2 used) 1 O-Shifter Yoke 16-Disconnect Shifter Lever
f&Lock Washer (2 used) ll-Aluminum Washer lit-washer
&Washer (2 used) 12-Left-Hand Shifter Yoke Shaft M-Spring

Fig. 42-Tow Disconnect

Inspect shifter yoke shoes (13, Fig. 42) for wear and
damage.

inspect splines on shaft (9) and yoke (10) for wear


and damage.

Inspect O-rings (8) for cuts or other damage.

Make sure spring (18) will retain latch (1) in stop


(14).

Replace all parts as necessary.

L,%+o in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0350-24 Gears, Shafts, Bearings and Power Shift Clutch TM- 1188 (Jul- 79)

Planetary Pack Install sealing ring (5, Fig. 41) on bearing retainer
(19) and hook ends of sealing ring together. Apply
If the reduction gear shaft, reduction gear shaft
grease to sealing ring to keep it centered in ring groove
bearings or transmission case have been replaced, the
during bearing retainer installation.
reduction gear shaft bearing adjustment should be
made before the planetary pack is installed. See page
If the reduction gear shaft bearings, reduction gear
0350-25.
shaft or transmission case were replaced, the reduc-
tion shaft bearing adjustment must be made. See page
Install new O-ring seals in the brake control oil
0350-25.
passages in the bottom of the transmission case. Be
careful not to move these O-rings out of position when
If these parts were not replaced, the original shim
installing the planetary pack.
pack can be used.

Install planetary pack and tighten planetary pack-


Install shims (6), bearing retainer (19), baffle (20),
to-transmission case cap screws to 55 -c 6 lb-ft (73 I 8
cap screws (1 and 2), and oil line (18).
Nm) (8 2 0.8 kg-m).

Tighten cap screws (1 and 2) to 55 lb-ft (73 Nm) (8


Install support housing (18, Fig. 1) and secure with
kg-m).
snap ring.

Install washer (11, Fig. 42) on shaft (12). Install shaft


Reduction Gear Shaft
(12) into transmission case and shifter yoke (10).
and Tow Disconnect
Install bearing cup (15, Fig. 41) into transmission Install O-ring (8) on shaft (9). With shifter yoke (10)
case. in the engaged position, install shaft (9) so that hole in
the shaft is indexed approximately 10 degrees down
Install sealing rings (11, Fig. 41) on reduction gear from horizontal towards the front of the grader.
shaft (10).
Install retainer (7), disconnect shifter stop (14) and
Install shifter yoke shoes (13, Fig. 42) into shifter lever (16) with latch (1).
yoke (10).
Pull latch (1) out and rotate lever (16) rearward until
Assemble shifter yoke (10) and disconnect shifter lever stops.
collar and lower into transmission case.
Loosen cap screws (2, Fig. 43) on stop and align
Slide reduction gear shaft (10, Fig. 41) into trans- adjustment mark (4) on stop with the front edge of lever
mission case far enough to retain collar (12). (3).

Lower bearing cone (14) and reduction gear into Tighten cap screws (2).
case. Slide reduction gear shaft into position.
Move lever to the engaged position on stop and
Install bearing cone (8) and bearing cup (7). install spring (15, Fig. 42).

Install steel ball (4) and spring pin (3, Fig. 42) if
removed.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM&1 I88 (J&78) Gears, Shafts, Bearings and Power Shift Clutch 0350-25

Transmission Clutch Pack


Install high and low-range drive shafts.

Place a new gasket on the oil pump manifold and


install clutch pack into clutch housing.

Install cap screws and tighten to 3.5 lb-ft (47 Nm) (5


kg-m).

Refer to Group 0400 and install engine.

Refer to Group 0841 and install transfer drive hous-


ing.

l--Shifter Yoke Shaft 3-Disconnect Lever


2-Cap Screw 4-Adjusting Mark

Fig. 43-Tow Disconnect Lever Stop Adjustment

Reduction Gear Shaft Bearing


Preload Adjustment
Install enough shims (6, Fig. 41) to get end play on
the reduction shaft (10).

Install bearing retainer (19) without the sealing ring


(5) and torque cap screws.

Place a steel ball on the end of the shaft to prevent


inaccurate readings due to run-out. Use a sticky sub-
stance to hold the ball in place.

Place a dial indicator on the steel ball.

Push on the shaft while rotating it back and forth until


the needle stops and take a reading.

Pull on the shaft while rotating it back and forth until


the needle stops and take a reading.

Remove shims that are 0.000 to 0.002 in. (0.00 to


0.05 mm) greater than the end play reading.

Use this shim pack for final assembly.

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0350-26 Gears, Shafts, Bearings and Power Shift Clutch TM- 1188 (J&78)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Mar-80) Hydraulic System 0360-l

Group 0360
HYDRAULIC SYSTEM
TRANSMISSION OIL PUMP
GENERAL INFORMATION REPAIR
NOTE: Individual components of the JD670-A
(09363- ) and the JD672-A transmission oil
pump are not offered for service except the cap
screws, packing, oil seal and bushing. If any part is
worn or damaged, a new pump assembly must be
installed.

T61636N
l-Bushing 6-Ball Bearing
2-Bushing 7-Thrust Washer
l-Transmission Oil Pump
IClutch Manifold &Snap Ring
4-Clutch Drive Shaft g-Pump Housing
Fig. I-Power Shift Transmission
6-Snap Ring lO-Cap Screw (6 used)

The transmission oil pump is located in the rear of Fig. Z-Clutch Manifold
the transmission clutch housing. It supplies oil to
operate the clutches and brakes in the transmission Remove snap ring (8, Fig. 2) and remove transmis-
and to lubricate the transmission. It also provides oil to sion drive shaft.
supply the main hydraulic pump.
Inspect ball bearing (6) for wear, damage or rough-
REMOVAL ness of rotation. Replace if necessary.
Refer to Group 0841 to remove the transfer drive
Remove cap screws (10) and separate clutch man-
housing.
ifold (3) from pump body (9).
NOTE: When disconnecting hydraulic front wheel
drive oillines, take care so that contamination does not
enter system. Install caps or plugs on all fittings.

Refer to Group 0350 to remove the transmission oil


pump and clutch packs and to disassemble the clutch
packs.

l-Bushing 6-Pump Housing


2-Oil Pump Internal Gear 7-Gap Screw
3-Oil Pump External Gear 6-Clutch Manifold
4-Bushing g-Steel Ball
!&Gasket
Fig. 3-Pump Housing

Litho in U.S.A.
3 Transmission JD67Q-A and JD672-A Motor Graders
0360-2 Hydraulic Sys tern TM- 1188 (Jun-83)

Be careful not to lose steel balls (9, Fig. 3).

Inspect bushings (1 and 4) for wear and scoring.

I.D. of new bushing (1) is 1.568 to 1.569 in. (39.83 to


39.85 mm). Press bushing flush with edge of bushing
bore.

I.D. of new bushing (4) is 1.567 to 1.5705 in. (39.81 to


39.89 mm). Press bushing flush with edge of bushing
bore nearest oil pump.

Remove cap screw (7) and separate pump housing


(6) from pump body.
,_

l-Oil Seal

Fig. 5-Oil Pump Body

Apply T43511 LOCTITE Clean and Cure Primer or


equivalent to oil seal bore of oil pump body.
TEn944NY
Apply T43514 LOCTITE Plastic Gasket or equivalent
I-Pump Body 3-Internal Gear
P-Bushing 4-External Gear to oil seal bore of oil pump body.

Install oil seal (1) 1.06 in. (26.9 mm) below top surface
Fig. #-Pump Body
of oil seal bore with the sealing lips down.
Remove and inspect pump gears (3 and 4, Fig. 4) for
chipped or grooved teeth. Width of new gears is 1 .1226
to 1.1232 in. (28.514 to 28.529 mm) for early pumps.
Width of new gears is 1.3247 to 1.3253 in. (33.647 to
33.663 mm) for later units.

Inspect bushing (2) for wear and scoring. 0.D.. of new


bushing is 2.4485 to 2.4495 in. (62.192 to 62.218 mm).
T6945N
Inspect pump body for scoring and wear. Depth of
gear bore in a new pump body is 1 .1247 to 1 .I 257 in. l-Chamfered Edge
(28.567 to 28.593 mm) for early units. Depth of gear
Fig. 6-Oil Pump lntemal Gear
bore in a new pump is 1.3273 to 1.3283 in. (33.713 to
33.739 mm) for later units. Lubricate all parts with a light film of oil during assem-
bly.
Inspect oil seal (1, Fig. 5) for wear and damage.
Install oil pump internal gear (3, Fig. 4) with the cham-
fered edge (1, Fig. 6) to the bottom of the gear bore in
Replace parts as necessary.
the pump body (1, Fig. 4).

IMPORTANT: Thoroughly coat all sides and faces


of gears (3 and 4) with clean hydraulic oil prior to
assembly. Never assemble a fixed clearance pump
dry. Premature pump scoring or seizure could result.

LOCTITE is a trademark of the Loctite Corp. ,

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Mar-80) Hydraulic System 0360-3

TRANSMISSION CONTROL
VALVE ASSEMBLY
GENERAL INFORMATION

The transmission control valve assembly consists of


the transmission control valve housing, accumulators,
and the shift valve housing, all of which are located on
the left-hand side of the transmission case (Fig. 8).

REMOVAL

i-Bushing 4-Pump Body


2-Pump Housing !5-External Gear
3-Packing B-Internal Gear
7-Oil Seal

Fig. 7-Pump Gears Installed

Install external gear (5, Fig. 7) and packing (3).

Install pump housing (2) on pump body (4) and


install cap screw (7, Fig. 3). Tighten cap screw (7) to 20
lb-ft (27 N.m) (3 kg-m).

Install a new gasket (5) between the pump housing


(6) and clutch manifold (8).

Install steel balls (9) into the check ball seats in the
clutch manifold.

Assemble manifold (8) to pump housing (6) and


install cap screws (10, Fig. 2). Tighten cap screws (10)
to 20 lb-ft (27 N-m) (3 kg-m).
l-Forward-Reverse 6-Reverse Cam Switch
Modulator (JD672-A)
Install clutch drive shaft (4, Fig. 2) and secure with
2-C3 Pressure Switch Reverse Warning Switch
snap ring (8). (JD672-A Only) (JD670-A)
3-B3 Pressure Switch ‘I-Forward Cam Switch
Install sealing rings in the three ring grooves farthest (JD672-A Only) (JD672-A Only)
from the oil pump. 4-Reverse Warning Switch t&Direction Selector Arm
(JD672-A Only) g--Speed Selector Arm
5-Start Safety Switch 10-l to 4 Cam Switch
INSTALLATION (JD672-A only)
1 l-Transmission Control
Refer to Group 0350 to assemble clutch packs and
Valve
install in clutch housing.
Fig. &Transmission Control Valve

Tag all wires and terminals to aid in assembly.

Disconnect wires from switches (2, 3, 4, 5, 6, 7, and


10, Fig. 8) and cables from speed and direction selec-
tor arms (8 and 9).

Disconnect modulator oil lines from control valve


(11).

Remove cap screws and valve.

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0360-4 Hydraulic System TM- 1188 (Mar-80)

REPAIR

l-Spring Pin lO-Link (2 used)


2-Spring Pin 11-Spring Pin (2 used)
3-Control Valve Cover 12-Control Valve
4-Gasket 13--Reverse Valve
5-Shim (as required) 14-Control Valve Housing
6-Control Valve Arm lli-Spring
l-Speed Selector Arm 6-Shift Valve Housing 7-Reverse Valve Arm 16-Steel Ball

PI 2-Direction
3-Reverse
Selector Arm
Warning or
7-Cover
8-Gasket
8-Washer (2 used)
g--Cotter Pin (2 used)
17-Detent
18-Spring
Reverse Cam Switch O-Cap Screw
4-Control Valve Cover (6 used) Fig. lo-Control Valve Spools
5-Gap Screw (5 used)

I Fig. g-Transmission Control Valve Removed

I Remove cap screws (9, Fig. 9) and separate shift


valve housing (7) from control valve.

I released
NOTE: Detent springs (15 and 18, Fig.
when gasket plate is removed.
10) will be

Transmission Control Valve


I Remove cover (3, Fig. 10) and valves (12 and 13).

Drive out spring pins (11) to remove valves (12 and l-Shaft (2 used) g--Reverse Valve Arm
2-Spring (2 used) lo--Oil Seal (2 used)
13).
3-Washer (2 used) 11-Gasket
4-Felt Washer (2 used) 12-Control Valve Cover
I If cover (12, Fig. 11) or oil seals (10) must be 5-Spring Pin (2 used) 13-Link (2 used)
replaced, drive out spring pins (5 and 6) and remove B-Spring Pin (2 used) 14-Control Valve Arm
shafts (1). 7-Cotter Pin (2 used) 15-Shim (as required)
8-Washer (2 used)

Fig. 1 l-Cover Assembly

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Dee-87) Hydraulic Sys tern 0360-s

Inspect valves for scoring, wear and damage. O.D. Inspect pistons (7, Fig. 12) and piston bores for
of new valves (12 and 13, Fig. 10) is 0.7480 to 0.7490 wear, scoring and damage.
in. (19.000 to 19.025 mm).
O.D. of new pistons is 1.8090 to 1.8096 in. (45.949
I.D. of valve bores in a new housing is 0.7495 to to 45.964 mm).
0.7505 in. (19.037 to 19.063 mm).
Piston bore diameter in new housing (1) is 1.8115
to 1.8125 in. (46.012 to 46.038 mm).

Replace parts as necessary.

Use new O-rings, seals and gaskets in assembly.


Apply a light coat of oil to all internal parts to aid in
assembly.

Install a new gasket (10). Install cover (11) and


tighten cap screws to 35 lb-ft (47 N.m) (5 kg-m).

Coat lips of seals (10, Fig. 11) with Lubriplate or an


equivalent and install in cover (12) with lips facing
bottom of seal bore.

Install control arms (9 and 14) in cover with bearing


against machine boss in cover.

Use shims (15) to fill the gap between arm (14) and
cover (12).

When installing spring pins in arms (9 and 14)


make sure slot on inner spring pin (5) aligns with slot
on outer spring pin (6).

T6700AA Attach control valves (12 and 13, Fig. 10) to links
(10) in cover (3). With new gasket (4) in position on
l-Control Valve Housing 11 -Cover cover, assemble cover with valves on the housing.
2-Shim (AR) ( -010576) 12-Lock Washer (12 used)
O-Ring (2 used) (010577- ) 13-Cap Screw (4 used)
14-Washer
See Group 1674 and 1675 to adjust switches (2,3,
3-O-Ring (9 used)
4-Plug (9 used) 15-Spring (3 used) 4, 5, 6, 7 and 10, Fig. 8) if required.
5-Switch Is-Detent (3 used)
6-Orifice 17-O-Ring (2 used)
7-Piston (2 used) 18-Plug (2 used)
6-Spring (2 used) 19-Plug (004856- )
g--Spring (2 used) 20-O-Ring (004856- )
1 O-Gasket

Fig. 12-Accumulator Assemblies

Remove cover (11, Fig. 12) to remove accumulators.

Check springs (8 and 9) for damage and proper


strength. Free length of outer springs (8) is 4.09 in.
(104 mm). Test length is 2.91 in. (74 mm) at 205 & 20
Ibs. force (912 k 89 N).

Free length of inner spring (9) is 3.78 in. (96 mm).


Test length is 2.91 in. (74 mm) at 111 + 11 Ibs. force
(494 f 49 N).

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0360-6 Hydraulic Sys tern TM- 1188 (Mar-80)

Shift Valve Housing Install dump valve (6, Fig. 13) with the drilled end 1
facing outward.

Install spring (5) and special screw (4). Stake special


screw in two places

Coat all parts with the same type of oil used in the
transmission before assembly.

Replace all O-rings and gaskets.

l-Gasket 8-O-Ring (4 used) Refer to Fig. 13 during assembly. I


P-Plate B-Shift Valve (4 used)
3-Gasket lO-Spring (4 used)
4-Special Screw 11-Washer (4 used)
Install shift valves (9) into the housing (7) with the
5-Spring 12--Retaining Ring (4 used) drilled end of shift valves facing outward.
g--Dump Valve 13-Gasket
7-Shift Valve Housing 14-Cover Install springs (lo), washers (1 l), and retainers (12).

Fig. 13-Shift Valves


Install steel ball (16, Fig. lo), detent (17) and springs 1
(15 and 18) into the detent bores in the control valve
Remove special screw (4, Fig. 13) to remove dump
housing.
valve (6).

Install gaskets (1 and 3, Fig. 13) and plate (2) onto 1


Remove retainers (12) to remove shift valves (9).
the control valve housing. Take special care to see that
they are positioned correctly when assembling shift
inspect valve spools (6 and 9, Fig. 13) for wear and
valve to control valve housing.
scoring.
Install shift valve housing (7) gasket (13) and cover
O.D. of new dump valve (6) is 0.6227 to 0.6233 in.
(14). Tighten cap screws to 20 lb-ft (27 N-m) (3 kg-m).
(15.817 to 15.832 mm).

INSTALLATION
O.D. of new shift valve spool is 0.4977 to 0.4983 in.
(12.642 to 12.657 mm). Position transmission control valve to transmission
case. Install cap screws and tighten to 45 lb-ft (61 N.m)
Inspect valve bores in housing (7) for scoring and (6 kg-m).
wear. I.D. of dump valve bore in new housing (7) is
0.6245 to 0.6255 in. (15.862 to 15.888 mm). I.D. of shift Connect oil lines, wires and control cables using Fig.
valve bore in new housing is 0.4995 to 0.5005 in. 8 as a guide. I
(12.687 to 12.713 mm).

Inspect springs for damage and proper strength.

Free length of shift valve spring (10) is 1.39 in. (35.3


mm). Test length is 0.81 in. (20.6 mm) at 6.8 to 8.4 Ibs.
force (30 to 37 N).

Free length of dump valve spring (5) is 1.12 inch


(28.4 mm). Test length is 0.84 inch (21.3 mm) at 32 to
38 Ibs. force (142 to 169 N).

Replace parts as necessary.

bitho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Mar-80) Hydraulic Sys tern 0360-7

TRANSMISSION OIL REMOVAL


PRESSURE REGULATING Disconnect hydraulic lines (1 and 2, Fig. 14) at the )
VALVE valve.

GENERAL INFORMATION Remove the fitting from the valve that hydraulic line
(2) was connected to so cap screw (5) can be re-
moved.

Disconnect wire from oil temperature sending unit


(4).

Remove cap screws (5) and remove valve.

REPAIR
Refer to Fig. 15, during disassembly and assembly 1
of the pressure regulating valve.

During disassembly tag valves and springs so they


can be reinstalled in the bore from which they were
removed.

Note the number of adjusting shims (15) under valve


spring (10) when removing valve from housing.

Inspect all parts for wear or damage. Replace parts


as necessary.
l-Hydraulic Line 4-Oil Temperature
(to transmission oil Sending Unit
cooler) 6-Cap Screw (7 used) Check valve and housing for excessive scoring.
Z-Hydraulic Line B-Lock Washer (7 used)
(lube relief) 7-Washer (7 used) Measure O.D. of valve. New valves have an O.D. of
3-Valve Housing 0.6645 to 0.6655 inch (16.878 to 16.904 mm).
Fig. 14-Transmission Oil Pressure Regulating
Valve Location (JD672-A Shown) Measure I.D. of valve bores in housing (3). New
housing valve bores measure 0.6675 to 0.6685 inch
The transmission oil pressure regulating valve is (16.955 to 16.98g mm).
located on the right side of the clutch housing.
Test springs and compare the results with the fol-
The pressure regulating valve housing contains the lowing specifications.
transmission oil filter relief valve, the lube relief valve,
the oil pressure regulating valve and the oil cooler relief Cooler relief valve spring (9)
valve. (free length) . _. . . . . . . . .4.55 in. (115.6 mm)
(test length). . . . . . . . . . . 3.53 in. (89.7 mm)
at 35.7 to 43.7 Ibs. force
(159. to 194 N)

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0360-8 Hydraulic System TM- 1188 (Mar-80)

Pressure regulating valve spring (10, Fig. 15) I


(free length) . . . _. . .5.05 in. (128.3 mm)
(test length). . . . . . . . .4.44 in. (112.8 mm)
at 55 to 67 tbs. force
(245 to 298 N)

Lube relief valve spring (11)


(free length) . . ... . . .2.83 in. (71.9 mm)
(test length). .. .... . .2.13 in. (52.1 mm)
at 12 to 14 Ibs. force
(53 to 62 N)

Filter relief valve spring (12)


(free length) . . . . . . . . . .3.71 in. (94.2 mm)
(test length). . . . . . . . . . . . . .2.61 in. (66.3 mm)
at 24.3 to 29.7 Ibs. force
(108 to 132 N)

Use new O-rings in assembly. Oil all internal parts


prior to assembly.

When installing valves in housing, use the same


number of shims (15, Fig. 15) under valve spring (10) 1
as were removed.

INSTALLATION
Gaskets should be replaced whenever the regulat-
ing valve is removed. To accomplish this, it will be
necessary to remove the transmission clutch valve.

If removed, install clutch valve.

Locate pressure regulating valve assembly on


transmission clutch housing and tighten cap screws to
l-Plug 10-Spring (blue)
2-O-Ring ll-Spring (yellow)
45 lb-ft (61 N.m) (6 kg-m).
Z&Pressure Regulating 12-Spring
Valve Housing 13-Plug (2 used) Connect hydraulic and electrical lines to housing.
4-Filter Relief Valve 14-O-Ring (3 used)
6-O-Ring (4 used) 16-Shim (as required)
ADJUSTMENT
B-Lube Relief Valve 1&Plug
7-Pressure Regulating 17-Washer (2 used) Test setting of pressure regulating valve. If pressure
Valve 18-Plug
setting is low, add shims (15). Remove shims if pres-
8-Cooler Relief Valve 19-Plug
g--Spring 29-Orifice (3 used)
sure setting is high.

Fig. 15-Oil Pressure Regulating Valve Assembly


I

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Mar-80) Hydraulic System 0360-9

TRANSMISSION CLUTCH
VALVE
GENERAL INFORMATION REMOVAL
Disconnect spring (1, Fig. 16) cable (7) and oil 1
pressure tube (8) from the clutch valve.

Disconnect wires from the clutch pressure switch


(9).

Remove cap screws (31, Fig. 17) and remove clutch 1


valve from clutch housing.

REPAIR
Use Fig. 17 for identification of parts and for refer- 1
ence during disassembly and assembly.

Remove special pin (19) holding clutch valve control


shaft (18) to clutch control shaft link (20).

Remove special plug (26) from housing and pull


clutch valve assembly from the housing.

l--Spring 6-Clamp Disassemble valve.


2-Yoke 7-Cable
3-Valve Operating 8-Transmission Oil
Rod Pressure Tube
Remove control shaft (18) and remove oil seal (13).
4-Clutch Valve 9-Clutch Pressure Switch
Control Lever (JD672-A Only) Inspect all parts for wear or damage. Replace parts
!&-Cable Clamp 1 O-Lever Extension as necessary.
Bracket 1 l-Clutch Valve

Fig. 16-Clutch Valve Location


Check clutch valve and housing bore for excessive
(JD672-A Shown) scoring.

This clutch valve controls the supply of pressure oil Check valve springs.
to the Cl and C2 clutches. When the pedal is de-
pressed, oil pressure is cut off from the clutch ele- Spring (27) free length is 2 ? 0.03 in. (51 -c 8 mm)
ments. The clutch pedal can also be used for emer- and test length is 1.41 in. (35.7 mm) at 13 ? 1 Ibs. force
gency stops. (58 t 4 N).

Spring (21) free length is 1.3 ? 0.03 in. (33 t 8 mm)


and test length is 1.09 in. (27.8 mm) at 17 ? 2 Ibs. force
(76 +- 9 N).

Spring (22) free length is 0.5 r 0.03 in. (13 + 8 mm)


and test length is 0.34 in. (8.7 mm) at 4 5 0.4 Ibs. force
(18 t 2 N).

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0360-l0 Hydraulic System TM- 1188 (Dee-87)

T61075F

l-Spring 11 -Lever Pivot Shatt 21-Spring 32-Clutch Valve Control


2-Cotter Pin (2 used) 12-Dowel Pin (2 used) 22-Spring Lever
3-Pin 13-Oil Seal 23-Spring Pin 33-Washer
4-Yoke M-Clutch Valve Housing 24-Clutch Valve 34-Snap Ring
S-Jam Nut 1 %-Gasket 25-O-Ring 35-Plug
B-Spring Pin 16-Plate 26-Plug 36-Cap Screw
7-Valve Operating Arm 1 ‘I-Gasket 27-Spring 37-Lever Extension
I-Valve Operating Rod 18-Clutch Control Shatl 28-Shim (as required) 38-Nut
g-O-Ring (3 used) 19-Pin (2 used) 29-Clutch Valve Shaft 39-O-Ring (507334- )
lo--Plug (3 used) PO-Link 30-Lock Washer (7 used) 40-Plug (607334- )
31-Cap Screw (7 used) 41-Dowel Pin (2 used)

Fig. 17-Clutch Valve Assembly

Check clutch valve and housing bore for excessive install seal (13, Fig. 17) flush with housing (14) with
scoring. lips of seal toward bottom of seal bore.

Compare O.D. of clutch valve (24, Fig. 17) with new Locate control shaft (18) in housing.
part dimension of 0.6861 to 0.6865 inch (17.427 to
17.437 mm). Assemble clutch valve and shaft assembly and
install in housing. Connect valve shaft to control
Replace O-rings, and seals in assembly. Lightly oil shaft link with pin (19).
all internal parts proper to assembly.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Mar-80) Hvdraulic Svstem 0360-l 1

INSTALLATION FORWARD-REVERSE
I Gaskets (15 and 17, Fig. 17) should be replaced MODULATOR
whenever the clutch valve is removed. To accomplish
this, it will be necessary to remove the transmission oil GENERAL INFORMATION
pressure regulating valve assembly (see page 0360-
7).

Locate clutch valve housing on transmission clutch


housing and install attaching hardware.

If removed, install pressure regulating valve (see


page 0360-8).

Connect linkage at the valve.

ADJUSTMENT
1 Disconnect the return spring (1, Fig. 17) and the
yokes from the clutch valve control lever (32) and lever
extension (37).

Rotate both the clutch valve control lever (32) and


the valve operating arm (7) counterclockwise until they
hit the stops.

With the operating arm (7) and the control lever (32)
against the stops, adjust the yoke on the operating arm l-Forward-Reverse 7-Forward Cam Switch
so that the hole in the yoke (4) aligns with the hole in Modulator (JD672-A Only)
the control lever (32). Then turn yoke l/2 turn coun- 2-C3 Pressure Switch 8-Direction Selector
terclockwise to lengthen the rod. Attach the yoke (4) to (JD672-A Only) Arm
3-N Pressure Switch g--Speed Selector Arm
the upper hole in the control lever (32).
(JD672-A Only) 10-l to 4 Cam Switch
4-Reverse Warning (JD672-A Only)
1 Adjust yoke on control cable (7, Fig. 16) so when Switch (JD672-A Only) il-Transmission Control
control lever (4) is rotated counterclockwise against the S-Start Safety Switch Valve
stop, the bottom side of the clutch pedal clears the floor 6--Reverse Cam Switch
(JD672-A)
plate.
Reverse Warning Switch
(JD670-A)

Fig. Id-Forward-Reverse Modulator Location

The forward-reverse modulator (1, Fig. 18) is a


cylinder with a floating piston. One end of the modula-
tor is plumbed into the C3 circuit and the other end is
plumbed into the B3 circuit. When the transmission is
shifted from forward to reverse or reverse to forward,
the modulator piston will have to move to the other end
of the cylinder before pressure oil can engage either
C3 or 83. This increases the time to change directions
resulting in a smoother shift.

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0360-12 Hydraulic Sys tern TM- 1188 (Jun-83)

T62146N

l-Retaining Ring (2 used) 5-Cylinder a--Piston


2-Cap (2 used) g--Backup Ring (2 used) g--Backup Ring
3-Backup Ring (2 used) 7-O-Ring (2 used) lo--Spacer (as needed)
4-O-Ring (2 used)
Fig. Y9-Forward-Reverse Modulator Assembly

REMOVAL INSTALLATION
Disconnect hydraulic lines from modulator (1, Fig. 18) Position modulator to transmission and install attach-
and remove attaching hardware. ing hardware. Be sure to install end of modulator with
spacer in it toward rear of machine.
REPAIR
Connect hydraulic lines.
Remove snap-rings (1, Fig. 19) and disassemble mo-
dulator.

O-rings and backup rings should be replaced when


the modulator is disassembled.

Inspect all parts for damage. Replace as necessary.

Apply oil to all parts to aid in assembly.

Refer to Fig. 19 to assemble modulator.

NOTE: Spacers (10) are not to be used as original


equipment but can be used to decrease the shift time for
forward and reverse direction changes if the customer
prefers a faster shift time. The spacers are available in
0.5 in. (13 mm) and 0.75 in. (19 mm) thicknesses. The
maximum thickness of spacers that can be installed is
2.0 in. (51 mm).

Spacer (10) (if used) must be installed in the 83 end


(rear) of the cylinder.

The piston (8) must be installed with the larger cavity


toward the C3 (forward) end of the modulator.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Mar-so) Hvdraulic &stem 0360-l 3

TRANSMISSION OIL FILTER ASSEMBLY


GENERAL INFORMATION REPAIR

T61647N

l-Special Cap Screw 6-Spring


2-O-Ring (2 used) g--Washer
J-Transmission Oil Filter 7--Retainer
Cover G-Retaining Ring
4-Packing g--Oil Filter Element

Fig. 2 I- Transmission Oil Filter Assem b/y


1
l-Transmission Filter 2-Transmission Filter
Restriction Switch Check packings, O-rings, and back-up rings for
wear or failure. Replace parts as necessary.
I Fig. M-Transmission Filter Location

Change filter element (9, Fig. 21) at regular time 1


The transmission filter, located on the right side of intervals or whenever clogged.
1 clutch housing (Fig. 20), is of the full-flow type and
contains a replaceable element. Place O-ring (2, Fig. 21) on special cap screw (1). 1

REMOVAL Insert special cap screw through transmission oil


Loosen and remove special cap screw (1, Fig. 21). filter cap.

Remove filter assembly. Put packing (4), spring (5) washer (6), retainer (7),
retaining ring (8), and filter element (9) on as shown in
Fig. 21. I

INSTALLATION
Install filter assembly on unit using special cap
screw (1, Fig. 21) to align parts. I

Tighten cap screw (1) to 45 lb-ft (61 Nm) (6 kg-m).

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0360-l 4 Hydraulic System TM- 1188 (Mar-80)

TRANSMISSION FILTER RESTRICTION SWITCH

T41284N

l-90” Elbow (2 used) 5-Spring g--Spring Guide


2-Plug 6-Shim lO-To Outlet of Transmission
3-O-Ring 7-Special Plug Filter
4-Valve &-Spring 11-Body
12-To Inlet Transmission Filter

I Fig. 22-Transmission Filter Restriction Switch

GENERAL INFORMATION REPAIR


The transmission filter restriction switch is used to Inspect valve (9, Fig. 23) for burrs or excessive I
monitor the condition of the transmission oil filter. wear. Replace as necessary.
When the pressure difference between 10 and 12, Fig.
1 22 increases to 61 psi (421 kPa) (4 bar), valve (4) Check spring (1) for test length of 1.58 in. (40.1 mm)
moves down completing an electrical circuit, causing at 21 + 2.1 Ibs. force (93 c 9 N). Free length is 2.32 in.
indicator light on instrument panel to glow. This will tell (59 mm).
the operator that the filter is plugged.
Check spring (4) for test length of .50 in. (12.7 mm)
REMOVAL at 20 _’ 2 Ibs. force (89 -c 9 N). Free length is 0.89 in.
(22.5 mm).
Refer to Figs. 20 and 23 for removal.
I
Add or deduct shims (3) for electrical contact at 61
psi (421 kPa) (4 bar). I

INSTALLATION
Refer to Figs. 20 and 23 to install transmission filter 1
restriction switch.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Mar-80) Hydraulic System 0360-l 5

16

l-Spring g--Special Plug 11 -Body


2-Spring Guide 7-Nut 12-Plug
3-Shim (4 used) B-U-Bolt 13-Bracket
4-Spring g-Valve ll-Lock Washer (2 used)
6-O-Ring (2 used) 10-90” Elbow (2 used) 16-Nut (2 used)
16-Washer (2 used)

Fig. 23-Transmission Filter Restriction Switch

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0360-l 6 Hydraulic System TM- 1188 (Mar-80)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Jul- 79) Clutch Disconnect and Controls 0370-I

Group 0370
CLUTCH DISCONNECT AND CONTROLS
CLUTCH LINKAGE
GENERAL INFORMATION

25
T64300F
24

l--Spring 8-Washer (as required) 14-Disconnect Clutch 26-Pipe Seal


2-Disconnect Bracket %-Pivot Handle al--Band (2 used)
3-Special Nut (2 used) 1 “Washer E-Rod 22-Cap Screw (2 used)
4-Cap Screw (2 used) il-Cotter Pin (2 used) 16-Hand Grip 23-Cable Clamp
FL-Spacer (2 used) 12-Nut (4 used) 17-Spring Pin 24-Pin
6-Cable X%-Disconnect Handle 18-Cotter Pin 2!3-Adjustable Yoke
7-Cap Screw (4 used) Catch %-Pin

Fig. 1-Clutch Disconnect Linkage

Litho in U.S.A.
3 Transmission JDUO-A and JD672-A Motor Graders
0370-2 Clutch Disconnect and Controls TM- 1188 (Jul- 79)

The transmission disconnect clutch allows the en-


gine to be disengaged from the transmission for cold
weather engine starting.

As the clutch control lever is pulled upward, the


clutch cable actuates the control linkage rotating the
clutch fork shaft. This forces the release bearing for-
ward against the pressure plate release levers. The
clutch release levers retract the clutch pressure plate,
releasing the driven disk from the pressure plate and
driving surface of the flywheel, thus disconnecting the
engine from the transmission.

IMPORTANT: instruct the operator to engage


the transmission disconnect clutch slowly, imme-
diately after the engine is started. Operation of the
engine while the transmission oil pump is discon-
nected will result in damage to the main hydraulic
pump.

REMOVAL
Disassemble clutch control linkage using Figs. 1 and
2 as a guide.

Remove cotter pin (18, Fig. 1) and pin (19) to 5-Disconnect Cable
l-clutch Fork Shaft
disconnect cable (6) from handle (14). 2-Spring GYoke
3-Disconnect Bracket 7-Pin
Remove cotter pin (11) to remove handle (14). 4-Cable Clamp O-Transfer Drive
Housing

Remove pin (7, Fig. 1) to disconnect yoke (6) from


fig. 2-Disconnect Clutch Controls
clutch fork shaft (1).
INSTALLATION
Remove clamp (4) and loosen bulkhead nuts on
cable to remove cable. Coat all pivoted joints of clutch linkage with AT30408
High Temperature Grease or an equivalent.
REPAIR
Install disconnect handle pivot (9, Fig. 1) to left rear
Inspect cable for wear, binding or broken strands. inside surface of cab wall.

Inspect pivot points for wear. Install disconnect handle catch (13) to left front
inside surface of cab wall.
Replace parts as necessary.
Position and secure clutch cable (6) with pins (19
and 24) and cotter pins (11 and 18).

Tighten bulkhead nuts and install clamp (4, Fig. 2).

Install pipe seal (20, Fig. 1) by wrapping around


cable next to bulkhead fitting on outside of cab. Secure
pipe seal with ties (21) while seal is in compressed
wrapped state.

Operate rear steer to make sure that cable does not


pull tight when frames are articulated.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (J&78) Clutch Disconnect and Controls 0370-3

ADJUSTMENT REPAIR
Install enough washers (8, Fig. 1) behind catch (13) Inspect clutch fork shaft, clutch fork, and release
to assure handle (14) will be retained properly on bearing carrier for wear and damage.
catch.
Inspect clutch release bearing (6) for wear.
Position catch (13) so that 1.45 inches (36.8 mm) of
cable travel is provided when the handle is moved from Replace parts as necessary.
its fully released position to being retained on the catch
(13). INSTALLATION
Coat all pivoted joints of clutch assembly with John
With the clutch control handle (14) in the released
Deere Never-See2 Lubricant or an equivalent.
position, adjust yoke (6, Fig. 2) to align with bottom
hole in clutch shaft lever (1) with the lever (1) in its
Install clutch fork (4, Fig. 3) with cored holes to rear.
extreme rearward position.

Install clutch release bearing (6) with the largest


CLUTCH SHAFT AND outside diameter toward clutch and flush with clutch
side of hole.
CARRIER ASSEMBLY
Operate the clutch fork shaft (1) by hand several
REMOVAL times after assembly to be sure the bearing carrier (7)
Refer to Group 0841 and remove transfer drive moves freely on the carrier sleeve.
housing.
Refer to Group 0841 and install transfer drive hous-
Remove bearing carrier (7, Fig. 3) from carrier ing.
sleeve and clutch fork (4).

Remove cotter pin (3) and pin (2) from clutch fork
and remove clutch fork shaft (1) and clutch fork (4)
from transfer housing.

T59529F

l-Clutch Fork Shaft 4-CPlutch Fork GRelease Bearing


2-Pin EL-Dowel Pin (2 used) 7-Release Bearing Carrier
3-Cotter Pin

Fig. 3-Clutch Shaft and Carrier Assembly

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0370-4 Clutch Disconnect and Controls TM- 1188 (J&78)

CLUTCH ELEMENTS
GENERAL INFORMATION
The engine disconnect clutch allows the engine to
be disconnected from the transmission for cold
weather starting.

The engine disconnect clutch is a simple dry-disk


assembly mounted on the engine flywheel. The clutch
disk is held in engagement by six clutch springs.

When the disconnect clutch is engaged, engine


power is transmitted from the engine crankshaft to the
transmission via the transfer drive.

IMPORTANT: instruct the operator to engage


the engine disconnect clutch slowly, immediately
after the engine has started. Operation of the en-
gine while the transmission oil pump is discon-
nected will result in damage to the main hydraulic
pump. l--Clutch Disk 4-Pressure Plate
2-Cap Screws (6 used) Assembly
REMOVAL 3-Flywheel

Refer to Group 0841 and remove transfer drive Fig. 4-Disconnect Clutch Elements
housing.

Remove six cap screws (2, Fig. 4) securing clutch


pressure plate assembly (4) to engine flywheel.

Note location of spacers (11, Fig. 5) when removing


pressure plate assembly from flywheel. The spacers
are located between the pressure plate and the fly-
wheel.

Remove clutch disk (1, Fig. 4) from flywheel hous-


ing.

Remove pilot bearing (15, Fig. 6) if required.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (U-78) Clutch Disconnect and Controls 0370-5

REPAIR

l-Pressure Plate j-Pivot Pin (3 used) g-Adjusting Screw Washer


a-Bracket 6-Return Clip (3 used) (3 used)
3-Release Lever 7-Adjusting Screw (3 used) lo--Spring Cup (6 used)
4-Pressure Spring (6 used) E-Adjusting Screw Lock Nut 11-Spacer (6 used)
(3 used)

Fig. dsectional View of Clutch Pressure P/ate Assembly

Refer to Figs 5 and 6 for identification of parts, Assemble release levers (3) and bracket (2) with
new pivot pins (5). Peen over ends of pins (5) to secure
The clutch pressure plate assembly is disassembled assembly.
by placing the pressure plate assembly on a flywheel in
a hydraulic press and applying a load to the release Make certain slots in bracket (2) align with the
levers. Remove return clips (6). Loosen lock nuts (8) pressure plate drive lugs.
and back out the three adjusting screws (7).
Place assembly on a hydraulic press and apply
Gradually release load on press. Clutch may now be pressure on the levers (3) directly above the pressure
disassembled. springs (4) while forcing the springs into position in
bracket (2).
Release levers (3) may be removed from bracket (2)
by grinding off peened ends of pivot pins (5). Install adjusting screws (7) with lock nuts (8) and
return clips (6). Release assembly from press.
Inspect all parts for. wear, rust and other damage.
Replace parts as needed.

Before assembling pressure plate assembly, apply


lubriplate to sides of driving bosses on pressure plate
(1, Fig. 5)

Litho in U.S.A.
.,.

3 Transmission JD670-A and JD672-A Motor Graders


0370-6 Clutch Disconnect and Controls TM- Il.88 (J&78)

INSTALLATION

T61649N

l-Cap Screw (6 used) 6-Pivot Pin (3 used) g-Cap Screw (6 used) 13-Pressure Plate
2-Return Clip (3 used) GRelease Lever (3 used) lo--Lock Washer (6 used) M-Clutch Disk
3-Lock Nut (3 used) ‘I-Spring (6 used) 11 -Bracket 16-Pllot Bearing’
4-Washer (3 used) &Spring Cup (6 used) 12-Spacer (6 used) :

F&. 6-Pressure Plate Assembly

Pack bearing (15, Fig. 6) and fill cavity in crankshaft Adjust height of clutch release levers (3, Fig. 5) to
with John Deere High Temperature Grease or an 2.228 t 0.030 in. (56.59 c 0.76 mm) using modified
equivalent. JD264 clutch gauge (See Specificationsand Special
Tools).
Install bearing (15) with shielded side toward clutch
surface of flywheel. Drive the bearing on the outer race After release levers are adjusted and lock nuts se-
only to prevent bearing damage. cured, install the return clips. Exercise the levers sev-
eral times and recheck adjustment.
Use an old transmission drive shaft or a clutch
aligning tool (JDE 52) when installing clutch disk and Variation between levers, in a plane perpendicular to
clutch pressure plate assembly. centerline not to exceed 0.015 in. (0.38 mm).

Install clutch disk (14) with hub side facing flywheel. Refer to Group 0841 and install transfer drive hous-
ing. :
Align clutch disk assembly with clutch shaft bearing
when assembling clutch assembly to flywheel.

Insert spacers between flywheel and pressure plate


bracket (11).

Tighten pressure plate-to-flywheel cap screws (9) to


35 -c 4 lb-ft (47 -c 5 Nm) (5 or 1 kg-m).

Litho in U.S.A.
Transmission 3
JD670-A and JD672-A Motor Graders
Specifications and Special Tools 0399-l
TM- 1188 (Jul-78)

Group 0399
SPECIFICATIONS AND SPECIAL TOOLS
HOUSINGS AND COVERS
SPECIFICATIONS AND TORQUE VALUES

1 - Internal clutch housing-to-


transmission case cap screws . . 170 lb-ft
(230 Nm)
(24 kg-m)
2- Press dowel pins to bottom of bore.
3- Clutch housing-to-transmission
adQ case cap screws . . . 300 lb-ft
(407 Nm)

‘b 1
(41 kg-m)

2
b

Fig. l-Transmission Clutch Housing

1 - Clutch housing-to-transmission
case dowel pins to extend. . . . . . . . . I .06 inch
(26.9 mm)

Fig. PTransmission Case

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0399-2 Specifications and Special Tools TM- 1188 (Jul- 78)

GEARS, SHAFTS, BEARINGS AND POWER SHIFT CLUTCH


SPECIFICATIONS AND TORQUE VALUES

Q1I
1 - Press bushing, with side notches opposite
driver, below rear surface of
I c1 C2 clutch drum. . . . . . . . . . . . . . . . . . .0.06 in.
2 - I.D. of new bushing. . . . . . . 2.5055 to 2.5065 in.
/x// /4

TE165ON

Fig. 3-C2 Clutch Drum and Bushing

1 - Press dowel pins in clutch separator


plate to protrude from
either side . . . . . ... . _. . . . .0.22 in.
(5.6 mm)

T37918

Fig. 4-Clutch Separator Plate

1 - Press bushing flush with end of bushing bore


2 - I.D. of bushing . . . . . . . . . . . 1.0025 to 1.0045 in.

llS0961N

Fig. 5-Clutch Drive Shaft

Litho in U. S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (J&78) Specifications and Special Tools 0399-3

GEARS, SHAFTS, BEARINGS AND POWER SHIFT CLUTCH


SPECIFICATIONS AND TORQUE VALUES-Continued

1 - Pump housing-to-pump body cap screw


torque . . . .. . 20 lb-ft (27 Nm) (3 kg-m)
2 - Manifold-to-pump housing cap screw
torque . . . . . . . . . 20 lb-ft (27 Nm) (3 kg-m)
3 - Clutch assembly-to-housing cap screw
torque . . . . . . . . 35 lb-ft (47 Nm) (5 kg-m)

Fig. 6-Pump Torque Values

1 - C2 clutch drum-to-Cl clutch


drum cap screws . . . . ... . . 20 lb-ft
1

Yw@ (27 Nm)


(3 kg-m)

T36672N

Fig. 742 and C2 Attaching BoMs

- Return spring free length. . . . . . . . 2.70 inches

(1223 t 122 N) (125 r 12 kg) force applied.

T38676N
i-0-i
2

Fig. 8-U, CZ and C3 Piston Return Spring

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0399-4 Specifications and Special Tools TM- 1188 {Dee-87)

GEARS, SHAFTS, BEARINGS AND POWER SHIFT CLUTCH


SPECIFICATIONS AND TORQUE VALUES-Continued

1 - Bushing from end of high-range


drive shaft . . a . . . . . . . . . . . . . . . . . . . 0.400 in.
(0.0157 mm)
2 - I.D. of new bushing . . . . . . . . 1.327 to 1.329 in.
(33.71 to 33.76 mm)

T50297N

Fig. 9-Hi-Range Drive Shaft with Bushing

1 - Planet brake piston housi,ng bolts . .

2 - C3 clutch housing
cap screws . . . . . . . . . . ~ . . . . . . . .

t-/g. IO-Planetary Pack Assembly

bitho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Jul- 78) Specifications and Special Tools 0399-5

GEARS, SHAFTS, BEARINGS AND POWER SHIFT CLUTCH


SPECIFICATIONS AND TORQUE VALUES-Continued

1- Press bushing, with notched end toward


bottom of bore, below surface
of cover . . . . . . . . . . . . .O.OO to 0.02 in.
(0.0 to 0.5 mm)
2 - I.D. of bushing . . . 2.366 to 2.368 in.
(60.10 to 60.15 mm)

T38678N

Fig. 11-Plane1 Pinion Carrier Front Cover

1 - Rear retainer-to-planet pinion


carrier cap screws. . . . . . . . . . . . . . .(;y;;;

(4 kg-m)
2 - Front retainer-to-planet pinion
carrier cap screws . . . . . . . . . . . . .(3; 1;;

(5 kg-m)
3 - Pinion shaft retainer to planet pinion
carrier cover cap screws ..... .. .(;!I y;
TS3689??
(1 km)
Fig. 1BPlanef Pinion Carrier

1 - Return spring test length . . . . . . 0.625 inch


(15.88 mm) with a 23.5 to 28.5 lb.
(105 to 127 N) (11 to 13 kg) force applied.
2 - Return spring free length.. . ..... 0.83 inch
(21 .l mm)

T38675N

Fig. 13-81, 8.2 and 84 Piston Return Spring

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0399-6 Soecifications and Soecial Tools TM- 1188 (Jul- 78)

GEARS, SHAFTS, BEARINGS AND POWER SHIFT CLUTCH


SPECIFICATIONS AND TORQUE VALUES-Continued

1 - Return spring test length . . . . . . . . . . . 1.12 in.


(28.5 mm) with a 23.4 to 28.6 lb. (104 to 127 N)
(11 to 13 kg) force applied.
2- Return spring free length. _. _. . . . . . . 1.54 in.
(39.1 mm)

T38675N

Fig. 14-83 Pision Return Spring

1 - Planetary pack-to-transmission
case cap screws . . . . _. . . . .55 2 6 lb-ft
(75 t 8 Nm)

w 2
2 - I.D. of new bushing.

Align notches
housing.
in bushing
(7.6 k 0.8 kg-m)
. . . . . . . .3.7562 inches
(95.407 mm)
with notches in 83 brake

-Q

Fig. 15-83 Brake Piston Housing

1 - Inside diameter of new


bushing . . . . . . . . , . . . . . . 1.9425 to 1.9445 in.
(49.340 to 49.390 mm)
2- Cup protrudes from bottom
of piston bore . . . . . . . . . . . . . . . . . .0.03 in.
(0.8 mm)
3- Inside diameter of new
bushing . . . . . . . . .~. . . . . 2.128 to 2.130 in.
(54.051 to 54.102 mm)
Install bushing with long chamfer facing out.
Fig. 16-C3 Piston Housing 4- Dowel pin protrudes from bottom
piston bore . . . . . . _. . . . . . . . . . .0.39 in.
(9.9 mm)
5- Press bushing below surface
of C3 piston housing. . . . . . _ . . . . . 0.19 in.
(4.8 mm)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Jul-79) Specifications and Special Tools 0399-7

GEARS, SHAFTS, BEARINGS AND POWER SHIFT CLUTCH


SPECIFICATIONS AND TORQUE VALUES-Continued

1 - Press bushing below end of


shaft .... T ..,,............. 0.06 to 0.10 in.
(1.5 to 2.5 mm)
I. D. of new reduction
shaft bushing . . . . . . . . . 0.752 to 0.754 in.
(19.10 to 19.15 mm)

Fig. 17-Reduction Gear Shaft Bushing

Reduction gear shaft bearing


preioad . . . . . . . . . . . . . . . . . . . 0.000 to 0.002 in.
(0.00 to 0.05 mm)
2 Bearing retainer-to-transmission case
cap screws .. . ..... ... . 55 lb-ft
(73 Nm)
(8 kg-m)

T61652N

Fig. l&Reduction Gear Shaft

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0399-8 Specifications and Special Tools TM- I 188 (Jul-79)

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES

1 - I.D. of new bushing. .. . . 1.568 to 1.569 in.


(39.83 to 39.85 mm)

I
T61653N

Fig. 19-Clutch Oil Manifold

1 - Press bushing flush with this surface.


2 - I.D. of new bushing.. . 1.5675 to 1.5705 in.
(39.81 to 39.89 mm)

,l’50304N

Fig. 20-Transmission Oil Pump Housing

1 - Width of gears
(early units). . . . . . . . . . 1.1226 to 1.232 in.
(28.514 to 28.530 mm)
(later or replaced units) 1.3247 to 1.3253 in.
(33.647 to 33.663 mm)

T27813

Fig. Zl-Transmission Oil Pump Gears

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- I 188 iJul-79) Specifications and Special Tools 0399 -9

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

1 - 0. D. of bushing in
new pump body.. .. 2.4485 to 2.4495 in.
(62.192 to 62.217 mm)
2 - Depth of gear bore
in pump body
(early units). . . . 1.1247 to 1.1257 in.
(28.567 to 28.593 mm)
(later or replaced units) . 1.3273 to 1.3283 in.
(33.713 to 33.739 mm)

T616548
fig. 22-Pump Body

1 - Pump housing-to-pump body cap screw


torque ... .. . .. . . . . . 20 lb-ft
(27 Nm)
(3 kg-m)
2 - Manifold-to-pump housing cap screw
torque.. . . . . . 20 lb-ft
(27 Nm)
(3 kg-m)
T27815
3 - Clutch assembly-to-housing cap screw
torque .. .. . . . . . . 35 lb-ft
Fig, 23-Charge Pump Torque Values (47 Nm)
(5 kg-m)

1 - Detent springs
Free length . . 1.16 in. (30 mm)
Test length . . .. . 0.83 in. (21 mm)
when compressed with 6 to 7 Ibs.. (27 to 31 N)
(2.7 to 3.2 kg)
2 - Accumulator outer springs
Free length ..... . . . 4.09 in. (104 mm)
Test length . . ... 2.91 in. (74 mm)
B when compressed with 205 + 20 Ibs. (912 2
T609671v 5-s
89 N) (93 + 9 kg)
Fig. 24-Transmission Control Valve Springs 3 - Accumulator inner springs
Free length . . . _. . . 3.78 in. (96 mm)
Test length . . _. . . . . 2.91 in. (74 mm)
when compressed with 111 + 11 Ibs. (494 ?
49 N) (50 t 5 kg)
4 - 0. D. of new accumulator
piston .. .. 1.8090 to 1.8096 in.
(45.949 to 45.964 mm)
5 - Accumulator cover cap screws . 35 lb-ft
(47 Nm)
(5 kg-m)
6 - Transmission control valve to
transmission case cap screws . 45 lb-ft
(61 Nm)
(6 kg-m)
Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0399-10 Specifications and Special Tools TM- I 188 (Jul- 79)

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

1 - O.D. of lands on control


valves . . . . . . . . . . . . . 0.7480 to 0.7490 in.
(19.000 to 19.025 mm)

CT503068

Fig. 25Transmission Control Valve Lands

1 - I.D. of valve bores in


housing . . . . . . . . . . . . . . . . 0.7495 to 0.7505 in.
(19.037 to 19.063 mm)

IT27868

Fig. Z&Control Valve Housing Bores

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Jul-79) Specifications and Special Tools 0399-11

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued
1 - I.D. of shift valve housing
bore . . . . . . . . . . . . . 0.4995 to 0.5005 in.
(12.687 to 12.713 mm)
2 - I.D. of dump valve housing
bore . . . . . . . . . . . 0.6245 to 0.6255 in.
(15.862 to 15.888 mm)

Fig. 27-Shift Valve Housing Bores

1 - Dump valve spring free length .. 1.12 inch


(28.4 mm)
Dump valve spring test length .
0.84 inch
(21.3 mm)
when compressed with 32 to 38 tbs.
(142 to 169 N) (14.5 to 17.2 kg)

2 - O.D. of dump valve.. . . 0.6227 to 0.6233 in.


(15.82 to 15.83 mm)

3 - O.D. of lands of shift


valves.. . _. . . . . . . . 0.4977 to 0.4983 in.
(12.64 to 12.66 mm)

4 - Shift valve springs free length . . 1.39 in.


(35.3 mm)
Shift valve springs test length. .. 0.81 in.
(20.6 mm)

T60368N
iz c3 when compressed with 6.8 to 8.4 Ibs.
(30 to 37 N) (3 to 4 kg)

Fig. 2CTransmission Shift Valve 5 - Shift valve cover cap screws ... . 20 lb-ft
(27 Nm)
(3 kg-m)

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0399-12 Specifications and Special Tools TM- 1188 (Jul- 79)

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued
1 _ Free length . .. ..... 1.3 t 0.03 in.
(33 f: 8 mm)
Test length . . . . _. . . . .1.09 (27.8 mm)
when compressed with 17 t 2 Ibs (76 ? 9 N)
(8 + 1 kg)
Free length . . . . . . . . . . .0.5 -e 0.03 in.
(13 + 8 mm)
Test length . . . . . . . . . . .0.34 in. (8.7 mm)
when compressed with 4 2 0.4 Ibs. (18 2 2 N)
(2 & 0.: kg)
Free length . . . . . . . .-. . . . . 2 _t 0.03 in.
(51 2 8 mm)
Test length . . . . . . . . . . .1.41 in. (35.7 mm)
when compressed with 13 f 1 lb. (58 2 5 N)
(6 + 1 kg)

l’37928

Fig. 29-Check Valve Springs

1 - O.D. of clutch valve . . . . 0.6861 to 0.6865 in.


(17.427 to 17.437 mm)

4‘ \

1
I
tw

T27863~

Fig. 30-Transmission Clutch Valve

1 - I.D. of valve bores.. .. 0.6675 to 0.6685 in.


(16.95 to 19.98 mm)

2- Pressure regulating valve housing


cap screws . . . . . . . . . . . . 45 lb-ft
(61 Nm)
(6 kg-m)

T60969N

Fig. 31-Transmission Oil Pressure Regulating


Valve Housing

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Jul- 78) Specifications and Special Tools 0399-l 3

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

1 - Oil filter bypass spring


(free length) . . . .-. . , .-. . 3.71 in. (95 mm)
(test length). . . . ....... 2.61 in. (66 mm)
when compressed with 24 to 30 Ibs. (107 to 134
N) (11 to 14 kg)

Lube oil relief valve spring


(free length) . . . . . . . . . . 2.83 in. (72 mm)
(test length). . . . . . . 2.13 in. (54 mm)
when compressed with 12 to 14 Ibs. (5.3 to 62 N)
(5 to 7 kg)

Clutch oil pressure valve spring


(free length) . . . . . . . . . 5.05 in. (129 mm)
(test length). . . . . . . . . . . . 4.44 in. (113 mm)
when compressed with 55 to 67 Ibs. (245 to 299
N) (25 to 31 kg)

Cooler relief valve spring


(free length) . . . . . . . . . . 4.55 in. (116 mm)
(test length). . . . . . . . . . . . . . 3.53 in. (90 mm)
when compressed with 36 to 44 Ibs. (160 to 196
N) (16 to 21 kg)

5 - O.D. of valves .. . .. 0.6645 to 0.6655 in.


(16.878 to 16.904 mm)

Fig. 32-Transmission Oil Pressure Regulating


Valve Springs and Valves

1 - Special cap screw.. ... .. ._ . . . 45 lb-ft


(61 Nm)
(6 W-4

Fig. 33-Transmission Oil Filter

Lifho in U.S.A.
3 : Transmission JD670-A and JD672-A Motor Graders
0399-14 Specifications and Special Tools TM- 1188 (J&78)

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

1 - Upper spring free length . . . . . . . . . . . .2.32 in.


(59 mm)

test length . . . . . . . . . . . . .I .58 in.


(40.1 mm)
Q

with a 21 + 2.1 lb. (93 & 9 N)


iit
(10 I 1 kg) load applied
0
1 - Lower ‘;pring free length ....... . . . .0.89 in.
(22.5 mm)

w 0, \
test length . . . . . . . . . . . . .0.50 in.
with a 20 1 2 lb (89 -c 9 N)
r (9 & 0.9 kg) force applied

Fig. 34-Filter Restriction Switch

--Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- 1188 (Jul-78) Specifications and Special Tools 0399-15

CLUTCH DISCONNECT AND CONTROLS


SPECIFICATIONS AND TORQUE VALUES

1. Pressure plate-to-flywheel
cap screws.. ... . . . . .35 t 4 lb-ft
(47 2 5 Nm)
(5 t 0.5 kg-m)

T38742~

Fig. 35-Clutch Pressure Plate

1. Adjust height of clutch release levers


from machined surface of flywheel
to . . . ... .. . . . 2.226 2 0.030 in.
(59.59 k 0.76 mm)

NOTE: Variation between levers, in a plane perpen-


dicular to centerline, not to exceed 0.015 in. (0.38 mm).

T40774N

Fig. 36-Clutch Pressure plate

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0399-16 Specifications and Special Tools TM- 1188 (Jul- 78)

GEARS, SHAFTS, BEARINGS AND POWER SHIFT CLUTCH


SPECIAL TOOLS
Essential Tools
Tool Tool Number USe

JDT-24 Used to remove and/or install


clutch piston return spring snap
ring.

T37931

Fig. 37-Spring Compressor

HYDRAULIC SYSTEM
SPECIAL TOOLS
Convenience Tools
TOOI Tool Number USe

JDT-13 To protect oil seal when assem-


bling transmission oil pump

Fig. 38-Oil Seal Protector

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transmission 3
TM- I 188 (J&78) Specifications and Special Tools 0399-17

CLUTCH DISCONNECT AND CONTROLS


SPECIAL TOOLS

Essential Tools

Tool Tool No. Use

JDE-52 Used to properly line up clutch


disk.

f/g. 39-Universal Clutch Aligning Sef

JD-264 Used to properly adjust clutch

1, JSTR
k,,I
fingers.

1 - Gauge dimension. .. . . 2.228 i 0.030 in.


(56.59 2 0.76 mm)
2- Notch width.. . . . . . . . . . . . . . 0.480 to 0.520 in.
(12.19 to 13.21 mm)

-I- f40775N

Fig. 40-Modified Clutch Finger Adjusting Gauge

Litho in U.S.A.
3 Transmission JD670-A and JD672-A Motor Graders
0399-18 Specifications and Special Tools TM- 1188 (J&78)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Engine 4
TM- 1188 (Dee-87) Engine Removal and lnstalla tion 0400-l

Section 4
ENGINE
CONTENTS OF THIS SECTION

Page Page
GROUP 0400 - REMOVAL AND GROUP 0499 - SPECIFICATIONS AND
INSTALLATION SPECIAL TOOLS
6414 - John Deere Engine Repair ...... 0400-3 Specifications and Torque Values ......... 0499-l
Engine Engine Break-In .............................. 0499-I
Remove ........................ 0400-3 Oil System .................................... 0499-2
Install .......................... 0400-5 Fuel Injection System ........................ 0499-2
Oil Pan Fuel Injection System ........................ 0499-3
Remove and Install ................ 0400-6 Turbocharger.. ............................... 0499-6
Injection Pump Water Pump .................................. 0499-6
Remove ........................ 0400-6 Starting Motor and Fastenings ............. 0499-7
Install and Time .................. 0400-8 Special Tools ................................. 0499-9
Fuel System Fuel Injection System ........................ 0499-9
Bleed .......................... 0400-9 Starting System ............................. 0499-l 0
Fuel Injection Nozzles Starting Motor Fastenings .................. 0499-l 1
Remove ....................... 0400-l 0
Install ......................... 0400-I 1
Turbocharger
Remove ....................... 0400-l 1
Install ......................... 0400-l 1
Water Pump
Remove ....................... 0400-l 2
Install ......................... 0400-12

GROUP 0422 - STARTING MOTOR AND


FASTENINGS
General Information ................. 0422-l
Removal ......................... 0422-2
Testing and Diagnosis ............... 0422-3
Repair ........................... 0422-4
Installation ....................... 0422-10

Litho in U.S.A.
4 Engine JD670-A and JD672-A Motor Graders
0400-2 Engine Removal and Installation TM-1 188 (Dee-87)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Engine 4
TM- 1188 (Dee-87) Engine Removal and Installation 0400-3

Group 0400
REMOVAL AND INSTALLATION
6414 - JOHN DEERE ENGINE REPAIR- Remove pre-cleaner (1, Fig. 1).
USE CTM-4
Remove muffler (2, Fig. 1).
For complete repair information the component
technical manual (CTM) is also required. Remove left and right (3, Fig. 1) side shields.

Use the component manual in conjunction with Using a hoist, lift off hood (4, Fig.1) as an assembly.
this machine manual.
Drain engine oil.

REMOVE ENGINE
NOTE: The engine, radiator and hydraulic pump
can be removed as an assembly.
1 -Grille Screen 2-Grille Housing

Fig. P-Grille Housing

Remove front grille screen (1, Fig. 2).

Remove grille housing (2, Fig. 2).

Remove rear screen (5, Fig. 1).

Close fuel line at tank.

Disconnect battery negative (-) cable.

Disconnect fuel line at tank.

1-Pre-Cleaner 4-Hood
P-Muifler 5-Rear Screen
3-Right Side Shield

Fig. l-Hood Removal

Lifho in U.S.A.
4 Engine JD670-A and JD672-A Motor Graders
0400-4 Enaine Removal and Installation TM- 1188 (Dee-87)

Disconnect speed control (Fig. 4).

Disconnect rear lights and horn wiring.

Disconnect and cap all hydraulic lines at pump.

Remove hydrostatic oil filter and lay to the side


(JD672-A only).

Remove air conditioning compressor and lay to


the side; do not disconnect refrigerant lines.

Attach lifting eyes to engine.

Position hoist over engine.

l-Wiring Harness 3-Fuel Return Line Attach JD244 Lifting Eyes or JDG19 Lifting Brackets
P-Engine Crankcase Vent 4-Starting Aid Wires to engine.
5-Right Heater Hose
Attach JDG-1 Lifting Device (1, Fig. 6) or D-
Fig. 3-Right Side of Engine 01043AA Load Positioning Sling to lifting eyes or
brackets.
Disconnect both right and left heater hoses.
Connect hoist to engine.
Disconnect wiring harness.

Remove engine crankcase vent (2, Fig. 3).

Disconnect fuel return line (3) at tank.

Disconnect oil drain line from transmission


housing.

Disconnect starting aid wires (4).

Fig. 4-Speed Control

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Engine 4
TM- 1188 (Dee-87) Engine Removal and Installation 0400-5

Separate engine front supports (Fig. 5). INSTALL ENGINE

Position engine, radiator and hydraulic pump over


frame.

Lower into position.

Align flywheel housing of engine with dowels in


transfer housing.

Install engine-to-transfer housing hardware.

Install front support (Fig. 5) hardware.

Connect hydraulic plumbing.

Connect heater hoses.


Fig. 5-Engine Front Support
Connect all electrical wiring.
Remove bolts from transfer housing.
Fill crankcase with proper oil.
Separate engine from transfer housing.
Replace radiator coolant if removed.
Lift engine, radiator and hydraulic pump slowly
from the frame. Check to be sure all lines and wiring Reconnect fuel lines.
have been disconnected. (Fig. 6).
Open fuel shut off.

Check all bolts for tightness and proper torque.

Remove JDG-1 lifting bracket*.

Replace crankcase vent.

Connect starting aid.

Replace engine oil drain line.

Reinstall grille housing and screen.

Reinstall hood and side shields.

l-JDG-1 Lilting Device* Install rear screen.

Fig. &Lifting Engine Replace pre-cleaner and muffler.

Connect battery cable.

Replace hydrostatic oil filter (JD672A only).

Replace air conditioning compressor (Refer to


group 1830).

*Replaced by D-01 043AA Load Positioning Sling.

Litho in U.S.A.
4 JD670-A and JD672-A Motor Graders Engine
0400-6 TM- 1188 (Dee-87) Fuel Injection System

REMOVE AND INSTALL OIL PAN Use the following method to remove the injection
pump:
Remove engine from unit to remove and install oil
pan. Remove timing hold cover (6, Fig. 1) and install
timing window (19918) on injection pump.
REMOVE INJECTION PUMP
Using a flywheel turning tool, rotate the engine
until timing mark on governor weight retainer is in
line with timing mark on cam ring (Fig. 2).

Install timing pin through flywheel housing into the


timing bore of flywheel to lock engine on TDC.

l--Fuel Return 4-Fuel Inlet


P-Throttle Cable I-Cam Advance
3-Injection Lines Mechanism
B-Timing Hole Cover

Fig. l-Fuel injection Pump

l-Governor Weight P-Cam Ring


NOTE: The fuel injection pump pressurizes fuel Retainer
and sends it through high pressure lines to the
injection nozzles. Fig. P-Injection Pump Timing Marks

Clean the injection pump, lines, and area around Disconnect the speed control cable at injection
the pump with cleaning solvent or a steam cleaner.
pump.

IMPORTANT: Never steam clean or pour cold water


on an injection pump while the pump is running or
while it is warm. To do so can cause seizure of
pump parts.

Litho in U.S.A.
Engine JQ670-A and JD672-A Motor Graders 4
Fuel Injection System TM-l 188 (Dee-87) 0400-7

A CAUTION: Escaping diesel fuel under pres- Use the following specifications to calibrate the
sure can have sufficient force to penetrate injection pump.
the skin causing serious personal injury. Before dis-
connecting lines, be sure to relieve all pressure. IMPORTANT: In order to obtain proper test results,
do the following:
Fuel escaping from a very small hole can be
almost invisible. Use a piece of cardboard or wood, Use 0.25 in. (6.4 mm) O.D. by 0.093 in. (2.36 mm)
rather than hands to check for escaping fuel. I.D. by 20 in. (508 mm) long test lines.

If injured by escaping fuel, see a doctor at once. Use 12SD12 Rober Bosch Calibrating Nozzles,
Serious infection or reaction can develop if proper 2500 psi (172 bar) (176 kg/cm*) opening pressure.
medical treatment is not administered immediately. Use JDF-2 Test Oil, or a test oil equivalent to SAE
J967A with a 34 to 36 SUS rating with oil at 100°F
To relieve pressure in the fuel system, slightly (38%).
crack high pressure injection line connections at
nozzles. Test oil should be 110” to 115OF (43’ to 46°C).

Disconnect injection pump inlet and pump-to- Operate pump clockwise (viewed from drive end)
nozzle fuel lines (3 and 4, Fig. 1). at 500 rpm wide open throttle (WOT) for 10 minutes
prior to test.
IMPORTANT: When removing injection lines to
nozzles, be sure not to turn outlet fittings in pump. NOTE: Pump operates at l/2 engine rpm. All rpm
Turning of these fittings may cause internal injection given are test stand rpm unless otherwise noted.
pump damage.

Disconnect fuel return line (1, Fig. 1).

Clean area around timing gear cover and remove


cover. Remove the injection pump drive shaft nut
and washer. Remove gear being careful not to lose
Woodruff key.

Remove mounting nuts.

Remove pump, Be sure to cap all injection pump


and fuel line openings to prevent entry of con-
taminants.
T51322N
Repair
Fig.3-DeliverySequence
For injection pump repair information, refer to TM-
1109 “Fuel Injection Equipment-RoosaMaster”
NOTE: 1 to 3 psi (0.07 to 0.27 bar) (0.07 to 0.27
(Industrial).
kg/cm2) supply pressure required at pump inlet.

Litho in U.S.A.
4 JD670-A and JD672-A Motor Graders Engine
0400-8 TM- 1188 (Dee-87) Fuel Injection System

Transfer pump vacuum (200 rpm) INSTALL AND TIME INJECTION PUMP
(minimum) . . . . . . . . . . . . . . . . . . . . . . . . 18 in. Hg.
(60.9 kPa) Check engine timing to make sure that No. 1
(609.5 mbar) piston is at TDC. If the engine was rotated after the
injection pump was removed, crank the engine until
Transfer pump pressure (1150 rpm) . . . 82 to 92 psi No. 1 piston is starting the compression stroke. Install
(565 to 634 kPa) (5.7 to 6.3) timing pin in the flywheel housing.

Automatic speed advance The compression stroke can be determined by


w removing the rocker arm cover and turning the engine
300to500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1° until both valves are closed on No. 1 cylinder, and
700t0800..............................5° increased turning effort is noted. Continue turning
by925...........................6OItl/2O the engine until timing pin engages the timing hole in
flywheel.
Minimum cranking speed
delivery (75 rpm) Remove injection pump timing hole cover (6, Fig.
Volume . . . . . . . . . . . . . . . 48 cm3/1000 strokes 1) and install timing window. Rotate pump drive shaft
Transfer pump pressure and align the timing mark on governor weight retainer
(minimum) . . . . . . , . , . . . . . . . . . . . . . . . . 12 psi hub with the timing mark on the cam ring (Fig. 2).
(83 kPa) (1 bar)
Check pump mounting flange packing for damage
Fuel delivery (750 rpm) or wear. Replace if necessary.
Volume . . . . . . . . . . . 89 to 93 cm311000 strokes
Maximum variation Install injection pump on the engine being sure
between cylinders ~ . . . . . . . 7 cm311000 strokes Woodruff key enters the gear. Tighten the mounting
bolt nuts to 20 lb-ft (27 N.m) (2.8 kg-m).
Fuel delivery (1150 rpm)
Volume . . . . . . . . . . . 84 to 88 cm3/1000 strokes Recheck pump timing mark alignment. If correct,
Maximum variation install the washer and nut onto pump shaft and
between cyclinders . . . . . . ~ 4 cm3/1000 strokes tighten to 140 to 150 lb-ft (190 to 203 N-m) (19 to 21
kg-m).
High idle (WOT) (1275 rpm)
Volume . . . . . . . . . . . 10 to 12 cm311 000 strokes Remove the timing pin from cylinder block. Rotate
Maximum variation the engine l-l /2 revolutions in direction of rotation,
between cylinders . . . . . . . . .4cm3/1000 strokes then install timing pin in cylinder block. Continue to
turn engine until timing pin engages the timing hole
Governor cut-off (13 rpm) in flywheel. Recheck the alignment of injection pump
Volume . . . S. . . . . . . . .5 cm3 maxIlO strokes timing marks. If marks are not in line, loosen the
pump mounting bolts and bring marks into alignment
Low idle (400 rpm) by turning pump. Retighten mounting bolts to 20 lb-ft
Volume . . . . . . . . . . . 10 to 12 cm3/1000 strokes (27 N.m) (2.8 kg-m).
Maximum variation
between cylinders . . . . . . . . 4 cm311000 strokes IMPORTANT: The normal backlash of gears is
enough to throw the pump timing off by several
Check shut-off at (200 rpm) degrees, resulting in poor engine performance. There-
Volume . . . . . . . . . ~ . . .2 cm3 max/ 1000 strokes fore, it is very important that the timing of the pump
be rechecked after it has been installed.

Litho in U.S.A.
Engine JD670-A and JD672-A Motor Graders 4
Fuel Injection System TM-l 188 (Dee-87) 0400-g

Bleed the fuel system.

After bleeding the fuel system, the automatic cam


advance should be checked for proper adjustment.

BLEED FUEL SYSTEM


After removing any components of the fuel system,
air should be removed by bleeding. Bleeding is also
necessary whenever the fuel tank has been emptied.

Fig. 4-Injection Pump-To-Nozzle Line Connections

Remove caps from injection pump and fuel line


openings.

Connect the injection pump-to-nozzle lines. Re-


ferring to Fig. 4, connect No. 1 outlet first and
continue around the pump head in a counterclock- Fig. 5-Filter Bleed Plug

wise direction attaching lines in order of engine


firing (1-5-3-6-2-4). Loosen the filter bleed plug (Fig. 5). Pump the
primer lever on the fuel pump until most of the air
IMPORTANT: When removing and tightening bubbles in the filter are gone and fuel flows from the
injection pump to nozzle lines, be sure not to turn bleed plug. Tighten the bleed plug and leave the
injection pump fittings. Turning of these fittings may primer lever in the down position.
cause internal injection pump damage.
NOTE: If the primer does not pump fuel and no
Tighten injection pump-to-nozzle line connections resistance is felt at the upper portion of the lever
to 20 lb-ft (17.6 N.m) (1.8 kg-m). stroke, turn the engine with the starter to change the
fuel pump cam position.
Connect the speed control rod, fuel inlet line and
return line to the injection pump.

Remove timing pin from engine, and plug opening.

Remove timing window and install injection pump


timing hole cover, and engine timing gear cover. Use
new gaskets when necessary.

Litho in U.S.A.
4 JD670-A and JD672-A Motor Graders Engine
0400-l 0 TM-l 188 (Dee-87) Fuel lniection Svstem

REMOVE FUEL INJECTION NOZZLES Disconnect nozzle from fuel line and at nozzle
inlet connector (7, Fig. 6) using two wrenches. Discon-
NOTE: The injection nozzles (one for each cylinder) nect leak-off line (2) by pulliing boot off leak-off
spray high pressure fuel into the combustion connector (1).
chambers.
Remove nozzle hold down cap screw and washer
IMPORTANT: Disconnect battery ground strap or (4) clamp (6), and spacer (5).
turn battery disconnect switch to off before working
on nozzles close to the alternator to prevent acci- Remove injection nozzle. If nozzle cannot be easily
dental short circuits through tools. removed from cylinder head, use a JDE-38 nozzle
puller (Fig. 7).

l-Leak-Ott Connection 4-Cap Screw and Washer


l-JDE-36 Nozzle Puller l-Injection Nozzle
l--Leak-On Line B-Spacer
3-Injection Nozzle B-Hold Down Clamp
7-Nozzle Inlet Connector Fig. 7-Using Tool to Remove Nozzles

Fig. b-Removing injection Nozzle IMPORTANT: Do not use a screwdriver or similar


tool to pry injection nozzles from cylinder head.

A CAUTION: Escaping diesel fuel under pres- Doing so may cause distortion and permanent
sure can have sufficient force to penetrate damage to the nozzles.
the skin, causing serious personal injury. Before
disconnecting lines, be sure to relieve all pressure.
Before applying pressure to the system, be sure all
connections are tight and that lines and hoses are
not damaged. Fluid escaping from a very small hole
can be almost invisible. Use a piece of cardboard or
wood, rather than hands, to search for suspected
leaks. If injured by escaping fluid see a doctor at
once. Serious infection or reaction can develop if
proper medical treatment is not received immediately.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Engine 4
TM-1 188 (Dee-87) Fuel injection System 0400-l 1

INSTALL FUEL INJECTION NOZZLES INSTALL TURBOCHARGER


Clean nozzle bore in engine cylinder head using Just prior to mounting the turbocharger, prime the
JDE-39 Nozzle Bore Cleaning Tool. turbocharger lubrication system. Fill the center
housing with engine oil through the oil drain hole.
Insert nozzle using a twisting motion. Turn the rotating assembly by hand to lubricate the
Install nozzle hold-down spacer, clamp, washer, bearings and thrust washer.
and cap screw. Hand tighten cap screw.
Install turbocharger on engine, and install new
Connect fuel line to nozzle inlet and hand tighten. rubber O-rings on coupler (turbocharger-to-intake
manifold). Use a new mounting gasket.
Install leak-off line.

Tighten nozzle hold-down cap screw to 20 lb-ft Check alignment of compressor housing to intake
(27 N.m) (2.8 kg-m), and tighten inlet connector to 35 manifold. If necessary, rotate compressor housing
lb-f-t (47 N.m) (4.8 kg-m). so manifold coupling is radially centered in com-
pressor housing and intake manifold.
Bleed the fuel system.
Tighten the mounting stud nuts, then tighten the
REMOVE TURBOCHARGER back plate-to-compressor housing cap screws. Bend
NOTE: The turbocharger is located on the top of the ears of lock plate against head of cap screws.
the engine near the exhaust manifold, The turbo-
charger operates by means of exhaust gases to draw When installing turbocharger exhaust adapter and
in clean air from the air cleaner and deliver it under exhaust elbow be certain that the installation does
pressure through the intake manifold to the combus- not apply a force on the turbine housing. The exhaust
tion chambers. adapter must have l/16 inch (1.6 mm) minimum end
play and rotate freely.
Remove engine side shields, precleaner, exhaust
stack, and hood. IMPORTANT: Compressor to intake manifold hose
clamps must be properly positioned and tightened.
Remove exhaust adapter. Plug or cover air opening
in turbocharger.
Inspect the air cleaner-to-turbocharger hoses to
Disconnect air intake pipe and plug or cover see that they are in good condition. If they are not,
opening. Disconnect oil inlet and outlet lines. Plug or replace with new ones. Install air intake pipe, and
cover openings. tighten hose clamps to 70 5 5 lb-in (7.9 -1- 0.6 N.m)
(0.81 5 0.06 kg-m).
Remove attaching hex nuts from basic turbocharger
and remove turbocharger. IMPORTANT: Since the greatest amount of suction
occurs between the air cleaner and turbocharger, it
is essential that the hose connections are tight to
prevent entry of dirt into the engine.

Connect the lubricating oil inlet manifold and return


pipe to the turbocharger, using new gaskets.

When starting engine with a new or repaired turbo-


charger, place speed control lever in the shut-off
position and crank the engine with the starter until
the engine oil pressure indicator light goes out. Start
and run engine at low idle while checking oil inlet
and air passage connections for leaks.

l-Exhaust Adapter 4-Cap Screws


2-Exhaust Stack S-Oil Line
t-Air Intake Hose

Fig. 1 -Turbocharger Removal

Litho in U.S.A.
4 JDUO-A and JD672-A Motor Graders Engine
0400-12 TM- 1188 (Dee-87) Water Pump

REMOVE WATER PUMP


NOTE: The centrifugal-type water pump is attached
directly to the cylinder block and is driven by the fan
belt. A bellows-type seal assembly is pressed into
the pump housing between the pre-lubricated ball
bearing and the impeller. If the seal becomes worn
or damaged, water will escape through the drain
hole in the bottom of the pump housing.

Remove radiator.

Remove fan belts.

Remove cap screws and remove water pump.

INSTALL WATER PUMP


Using a new gasket, install pump rear cover on
pump assembly. Tighten attaching cap screws to 35
lb-ft (47 N.m) (4.8 kg-m).

Install radiator.

Fill radiator with soft clean water and proper


additive.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Engine 4
TM- I 188 (J&78) Starting Motor and Fastenings 0422-I

Group 0422
STARTING MOTOR AND FASTENINGS
GENERAL INFORMATION

l’27645N
l-Plunger 7-Bushing 13-Oil Seal 18-Pinion Stop
P-Shunt Field Terminal a-Thrust Washer 14-Bushing 26-Bushing
3-Solenoid Assembly g-Commutator 1!5-Felt 21-Snap Ring
4-Field Connector l6-Field Windings 16-Brake Washer 22-Drive End Housing
!%End Frame Cover 11-Armature 17-Wear Pads 23-Shift Lever
B-Brush 12-Pole Shoe 16-Overrunning Clutch

F@. l-Solenoid View of Starting Motor

The John Deere Starting Motor is located on the The armature is supported on three bushings, one
right side of the engine flywheel housing. each in the drive housing, center bearing housing, and
commutator end frame. The core of the armature con-
The starting motor consists of a drive housing, sists of laminations of thin sheet iron. The outer rims of
overrunning clutch and pinion, drive lever, center laminations are slotted to receive the armature coils.
bearing housing, solenoid switch, armature, yoke and The armature coils are arranged and connected in
field windings, brushes, and commutator end frame. such a way that current flows through all of them at the
same time, thus each coil provides a turning force.

Litho in U.S.A.
4 Engine JD670-A and JD672-A Motor Graders
0422-2 Starting Motor and Fastenings TM- 1788 (J&78)

The field windings are wound on steel pole cores The overrunning clutch is a freewheeling device like
which are affixed to the yoke. They are connected in that of a bicycle permitting it to coast when the pedals
series with armature coils through brushes and com- are not operated. In like manner, the overrunning
mutator segments. clutch transmits power from the armature to the fly-
wheel through the pinion, and it also allows the pinion
The shunt winding is incorporated in the field wind- to overrun and turn faster than the armature after the
ings and is connected in parallel with the armature. engine has started.

The solenoid switch incorporates two windings-a IMPORTANT: Never run the starting motor more
pull-in winding and a hold-in winding. These are than twenty seconds at a time or overheating will
wrapped around a hollow core. A cylindrical iron result. Allow motor to cool at least two minutes
plunger is placed part of the way in the hollow core. A before running it again.
contact plate is attached to the plunger, and two
counter contacts are so placed that the plunger move- For additional information on starting motors,
ment forces the plate against the contacts. This closes pas refer to “Starting Circuits” in FOS Manual -
the circuit between the battery and the starting motor. ELECTRICAL SYSTEMS.
0 0
At the same time, the plunger movement pushes out
the overrunning clutch and pinion unit which is linked to
the plunger by means of the drive lever, and the pinion
meshes with the flywheel ring gear.

REMOVAL

Disconnect battery ground strap from battery.

Open right engine side shield.

Disconnect wires from starting motor.

Remove three cap screws attaching starting motor


to flywheel housing.

Remove starting motor.

NOTE: The JDE-80 Starter Wrench might be nec-


essary to remove the rear attaching cap screw.

l-Battery Terminal a--Mounting Screw (3 used)

&I. a-Removing Starting Motor

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Engine 4
TM- 1188 (Jul-78) Starting Motor and Fastenings 0422-3

TESTING AND DIAGNOSIS

Solenoid Tests (Starting Motor Removed) Solenoid Return Test

To prevent damage, solenoid must be on starting


motor when testing the windings. Remove terminal
cover and field coil connector. Disconnect shunt field
winding lead from terminal on field frame. Replace
solenoid if it fails one of the following tests.

Solenoid Pull-in Test

l-24-Volt Source 2-Switch

Fig. 4Return Test

Make connections shown in Fig. 4. Close the switch


and pull the drive out until the pinion contacts the ’
0
pinion stop. When released, the drive should return
without hesitation.
l-24-Volt Source Ma&on Pile Resistor
2-Voltmeter 4-Heavy Jumper Wire No Load Test

Fig. 3-Pull-h Test

Make connections shown (Fig. 3). With 24 volts


applied, the solenoid should push the pinion out to the
pinion stop when the jumper wire is connected. Re-
move jumper wire. The drive should remain out at
pinion stop. Current through jumper wire will be ap-
proximately 70 amps, so use a heavy jumper wire and
remove it. soon after pinion is at stop.

l-24-Volt Source 4-Voltmeter


2-Carbon Pile Resistor CSwitch
3-Ammeter GTachometer

Fig. ~-NO Load Test

Make connections shown in Fig. 5. The starting


motor current draw should be 70 amps maximum at 24
volts. The armature speed should be to 4400 rpm and
higher.

Litho in U.S.A.
4 Engine JD670-A and JD672-A Motor Graders
0422-4 Starting Mo for and Fastenings TM- 1188 (J&78)

No Load Test Diagnosis ,Low Speed, High Current Draw

Excessive friction.
Fails to Operate, Low Current Draw
Shorted armature.
Open series field circuit. Grounded armature or fields.
Open armature coils.
Defective brush contact with commutator. High Speed, Low Current Draw
Open shunt field circuit.
Fails to Operate, High Current Draw

Grounded terminal or fields. High Speed, High Current Draw


Seized bearings.
Shorted series field coils.

Low Speed, Low Current Draw

High internal resistance.


Defective brush contact with commutator.

REPAIR

Disassembly

l-Pips Coupling P-Pinion Stop


1-Cover 4-Shunt Winding Lead 3-Pinion
P-Solenoid Assembly 6-Drive End Housing
3-Field Coil Connector g-Center Searing Hous,ing Fig. T-Removing Pinion Stop

Fig. g-starting Motor Disassembly


Remove drive end housing (2, Fig. 8). Drive pinion
stop (2, Fig. 7) toward pinion (3) and remove snap ring
NOTE: Starting motor has metric bolts and nuts
(19, Fig. 8) and pinion stop (18). Remove armature
except for those on the solenoid switch cover (70, Fig.
(12) from center bearing housing (8). Remove over-
8). running clutch assembly (4) brake washer (17), and
shift lever wear pads.
Disconnect shunt winding lead (4, Fig. 6). Remove
terminal cover, field coil connector (3), and solenoid
Remove shift lever pivot (5, Fig. 8) and shift lever
assembly (2).
(7).
Remove end frame cover (1, Fig. 6), gasket (31, Fig.
8) brushes (33), commutator end frame assembly (35)
and the brush ground strap (29). Remove field frame
(36).

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Engine 4
TM- 7 188 (Jul-78) Starting Motor and Fastenings 0422-5

!l’31424N

l-Drive End Bushing 11-Shunt Winding Lead 21-Field Winding 31-Gasket


2-Drive End Housing 12-Armature 22-Pole Shoe (4 used) 32-Commutator End
3-Packing 13-Bakelite Washer at--Square Washer Frame Bushing
4-Overrunning Clutch 14-Oil Seal 24-Insulating Bushing 33-Brush (4 used)
S-Shift Lever Pivot l!+Center Bearing Bushing 25-Square Insulator 34-Brush Spring (4 used)
6-O-Ring 16Oil Felt 26Special Bolt 36-Commutator End Frame
7-Shift Lever 17-Brake Washer 27-Field Coil Connector 36Field Frame
8-Center Bearing Housing 18-Pinion Stop PI-Terminal Cover
O-Solenoid Winding 1 B-Snap Ring 29-Brush Ground Strap
l&Solenoid Switch Cover 26-Shunt Winding Ground 36-End Frame Cover
Screw

Fig. S-Starting Motor

Cleaning Do not immerse the drive end housing, overrunning


clutch, center bearing housing, or commutator end
When cleaning component parts, do not immerse
frame in cleaning solvent. All of these parts have been
the solenoid, field windings or armature in cleaning
prelubricated and solvent will wash this lubricant away.
solvent. Immersing any of these in solvent may dam-
These components should be cleaned in the same
age their insulation. These may be cleaned by wiping
method just mentioned, using a cloth slightly moist-
the parts with a cloth that has been slightly moistened
ened with cleaning solvent and then wiped dry with a
with cleaning solvent and then wiped dry with a clean
clean dry cloth.
dry cloth.

Litho in U.S.A.
4 Engine JD670-A and JD672-A Motor Graders
0422-6 Starting Motor and Fastenings TM- 1188 (J&78)

All other parts which are not made of rubber or Armature


mentioned above can be dipped in clean solvent to
remove all oil and dirt. Maximum commutator runout is 0.016 inch (0.41
mm). If necessary, turn commutator and undercut in-
Bushings sulation to l/32-inch (0.79 mm). Undercut should
never be less than 0.008 inch (0.20 mm). Commutator
Install a new oil seal (14, Fig. 6) and a new oil felt O.D. must be 1.77 inches (44.9 mm) or more. Clean
(16) saturated with engine oil when replacing center copper dust from between the segments.
bushing.
Check armature for opens, shorts and grounds.
When replacing bushings, press the new bushings Burned edge of commutator bar indicates an open
in from the chamfered end. Make a bushing driver as circuit.
shown in Group 0499 or use the following handle and
disks from the D-01044AA Basic Set. Align hole in Short Circuit Test
commutator and lubrication wick.
Place the armature in a growler and hold a hacksaw
blade above each slot while slowly rotating the arma-
Commutator and Drive End Bushing Tools
ture. If a coil is shorted, the blade will be attracted to
Bushing Bushing
and repelled from the slot very rapidly resulting in a
Component Removal Installation growling sound.

27487 27487 A short circuit most often occurs because of copper


2749 1 dust or filings between two commutator segments. A
27492 short of this nature can be corrected by removal of
Disk 27494 27495 such material.
Disk (pilot) 27493 27493
Ground Circuit Test
Center Bushing Tools

Component Bushing Oil Seal

Handle 27487 27487


Disk 27505 27512
Disk (pilot) 27501 27501

Commutator and Drive End Bushing


Specifications*

I.D. of bushing . 0.6693, to 0.6704 in.


(17.00 to 17.03 mm)
Oil clearance.. . . . 0.0036 IO 0.0070 in.
(0.09 to 0.18 mm) F@ B-Armature Ground Test
Maximum clearance . .. .0.016 in. (0.41 mm)
Bushing depth.. . .. . 0.008 to 0.022 in.
(0.20 to 0.56 mm)

*Reaming may be necessary after installation.

Center Bushing Specifications

I.D. of bushing .. .. . . 1.182 to 1.184 in.


(30.02 to 30.07 mm)
Maximum clearance . . .. 0.0236 in. (0.60 mm)
Bushing depth.. .. . . . 0.017 to 0.032 in.
(0.43 to 0.81 mm)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Engine 4
TM- 1188 (Jul- 78) Starting Motor and Fasfenings 0422-7

With the ohmmeter set to read on its highest scale, Overrunning Clufch and Pinion
place one test lead on the commutator and the other
Do not immerse the overrunning clutch and pinion in
lead on the armature core or shaft (Fig. 9). If the test
a cleaning solvent. The unit has been pre-lubricated
meter indicator swings towards zero, the armature is
and solvent will wash lubricant away. It may be cleaned
grounded. Replace armature.
with a cloth moistened with a cleaning solvent and
wiped dry.
Open Circuit Test

Rotate the pinion. Pinion gear should rotate


smoothly (but not necessarily easily) in one direction,
and should not rotate in the opposite direction.

If the pinion gear does not rotate smoothly, or if it is


worn, chipped, or burred, it should be replaced.

Field Windings and Shunt Windings

Ground Circuit Test

Fig. 7GOpen Circuit Test

With the ohmmeter set to read on its lowest scale,


place one test lead on the commutator segment and
the other test lead on an adjacent segment (Fig. 10).
Repeat this operation for all segments by moving one
lead at a time. If the test meter indicator does not swing
to zero and remains stationary, the armature coil be-
tween these two segments is open. Replace armature.

Burned commutator segments are usually an indi-


cation of an open circuited coil.

Fig. 12-Ground Tesl

Remove the screw and hang the eyelet terminal in


the air. Using an ohmmeter set to read on its highest
scale, place one test lead on the copper terminal bolt
and the other lead on a clean spot of the field frame
Fig. 11 -Checking Armature Runout
(Fig. 12). If the ohmmeter dial indicator swings toward
zero, a grounded circuit is indicated. Replace the field
windings.
Place armature in V-blocks and check for a bent
shaft as shown in Fig. -11. Replace armature if shaft
runout exceeds specification. Runout should not ex-
ceed 0.006 inch (0.15 mm).

Litho in U.S.A.
4 Engine JD670-A and JD672-A Motor Graders
0422-8 Starting Motor and Fastenings TM- 1188 (J&78)

Open Circuit Test To check the field windings for an open circuit set
the ohmmeter to read on its lowest scale and place one
test lead on the copper terminal bolt and the other lead
on the bare field end (Fig. 14). If the ohmmeter dial
indicator does not swing to zero, the field windings are
open-circuited. Replace the field windings.

Before removing pole shoes, scribe a mark on the


pole shoe and the field frame to be sure they will be
assembled in their original position. Tighten pole shoe
screws with 30 lb-ft (41 Nm) (4 kg/m).

Brushes
Replace brushes if they are oil soaked or if they are
worn shorter than 5/8 inch (15.9 mm). Check brush
insulated holders for grounds.
Fig. 13-Shunt Winding Open Circuit Test

To check the shunt windings, set the ohmmeter to


read on its lowest scale. Place one test lead on the
terminal bolt and the other lead on the eyelet terminal
(Fig. 13). If the ohmmeter does not swing to zero, it is
open circuited and the field winding assembly will have
to be replaced.

Fig. 15-Brush Holder Insulation Test

With the ohmmeter set to its highest reading scale,


connect one test lead onto the commutator end frame
and the other lead to the brush holder Fig. 15. If the dial
indicator swings toward zero, the positive brush holder
is grounded and should be replaced.

Fig. 14-Field Winding Open Circuit Test

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Engine 4
TM- 1188 (Jul-78) Starting Motor and Fastenings 0422-g

IMPORTANT: Solenoid contacts and plunger


will be damaged if current is applied to solenoid
when it is removed from starting motor.

Remove nuts from solenoid “S” terminal and pull-in


terminal. Then remove switch cover (3, Fig. 17).

When installing switch cover (3), place “S” terminal


gaskets on winding terminal align main contact verti-
cally, and place packing (2) on switch cover.

Assembly
To assemble the starting motor, reverse the disas-
sembly procedures. Use new seals and packings.

Lubricate the shift lever, overrunning clutch, thrust


washers, bushings, and armature bearing surfaces
with John Deere Multi-Purpose Lubricant or equiva-
lent.

If the shift lever was removed, tighten the shift lever ’


Fig. 16-Measuring Brush Spring Tension 0
pivot screw with 30 lb-ft (41 Nm) (4 kg-m). Bend
washered edge of screw down to prevent loosening.
Measure the brush spring tension with a spring
scale. The brush spring tension should be a mimimum
Tighten center bearing housing to field frame bolts
of 40 ounces (11 N) (1 kg), as the spring just leaves the
with 6 lb-ft (8 Nm) (0.8 kg-m). Tighten drive end and
brush holder. When taking the reading, the scale
commutator end frame bolts with IO lb-ft (14 Nm) (1
should be on a line parallel with the edge of the brush
kg-m).
holder.

Solenoid

l-Brush 3-Brush Spring


2-Brush Leads
l-Solenoid Windings 7-Plunger Return Spring
a--Packing 9-Contact Plate Spring Fig. Id-Brush Insfaallation
3-Switch Cover 9-Insulator Bushing
4-Cover Screws lO-Contact Plate
When installing the brushes, twist brush leads 180
5-Plunger Cover 11-Casteliated Nut
GPlunger degrees (Fig. 18). Press the leads of the insulated
brush down against the brush.
Fig. f7-Solenoid

Litho in U.S.A.
4 Engine JD670-A and JD672-A Motor Graders
0422-10 Starting Motor and fastenings TM- 1188 (J&78)

Connect a 24”volt source, rheostat, ammeter, con-


trol switch, voltmeter, and tachometer to starting motor
as shown in Fig. 20.

Starting motor should rotate smoothly at a constant


speed of at least 4400 rpm at 24 volts with a maximum
current draw of 70 amperes.

INSTALLATION

l-Pinion Slop 3-Washer (Remove After


2--Retaining Ring Using)

Fig. IQ-Installing Pinion Sfop

Slide pinion stop onto shaft, with open side toward


end of shaft. Install retaining ring in groove. Force
pinion stop over ring, using a washer and two pairs of
pliers as shown in Fig. 19. Remove washer.

Give the assembled motor a no-load test. Solenoid


action during the test should be satisfactory.
i-Positive Battery 3-Starting Motor
No Load Test (After Assembly) Cable 4-Solenoid
2-Solenoid to Starting 5-Solenoid to Starting
Circuit Relay Circuit Relay

Fig. PI-Solenoid Wire Connections

Install starting motor and secure to flywheel housing


with cap screws.

Connect wires to starting motor.

Connect battery ground strap.

T34507N

l-24 Volt Source trVoltmeter


2-Rheostat GStarting Motor
3-Ammeter 7-Tachometer
4-Control Switch

Fig. 3%No Load Test (After Assembly)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Engine 4
TM- 1188 (Mar-80) Specifications and Special Tools 0499-l

Group 0499
SPECIFICATIONS AND SPECIAL TOOLS
ENGINE BREAK-IN
SPECIFICATIONS AND TORQUE VALUES

NOTE: Whenever possible, use a dynamometer to provide a more accurate break-in, assuring proper initial
seating of new piston rings.

Remarks

CHECK OIL

PRESSURE,

1900 TO 2200 RPM COOLANT

(3/4 THROTTLE) TEMPERATURE,

AND LEAKAGE

FIELD ONLY

*Loads can be simulated in the field by controlled operation.


**After this run, loosen cylinder head bolts 45 degrees: then retighten bolts one at a time, in sequence (Group
0409), to 95 lb-ft (129 N-m) (13 kg-m). Loosen rocker arm support cap screws; then retighten to 35 lb-ft (47 N-m)
(5 kg-m). Check and reset valve clearance (Group 0402). Loosen exhaust manifold cap screws and nuts; then
retighten to 35 Ib-ft (47 N-m) (5 kg-m).
+After break-in, drain crankcase oil, and remove oil filter. Install new filter and fill crankcase to proper level with
proper oil. Remove turbocharger oil inlet screen.

Litho in U.S.A.
4 JD670-A and JD672-A Motor Graders Engine
0499-2 TM- 1188 (Dee-87) Specifications and Special Tools

OILING SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

Fig. 28-Oil Pan Cap Screw Torque

FUEL INJECTION SYSTEM


SPECIFICATIONS AND TORQUE VALUES

Fuel Injection Pump Model number . . . . . . . . . . . . . . . . DM4627MB2878


Part number . . . . . . . . . . . . . . . . . . . . . . .AR72306
Roller-to-roller distance . . . . . .1.9640 f 0.0015 in.
( f 0.038 mm)
Governor linkage gap . . . . . . . . . 0.125 to 0.165 in.
(3.18 to 4.19 mm)

IMPORTANT: In order to obtain proper test results,


do the following:

Use 0.25 in. (6.4 mm) O.D. by 0.093 in. (2.36 mm)
I.D. by 20 in. (508 mm) long test lines.

Use 12SD12 Robert Bosch Calibrating Nozzles,


2500 psi (172 bar) (176 kg/cm2) opening pressure.
Use JDF-2 Test Oil, or a test oil equivalent to SAE
J967A with a 34 to 36 SUS rating with oil at lOOoF
(38°C).

083A
v Test oil should be 110’ to 115°F (43’ to 46OC).

Fig. 334njection Line Connection


Operate pump clockwise (viewed from drive end)
at 500 rpm wide open throttle (WOT) for 10 minutes
prior to test.

Litho in U.S.A.
Engine JD670-A and JD672-A Motor Graders 4
Specifications and Special Tools TM-l 188 (Dee-87) 0499-3

FUEL INJECTION SYSTEM


SPECIFICATIONS AND TORQUE VALUES-Continued

NOTE: Pump operates at l/2 engine rpm. All rpm


given are test stand rpm unless otherwise noted.

NOTE: 1 to 3 psi (0.07 to 0.27 bar) (0.07 to 0.27


kg/cm2) supply pressure required at pump inlet,

Transfer pump vacuum (200 rpm)


(minimum) . . . . . . . . . . . . _ _ . . . . . . . . . . 18 in. Hg.
(609.5 mbar)

Transfer pump pressure (7150 rpm) . . . 82 to 92 psi


(5.7 fo 6.3 bar) (5.8 to 6.5 kg/cm2)

Automatic speed advance


m
300to500..............................1”
700to800..............................5’
by925 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6”f1/2”

Minimum cranking speed


delivery (75 rpm)
Volume _ . , . . . . . . . . . . . . 48 cm3/1 000 strokes
Transfer pump pressure
(minimum) . . . . . . . , . . . . . . . . . . . . . . . .12 psi
(1 bar) (1 kg/cm*)

Fuel delivery (750 rpm)


Volume . . . . . . . . . . . 89 to 93 cm311000 strokes
Maximum variation
between cylinders . . . . . . . . 7 cm3/1000 strokes

Fuel delivery (1150 rpm)


Volume . . . . . . . . . . . 84 to 88 cm3/1000 strokes
Maximum variation
between cylinders . . . . . . . . 4 cm3/1000 strokes

High idle (WOT) (1275 rpm)


Volume . . . . . . . . . . . 10 to 12 cm311 000 strokes
Maximum variation
between cylinders _ . . . . . . . 4 cm311 000 strokes

Governor cut-off (1300 rpm)


Volume . . . . . . . . . . . .5 cm3 maxi1 000 strokes

Low idle (400 rpm)


Volume . . . . . . . . . . . 10 to 12 cm3/1 000 strokes
Maximum variation
between cylinders . . . . . . . 4 cm311000 strokes

Check shut-off at (200 rpm)


Volume . . . . . . . . . . . . .2 cm3 max/lOOO strokes

Litho in U.S.A.
4 Engine JD670-A and JD672-A Motor Graders
0499.4 Specifications and Special Tools TM- 1188 (Dee-87)

FUEL INJECTION SYSTEM


SPECIFICATIONS AND TORQUE VALUES-Continued

Fig. 354njection Pump and Nozzles

1 - injection nozzle inlet torque . . . . . . . . . 35 Ib-ft 5 - Timing hole cover screw


(47 N.m) (5 kg-m) torque . . . . . . . . . . . . . . . . . . . . 15 to 20 lb-in
(1.7 to 2.6 N.m) (0.17 to 23 kg-m)
2 - Injection line connector screw
torque . . . . . . . . . . . . . . . . . . . . . . . . . 20 lb-ft 6 - Fuel inlet screw torque . . . . . . . . . , . , 20 lb-ft
(17.6 N-m) (1.8 kg-m) (27 N.m) (3 kg-m)

3 - Drive hub nut torque . . . . . . . .140 to 150 lb-ft 7 - Injection nozzles hold-down cap screw
(190 to 203 N-m) (19 to 21 kg-m) torque . . . _ . . . . . . . . . . . . . . . . . . . 20 lb-ft
(27 N.m) (3 kg-m)
4 - Mounting bolt nut torque . . . . . . . . . . . 20 lb-ft
(27 N.m) (3 kg-m)

bitho in U.S.A.
JD670-A and JD672-A Motor Graders Engine 4
TM- 1188 (Dee-87) Specifications and Special Tools 0499-5

FUEL INJECTION SYSTEM


SPECIFICATIONS AND TORQUE VALUES-Continued

Model number . . . . . . . . . . . . . . . . . . . . . . . .20505

Part number . . . . . . . . . . . . _ . . . . , . . . . .AR68364

Number of orifices. . . . . . . . . . . . . . . . . . . . . . . . .4

Orifice size . . . . . . . . . . . . . . . . . . . . . . . . 0.012 in.


(0.30 mm)

NOZZLE SETTINGS

Nozzle opening
pressure (new) . . . . . . . . . . . . . .3150 to 3250 psi
(21 719 to 22 408 kPa) (217 to 224 bar)

Nozzle opening
pressure (used) . . . . . . . . . . . . .2950 to 3050 psi
(20 340 to 21 029 kPa)(203 to 210 bar)

Return oil leakage . . . . . . . . . .3 to 10 drops per 30


seconds at 1500 psi
(10 342 kPa) (103 bar)
from first drop
(service only)

Nozzle valve lift. . . . . . . . . . . . l/2 5 l/8 turn from


bottom (0.009 in [0.23 mm]
nominal)

1 - Pressure adjusting screw-


to-nozzle body lock nut
torque . . . . . . . . . . . . . . . . . . . . 70 to 80 lb-in
(7.9 to 9.0 N.m) (0.81 to 0.92 kg-m)

2- Lift adjusting screw


lock nut torque. . . . . . . . . . . . . . 35 to 45 lb-in
(4.0 to 5.1 N.m) (0.40 to 0.52 kg-m)

Litho in U.S.A.
4 JD670-A and JD672-A Motor Graders Engine
0499-6 TM- 1188 (Dee-87) Specifications and Special Tools

TURBOCHARGER
SPECIFICATIONS AND TORQUE VALUES

1 - Radial bearing movement . . . . . . . . . . 0.003 in.


(0.08 mm) to 0.006 in. (0.15 mm)
2- Rotating assembly axial end
play . . . . . . . . . . ~ , . . . . . . 0.001 in. (0.03 mm)
to 0.004 in. (0.10 mm)
3- Impeller nut torque . . . . . . . . . . . 18 to 20 lb-in.
(2.0 to 2.6 N-m) (0.21 to 0.23 kg-m)
plus an additional 90° turn
4- Lock plate bolts torque . . . . . . . .40 to 60 lb-in.
(4.5 to 6.8 N.m) (0.46 to 0.69 kg-m)
5- Turbo housing to center housing nut
torque . . , . . . . . . . . , . . . . . . . .lOO-130 lb-in.
(11.3 to 14.7 N.m) (1.15 to 1.50 kg-m)
Air intake hose clamp
T27628N 4 torque . . , . . . . . . . . . . . . . . . . . . 70+5Ib-in.
Fig. 36-Turbocharger (7.9 + 0.6 N.m) (0.81 f 0.06 kg-m)

WATER PUMP
SPECIFICATIONS AND TORQUE VALUES

Water pump rear cover-to-cylinder block


attaching cap screws torque . . . . . . . . . . . . 35 lb-ft
(47 N.m) (4.8 kg-m)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Engine 4
TM- 1188 (Dee-87) Specifications and Special Tools 0499-7

STARTING MOTOR AND FASTENINGS


SPECIFICATIONS AND TORQUE VALUES-Continued

2 - Center housing bushing


(Fig. 40) I.D. . . . . . . . . . . . . . 1.182 to 1.184 in.
(30.02 to 30.07 mm)
Wear tolerance (maximum) . . . . . . ;;o.l;b”“,in;

Oil clearance wear


tolerance .. .. . . .... .. ... ... . iOO~.oo3~fSni

Depth . . . . . . . . . . . . . . . . . . 0.0 17 to 0.037 in.


(0.43 to 0.94 mm)
Armature (Fig. 40)
Armature runout . . . . . . . . . . . . . . . . . 0.006 in.
(0.15 mm)
Commutator runout . . . . . . . . . . . . . . 0.016 in.
(0.41 mm)
Commutator minimum undercut . . . . . 0.008 in.
(0.20mm)
Commutator O.D. . . . . . . . . . . . . . . . . . 1.77 in.
(44.9 mm)
- Torque-pole shoe screws
(Fig. 40) . . . . . . . . . . . . . . . . . . . . . . . . 30 lb-ft
(41 N.m) (4 kg-m)
5 - Torque-shift lever pivot
screw (Fig. 40) . . . . . . . . . . . . . . . . . . . 30 lb-ft
(41 N.m) (4 kg-m)
6 - Torque-center bearing
housing to field frame
(Fig. 40) . . . . . . . . . . . . _ . . . . . . . . . . . . 6 lb-ft
(8 N.m) (0.8 kg-m)
7 - Torque-commutator frame and
drive housing (Fig. 40) . . _ . . . . . . . . . . 10 lb-ft
(14 N.m) (1 kg-m)
8 - Clearance between pinion
and pinion stop (Fig. 40) . . . _ 0.012 to 0.185 in.
(0.30 to 4.70 mm)
1 - Brush minimum length . . . . . . . . . . . . . 5/8 in.
(15.88 mm)

Fig. 41 -Measuring Brush Length

Litho in U.S.A.
4 Engine JD670-A and JD672-A Motor Graders
0499-8 Specifications and Special Tools TM-l 188 (Dee-87)

STARTING MOTOR AND FASTENINGS


SPECIFICATIONS AND TORQUE VALUES-Continued

1 - Brush spring minimum


tension . . . . . . . . . . . . . ..~ . . . ..-.... 4002
(11 NJ (1 kg)

Fig. 42-Checking Brush Spring Tension

bitho in U.S.A.
JD670-A and JD672-A Motor Graders Engine 4
TM- 1188 (Dee-87) Specifications and Special Tools 0499-g

FUEL INJECTION SYSTEM


SPECIAL TOOLS

Essential Tools

Tool Tool Number Use

JDE-38 Nozzle Puller - To remove fuel


injection nozzles.

Fig. 67-Nozzle Puller


JD-258 Carbon Stop Seal Installation Tool -
To install carbon stop seal on
nozzles.

Fig. 68-Seal /nsta//ation Tool


JDE-39 Nozzle Bore Cleaning Tool - To
clean nozzle bore in cylinder head.

Fig. 69-Cleaning Tool 19918 Timing Window - To adjust injec-


tion pump cam advance.

Fig. 704njection Pump Timing Window

Litho in U.S.A.
4 JD670-A and JD672-A Motor Graders Engine
0499-10 TM-1 188 (Dee-871 Specifications and Special Tools

STARTING SYSTEM
SPECIAL TOOLS

Convenience Tools

Tool Tool Number Use

-a-- To test armature for shorts opens


and grounds.

Fig. 75-Armature Tester

To undercut armature and com-


mutator.

Fig. I&Armature and Commutator Turning


and Undercutting Tool

Litho in U.S.A.
Engine JD670-A and JD672-A Motor Graders 4
Specifications and Special Tools TM- 1188 (Dee-87) 0499-11

STARTING MOTOR AND FASTENINGS


SPECIAL TOOLS

Essential Tools

Tool Tool Number Use

Commutator and Drive End Bushing Tools

1 - 27487 Handle - For removing and instal-


ling commutator and drive end
bushings.

Disk - For removing commutator


and drive end bushing.
1”2?67ON

Fig. 77-Bushing Removal 27495 Disk - For installing commutator


and installation and drive end bushing.

3 - 27491 and
27492 Disk Spacer - For removing and
installing commutator and drive
end bushing.

4 - 27493 Disk Pilot - For removing and instal-


ling commutator and drive end
bushing.

Litho in U.S.A.
4 JD670-A and JD672-A Motor Graders Engine
9499-12 TM- 1188 (Dee-87) Specifications and Special Tools

STARTING MOTOR AND FASTENINGS


SPECIAL TOOLS-Continued

Essential Tools-Continued

Tool Tool Number Use

Center Bushing and Oil Seal Tools (See Fig. 77)

1 - 27487 Handle - For installing center


bushing and oil seal.

2 - 27505 Disk - For installing center bushing.

3 - 27512 Disk - For installing center oil seal.

4 - 27501 Disk Pilot - For installing center


bushing and oil seal.

Commutator and Drive End Bushing Tool

Dimension Removal Installation

A 1 in. 1 in.
(25 mm) (25 mm)
B 0.732 to 0.736 in. 0.732 to 0.736 in.
(18.59 to 18.69 mm) (18.59 to 18.69 mm)
C 0.661 to 0.665 in. 0.661 to 0.665 in.
(16.79 to 16.89 mm) (16.79 to 16.89)
D 2 in. 3.94 in.
(51 mm) (100.08 mm)
E 0.901 to 0.909 in. 0.018 to 0.022 in.
(22.89 to 23.09 mm) (0.46 to 0.56 mm)
F 0.783 to 0.791 in. 0.783 to 0.791 in.
(19.89 to 20.09 mm) (19.89 to 20.09 mm)

Fig. 78-Dimensions for Shop-Made Bushing Driver

Litho in U.S.A.
Engine JD670-A and JD672-A Motor Graders 4
Specifications and Special Tools TM- 1188 (Dee-87) 0499-13

STARTING MOTOR AND FASTENINGS


SPECIAL TOOLS-Continued

Essential Tools-Continued

Tool Tool Number Use

Center Bearing Bushing Tool (See Fig. 78)

Dimension Removal Installation


A 1.57 in. 1.57 in.
(39.9 mm) (39.9 mm)
B 1.36 to 1.37 in. 1.36 to 1.37 in.
(34.5 to 34.8 mm) (34.5 to 34.8 mm)
C 1.17 to 1.18 in. 1.17 to 1.18 in.
(29.7 to 30.0 mm) (29.7 to 30.0 mm)
D 2 in. 2 in.
(50.8 mm) (50.8 mm)
E 0.95 to 1.02 in. 0.018 to 0.02 in.
(24.1 to 25.9 mm) (0.46 to 0.51 mm)
F 0.866 to 0.945 in. 0.966 to 1.000 in.
(22.0 to 24.0 mm) (25.54 to 25.40 mm)

JDE-80 Starter Wrench - To remove and


install rear mounting nut on starting
motor.

Fig. 79-Starter Wrench

Litho in U.S.A.
4 JD670-A and JD672-A Motor Graders Engine
0499-14 TM-1 188 (Dee-87) Specifications and Special Tools

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Engine Auxiliary Systems 5
TM- 1188 (J&78) Cold Weather Sfartina Aids 0505-l

Section 5
ENGINE AUXILIARY SYSTEMS
CONTENTS OF THIS SECTION

Page Page
GROUP 0505 - COLD WEATHER STARTING GROUP 0520 - INTAKE SYSTEM
AIDS Air Cleaner
General Information .................... 0505-3 General Information . 0520-l
Starting Aid Solenoid ................... 0505-3 Removal . .. 0520-l
Removal ............................ 0505-3 Repair . . 0520-l
Repair.. ............................ 0505-3 Installation. . .. . 0520-l
Installation. .......................... 0505-3 Pre-Cleaner
Starting Aid Switch General Information . 0520-2
Removal ............................ 0505-3 Removal . . 0520-2
Repair .............................. 0505-4 Repair . . . . . 0520-2
Installation. .......................... 0505-4 Installation. .. . . 0520-2
Starting Aid Adapter, Line and Nozzle
Removal ............................ 0505-4 GROUP 0540 - MOUNTING FRAME
Repair .............................. 0505-4 Removal .. .. . 0540-l
Installation. .......................... 0505-4 Installation. . .. ... . . 0540-2
Engine Coolant Heater
Removal ............................ 0505-4 GROUP 0560 - EXTERNAL FUEL SUPPLY
Repair .............................. 0505-4 SYSTEMS
Installation ........................... 0505-4 General Information ............ 0560-2
Removal ...................... 0560-2
GROUP 0510 - COOLING SYSTEMS Repair ........................ 0560-2
Radiator and Fan Shroud Installation ..................... 0560-2
General Information .................. 051 O-l
Removal ............................ 051 O-l GROUP 0599 - SPECIFICATIONS AND
Repair .............................. 051 O-2 SPECIAL TOOLS
Installation. .......................... 051 O-2 Engine Cooling System _ . . 0599-l
External Fuel Supply System . . 0599-l
GROUP 0515 - SPEED CONTROLS
General Information .................... 0515-l
Removal .............................. 0515-I
Repair ................................ 0515-2
Installation ............................. 0515-2

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5 Engine Auxiliary Sys terns JD670-A and JD672-A Motor Graders
0505-2 Cold Weather Starting Aids TM- 1188 (Jul- 78)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Engine Auxiliary Systems 5
TM-l 188 (Jul-78) Cold Weather Starting Aids 0505-3

GENERAL INFORMATION Repair


The cold weather starting aid on the Motor Grader The solenoid is not repairable. If the solenoid is
consists of a starting aid solenoid with fluid container, a defective, it must be replaced.
tube from the solenoid to a nozzle in the air intake
manifold and a button switch. Test solenoid as described in Group 9015.

The starting aid solenoid will spray fluid as long as Installation


the switch button is depressed with the transmission in
Mount solenoid and can on engine and connect
neutral and the key switch on IGN.
wires and tube.

The starting aid switch is located on the upper left


STARTING AID SWITCH
side of the instrument console. The solenoid and fluid
can are on the right side of the engine above the
Removal
engine oil filter housing.
Remove four screws from instrument panel and pull
IMPORTANT: To avoid damage, crank engine panel out just far enough to gain access to the switch.
one or two revolutions before depressing starting
aid switch. Depress starting fluid switch only when Remove switch cap, disconnect wires, remove re-
the engine is cold and cranking. taining hardware and remove switch.

IMPORTANT: To prevent dirt from entering the


can sealing area, a container of starting fluid
should be in place on the solenoid at all times.

The motor grader may also be equipped with an


electric engine coolant heater to aid in cold weather
starting.

STARTING AID SOLENOID

Removal
Open right engine side shield, disconnect wire (1,
Fig. 1) and tube (2) from solenoid, remove attaching
hardware (3) and remove solenoid (4).

l-Switch 24nstrument Panel

Fig. P-Starting Aid Switch

l-Wire 3-Attaching Hardware


2-Tube 4-Solenoid

Fig. 1-Remove Starting Aid Solenoid

Litho in U.S.A.
5 Engine Auxiliary Systems JD670-A and JD672-A Motor Graders
0505-4 Cold Weather Starting Aids TM- 1188 (J&78)

Repair ENGINE COOLANT HEATER


The switch is not repairable. If the switch is defec- Removal
tive, it must be replaced.

Test the switch as described in Group 9015.

Installation
Install switch, connect wires and install instrument
panel.

STARTING AID ADAPTER, LINE AND


NOZZLE
Removal
159499N
Remove line by disconnecting at starting aid sole-
l-Gasket 4-Heater Assembly
noid and at nozzle holder.
2-O-Ring 5-Card
3-Split Ring
Unscrew nozzle holder from air intake manifold and
remove nozzle and holder. Fig. 3-Engine Coolant Heater

Repair Remove the cord (5, Fig. 3) or cap (part of key 4).

Se sure hose and openings in nozzle are open.


Remove the clamping nut (part of key 4) to remob
Clean or replace as necessary.
the engine coolant heater.

Installation Repair
Install nozzle and holder with arrow on nozzle
The heater cannot be repaired. If defective, it must
pointing toward center of engine.
be replaced.

Connect line to solenoid and nozzle holder.


Installation
Insert a new gasket (1) into the adapter (part of key
4). Place a new O-ring (2) onto the adapter. Thread the
adapter securely onto the heating element.

Place the split ring (3) and clamping plate (part of


key 4) onto the heater element. Start clamping nut (part
of key 4) onto heater element.

Install heater element into engine block. Tighten


clamping nut. As the clamping nut is tightened, it will
exert pressure against the clamping plate. The clamp-
ing plate will then put pressure on the split ring, causing
it to expand and retain the heater in place.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Engine Auxiliary Systems 5
TM- 1188 (J&78) Engine Cooling System 0510-l

Group 0510
ENGJNE COOLING SYSTEM
RADIATOR AND FAN SHROUD

General Information Removal


The engine cooling system consists of the radiator Remove engine side shields, hood, grille screen and
and fan. grille housing.

The radiator is located at the front of the engine Drain radiator.


frame and is of the tube and fin type core construction.
The pressure type radiator cap is located on the top of Disconnect radiator hoses and remove radiator.
the radiator to maintain pressure in the cooling system.

l-Fan 4-Cap Screw (4 used)


l--Shroud G-Radiator
3-Lock Washer (4 used)

F@. i-Radiator, Shroud and Fan

Litho in U.S.A.
5 Engine Auxiliary Systems JD670-A and JD672-A Motor Graders
051 o-2 Engine Cooling System TM- 1188 (J&78)

Repair Look for bubbles which indicate the location of leak.

For information on testing and repairing radi- NOTE: Repairs should be done only by experi-
m ator, refer to “Cooling System” in FOS Man- enced radiator service technicians.
ual - ENGINES.
Cl 0 Check radiator cap for defects. Cap should maintain
6.25 to 7.50 psi (0.4 to 0.5 bar) (0.4 to 0.5 kg/cm*)
pressure.
Visually check the radiator for leaks or damage.
Installation
If no leaks can be seen but leaking persists perform
Follow removal procedure in reverse order.
the following tests:
Be sure all hose connections are tight.
Install radiator cap and plug the overflow tube and
outlet tube.
Fill cooling system to the internal tank baffle (ap-
proximately 4 in. [102 mm] below the filler neck top)
Attach an air hose to the inlet connection.
with proper coolant.

Apply a maximum of 10 psi (1 bar) (1 kg/cm*) air


pressure and submerge in tank of water.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Engine Auxiliary Systems 5
TM- 1188 (Jul- 79) Speed Controls 0515-l

Group 0515
SPEED CONTROLS
GENERAL INFORMATION REMOVAL
The speed control system consists of a hand control Refer to Figs. 1, 2, 3 and 4 when removing speed
lever which is connected to the injection pump by control linkage components.
means of control cable and linkage. The grader is
equipped with accelerator and decelerator pedals Note how inner arm (5, Fig. 2), center arm (6), outer
which are used to allow the operator to regulate speed arm (8), and spring (7) are located in relation to each
without using the hand control lever. other for proper assembly.

INNER SPEED
CONTROL ARM

T66695N

l-Cap Screw 7-Washer (2 used) 13-Yoke (2 used) 18-Pipe Spacer


2-Jam Nut &Knob M-Pin (2 used) lg-Spring
3-Facing (2 used) g-stop l!+Jam Nut (2 used) lo-Washer
4-Plate (2 used) lo--Nut (2 used) 16-stop Pl-Special Nut
5-Cap Screw (2 used) 1 l-Speed Control Lever 17-Speed Control Rod 22-Cap Screw (2 used)
S-Lock Washer (4 used) 12-Cotter Pin (2 used)

Fig. I-Speed Control Lever and Linkage

Litho in U.S.A.
5 Engine Auxiliary Systems JD670-A and JD672-A Motor Graders
0515-2 Speed Controls TM- 1188 (Jul- 79)

I\ II
\\
\\
\\
\\ SPEED CONTROL
\\
\ \-LEVER ROD
\ '\
'I
!I

&J .. ,..

l'61063N

l-Cap Screw (2 used) O-Bushing (6 used) ‘I-Spring


2-Washer (2 used) 6-inner Arm 8-Outer Arm
%-Throttle Linkage Pin Center Arm

Fig. P-Speed Control Arms

REPAIR INSTALLATION
Examine all parts for bent or broken conditions. IMPORTANT: Use care when connecting cable
(5, Fig. 4) to the injection pump to avoid too sharp a
Check bushings (4, Fig. 2) for excessive wear or bend in the cable.
deterioration.,
Tighten special nut (21, Fig. 1) until 8 Ibs. (36 N) (4
When replacing bushings, press flush to outside of kg) pull is required at the end of the speed control lever
casting. to move the lever.

Refer to Group 9010 for speed control linkage ad-


justment.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Engine Auxiliary Systems 5
TM- 1188 (Jut- 78) Speed Controls 0515-3

OUTER SPEED
-CONTROL ARM

l'61064N

l-Retaining Ring (4 used) 5-Cotter Pin (2 used) g--Pin (2 used)


P-Special Pin S-Yoke (2 used) 1 O-Decelerator Pedal
3-Sleeve (4 used) 7-Jam Nut (2 used) 1 l-Special Pin
4-Accelerator Pedal 8-Rod

Fig. d-Accelerator and Decelerator Pedals and Linkage

l-Pin (2 used) 4-Jam Nut (2 used)


a-Yoke (2 used) 5-Speed Control Cable
E&Cotter Pin (2 used)

Fig. 4-Speed Control Cable

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5 Engine Auxiliary Systems JD670-A and JD672-A Moior Graders
0515-4 SDeed COntfOlS TM- 1188 (Jul-78)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Engine Auxiliary Systems 5
TM- 1 I88 (Jul-78) Intake System 0520-I

Group 0520
INTAKE SYSTEM
AIR CLEANER
.,
General Information Removal
Remove engine side shields, exhaust stack, pre-
cleaner, and hood.

Remove air cleaner.

Repair
Replace the filter elements if damaged, after one
year of service, or if elements are not responding to
cleaning indicated by excessive smoke or loss of
power.

Refer to FOS Manual - ENGINES - for infor-

rlF@s mation on cleaning air cleaner elements.

IMPORTANT: Never operate engine without


filter elements and cover in place.
Fig. l-Air Cleaner
Check air restriction indicator tube for holes, cracks,
The air cleaner assembly consists of two filter ele- and kinks. Replace if necessary.
ments and an air restriction indicator.
Installation
Air enters the air cleaner body and passes through
the primary element to remove impurities. If the pri- Follow removal procedure in reverse order.
mary element fails, the safety element will remove dirt
particles. Check all air intake system fittings for possible air
leaks.
An air restriction indicator is located on the dash
panel. It warns the operator of excessive restriction in
the system.

Litho in U.S.A.
__--._
5 Engine Auxiliary Systems -- JD670-A and JD672-A Motor Graders
0520-2 Intake System TM- 1188 (J&78)

PRE-CLEANER

General Information
> A pre-cleaner is included in the air intake system. Its
purpose is to stop any large dirt particles from entering
the system.

Removal
Remove pre-cleaner from air cleaner intake tube.

Repair
Refer to Fig. 2 during disassembly and assembly of
the pre-cleaner.

Remove dirt and contaminants from bowl (3).


+ 9495

Replace damaged or broken parts.


1-Pre-Cleaner 3-Bowl
l-Cover 4-Sleeve
Installation
Fig. 2-Pre-Cleaner
Install pre-cleaner on air cleaner intake tube.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Engine Auxiliary Systems 5
TM- 1188 (J&78) Mounting Frame 0540: 1

Group 0540
MOUNTING FRAME
REMOVAL Remove cap screws attaching engine support shims
to the transmission, if necessary.
Remove hood (Group 1910).
Remove cap screws attaching engine left support to
Support front of engine.
hydraulic pump support and to transmission.

If grader is equipped with front wheel drive, remove


Remove support.
cap screws attaching rear sensor to engine support.
Remove cap screw attaching engine support shims
Remove cap screws attaching engine right support
to the transmission if necessary.
to hydraulic pump support and to transmission.

Remove support.

IMPORTANT: Shims under the engine support


need to be removed and the engine support re-
shimmed only if the transmission, engine, transfer
drive housing, clutch housing, differential cover,
or hydraulic pump support are replaced.

l'61066N

I-Cap Screw 4-Left Support


2-Washer 5-Shim
3-Right Support GHydraulic Pump Support

Fig. I-Engine Mounting Supports

Litho in U.S.A.
5 Engine Auxiliary Sys terns JD670-A and JD672-A Motor Graders
0540-2 Mounting Frame TM- 1188 (J&78)

INSTALLATION The shims are cap screwed to the transmission


cover.
IMPORTANT: Shims under the engine support
need to be removed and the engine support re- Secure engine supports to transmission cover.
shimmed only if the transmission, engine, transfer
drive housing, clutch housing, differential cover, Install rear sensor on right support (Group 1675).
or hydraulic pump support are replaced.
Install fuel tank and battery housing with fuel tank
Hoist the engine complete with radiator and, hy- and batteries in housing.
draulic pump into position in the frame. Attach engine
to the engine supports. Connect electrical wiring. Connect fuel lines and
speed control linkage.
Install the transfer drive housing (if removed) (see
Group 0841). The engine rotation tool can be used to Install hood (see Group 1910).
aid’ in lining up the splines on the shaft.
Install muffler, pre-cleaner and engine side shields.
If a new engine, transmission, transfer drive hous-
ing, clutch housing, or differential cover has been Bleed the fuel system (see Group 0413).
installed, install the engine as follows:

Remove the shims located under the engine sup-


ports.

Hoist the engine complete with the radiator and


hydraulic pump into position in the frame. Install the
transfer drive housing to the transmission clutch hous-
ing. Attach engine to the transfer drive housing only.
The engine rotation tool can be used to aid in lining up
the splines on the shaft.

Install front engine supports on the hydraulic pump


support and tighten cap screws to 170 lb-ft (230 Nm)
(24 kg-m).

Remove any blocks or lifting devices supporting


engine assembly so that full engine weight rests on the
transfer drive housing.

Measure the gap between bottom surface of engine


support and transmission cover pads. Select shim
packs 0.020 inch (0.51 mm) thicker than the gap. Raise
engine only enough to install shim pack.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Engine Auxiliary Systems 5
TM- 1188 (Dee-87) External Fuel Supply System 0560-l

Group 0560
EXTERNAL FUEL SUPPLY SYSTEM

T60425N

l-Drive Screw (5 used) 12-Side Support (2 used) 23-Fuel Return Hose


2-Lock Washer (5 used) ( -506106) 13-Washer (4 used) 24-Leak-Gft Line
G-Cover 14-Cap Screw (4 used) 25-90’ Elbow
cl-Fuel Gauge Sender 15-Washer (8 used) 26-Clamp
S-Gasket Is-Special Nut (8 used) 27-Lock Washer
6-Fuel lank 17-Cap Screw (4 used) I&Nut
7-Fuel Tank Cap M-Pad (8 used) ( -007833) 29-Cap Screw
&-Cap Screw (4 used) 19-Band (2 used) 30-Fuel Hose
g--Pad (4 used) 20-Pad 31-Valve
lo-Bottom Support (2 used) 21-90° Elbow 32-Drain Hose
il-Special Nut (4 used) 22-Clamp (2 used) .33-Drain Cock

Fig. I-External Fuel Supply Sysfem

Litho in U.S.A.
5 Engine Auxiliary Sys terns JD670-A and, JD672-A Motor Graders
0560-2 External Fuel Supply System TM- 1188 (J&78)

GENERAL INFORMATION Fuel Level Sending Unit


The external fuel supply system consists of fuel tank If only the fuel sending unit has to be replaced,
and fuel lines. disconnect rear wiring harness at connectors at rear of
engine block. Remove left hood and remove fuel level
The fuel tank is mounted on the rear of the engine sending unit.
frame. A drain cock and fuel shut-off valve are located
at the bottom of the fuel tank. REPAIR

REMOVAL A CAUTION: Cleaning and repairing a fuel


tank is very dangerous. Live sparks,
Fuel Tank - JD670-A smoking, or fire of any nature should never be
permitted in the vicinity of the cleaning or repairing
Open side doors for access to fuel tank.
operation.

Remove rear grille panel. Disconnect wiring harness


Fuel tank can be checked for leaks using 3 psi (0.2
connectors at front of fuel tank and remove light panel.
bar) (0.2 kg/cm’) air pressure.

Drain fuel from tank.


Refer to FOS Manual - ENGINES - for de-
F@s tailed information on repair of fuel tanks.
Disconnect fuel lines at tank.
0 Q
Remove the rear cap screws on both fuel tank
supports, then loosen the front cap screws. This will
INSTALLATION
allow the fuel tank to pivot down to the rear for clear-
ance of the filler neck past the bumper housing. Install fuel tank and connect.fuel lines.

Remove the bands (19, Fig. 1) and remove the fuel Connect wiring harness and install light panel and
tank by sliding out rear of bumper housing. rear grille panel.

Fuel Tank - JD672-A Be sure drain cock is closed and fuel shut-off valve
is open.
Open side doors for access to fuel tank.
Fill fuel tank with proper fuel.
Remove rear grille panel. Disconnect wiring harness
and remove light panel.

Drain fuel from tank.

Disconnect fuel lines at tank.

IMPORTANT: Be careful not to damage front


wheel drive components while removing service
housing.

Remove rear service housing (Group 1747).

Remove the bands (19, Fig. 1) and remove the fuel


tank by sliding out rear of bumper housing.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Engine Auxiliary Sys terns 5
TM-l 188 (J&78) Specifications and Special Tools 0599-I

Group 0599
SPECIFICATIONS AND SPECIAL TOOLS
ENGINE COOLING SYSTEM
SPECIFICATIONS AND TORQUE VALUES

Cooling system capacity.. . ... . . . 7 gal.


(26.5 L)

Radiator test pressure . . .... . . 10 psi


(1 bar) (1 kg/cm2)

Radiator cap test pressure . 6.25 to 7.50 psi


(0.4 to 0.5 bar) (0.4 to 0.5 kg/cm*)

MOUNTING FRAME
SPECIFICATIONS AND TORQUE VALUES

Mounting frame cap


screw torque . ... .. ... .. . 170 lb-ft
(230 Nm) (24 kg-m)

EXTERNAL FUEL SUPPLY SYSTEM


SPECIFICATIONS AND TORQUE VALUES

Fuel tank capacity . ... . _. . .. ... 60 gal.


(227 L)

Fuel tank test pressure.. . .... .... .... 3 psi


(0.2 bar) (0.2 kg/cm*)

Litho in U.S.A.
5 Engine Auxiliary Sys terns JD670-A and JD672-A Motor Graders
0599-2 Specifications and Special Tools TM- 1188 (Jul-78)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transfer Drive a
TM- 1188 (J&78) Housings and Covers 0841 -I

Section 8
TRANSFER DRIVE
CONTENTS OF THIS SECTION

Page Page
GROUP 0841 - HOUSING AND COVERS GROUP 0899 - SPECIFICATIONS AND
General Information _. . . . .. . . . 0841-3 SPECIAL TOOLS
Removal . ... . _. . . . _ . 0841-3 Specifications and Torque Values
Repair . ... ... . . . . ... 0841-4 Housing and Covers. . . . . . . . . . . . . . 0899-l
Installation. .. .. . .... .. . . 0841-5 Gears, Shafts, Bearings . . . _. . . . . . . 0899-3

GROUP 0851 - GEARS, SHAFTS, BEARINGS


General Information . . . . . . . . . . . . . 0851-l
Removal . . . . . . . . . . . . 0851-2
Repair
Input Gear Assembly
Disassembly. . . . . . . . . . . . . . . _ 0851-4
Assembly . . .. . . . . . . . 0851-4
Upper and Lower Idler Gear Assembly
Disassembly....................... 0851-5
Assembly . ... . .. . . . . . . _ 0851-5
Output Gear Assembly
Disassembly. ... . . . . . . . . _ 0851-8
Assembly . . . . . . . . . . . . . . . 0851-7
Cleaning, Handling and Inspecting . . . . 0851-7
Installation
Output Gear Assembly . . . . . . . . . . _. . 0851-8
Idler Gear Assembly. . . . . . . . . . _ . 0851-8
Input Gear Assembly . . . . . _. . . . . . . 0851-l 0

Lifho in U.S.A.
8 Transfer Drive JD670-A and JD672-A Motor Graders
0841-2 Housings and Co,vers TM- 1188 (Jul-78)

/ Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transfer Drive 8
TM- 1188 (Mar-80) Housings and Covers 0841-3

Group 0841
HOUSINGS AND COVERS
GENERAL INFORMATION
The transfer drive unit is located at the rear of the
motor grader. It transmits power from the engine to the
transmission.

The transfer drive housing contains the input gear,


two idler gears and the output gear. It also contains the
disconnect clutch shaft and carrier assembly.

REMOVAL
Refer to Group 4201 and remove rear-mounted
ripper and rear valve from engine frame (if so
equipped).

Disconnect battery ground strap.

Remove drawbar from transfer drive housing (if so


equipped).
Fig, l-Location of Transfer Housing Drain Line
Remove muffler, pre-cleaner, hood and fuel tank
housing. Make sure to disconnect all fuel and electrical
connections from fuel tank before removing.

Remove plug (9, Fig. 3) and drain lubricant from


transfer drive housing. NOTE: Approximate/y 7 gal.
(3.8 L) of oil will be drained.

Remove oil lube line from transmission clutch hous-


ing to transfer drive housing.

Remove transfer case drain line (Fig. 1)


I

Disconnect spring (2, Fig. 2) from clutch disconnect


shaft (1) (if so equipped).

Remove clutch disconnect cable (5) from shaft (if so


equipped).

Refer to Group 2160 and remove front wheel drive


hydraulic pump (if so equipped).

IMPORTANT: When removing the pump, be


l-Clutch Disconnect 4-Adjustable Yoke
certain to clean the outside of the pump thorough-
Shaft 6-Disconnect Cable
ly. Either steam clean or wash with solvent. Also, 2-Spring B-Transfer Housing
clean surrounding area so dirt will not get into 3-Disconnect Bracket
system when hoses are disconnected.
Fig. P-Disconnect Clutch Controls

Litho in U.S.A.
8 Transfer Drive JD670-A and JD672-A Motor Graders
0841-4 Housings and Covers TM- 1188 (Mar-80)

NOTE: Support rear of engine to aid in eliminating


engine weight on shafts when removing the transfer
drive housing and in aligning shafts when installing the
transfer drive housing.

Screw an eyebolt into the top of the transfer drive


housing. Other suitable lifting devices can also be
used.

Attach a hoist to the eyebolt, remove cap screws


securing transfer drive to engine and transmission
clutch housing.

Guide the transfer drive housing back off of dowel


pins.

REPAIR
Refer to Group 0370 and remove disconnect clutch
shaft and carrier.

Refer to Group 0851 and remove gears, shafts and 2’60883


bearings.
I-Cap Screw (10 used) 8-Lock Washer (6 used)
2-Lock Washer (10 used) 9-Pipe Plug (2 used)
Clean transfer drive housing (5, Fig. 3) thoroughly 3-O-Ring IO-Lock Washer (6 used)
and inspect for excessive wear, cracks or other dam- 4-90 Deg. Adjustable Ii-Cap Screw (6 used)
Elbow 12-Gap Screw (2 used)
age. Replace housing if necessary.
6--Transfer Drive 13-Gap Screw (4 used)
Housing 14-Gap (w/o disconnect
Drive dowel pins (6) in upper half of transfer drive 6-Dowel Pin (2 used) clutch)
housing until pins bottom out. 7-Hex Nut (6 used)

Fig. 3-Transfer Drive Housing

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transfer Drive 8
TM- I 188 (Mar-80) Housings and Covers 0841-5

INSTALLATION
Refer to Group 0851 and install gears, shafts and
bearings.

Refer to Group 0370 and install bearing carrier.

Apply John Deere Never-See2 Lubricant or an


equivalent to splines on the transfer drive input shaft
before installing. Remove excess Never-See2 from
shaft.

Hoist transfer drive housing (7, Fig. 4) on unit align-


ing splines on transfer drive input shaft with clutch disk.

NOTE: The transfer drive input shaft can be used to


align the disconnect clutch before reinstalling.

Install cap screws (1) and lock washers (2) securing


upper half of transfer drive to engine. Tighten cap
screws to 35 lb-ft (47 N-m) (5 kg-m).

Install cap screws (3) and lock washers (4) securing


lower half of transfer drive to transmission. Tighten cap
screws to 85 lb-ft (115 N.m) (12 kg-m).

Install cap screws (5) and bolts (6) and secure


transfer drive to transmission with lock washers (8, Fig.
3) and hex nuts (7). Tighten nuts to 300 lb-ft (407 N-m)
(41 kg-m).

Remove blocking securing rear of engine.

Connect disconnect clutch controls (if so equipped).

Install transfer case drain line (Fig. 1). T60684

Install oil lube line from transmission to transfer drive


l-Cap Screw (10 used) 6-Cap Screw (4 used)
housing. 2-Lock Washer (10 used) 6-Bolt (2 used)
%-Cap Screw (6 used) 7-Transfer Drive
Refer to Group 2160 and install front wheel drive 4-Lock Wash& (6 used) Housing
hydraulic pump (if SO equipped).
Fig. 4-Transfer Drive Housing Attaching
Hardware
Install fuel tank, hood, pre-cleaner and muffler.
Connect all fuel and electrical connections to fuel tank.
Refer to Group 4201 and install rear ripper and valve
(if so equipped).
Install drawbar (if so equipped).
Fill the transmission case with recommended oil, a
Connect battery ground strap.
filler cap, to dipstick level. (See Section I, Group V fo
the type of oil to use.)

IMPORTANT: Make sure that the front wher


drive pump is full of oil. Refer to Group 9016 fc
start-up procedure.

Litho in U.S.A.
8 Transfer Drive JD670-A and JD672-A Motor Graders
0841-6 Housinas and Covers TM- 1188 (Mar-801

Litho in U.S.A.
-
JD670-A and JD672-A Motor Graders Transfer Drive 8
TM- 1188 (J&78) Gears, Shafts, Bearings 085~~i

Group 0851
GEARS, SHAFTS, BEARINGS
GENERAL INFORMATION

T60886

(JD670-A) (JD67.SA)

l-Transfer Drive Housing E-Idler Shaft (2 used) a--Lower Quill


2-input Shaft 64Jpper Idler Gear 9-Dutput Gear
3-Upper Quill 7-Lower idler Gear 1 O-Drain Plug
4-Input Gear

Fig. l-Transfer Drive Unit Assembly

Litho in U.S.A.
r

8 Transfer Drive JD670-A and JD672-A Motor Graders


0851-2 Gears, Shafts, Bearings TM- 1188 (Jul-78)

Power is transferred from the engine, through en- Remove cap screw (2, Fig. 2) securing input gear to
gine clutch to the input gear (4, Fig. l), the two idler clutch drive shaft and separate parts.
gears (6 and 7), and the output gear (9) to the trans-
mission input shaft. Remove cap screws (29) securing upper and lower
idler shafts (19) to transfer housing and remove idler
The input gear in the JD672-A transfer drive unit shaft and gears.
provides power to the front wheel drive hydraulic
pump. Care must be taken to prevent loss of shims as the
idler gears are removed.
Transmission drive shaft and engine crankshaft
speeds are the same. NOTE: Transfer drive output gear (40) may be ser-
viced without removing transfer drive input gear and
REMOVAL upper and lower idler gears.

NOTE: Rear bearings in the input and output gear Remove six cap screws (31) securing lower quill
shafts may be inspected by removing hub caps. This (32) to transfer drive housing.
can be done without removing the transfer drive hous-
ing from motor grader. Remove lower quill and output gear assembly from
transfer drive housing. Be careful not to damage shim
Refer to Group 0841 and remove transfer drive pack.
housing.
IMPORTANT: After removing transfer drive unit,
Refer to Group 0370 and remove disconnect clutch do not disengage clutch disconnect as clutch disk
shaft and carrier. will fall out of alignment.

Remove six cap screws (16, Fig. 2) securing upper NOTE: The input shaft can be used to align the
quill (15) to transfer drive housing (5). clutch.

Remove upper quill, clutch drive shaft and input gear


as a unit from transfer drive housing. Be careful not to
damage shim pack.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transfer Drive 8
TM- 1188 (J&78) Gears, Shafts, Bearings 0851-3

160887

(Upper Idler and Input Gear Assembly)

(Lower Idler and Output Gear Assembly)

l-Hub Cap (2 used JD670-A) 14-Oil Seal 26-Washer (2 used)


Hub Cap (1 used JD672-A) 16-Upper Quill Assembly 29-Cap Screw (2 used)
P-Cap Screw 16-Cap Screw (6 used) 39-Lower idler Gear
3-Washer 17-Clutch Drive Shaft 31-Gap Screw (6 used)
4-Spacer i&O-Ring (2 used) 32-Lower Quill
ETransfer Drive Housing Is-Idler Shaft (2 used) 33-Oil Seal
GBearing Cup (2 used) 29-Bearing Cone (4 used) 34-Bearing Cup
7-Bearing Cone (2 used) 21-Bearing Cup (4 used) 36-Shim (as required)
&Input Gear 22-Snap Ring (4 used) 36-Shim (as required)
9-O-Ring 23-Upper Idler Gear 37-Shim (as required)
1 O-Shim (as required) 24--Spacer (2 used) 38-O-Ring
11-Shim (as required) 2%Shim (as required) 39-Bearing Cone (2 used)
12-Shim (as required) 26-Shim (as required) 49-Output Gear
Id-Bearing Cup 27-O-Ring (2 used) 41-P@ Plug

Fig. Z-Transfer Drive Gears, Shafis, and Bearings

Litho in U.S.A.
8 Transfer Drive JD670-A and JD672-A Motor-Graders
0851-4 Gears, Shafts, Bearings TM- 1188 (J&78)

REPAIR Remove bearing cup (1, Fig. 3) from upper quill (2).

Input Gear Assembly Remove bearing cones (3) from both ends of input
gear (4).
Disassembly
Remove other bearing cup (1) from transfer drive
housing.

Remove oil seal (5) from upper quill.

Inspect O-ring (6) for cuts or other damage. Replace


if necessary.

Refer to page 0851-7 for inspecting, cleaning and


handling of parts.

Assembly
Drive bearing cups (1, Fig. 3); one in transfer drive
housing and the other in upper quill (2) until cups
bottom out.

Install oil seal (5) in upper quill tight against shoulder


with spring side of seal toward bearing cup.

Install O-ring (6) on upper quill if replaced.

Press bearing cones (3) tight against shoulders on


input gear (4). Cones may be heated in oil (approxi-
mately 5 to 10 minutes) to not more than 250°F (121 “C)
to ease assembly.

l-Bearing Cup (2 used) 44nput Gear


A CAUTION: Oil fumes or oil can ignite
above 380°F (193°C). Use a thermometer
2-Upper Quill !kOil Seal and do not exceed 360°F (182°C). Do not allow a
3-Bearing Cone (2 used) 6-O-Ring flame or heating element to be in direct contact
with the oil. Heat the oil in a well-ventilated area.
Fig. 34nput Gear Assembly
Plan a safe handling procedure to avoid burns.

Protect assembly from damage and contamination.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transfer Drive 8
TM- 1188 (J&78) Gears, Shafts, Bearings 0851-S

Upper and Lower Idler Gear Assembly Remove idler shaft (8, Fig. 4) from idler gear as-
sembly.
Disassembly
Remove bearing cones (1) from idler shaft and idler
gear (6). NOTE: Keep respective shim pack (2) with
bearing cone when removed.

Spacer (3) will be free for removal.

Remove bearing cups (4) from idler gear.

Remove snap rings (5).

Inspect O-ring (7) and replace if necessary.

Refer to page 0851-7 for inspecting, cleaning and


handling of parts.

Assembly

Install snap rings (5, Fig. 4) in snap ring grooves of


idler gear (6).

Drive or press bearing cups (4) in idler gear tight


against snap rings.

Install bearing cone (1) with respective shim pack


(2). Place spacer (3) next to shim pack.

Install other bearing cone and shim pack.

NOTE: Shims may be replaced on either side of


T60890
spacer or all shims may be placed on one side of
spacer. :
0
l-Bearing Cone (4 used) 6-Upper Idler Gear
2-Shim (as required) Lower Idler Gear
3--Spacer (2 usad) 7-O-Ring (2 used)
4-Bearing Cup (4 used) &Idler Shaft (2 used)
5-Snap Ring (4 used)

Fig. 4-Upper and Lower Idler Gear Assembly

Litho in U.S.A.
8 Transfer Drive JD670-A and JD672-A Motor Graders
0851-6 Gears, Shafts, Bearings TM- 1188 (Jul- 78)

Output Gear Assembly

Disassembly

l-Idler Gear Assembly 4-Bearing Cone


24dler Shaft CWasher (2 used)
3-2 in. x 2 in. S-Bolt
(51 mm) Pipe 7-Nut

Fig. 5-Adjusting Idler Gear End Play

Adjust upper and lower idler gear bearings outside


of transfer drive housing.
l-Bearing Cup (2 used) S-Lower Quill
2-Bearing Cone (2 used) S-Oil Seal
Install idler shaft (2, Pig. 5) in idler gear assembly 3-Output Gear 7-Pipe Plug
(1). Place a 2 in. diameter pipe (3), 2 in. (51 mm) long 4-O-Ring
over idler shaft. Install a long bolt (6) with a 2 in.
: fig. d-Output Gear Assembly
a diameter washer (5) through idler shaft. Install another
washer on end of bolt and secure assembly with nut
(7). Place idler assembly in a vise.

Start with a shim pack that provides a measurable


amount of end play.

Tighten nut and adjust end play to 0.002 + 0.002 in.


(0.05 2 0.05 mm) by removing or adding shims. Rotate
idler gear while tightening.

After adjustment keep shim pack with respective


idler gear for installation.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transfer Drive 81
TM- 1188 (Jul- 79) Gears, Shafts, Bearings 0851-7 1

Remove bearing cups (1, Fig. 6) from lower quill (5) Cleaning, Handling and Inspecting i
and transfer housing.
Parts which have close operating tolerances must
be handled carefully to prevent nicking, scratching, or
Remove bearing cones (2) from both ends of output
denting. The slightest damage to these parts can result
gear (3).
in erratic operation and possible malfunction of the
transfer drive. These parts should be carefully handled
Remove pipe plug (7) from end of output gear.
and protected during removal, cleaning, inspection,
and installation.
Remove oil seal (6) from lower quill.

All parts must be clean to permit effective inspection.


Inspect O-ring (4) for cuts or other damage. Replace
During assembly, it is very important that no dirt or
if necessary.
foreign matter enters the transfer drive. Even minute
particles can cause the malfunction of close-fitting
Refer to this page for inspecting, cleaning and han-
parts.
dling of parts.

All metallic parts (except bearings) should be


Assembly
cleaned thoroughly with volatile mineral spirits, or by
Drive bearing cups (1, Fig. 6) one in transfer housing the steam-cleaning method. Do not use a caustic soda
and the other in lower quill (5) until cups bottom out. solution for steam cleaning. Gum and varnish deposits
should be removed by allowing the parts to soak in
install oil seal (6) in lower quill tight against shoulder varnish remover.
with spring side of seal toward bearing cup.
Parts should be dried with compressed air. Steam-
Install O-ring (4) on lower quill if replaced. cleaned parts should be oiled immediately after drying.

Press bearing cones (2) tight against shoulders on Clean oil passages by working a piece of soft wire
gear (3). Cones may be heated in oil (approximately 5 back and forth through the passages and flushing with
to 10 minutes) to not more than 250°F (121°C) to ease spirits. Dry the passages with compressed air.
assembly.
After cleaning, examine the parts and especially the

A CAUTION: Oil fumes or oil can ignite


above 380°F (193°C). Use a thermometer
oil passages to make certain they are entirely clean.
Reclean them, if necessary.
and do not exceed 360°F (182°C). Do not allow a
flame or heating element to be in direct contact Bearings that have been in service should be
with the oil. Heat the oil in a well-ventilated area. thoroughly washed in volatile mineral spirits.
Plan a safe handling procedure to avoid burns.
Before inspection, oil the bearings with the same
Install pipe plug (7) in end of output gear using a type of oil that will be used in the transfer drive.
non-hardening pipe joint compound. Remove excess
compound. NOTE: Never spin dry bearings with compressed 1
air. Do not rotate bearings while they are not lubricat-
Protect assembly from damage and contamination. ed.

Litho in U.S.A.
8 Transfer Drive JD670-A and JD672-A Motor Graders
0851-8 Gears. Shafts. Bearinas TM- 1188 (Dee-87)

Inspect bearings for roughness of rotation. Replace INSTALLATION


a bearing if its rotation is still rough after cleaning
and oiling. Output Gear Assembly
Install the output gear assembly (1, Fig. 7) into
Inspect bearings for scored, pitted, scratched,
transfer drive housing (2).
cracked or chipped races, and for indication of exces-
sive wear of rollers. If one of these defects is found,
Install shim pack (3) between housing and lower
replace the bearing.
quill (4). Measure and record end play.

Inspect the defective bearing’s housing and shaft


IMPORTANT: To avoid damaging O-ring (19)
for grooved, burred, or galled conditions that indicate
remove it from lower quill while adjusting end play.
the bearing has been turning in its housing or on its
shaft. If the damage cannot be repaired with crocus
Tighten lower quill cap screws (5) securely.
cloth, replace the defective parts.
Measure and adjust end play to 0.002 Y! 0.002 in.
Inspect lip-type oil seals for cuts and hardness.
(0.05 * 0.05 mm) by removing or adding shims
Replace the oil seals if these defects are found.
between housing and quill.

When replacing lip-type oil seals, make sure the


Install O-ring (19) on lower quill and tighten cap
lip of each oil seal is toward the oil to be sealed
screws (5) to 35 lb-ft (47 N-m) (5 kg-m).
(toward the inside of the unit). Use a nonhardening
seal compound on the outside of the seal to help
Idler Gear Assemblies
prevent oil leaks. Coat the inside of the seal with high
temperature grease (AT30408 or equivalent) to protect Install lower idler gear assembly (6, Fig. 7) and its
the seal during shaft installation and to provide shims in transfer drive housing. Care must be taken
lubrication during initial operation. to prevent shims from dropping out of position.

Inspect gears for scuffed, nicked, burred, or broken Install idler shaft (7) with a twisting motion to aid in
teeth. If the defect cannot be removed with a soft starting shims onto shaft. If shaft does not go in
honing stone, replace the gear. easily, remove shaft and check for shims out of
alignment or burrs on end of shaft.
Inspect gear teeth for wear that may have destroyed
the original tooth shape. If this condition is found, IMPORTANT: Do not drive shafts into position.
replace the gear.
Install O-ring (8) on cap screw (10) and secure
Inspect the thrust faces of gears for scores, idler shaft with washer (9) and cap screw. Tighten
scratches, and burrs. Remove such defects with a cap screw.
soft honing stone.
Using the same procedure, install the upper idler
Lubricate all O-rings with John Deere Multi-Purpose gear assembly.
Grease or an equivalent before installing.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transfer Drive a
l-AA-i fI)Q / II II-7R I Gears, Shafts, Bearings 0851-9

l-Output Gear Assembly


P-Transfer Drive Housing
3-Shims (use as required)
4-Lower Quill
+-Cap Screw (6 used)
6-Lower Idler Gear Assembly
Upper Idler Gear Assembly
7-Idler Shaft (2 used)
6-O-Ring (2 used)
O-Special Washer (2 used)
t6-Cap Screw (2 used)
II-Clutch Drive Input Shaft
1 a-Input Gear Assembly
13-Spacer
14-Washer
X-Special Cap Screw
16-Shims (use as required)
17-Upper Quill
16-Gap Screw (6 used)
19-O-Rings (2 used)
26-Hub Cap (2 used on JD670-A)
Hub Cap (1 used on JD672-A)

Fig, 7-Installing Gears, Shafts and Baarings

Litho in U.S.A.
8 Transfer Drive JD670-A and JD672-A Motor Graders
0851-10 Gears, Shafts, Bearings TM- 1188 (Dee-87)

Input Gear Assembly


install clutch drive input shaft (11, Fig. 7) in input
gear assembly (12). Install spacer (13).

Secure clutch drive input shaft to input gear with


washer (14) and cap screw (15). Tighten cap screw
to 35 lb-ft (47 N-m) (5 kg-m).

Install input gear and clutch drive shaft and upper


quill (17) in transfer drive housing.

Install shim pack (16) between housing and upper


quill (17). Measure and record end play.

IMPORTANT: To avoid damaging O-ring (19)


remove it from upper quill while adjusting end play.

Tighten upper quill cap screws (18) securely.

Measure and adjust end play to 0.002 & 0.002 in.


(0.05 AI 0.05 mm) by adding or subtracting shims
1-2.91 * 9.94 in. 2-Searing Tube
between housing and quill. (74 f 1 mm) 3-Clutch Drive Input
Shatt
Install O-ring (19) on quill and tighten cap screws
(18) to 35 lb-ft (47 N.m) (5 kg-m). Fig. 8-Installing Bearing Tube

Coat outside surface of hub caps (20) with Perma- Pack spline bore of output gear (1, Fig. 7) with
tex No. 2 Sealer or an equivalent before assembly. John Deere Never-See2 Lubricant or an equivalent.
Press hub caps into transfer drive housing.
Refer to Group 0370 and install disconnect clutch
Install bearing tube (2, Fig. 8) on clutch drive input shaft and carrier.
shaft (3) per dimension (1) to insure that end of tube
does not rupture oil seal. Lightly coat external spline end of clutch drive
input shaft (11) end which engages disconnect clutch
assembly, with John Deere Never-See2 Lubricant or
an equivalent.

Refer to Group 0841 and install transfer drive


housing.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transfer Drive 8
TM- 1188 (J&78) Specifications and Special Tools 0899-l

Group 0899
SPECIFICATIONS AND SPECIAL TOOLS
HOUSINGS AND COVERS
SPECIFICATIONS AND TORQUE VALUES

1. Drive dowel pins to bottom of bore in


upper half of transfer drive housing.

T40780N

Fig. l-Transfer Drive Housing

Litho in U.S.A.
8 Transfer Drive JD670-A and JD672-A Motor Graders
0899 -2 Specifications and Special Tools TM- 1188 (J&78)

HOUSINGS AND COVERS


‘SPECIFICATION AND TORQUE VALUES-Continued
1 - Transfer drive housing-
to-engine cap screws . . . . . . , . . . . 35 lb-ft
(47 Nm) (5 kg-m)

2 - Transfer drive housing-to-


transmission l/2 in. cap screws . . . . . . . 85 lb-ft
(115 Nm) (12 kg-m)

3 - Transfer drive housing-to-


transmission 3/4 in. cap
screws and bolts .... ...... . . 300 lb-ft
(407 Nm) (41 kg-m)

I%-0885

F@. P-Transfer Drive Unit Attaching Hardware

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Transfer Drive 8
TM- 1188 (J&78) Specifications and Special Tools 0899-3

GEARS, SHAFTS, BEARINGS


SPECIFICATIONS ANDTORQUEVALUES
1. Upper and lower idler
gear end play . . . . . . .... 0.002 +- 0.002 in.
(0.05 2 0.05 mm)

T37552N

1. Press bearing cones and cups into


position with a minimum force of . . 5000 Ibs.
(22 250 N) (2 268 kg)

2. Input and output gear


end play . . . . . .. . . 0.002 & 0.002 in.
(0.05 2 0.05 mm)

3. Upper and lower quill-to-transfer


drive housing cap screws.. . . . . . . . 35 lb-ft
(47 Nm) (5 kg-m)

4. Clutch drive shaft-to


input gear.. . . . . . . . . . . . . . . . . . 35 lb-ft
(47 Nm) (5 kg-m)

T40781N
Fig. 4-Transfer Drive Gears, Shafts, Bearings

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8 Transfer Drive JD670-A and JD672-A Motor Graders
0899-4 Specifications and Special Tools TM-l 188 (J&78)

GEARS, SHAFTS, BEARINGS


SPECIFICATIONS AND TORQUE VALUES-Continued

1 - Bearing Tube to extend from


second step of upper quill.. . . .2.91 + 0.04 in.
(74 + 1 mm)

Fig. 5-Bearing Tube

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JD670-A and JD672-A Motor Graders Steering System 9
TM- 1188 (Jul-79) Power Steerina 0920-l

Section 9
STEERING SYSTEM
CONTENTS OF THIS SECTION

Page Page
GROUP 0920 - POWER STEERING GROUP 0960 - HYDRAULIC SYSTEM-Continued
General Information . . . . ... .. 0920-3 Wheel Lean Valve and Rear Steer Valve
Removal . . . . ..... . ... 0920-3 General Information .................. 0960-8
Repair Removal ............................ 0960-9
Disassembly................... 0920-4 Repair ............................. 0960-I 0
Assembly . . . ... . . . 0920-4 Installation. ......................... 0960-l 3
Installation . . . . .. . ... 0920-5 Wheel Lean Valve Linkage
Checking Toe-in ... . ...... . 0920-6 Removal ........................... 0960-l 4
Toe-in Adjustment.. . .. ..: 0920-8 Repair ............................. 0960-14
Installation. ......................... 0960-l 4
GROUP 0960 - HYDRAULIC SYSTEM Cylinders
Steering Valve General Information ................. 0960-l 5
General Information .... . . . . 0960-l Removal ........................... 0960-l 5
Removal . . . ..... . 0960-2 Wheel Lean Cylinder .............. 0960-15
Repair Front Steer Cylinder ............... 0960-16
I Disassembly................... 0960-2 Rear Steer Cylinder ............... 0960-16
I Assembly ._ ... . . 0960-4 Repair ............................. 0960-I 7
Installation. . . .. . . 0960-5 Installation ......................... 0960-20
Steering Shaft and Tube
Removal . . . .. . . 0960-6 GROUP 0999 - SPECIFICATIONS AND
Repair . . . . . . . .._................ 0960-6 SPECIAL TOOLS
Installation. . ... . 0960-6 Specifications and Torque Values
Rear Steer Linkage Power Steering ...................... 0999-l
Removal . . . . . . . . _. 0960-7 Hydraulic System .................... 0999-2
Repair . . . . . . . . . . . . .._........... 0960-7 Special Tools
Installation. . . . .... . 0960-7 Hydraulic System .................... 0999-5

,Litho in U.S.A.
9 Steering System JD670-A and JD672-A Motor .Graders
0920-2 Power Steering TM- 1188 (Jul-79)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Steering System 9
TM- 1188 (J&78) Power Steering 0920-3

Group 0920
POWER STEERING
GENERAL INFORMATION
A bell crank assembly and tie rods provide means
for steering with the use of one steering cylinder.

Proper adjustment of tie rods can be made to obtain


a correct toe-in adjustment.

REMOVAL
Refer to Fig. 1 in disconnecting tie rod from either
the spindle (JD670-A) or the motor housing (JD672-A).

Remove cap screw (3, Fig. 1) and drive out pin (2).
Swing tie rod (1) away from its mounting.

Disconnect tie rod from other wheel assembly.

(JD670-A Tie Rod-To-Spindle)

(JD672-A Tie Rod-To-Motor Assembly)

l-Tie Rod (2 used) 4-Connector (2 used)


P-Pin (2 used) 5-Cap Screw (2 used)
f-Cap Screw (2 used) 6-Outer Yoke Pin (2 used)

Fig. l-Removing Tie Rods

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9 Steering System JD670-A and JD672-A Motor Graders
0920-4 Power Steering TM- 1188 (Jul- 78)

REPAIR
Disassembly
Remove cap screws (13, Fig. 3) and drive out inner
yoke pins (12). Remove tie rods from bell crank (6).

Remove cap screws (21) and drive out outer yoke


pins (18) from outer yokes (19).

Remove outer and inner yokes (14 and 19) from tie
rods (16).

Inspect bushings (4 and 5) for wear or damage.


Remove cap screws (24) when replacing the self-
aligning bushings (5).

Inspect bell crank (6) and yokes for cracks, wear or


other damage.
l-Cap Screw 4-Bell Crank Pin
P-Steering Cylinder Pin !+-Bell Crank Inspect pins and tie rods for worn or bent conditions.
3-Steering Cylinder

Replace parts as necessary.


Fig. P-Removing Bell Crank

Remove cap screw (1, Fig. 2) and drive out steering


Assembly
cylinder pin (2). Retract steering cylinder until it clears Install self-aligning bushings (5, Fig. 3) in bell crank
bell crank (5). (6) and secure with cap screws (24), washers (25) and
special nuts (10).
Remove cap screw from bell crank pin (4).
Drive bushings (4) flush with top and bottom of bell
Install a slide hammer or an equivalent in thread crank.
hole of bell crank pin and remove the pin.
Coat threads of outer yokes (19) and inner yokes
Remove bell crank (5) with tie rods as an assembly. (14) with John Deere Multi-Purpose grease or an
equivalent before assembly. Install yokes in tie rod
(16).

Align inner yokes to bell crank and install inner yoke


pins (12). Secure with cap screws (13) and nuts (10).

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Steering System 9
TM- 1188 (Jul-79) Power Steering 09204

10

T59933N

l-Grease Fitting (2 used) g--Special Nut (5 used) 17-L. H. Thread Nut (2 used)
P-Cap Screw 18-Special Nut (11 used) 18-Outer Yoke Pin (2 used)
3-Cap Screw 11-Grease Fitting (6 used) 19-Outer Yoke (2 used)
4-Bushing (2 used) 12-Inner Yoke Pin (2 used) PO-Connector (2 used)
5-Self-Aligning Bushing (2 used) If-Cap Screw (2 used) Ii-Cap Screw (2 used)
6-Bell Crank U-Inner Yoke (2 used) 22-Cap Screw (2 used)
7-Bell Crank Pin 15-R. H. Thread Nut (2 used) 23-Pin (2 used)
8--Steering Cylinder Pin 16-Tie Rod (2 used) 24-Cap Screw (2 used)
25-Washer (2 used)

Fig. 3-Bell Crank and Tie Rod Assembly

Align outer yokes (19, Fig. 3) with connector (20) so Align outer yokes with either the spindles (JD670-A)
grease fittings (11) are accessible and install outer or motor housings (JD672-A).
yoke pins (18). Secure with cap screws (21) and nuts
(10). Drive in,pin (23, Fig. 3) and secure with cap screws
(22) and nuts (10).
INSTALLATION
Grease all fittings before operation.
Position bell crank with tie rods assembly to front
axle. Install bell crank pin (7, Fig. 3) and secure with Refer to page 0920-6 for checking toe-in and page
cap screw (3) and nut (10).
0920-8 for the toe-in adjustment.

Position steering cylinder rod so steering cylinder


pin (8) can be installed. Secure with cap screw (2) and
nut (10).

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9 Steering System JD670-A and JD672-A Motor Graders
0920-6 Power Steerina TM- 1188 (Jul-79)

CHECKING TOE-IN JD670-A _ Turn wheels to align the steering cylinder


pin (1, Fig. 4) with the oscillation pin (2).
Position the unit on level ground or work floor.
or
Use the blade or scarifier hydraulics to lift the front
wheels off the ground. Securely block under the front
JD672-A - Draw a line through the center of plate (1,
axle.
Fig. 5) and through the center of bell crank
(2). Turn the wheels to align these two
lines.

Measure the distance (A, Fig. 6) from center to


center of tie rod pins. Measure the distance (B) from
center to center of tie rod pins. The measurement
between the two dimensions must be within 0.10 in.
(2.5 mm).

Measure the distance (C) and (D) from the floor (1)
to the center of the axle. Record measurement of each
side.

Use a piece of chalk and draw a horizontal line (2)


on the backside of each tire at the “C and D” height.
Draw a vertical line (3) through the horizontal line at the
approximate center of each tire. (See photo A)

2-Oscillation Pin
Measure and record the distance (E) between the
l-Steering Cylinder Pin
tire center lines at the “C and D” axle height.
Fig. 4-JD670-A Bell Crank Alignment
Now rotate the tires toward the front of the unit so
the horizontal lines (2) on the tires are again at the “C
and D” height. (See photo B)

Measure and record the distance (F) between the


tire center lines at the “C and D” axle height.

Distance “F” must be 0.0 to 0.50 in. (0.0 to 13 mm)


less than distance “E”.

If the unit does not fall within the above specification,


turn to page 0920-8 for the toe-in adjustment proce-
dure.

l-Axle Centerline 2-Bell Crank Centerline

Fig, 5-JD672-A Be// Crank Alignment

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Steering System --~ 9
TM- 1188 (Jul-79) Power Steerina 0920-7

Photo A (Rear View of Front Axle) Photo 8 (Front View of Front Axle)

l-Ground or Floor Line 2-Horizontal Centerline 3-Vertical Centerline

Fig. 64ocating Centerlines (JD670-A shown)

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9 Steering Sys tern JD670-A and JD672-A Motor Graders
0920-8 Power Steering TM- 1188 (Jul- 79)

TOE-IN ADJUSTMENT
The toe-in check on page 0920-6 must be done
before the toe-in adjustment can be made.

To adjust toe-in, loosen the tie rod nuts (2, Fig. 7)


and turn both tie rods (1) equally until toe-in is correct.
Tighten the nuts to 330 lb-ft (447 Nm) (45 kg-m).

After adjustments are made, steer front wheels to


the stops both ways and check for interferences.

(JD670-A shown)

l-lie Rod 2-Adjusting Nut

(JD672-A shown)

Fig. 7-Tie Rod and Adjusting Nut

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Steering System 9
TM- 1188 (Jul- 79) Hydraulic System 0960-l

Group 0960
HYDRAULIC SYSTEM
STEERING VALVE
GENERAL INFORMATION Neutral Position
Whenever the steering wheel is not moving, the
steering valve assumes the neutral position. In this
position the spool and sleeve are lined up in such a
way that oil flow through the valve is blocked. Oil can
neither flow from the pump through the valve nor can it
flow from the steering cylinder through the valve.

Left or Right Hand Turn


As the steering wheel is turned the valve spool is
turned by means of its direct connection to the steering
shaft. This movement aligns the valve spool passages
with the sleeve ports and pressure oil flows through the
valve.

Manual Steering
If there is no power to supply pressure oil to the
valve, the unit can be steered manually. When the
steering wheel is turned, the spool directs oil as de-
FIQ. l-Steering Valve
scribed above. If no pressure oil is available, the spool
will come into contact with the centering pin. The pin
The steering valve (Fig. 1) consists of a rotary spool then provides a direct mechanical connection to the
and sleeve assembly located inside the valve housing gerotor gear. As the gerotor is turned it pumps oil to the
with a gerotor at the end of the assembly. steering cylinder. Return oil from the cylinder is drawn
through a check valve between the inlet and outlet
ports to provide oil for manual steering operation. Thus
the unit can be steered manually until the grader is
brought to a stop.

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9 Steering System JD670-A and JD672-A Motor Graders
0960-2 Hydraulic System TM- 1188 (Jul- 79)

REMOVAL REPAIR

A CAUTION: Escaping fluid under pressure


can have sufficient force to penetrate the
Disassembly
skin, causing serious personal injury. Before dis- IMPORTANT: Before starting to disassemble
connecting lines, be sure to relieve all pressure. the steering valve be sure that the working area
Before applying pressure to system, be sure all and tools are absolutely clean.
connections are tight and that lines, pipes and
hoses are not damaged. Fluid escaping from a very The steering valve itself should be free of dirt and
small hole can almost be invisible. Use a piece of grease. Use a solvent to clean oil and grease from
cardboard or wood, rather than hands, to search valve. Also clean all paint from metering end of valve
for suspected leaks. so that no paint flakes will enter these closely fitted
parts during assembly.
If injured by escaping fluid, see a doctor at once.
Serious infection or reaction can develop if proper Do not use a shop cloth to clean parts. Lint deposits
medical treatment is not administered immediate- can disrupt a function or cause leaks. The parts should
ly- be rinsed clean in solvent and blown dry with an air
hose. Then place all parts on a clean lint free paper 1
Relieve pressure in hydraulic system by operating towel.
steering valve and brake valve with engine shut off.

Remove right-hand and left-hand side panels from


control console.

Remove cowl cover.

Disconnect and cap hydraulic lines from the steering


valve.

Remove the steering mounting cap screws.

Lift up and pull out steering wheel, tube and valve.

NOTE: Steering wheel, tube and valve are to be


removed as a complete unit.

1-Geroter Assembly 4-Cap Screw (7 used)


l-spacer Plate 5-O-Ring
3-Valve Housing GEnd Cap

Fig. P-Steering Valve Disassembly

Remove the seven special screws (4, Fig. 2) and


remove end cap (6) with O-ring (5).

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JD670-A and JD672-A Motor Graders Steering System 9
TM- 1188 (Jul- 79) Hydraulic System 0960-3

l-Valve Horising 6-End Cap


2-O-Ring (3 used) 6-Drive Shaft I-Valve Housing 7-Control Sleeve
*Control Sleeve 7-Geroter Assembly 2-O-Ring (3 used) 8-Centering Spring (6 used)
4-Cap Screw (7 used) S-Spacer 3-Cap Screw (7 used) 9-Geroter Assembly
. g--Spacer Plate &-End Cap lo--Pin
6-Drive Shaft 1 l-Spacer
fig. 3-Steering Valve Disassembly B-Control Spool 12-Spacer Plate

Carefully lift geroter assembly (7, Fig. 3) drive shaft Fig. 4-Steering Valve Disassembly
(6), spacer (8), and spacer plate (9).
Remove centering pin (10, Fig. 4).
NOTE: Remove spool and sleeve assembly only
when necessary. Tolerance in this area is very close Push the spool (6) so that it moves toward the
and when replacement is necessary the housing, spool splined end and remove it carefully from sleeve (7).
and sleeve must be ordered as a matched set. Rotate the spool slightly as you remove it. Push the
centering spring set (8) out of the spring slots in the
IMPORTANT: Always remove spool and sleeve spool.
assembly from the 14-hole end of the housing.

If it is necessary to disassemble the housing, spool,


and sleeve,assembly, be careful to prevent these parts
from binding. They are very closely fitted and must be
rotated slightly as they are withdrawn.

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9 Steering System JD670-A and JD672-A Motor Graders
0960-4 Hydraulic System TM- 1788 (Jul- 79)

l-Valve Housing 9-Geroter Assembly 17-Oil Seal


a--Cap Screw (7 used) 19-Pin 18-Quad Ring Seal
3-O-Ring (3 used) il-Thrust Race Is-Check Ball Seat
4-End Cap 12-Needle Thrust Bearing 28-Check Ball
5-Drive Shaft K&Thrust Race Pl-Check Ball Retainer
B-Control Spool 14-Spacer 22-Set Screw
T-Control Sleeve 15-Seal Gland Bushing 23-O-Ring (2 used)
&Centering Spring (6 used) 16O-Ring 24-Retaining Ring
25-Spacer Plate

Fig. 5-Steering Valve Disassembly

Remove set screw (22, Fig. 5) to remove check ball Remove snap ring (24, Fig. 5) and remove gland
seat (19), check ball (20) and check ball retainer (21). bushing (15), thrust races (11 and 13) and needle
bearing (12).

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Steering System 9
TM- 1188 (Jul- 79) Hydraulic System 0960-5

Assembly
NOTE: Replace all seals when assembling valve.
Clean valve parts thoroughly before assembly.

Install check ball retainer (21, Fig. 5), ball (20) and
ball seat (19) with new O-rings into housing (1). Install
set screw (22), flush or below mounting surface, and
tighten to 100 lb-in. (11.3 Nm) (1.15 kg-m).

Install O-ring (16) into housing.

Install gland bushing (15) with quad ring seal (18)


and oil seal (17). Install retaining ring (24).

Install thrust races (11 and 13) and needle bearing


(12) in housing.

If spool and sleeve assembly were disassembled,


install spool (6) in sleeve (7) carefully so that the spring
slots of both parts are at the same end. Coat both parts
with a film of oil and rotate while sliding parts together.
l-Geroter Star 2-Drive Shaft Timing Mark
Check spool and sleeve for free rotation. The spool
should rotate smoothly in sleeve when fingertip force is Fig. 6-Timing Geroter Star Gear And
applied at the splined end. Drive Shaft

Insert spring installation tool (60057) through both Install the drive shaft (5, Fig. 4) into the housing
spool and sleeve spring slots. Enter one end of spring making sure the cross slot in the control end of the
set into tool. Compress the other end of spring set and housing engages with the pin (10).
draw into place through the spool and sleeve.
Install the geroter assembly (9) onto the drive shaft
Install cross pin (10) until it is flush or slightly below and spacer plate.
diameter of sleeve.
NOTE: Place the geroter assembly onto the drive
Install spool and sleeve assembly so the splined end shaft so that the timing mark (2, Fig. 6) is in alignment
of the spool enters the fourteen hole end of the housing with one of the valleys on the geroter star (I). There
first. Rotate spool and sleeve assembly gently during are twelve teeth on the splined and six pump lobes on
assembly. the star. This means there are six possible correct
timing positions. If the parts slip during assembly re-
Install new O-ring (2, Fig. 4) on housing. peat timing procedure.

Place the spacer plate (12) on the steering motor


housing so that the bolt holes in the plate align with the
tapped holes in the housing. Install new O-ring in
geroter. Place the geroter section outer gear on the
spacer plate so that the bolt holes align.

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9 Steering System JD670-A and JD672-A Motor Graders
0960-6 Hydraulic System TM- 1188 (Jut- 791

Place the spacer (14, Fig. 5) in the end of the geroter STEERING CHECK VALVE
star. If the spacer does not drop flush with the gear
The steering check valve is located in the inlet port
surface, the drive has not properly engaged centering
of the steering valve. It prevents pressure spikes which
pin.
may be created in the steering circuit from passing to
the pressure control valve. A pressure spike in the
Install new O-ring (3) on end cap (4).
steering circuit might be caused by the front wheels
striking an object while turning.
Place the end cap over the assembly. Install two cap
screws finger tight to maintain alignment of the parts.
Install the remaining cap screws and tighten them
uniformly and alternately to 250 lb-in. (28 Nm) (3
kg-m).

INSTALLATION
Position steering valve assembly against the upper
steering tube in the unit. Rotate the steering wheel
while bringing the steering valve into contact with the
mounting surface. Install four cap screws and tighten to
250 lb-in. (28 Nm) (3 kg-m).

Connect all the hydraulic lines to the valve.

Start the engine. Cycle steering and check for leaks


at the line connections and in the steering valve hous-
ing joints.

Install side panels to cowl.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Steering System 9
TM- 1188 (Jul- 79) Hydraulic System 0960-7

STEERING SHAFT AND TUBE Disconnect rear steer linkage from rear steer con-
trol. Remove rear steer control and bushings from
REMOVAL steering shaft.

Remove snap rings (7), retaining ring (8) and bear-


ing (9).

Slide steering shaft (6) out of tube (10).

To remove tube, remove right-hand and left-hand


side panels from control console. Remove cap screws
and hydraulic tubes on steering valve. Remove valve
and tubes.

REPAIR
Inspect steering shaft (6) and bearing (9). Replace
as necessary.

INSTALLATION
Install tube (1.0, Fig. 7) and valve and tighten cap 1
screw with 250 lb-in. (28 Nm) (3 kg-m).

Slide steering shaft (6) into tube and make sure


l’59343N splines match up with spline in steering valve.

l-Emblem 7-Snap Ring (2 used) Install first snap ring (7), bearing (9), retaining ring
2-O-Ring &Retaining Ring
(8) and second snap ring (7).
3-Special Nut g-Bearing
4-Special Lock Washer VI-lube
5-Steering Wheel ll-Cap Screw (4 used) Install steering wheel (5) and tighten special nut (3)
6-Steering Shaft 12-Lock Washer (4 used) with 50 lb-ft. (68 Nm) (7 kg-m).

I Fig. 7-Steering Wheel and Shaft Bend two tabs of washer upwards against flat of nut.
Coat steering wheel shaft, nut and washer with JDM
I Remove emblem (1, Fig. 7) and special nut (3). G2B Rust Preventative or equivalent, undiluted prior to
installing steering wheel emblem.
Remove steering wheel (5).
Install emblem.

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9 Steering System JD670-A and JD672-A Motor Graders
0960-8 Hydra u/k Sys tern TM- 1188 (Jul- 79)

REAR STEER LINKAGE


REMOVAL
Remove steering wheel.

Remove panel from right-hand side of control con-


sole.

Disconnect rear steer linkage from rear steer con-


trol.

Slide rear steer control (3, Fig. 8) and bushings (1)


off steering shaft.

To remove linkage from control valve, remove shield


on main frame right in front of windshield.

REPAIR
Inspect all parts and replace as necessary.

If the rear steer cable needs replacing, secure the


new cable to the end of the old cable. As the old cable
is pulled out, the new cable will be pulled through and / TN359
be properly routed.
l-Bushing (2 used) 8-Joint, Ball
INSTALLATION 2-Knob, Control (2 used) O-Nut, 5/l 6”
3-Control, Rear Steering 1 O-Pin, Cotter,
Slide bushings and steering control on steering 4-Screw, Cap, 3/8” x 1” 3/32” x l/2”
shaft. 5-Link, Coupler 1 l-Plate, Pivot
GRod, Rear Steer 12-Bushing
7-Washer, Special 13-Nut, 318”
Install steering wheel and tighten nut with 50 lb-ft (68
Nm) (7 kg-m). Fig. b-Rear Steer Linkage

Connect linkage to rear of steer control and valve. Adjust linkage until the centerline between the two
knobs (2) is perpendicular to the ground.

Install shield on main frame and pane! on right-hand


side of control console.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Steering System 9
TM- 1188 (Jul- 79) Hvdraulic Svstem 0960-9

WHEEL LEAN VALVE


AND REAR STEER VALVE
GENERAL INFORMATION The wheel lean and rear steer valves are part of a
stack type control valve assembly mounted in the
control console (Fig. 9). I

The control valve assembly is of the closed-center


design. The assembly consists of nine valve sections,
an end plate and a port plate held together by four tie
bdts.

l-Tie Bolt (4 used) 7-Blade Side-Shift


2-End Plate B-Blade Rotation
3-Right-Hand Blade Q-Circle Side Shift
Lift lo--Blade Tilt
4-Left-Hand Blade Lift 1 l-Front Mounted
5-Wheel Lean Equipment
6-Rear Steer 12-Port Plate

Fig. IO-Control Valve Assembly

Orifice plates are located in the top and bottom work


ports of the wheel lean valve. No orifice plates are used
l-Control Valve 2-Plug (3 used)
in the rear steer valve. The orifice plates are installed
with the slotted side facing out. Each orifice plate is
I Fig. 9-Control Valve Assembly Location stamped with a number for identification.

The inlet and outlet ports are in the port plate (12) on
the left-hand end of the valve assembly.

Litho in U.S.A.
9 Steering System JD670-A and JD672-A Motor Graders
0960-10 Hydraulic System TM- 1188 (Jul- 79)

REMOVAL Remove left-hand and right-hand control console


covers and front covers.

A CAUTION: Escaping fluid under pressure


can have sufficient force to penetrate the Disconnect battery ground strap and then remove
skin, causing serious personal injury. Before dis- fuse block.
connecting lines, be sure to relieve all pressure.
Before applying pressure to system, be sure all Disconnect control linkage from valve spools.
connections are tight and that lines, pipes and
hoses are not damaged. Fluid escaping from a very Remove oil lines and cap.
small hole can be almost invisible. Use a piece of
cardboard or wood, rather than hands to search for Remove plugs (2, Fig. 9) from control console. Re- I
leaks. move the three valve mounting cap screws.

If injured by escaping fluid, see a doctor at once. Slide the valve assembly out the left side of control
Serious infection or reaction can develop if proper console.
medical treatment is not administered immediate-
ly.

Relieve pressure in hydraulic system by turning


steering wheel and operating brake pedals until no
response is felt. Due to lockouts in control valve as-
sembly, pressure in lines between cylinders and con-
trol valve cannot be relieved by operating control
levers. To relieve pressure slowly, crack fittings in lines
at control valve.

NOTE: If mo tor grader is left outside in cold weather


and then brought in to shop for repair, thermal lock may
take p/ace. Thermal lock is caused by trapped oil
expanding in the lines between control valve and cyi-
inder. As oil expands due to temperature change, it
causes trapped oil pressure to rise above system
pressure. When this takes place it is impossible to
operate function. To remedy this, crack a fitting be-
tween cylinder and control valve affected.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Steering System 9
TM-l 188 (Dee-87) Hydraulic System 0960-l 1

REPAl R

Disassembly

l-Dust Seal g--Spring (2 used) 16-Steel Ball 23-Bushing


l--Machine Screw (2 used) lo-Poppet (2 used) 17-Spring 24-Steel Washer (2 used)
3-Dust Seal Retainer 1 l-Seat (2 used) l&O-Ring 25-Spool Spacer
4-Breather Washer 12-O-Ring (2 used) 19-O-Ring 26-Centering Spring
5-Plug (2 used) 13-Plunger Assembly (2 used) 20-Spool Plug 27-Spool Screw
6-O-Ring (2 used) 14-Valve Housing 21-O-Ring 28-Cap Assembly
7-Backup Washer (2 used) 15-Spool 22-O-Ring
a-O-Ring (2 used)

Fig. 1 l-Wheel Lean and Rear Steer Control Valves

Refer to exploded view (Fig. 11) to disassemble Remove spool screw (27, Fig. 11) and spool
and assemble control valve. centering spring (26).

Remove the four tie bolts (1, Fig. 10) to separate Remove spool plug (20) spring (17) and steel ball
the valve assembly. (16).

Do not lose orifice plates when servicing valves. Remove plug assembly (5, Fig. 11) and poppet (10).

Remove machine screws (2, Fig. ll), dust seal Push one of the plunger assemblies (13) into valve
retainer (3) dust seal (1) and breather washer (4) against the other plunger assembly.
from valve housing (14).
NOTE: If plunger assembly cannot be pushed
Remove cap assembly (28) and pull spool assembly against other plunger assembly, pull assembly and
from valve housing. seat out of end of valve. Use small brass rod to drive
out remaining plunger and seat.

Litho in U.S.A.
9 Steering System JD670-A and JD672-A Motor Graders
0960-12 Hydraulic System TM- 1188 (Jul- 79)

Inspect all parts for wear, scoring or breakage. Re- Assembly


place as necessary. If spool or valve housing is dam-
Install all new O-rings and backup washers dipped
aged replace valve section.
in clean hydraulic oil before assembly.

Check that plunger assemblies are free of all foreign


Refer to Fig. 11 and install plunger assemblies and I
material.
seats.

Check that breathers in cap assemblies are free of


Use John Deere Loctite Cleaner and Cure Primer to
paint.
clean the threads and John Deere Loctite Thread’ Lock
and Sealer (Medium Strength) or equivalent to coat the
Check springs for fatigue. Replace as necessary.
threads before installing the following parts.

Spring (9, Fig. 11)


Tighten spool plug (20, Fig. 11) to spool (15) to 5 to 8 1
Free length.. . ... . . .0.692 in. (17.6 mm)
lb-ft (7 to 11 Nm) (0.7 to 1 kg-m).
Test length . . . .0.625 in. (15.9 mm)
compressed with 0.75 I 0.1 lb.
Tighten spool screw (27, Fig. 11) to spool to 5 to 8 1
(3.3 of: 0.4 N) (0.34 t 0.04 kg)
lb-ft (7 to 11 Nm) (0.7 to 1 kg-m).

Spring (17, Fig. 11)


Coat parts inside cap assembly (28) and spool area
Free length.. . . . . . . . . . .0.597 in. (15.2 mm)
under dust seal (1) with Lubriplate or its equivalent
Test length . . . . . . .0.531 in. (13.5 mm)
compressed with 1.250 & 1 lb.
Tighten cap assembly (28) to valve housing to 50 to
(5.56 + 0.44 N) (0.57 + 0.05 kg)
55 lb-ft (68 to 75 Nm) (7 to 8 kg-m). Do not use Loctite
on these threads.
Spring (26, Fig. 11)
Free length . . . . . . . .1.595 in. (40.5 mm)
When reassembling control valve assembly be sure
Test length . . _. . _. .0.937 in. (23.8 mm)
to install special washers (1, Fig. 12) with O-rings (2) )
compressed with 25 i 2.5 lb.
and O-rings (3) between all sections.
(111 -c 11 N) (11 + 1 kg)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Steering System 9
TM- 1188 (Jul- 79) Hvdraulic Svstem 0960-l 3

Install tie bolts (9, Fig. 12) and tighten evenly to 20 to


25 lb-ft (27 to 34 Nm) (3 to 4 kg-m).

IMPORTANT: Tighten tie bolts evenly to 20 to 25


lb-ft (27 to 34 Nm) (3 to 4 kg-m). An improper
torque may distort valve bodies, causing the valve
spools to stick, or cause leakage between valve
sections.

Install orifice plates (4, 5, 6, 7 and 8) in correct work


ports with slot facing out.

NOTE: A number for identification is stamped on


each orifice plate.

1-Special Washer 6-Orifice Plate


(20 used) 0.0625 in. (1.59 mm)
2-O-Ring (20 used) (Stamped 340)
3-O-Ring (10 used) 7-Orifice Plate (2 used)
4-Orifice Plate (2 used) 0.0700 in. (1.98 mm)
0.1405 in. (3.56 mm) (Stamped 343)
(Stamped 367) 8-Orifice Plate (2 used)
g-Orifice Plate (2 used) 0.1130 in. (2.87 mm)
0.0785 in. (1.99 mm) (Stamped 361)
(Stamped 346) g-Tie Bolt (4 used)
lO-Lock Washer (8 used)
il-Nut (8 used)

I Fig, 12-Orifice
Platesand O-Ring Location

Litho in U.S.A.
9 Steering System JD670-A and JD672-A Motor Graders
0960-14 Hydraulic System TM- 1188 (Jul- 79)

INSTALLATION
Mount control valve assembly to control console.
Install plugs in control console.

Connect control lever linkage.

Connect bottom tubes to their respective fittings


(Fig. 13) beginning with middle tubes. This offers
greater convenience when tightening connections. At-
tach upper tubes in same manner.

Install fuse block and reconnect battery.

Start unit and check for oil leaks,

Install control console covers.


l-Head End lo--Head End Blade
R.H. Lift Cylinder Side-Shift Cylinder
2-Rod End Ii-Circle Rotation Right
R.H. Lift Cylinder 12-Circle Rotation Left
3-Head End 13-Head End Circle
L.H. Lift Cylinder Side-Shin Cylinder
4-Rod End 14-Rod End Circle
L.H. Lift Cylinder Side-Shift Cylinder
6-Head End l!+Rod End Blade Tilt
Wheel Lean Cylinder Cylinder
6-Rod End l&Head End Blade Tilt
Wheel Lean Cylinder Cylinder
7-Rod End L.H. Cylinder 17-Head End Front
Head End R.H. Mounted Equipment
Cylinder Rear Steer Cylinder
8-Rod End R.H. Cylinder 18-Rod End Front
Head End L.H. Mounted Equipment
Cylinder Rear Steer Cylinder
g--Rod End Blade 1 g--Outlet
Side-Shift Cylinder 20-Inlet

Fig, 73-Control Valve Work Ports

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Steering System 9
TM- 1188 (Jul- 79) Hydraulic System 0960-l 5

WHEEL LEAN VALVE LINKAGE


REMOVAL REPAIR
Check bushings (3) for wear or damage.

Check linkage for ease of operation. Replace parts


as necessary.

INSTALLATION
Install following Fig. 14.

,--, I

IT1361

l-Knob GCotter Pin (2 used)


P-Nut 7-Link (2 used)
3-Bushing (2 used) s--Spacer
4-Wheel Lean Lever g--Cap Screw
5-Connecting Pin lo--Wheel Lean Valve
(2 used)

I fig, 14-Wheel Lean Valve Linkage

Remove covers to gain access to control linkage.

1 Remove linkage by following Fig. 14.

Litho in U.S.A.
9 Steering System JD670-A and JD672-A Motor Graders
0960-l 6 Hydraulic System TM- 1188 (Jul- 79)

CYLINDERS
GENERAL INFORMATION Support front end of unit.

The hydraulic cylinders used for grader steering


IMPORTANT: Block between wheel lean cast-
functions are double acting with V-packings. Piston
ings and axle frames before removing any lines so
rods are heat treated, chrome plated and polished.
that the wheels cannot lean.
Replaceable non-metallic wear rings are used on the
piston to prevent scoring at the cylinder barrels.
Using a chain hoist or a jack, lift front end up off the
floor far enough for left front wheel to pivot out for
See “Hydraulic Cylinders” in FOS Manual
l-l m6 “HYDRAULICS” for additional information on
cylinder removal. Place blocking under the axle.

L-J a
cylinders.
Disconnect link (1, Fig. 15) from right-hand and 1
left-hand wheel lean pivots. Slide link to the right-hand
side.

REMOVAL
If cylinder is operable, retract it and remove pin from

A CAUTION: Escaping fluid under pressure


can have sufficient force to penetrate the
rod end.

skin, causing serious personal injury. Before dis- Disconnect and cap cylinder hoses at the wheel lean
conrlecting lines, be sure to relieve all pressure. valve.
Before applying pressure to system, be sure all
connections are tight and that lines, pipes and Remove pin from head end of cylinder.
hoses are not damaged. Fluid escaping from a very
small hole can almost be invisible. Use a piece of Remove cylinder from front axle.
cardboard or wood, rather than hands, to search
for suspected leaks.

If injured by escaping fluid, see a doctor at once.


Serious infection or reaction can develop if proper
medical treatment is not administered immediate-
ly.

Wheel Lean Cylinder

l-Link 3-Left-Hand Wheel


2-Wheel Lean Cylinder Lean Pivot

Fig. 75-Wheel Lean Cylinder (JD670-A Shown)

Litho in U.S.A.
JD6?0-A and JD672-A Motor Graders Steering System 9
TM- 1188 (Jul- 79) Hydraulic System 0960-17

Front Steer Cylinder Rear Steer Cylinder

l--Bell Crank 3-Front Steering Cylinder


2-Tie Rod

Fig. 16-Front Steer Cylinder (JD670-A Shown)

l--Rear Steer Cylinder


I Retract cylinder (3, Fig. 16).
Fig. 77-Left-Hand Rear Steer Cylinder
Disconnect and cap hoses from rod and barrel ends (JD670-A Shown)
of cyjinder.
Disconnect and cap hoses from both ends of cylin-
Remove pins from both ends of cylinder and remove der (Fig. 17). I
cylinder.
Remove pins from both ends of cylinder and remove
cylinder.

Litho in U.S.A.
9 Steering System JD670-A and JD672-A Motor Graders
0960-I 8 Hydraulic System TM- 1188 (Jul- 79)

REPAIR

If cylinder packings have failed, some fragments of Remove piston rod, rod guide and piston from bar-
the deteriorated parts may have entered the system. rel.
Remove plumbing from control valve to cylinder and
flush hoses. Change transmission and hydraulic return Clamp the rod end in a vise taking care to prevent
filters. damage to the piston rod. Remove nut from end of rod.
Slide parts from end of rod.
Clamp the cylinder in a vise to prevent it from
turning. Remove set screw and rod guide. Use a
spanner wrench to loosen rod guide.

l-Bushing (4 used) 7-O-Ring 13-O-Ring


2-Head and Barrel &V-Packing l4-Backup Ring
34% Screw g--Piston 15-Rod Guide
4-Stop Nut lo--Snap Ring %-Wiper Seal
E-Piston Retainer 1 l-V-Packing 17-Piston Rod
6-Wear Ring 12-Wear Ring

Fig. l&Wheel lean Cylinder

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Steering System 9
TM- 1188 (Jul-79) Hydraulic Sys tern 0960-19

- T57730F

l-Barrel and Cap EL-Piston g-O-Ring 13-Wiper Seal


Z-Set Screw (i-V-Packing IO-Backup Washer 14-Bushing (2 used)
J--stop Nut 7-O-Ring II-Rod Seal 15-Piston Rod
4-Wear Ring 8-Piston 12-Rod Guide 16-Grease Fitting
17-Front Steering Cylinder

Fig. 19-front Steer Cylinder

18-

T59615F
l-Barrel and Cap 5-Piston Retainer g--Snap Ring 14-Rod Guide
2-Set Screw 6-V-Packing IO-V-Packing 15-Wiper Seal
3-Stop Nut 7-O-Ring 1 I-Wear Ring 16-Bushing
4-Wear Ring 8-Piston 12-O-Ring 17-Piston Rod
13-Backup Washer 18-Rear Steering Cylinder (2 used)

Fig. Z&Rear Steer Cylinder

Litho in U.S.A.
9 Steering System JD670-A and JD672-A Motor Graders
0960-20 Hydraulic System TM- 1188 (Jul- 79)

Wash all parts thoroughly with diesel fuel and in- Install new wiper seal (5, Fig. 21) in rod guide. )
spect the following:
Install new wear ring (4) in rod guide. Position
I. Barrel, rod guide and rod for scoring, and O-rings backup washer (6) and O-ring (2) on rod guide.
for surface damage.
Install the V-packing (3) in rod guide with apex of the
2. V-packings and wear rings for breaks, cuts or V toward the wiper seal and secure with snap ring (1).
embedded foreign material.
Slip rod guide assembly on piston rod being careful
3. Piston rod seal and wiper for wear or damage. not to damage packing.
Remove sharp edges from piston rod with emery cloth.
Installing Piston V-Packing
Repair kits are available for overhauling all cylin-
ders. Discard used parts and use all new parts provid-
ed in kits when assembling cylinders.

Lubricate all O-rings, seals, and packings before


assembly.

l-Piston Retainer 4-Nut


2-Wear Ring !&Cylinder Barrel
3-Piston

Fig. 22-Original Installation of V-Packing

V-packings are originally installed on the piston with


the apex of the V pointing away from the barrel (Fig.
22). When replacing V-packings in the field this pro-
cedure can be used if a suitable ring compressor is
2'34293111
available to compress packings when installed in cyl-
inders
l-Snap Ring 4-Wear Ring
2-O-Ring &Wiper Seal
3-V-Packing GBackup Washer

Fig. Pl-Rod Guide Components

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Steering System 9
TM- 1188 (Jul- 79) Hvdraulic System 0960-21

Connect link to left-hand wheel lean pivot.

Pivot right wheel in toward the unit and connect link


to right-hand wheel lean pivot.

Remove blocking from under axle and lower unit to


the ground.

Front Steer and Rear Steer Cylinders


Place the cylinder in position on the machine and
align the attaching holes. Insert pivot pins and secure
with cap screw. Connect the hydraulic lines, making
sure they are connected to the same ends of the
T31516N cylinder from which they were removed.

l-Piston Retainer 4-Nut


After replacing the cylinder, operate the cylinder
2-Wear Ring 5-Cylinder Barrel
3-Piston several times to remove air from the system.

Fig. 234nstallation of V-Packing


Without Compressor

If a suitable compressor is not available, assemble


the packings with the apex of the V pointing toward the
1 barrel (Fig. 23). This eliminates scuffing that may occur
in assembly; however, the V-packing may become torn
if the cylinder has to be disassembled in the future.

Position piston on piston rod. Install wear ring on


piston retainer. Position retainer and piston rod and
secure with stop nut. Tighten stop nut for wheel lean
and rear steer cylinders to 600 to 700 lb-ft (814 to 949
Nm) (83 to 97 kg-m) and tighten front steer cylinder
stop nut to 130 to 160 lb-ft (176 to 217 Nm) (18 to 22
kg-m).

Install piston rod assembly into barrel.

Secure piston rod assembly in barrel with rod guide


and tighten to 250 to 300 lb-ft (339 to 407 Nm) (35 to
41 kg-m). Install set screw and tighten after rod guide
is tightened to 40 lb-in (4.5 Nm) (0.46 kg-m).

INSTALLATION

Wheel Lean Cylinder


Position cylinder in front axle and install pin in head
end of cylinder. Connect hoses to wheel lean valve.

Pivot left wheel in toward the unit and connect rod


end of cylinder to left-hand wheel lean pivot.

Litho in U.S.A.
9 Steering System JD670-A and JD672-A Motor Graders
0960-22 Hydraulic System TM- 1188 (Jul- 79)

Litho’ in U.S.A.
JD670-A and JD672-A Motor Graders Steering System 9
TM- 1188 (Jul-79) Specifications and Special Tools 0999-l

Group 0999
SPECIFICATIONS AND SPECIAL TOOLS
POWER STEERING
SPECIFICATIONS AND TORQUE VALUES

T599348

Fig. I-Toe-In Adjustment

1 - Tighten tie rods adjusting nuts to 330 lb-ft (447 At axle height, the front measurement (“8”) between
Nm) (45 kg-m) tire centerlines must be 0.0 to 0.50 inch (0.0 to 13 mm)
less than the rear measurement (“A”).

Litho in U.S.A.
9 Steering System JD670-A and JD672-A Motor Graders
0999-2 Specifications and Special Tools TM- 1188 (Jul-79)

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES

Steering Valve

1 - End cap screw torque ,250 lb-in


‘(28’.6.f&1) (2.88 kg-m)

Steering valve fastening


cap screw torque . ,250 lb-in
‘(28..2’&j ii.88 kg-m)

Fig. BSteering Valve End Cap

1 - Steering wheel nut torque . . . . . . . 50 lb-ft


(68 Nm) (7 kg-m)

2593488

Fig. 3-Steering Wheel

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Steering System 9
TM- 1188 (J&78) Specifications and Special Tools 0999-3

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

Wheel Lean Valve and Rear Steer Valve


1 - Spring:
Free length.. _. . .0.692 in. (17.6 mm)
Test length . .0.625 in. (15.9 mm)
compressed with 0.75 & 0.1 lb.
(3.3 t 0.4 N) (0.34 c 0.04 kg)

6 T61363
2 - Spring:
Free length . .0.597 in. (15.2 mm)
Fig. 4-Wheel Lean Valve and Test length . .0.531 in. (13.5 mm)
Rear Steer Valve compressed with 1.25 + 1 lb.
(5.56 -c 0.44 N) (0.57 i 0.05 kg)

3 - Spool plug torque


with Loctite . _. . . 5 to 8 lb-ft
(7 to 11 Nm) (0.7 to 1 kg-m)
4 - Spring:
Free length . .1.595 in. (40.5 mm)
Test length . . . . .0.937 in. (23.8 mm)
compressed with 25 rt 2.5 lb.
(111 r 11 N) (11 i 1 kg)
5 - Spool screw torque
with Loctite . .. .. . . 5 to 8 lb-ft
(7 to 11 Nm) (0.7 to 1 kg-m)

6 - Cap assembly torque . . . .5C to 55 lb-ft


(68 to 75 Nm) (7 to 8 kg-m)

Wheel Lean Cylinder

1 - Rod diameter .. .. 1.9985 to 2.0015 in.


(50.76 to 50.84 mm)

2 - Cylinder bore . . . . . . 3.996 to 4.000 in.


(101.50 to 101.60 mm)

3 - Cylinder stroke ... . .4.84 -c 0.12 in.


(123.0 ? 3.0 mm)

Fig. 5-Wheel Lean Cylinder 4 - Rod guide torque., . . 250 to 300 lb-it
(339 to 407 Nm)
(35 to 41 kg-m)

5 - Set screw torque .. 40 lb-in.


(4.5 Nm)
(0.5 kg-m)
6 - Stop nut torque . .. . 600 to 700 lb-ft
(814 to 949 Nm)
(83 to 97 kg-m)

Litho in U.S.A.
9 Steering System JD670-A and JD672-A Motor Graders
09994 Specifications and Special Tools TM- 1188 (J&78)

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued
Front Steer Cylinder

1 - Cylinder bore . . .. 2.996 to 3.000 in.


(76.10 to 76.20 mm)

2 - Rod diameter . .. .. . 1.1485 to 1.2515 in.


(31.71 to 31.79 mm)
T37577B
3 - Set screw torque . .. .40 lb-in
Fig. &Front Steer Cylinder ‘(4.i‘ ti’hj ;0.5 kg-m)

4 - Rod guide torque.. . .. . 250 to 300 lb-ft


(339 to 407 Nm) (35 to 41 kg-m)

5- Cylinder stroke , . . .8.72 to 0.12 in.


(222 2 3.0 mm)

6- Stop nut torque ,. . 130 to 160 lb-ft


(176 to 217 Nm) (18 to 22 kg-m)

Rear Steer Cylinder

1 - Cylinder bore . .. ... . 3.496 to 3.500 in.


(88.8 to 88.9 mm)

2 - Rod diameter . .. .. 1.7485 to 1.75\5 in.


(44.4 to 44.5 mm)
T37578N
3 - Set screw torque . , .. ..... . .40 lb-in
Fig. 7-Rear Steer Cyhders (4.5 Nm) (0.52 kg-m)

4 - Rod guide torque.. . . . 250 to 300 lb-ft


(339 to 407 Nm) (35 to 41 kg-m)

5 - Cylinder stroke . . . , .“. .12.89 + O.-i2 in.


(328 c_ 3.0 mm)

6 - Stop nut torque . . 600 to 700 lb-ft.


(814 to 949 Nm) (83 to 97 kg-m)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Steering System 9
TM- 1188 (J&78) Specifications and Special Tools 0999-S

HYDRAULIC SYSTEM
SPECIAL TOOLS

Essential Tools

Tool No. Use

60057* install steering valve centering


springs

Fig. b-spring lnstalla tion Tool

Convenience Tools
D-01 053AA Remove and install rod guides.

Fig. g-spanner Wrench


(Adjustable from 1.5 to 4 inches
[38 to 102 mm])

*Order from: Char-Lyn Co.,


15151 Highway 5,
Eden Prairie, Minn. 55343

Litho in U.S.A.
9 Steering Systems JD670-A and JD672-A Motor Graders
0999-6 Specificstions and Special Tools TM- 1188 (Jul- 78)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Service Brakes 10
TM- 1188 (J&78) Active Elements 1011-l

Section IO
SERVICE BRAKES
CONTENTS OF THIS SECTION

Page Page

GROUP 1011 - ACTIVE ELEMENTS GROUP 1060 - HYDRAULIC SYSTEM


General Information ................. 1011-3 Brake Valve
Inspection .......................... 1011-3 General Information .. . . 1060-l
Removal ........................... 1011-4 Removal . . . . . .._................ 1060-l
Repair ............................. 1011-4 Repair . . . . . . . . 1060-2
Installation .......................... 1011-4 Installation. ... . .. .. 1060-4
Low Pressure Warning Switch
GROUP 1015 - CONTROLS LINKAGE General Information .. . .. . . 1060-5
General Information ................. 1015-l Removal . . .. . . .. ... 1060-5
Removal ........................... 1015-l Installation. .. . ... . 1060-5
Repair ............................. 1015-l Accumulator
Installation .......................... 1015-I General Information .. .. 1060-6
Removal ..__.__._._...___.__.,_. 1060-6
Repair . . . . . . .._.._..__.._...__._ . 1060-7
Pre-Charging Accumulator . . .. . 1060-8
Installation. . . . _ .. .. . . 1060-9

GROUP 1099 - SPECIFICATIONS AND SPECIAL


TOOLS
Specifications and Torque Values
Hydraulic System . . . . . . . . _. 1099-l
Special Tools
Hydraulic System . . . . . . . . . 1099-3

Litho in U.S.A.
10 Service Brakes JD670-A and JD672-A Motor Graders
1011-2 Active Elements TM-l 188 (J&78)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Service Brakes 10
TM- 1188 (Jul- 79) Active Elements 1011-3

Group 1011
ACTIVE ELEMENTS
GENERAL INFORMATION

l-Brake Backing Plate With Facings 3-Pressure Plate (3 used) 5-Paper Washer (3 used)
P-Brake Disk 4-Piston (3 used) 6-O-Ring (3 used)

fig. I-Brake Piston, Facing and Disk

The brake active elements are located in the trans- REPAIR


mission case and final drive housing.
Examine backing plate (1, Fig. 1) for worn or loose
linings.
The brakes are hydraulically-actuated, wet-disk
type. Braking action is achieved when the brake pis-
Inspect brake disk (2) for warped condition, wear or
tons force the revolving disk against the stationary
excessive play on final drive shaft.
backing plate.
Check brake pressure plate (3) for loose or worn
REMOVAL linings.

I
Refer to Group 0201 and remove final drive housing.

q
Examine pistons for pitting or scoring. Examine
Remove sun pinion and brake disk (2, Fig. 1) from bores for accumulation of any foreign material.
final drive shaft.
I
Replace all worn parts as necessary.
Remove final drive shaft.

Remove brake backing plate with facings (1, Fig. 1).

Remove brake pressure plates with piston (4)


Pressure plates can be pressed from pistons.

Litho in U.S.A.
10 Service Brakes JD670-A and JD672-A Motor Graders
1011-4 Active Elements TM- 1188 (J&79)

Soak brake piston paper washers (5, Fig. 1) in clean INSTALLATION


hydraulic oil before assembly.
Refer to Group 0201 and install final drive housing.

Install paper washers (5) in O-ring grooves toward


Make sure that the three dowel pins in each final
open end of piston bore and then install O-ring (6).
drive housing are firmly in place and backing plate has
not dropped off dowel pins before securing final drive
Press pistons (4) and pressure plates (3) together
housing to transmission case.
and install pistons in brake cylinders.
Refer to Group 9025 to bleed the brakes.
Install final drive shaft into differential. Slide final
drive sun pinion and brake disk (2) onto final drive
shaft.

Install brake backing plate (1) with brake facings


toward brake disk. Lugs on brake backing plate (1)
must align with the three dowel pins in final drive
housing, so that the brake facings on the backing plate
are opposite the facings on the pressure plate (3).

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Service Brakes 10
TM- 1188 (J&78) Controls Linkage 1015-l

Group 1015
CONTROLS LINKAGE
GENERAL INFORMATION Remove brake light switch and bracket.

Remove speed control rod.

Clean brake valve lines and couplings.

Slowly remove lines to relieve any pressure that may


be left in the accumulator.

Remove and cap brake valve lines.

Remove two cap screws and remove brake valve


with pedals and shaft from unit. Do not lose washer
used as a spacer between valve and mounting struc-
ture, upper hole.
160606
REPAIR
l-Left Brake Pedal G-Retaining Ring (2 used)
2-Bushing (2 used) GSpring Pin Remove retaining rings (5, Fig. 1) from pins (3) and
3-Pin (2 used) 7-Brake Pedal Shaft pull pins from yokes (4).
4-Yoke (2 used) &Right Brake Pedal
Drive spring pin (6) from pedal bracket and remove
FQ. i-Brake Pedals
brake pedal shaft (7) from pedal bracket and pedals.

The left brake pedal controls the left-hand brakes


Inspect parts for wear and damage. Replace as
and the right brake pedal controls the right-hand brake.
necessary.

The brake pedal shaft is held in place by a spring pin


If bushings (2) are replaced, press flush with edge of
located in the brake valve pedal bracket.
bore.
REMOVAL
INSTALLATION

A CAUTION: With engine stopped, relieve


hydraulic pressure in system by opening
Install brake pedals and shaft in pedal bracket. Line
up groove in shaft with hole in bracket and secure with
bleed screws on transmission case and depress- spring pin.
ing brake pedals or by pumping brake pedals until
no response is felt. Install pins in yokes and secure with new retaining
rings.
Remove the right-hand control console cover from
control console. Position brake valve in unit and fasten with cap
screws. Be sure washer is between mounting structure
and brake valve, upper hole.

Connect lines and speed control rod.

Install brake light switch and bracket.

Refer to Group 9025 and bleed the brakes.

Install console covers.

Litho in U.S.A.
10 Service Brakes JD670-A and JD672-A Motor Graders
1015-2 Controls Linkage TM- 1188 (J&78)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Service Brakes ill
TM- 1188 (J&78) Hydraulic Sys tern 1060-I

Group 1060
HYDRAULIC SYSTEM
BRAKE VALVE

General Information
A CAUTION: Escaping fluid under pressure
can have sufficient force to penetrate the
skin, causing serious personal injury. Before dis-
connecting lines, be sure to relieve all pressure.
Before applying pressure to system, be sure all
connections are tight and that lines, pipes and
hoses are not damaged. Fluid escaping from a very
small hole can be almost invisible. Use a piece of
cardboard or wood, rather than hands, to search
for suspected leaks.

If injured by escaping fluid, see a doctor at once.


Serious infection or reaction can develop if proper
medical treatment is not administered immediate-
ly*

A CAUTION: With engine stopped relieve


hydraulic pressure in system by opening
bleed screws on transmission case and depress-
ing brake pedals or by pumping brake pedals until
no response is felt.

Remove right-hand and left-hand control console


l-Brake Light Switch 4-Return Line cover from control console.
2-Pressure inlet Line 5-Speed Control Rod
Z-Pressure Lines G-Brake Pedals
(to brakes)
Remove brake light switch and bracket (1, Fig. 1).

Fig. I-Brake Valve Remove speed control rod (5).

The brake valve (Fig. 1) is mounted to the lower right Clean brake valve lines and couplings.
side of control mounting structure in control console.

The brake valve contains two separate valves in a


single housing. The left hand valve directs oil to the left
Slowly remove lines to relieve any pressure that may
be left in the accumulator. q
,

brakes and the right-hand valve directs oil to the right Remove and cap brake valve lines (2, 3 and 4).
brakes.
Remove two cap screws (18 and 20, Fig. 2) and
remove brake valve with pedals and shaft from unit. Do
not lose washer (19) used as a spacer between valve
and mounting structure upper hole.

Litho in U.S.A.
10 Service Brakes JD670-A and JD672-A Motor Graders
1060-2 Hydraulic Sys tern TM- 1188 (J&78)

T60608

l-Cap Screw (3 used) 12-Operating Rod (2 used) 22-O-Ring


a--Lock Washer (3 used) 13-Guide (2 used) SS-Connector
3-Nut (2 used) 14-O-Ring (2 used) 24-Left Brake Pedal
4-Retainer 15-Pedal Bracket 25-Bushing (2 used)
S-Spring Pin (2 used) 16Special Pin (2 used) 26Pin (2 used)
IS-Sleeve (2 used) 17-Gasket 27-Yoke (2 used)
7-Boot (2 used) 1a--Cap Screw 28-Retaining Ring (2 used)
%--Retainer (2 used) 19-Washer 29-Brake Pedal Shaft
9-O-Ring (2 used) PO-Cap Screw 30-Spring Pin
lo-operating Rod Spring (2 used) Pl-Lock Washer 31-Right Brake Pedal
11-Stop (2 used)

Fig. P-Brake Valve Operating Rod and Pedal Brackei

Repair Disassemble operating rod and boot assemblies


only if replacement of part is necessary. Spring (10) is
Disassembly
compressed and sleeve (6) is not threaded to operat-
Remove retaining rings (28, Fig. 2) from pins (26) ing rod.
and pull pins from yokes (27).

Drive spring pin (30) from pedal bracket (15) and Remove guides (13) and special pins (16) from
remove brake pedal shaft (29) from pedal bracket and pedal bracket. Check upper end of guides for erosion
brake pedals (24 and 31). or dirt buildup which may restrict full release of guide.
The failure to obtain full release of guide can cause
Remove cap screws (1) and lift pedal bracket with both brakes to be applied with one pedal due to failure
operating rods (12), guides (13), boots (7) and retainer of equalizing valve to close and can also cause slow
(4) from brake valve housing. release of individual brakes.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Service Brakes 10
TM- I 188 (J&78) Hydraulic System 1060-3

T59445N

l-Treated Paper Washer (2 used) 13-Steel Ball (3 used) 28-Brake Valve Housing
2-DRing (2 used) 14-GRing 28-Connecter (2 used)
3-Manual Brake Piston (2 used) 1 !&Connector 27-DRing (2 used)
4-Plunger (2 used) 1Check Valve Disk (2 used) 28-Equalizing Valve Spring (2 used)
!5-Plunger Return Spring (2 used) 17-Cheek Valve Disk Spring (2 used) 2g-GRing (4 used)
8-D-Ring (2 used) 18-GRing (3 used) 38-Equalizing Valve Shaft Guide
7-Inlet Valve Nipple (2 used) M-Plug (2 used) 31-CRing (2 used)
B-Backup Ring (2 used) 28-Plug 32-Backup Washer (2 used)
g-O-Ring (2 used) 21-Filter Screen 33-Sleeve (2 used)
1 O-Washer 22-C-Ring 34-Equalizing Valve Shaft
11-Inlet Guide Spring 23-Reservoir Check Valve Spring (2 used)
12-Inlet Guide 24-steel Ball

Fig. 3-Brake Valve

Remove manual brake piston (3, Fig. 3), plungers inspect all parts for wear, scoring or breakage and
(4) and springs (5) from brake valve housing (25). replace parts as necessary.
Valve plungers can be pressed from pistons by hand
pressure. Check orifices in plunger to make sure they Check springs for fatigue. Replace as necessary.
are open and clean.
Operating rod spring (10, Fig. 2) I
Use a deep-well socket to remove inlet valve nipple Free. length. 1.062 + 0.005 in. (27 2 0.13 mm) a
(7) from valve housing. Test length . . . . . . .0.885 in. (22.5 mm)
compressed with 210 ? 21 Ibs.
Remove equalizing valve shaft (34), sleeve (33), (935 t 93 N)
guide (30), steel ball (13) and spring (28). (95 + 10 kg)

Remove plugs (19), springs (17) and check valve


disk (16).

Remove plug (20), spring (23) and steel ball (24).


Clean or replace filter screen (21) as necessary.

Litho in U.S.A.
10 Service Brakes JD670-A and JD672-A Motor Graders
1060-4 Hydraulic System TM- 1188 (Jul- 78)

Plunger return spring (5, Fig. 3) Install equalizing valve springs, steel balls, guides,
Free length. . . ~. . . . 2.688 in. (68.26 mm) sleeves and shafts.
Test length . .. .. 1.688 in. (42.86 mm)
compressed with 43 lb. Install washer, spring, inlet guide, steel ball and
(191 N) connector.
(20 kg)
Install guides (13, Fig. 2) and special pins (16) in
Inlet guide spring (11, Fig. 3) pedal bracket. Use petroleum jelly to hold pins in
Free length. . . . . . .0.41 in. (10.5 mm) bracket.
Test length . .... . . . . .0.22 in. (5.6 mm)
compressed with 1.75 t 0.2 lb. Place boots, retainers, springs and stops on
(8 + 1 N) operating rods and install in pedal bracket. Be sure
(0.8 t 0.1 kg) boots fit into counterbore in pedal bracket.

Check valve disk spring (17, Fig. 3) Install retainer on pedal bracket. Using new gasket
Free length.. . . . . .1.25 in. (31.5 mm) attach pedal bracket to valve housing. Tighten cap
Test length . . . . .0.88 in. (22.4 mm) screws to 35 lb-ft (47 Nm) (5 kg-m).
compressed with 0.34 to 0.47 lb.
(1.53 to 2.09 N) Install yokes on operating rods. Adjust yokes so
(0.16 to 0.22 kg) centerline in yoke is 3 in. (76 mm) from surface of boot
retainer when the rod is in line with valves.
Reservoir check valve spring (23, Fig. 3)
Free length.. . ... . . .2.00 in. (50.8 mm) Install brake pedals and shaft. Line up groove in
Test length . . ... 1.625 in. (41.28 mm) shaft with pin hole in pedal bracket. Secure with spring
compressed with 0.19 + 0.06 lb. pin.
(0.8 ‘- 0.3 N)
(0.09 k 0.03 kg) install pins in yokes and secure with new retainer
rings.
Equalizing valve spring (28, Fig. 3)
Free length . . . . . . . . . . _0.50 in. (12.7 mm) Installation
Test length . . . . . . . . . . .0.375 in. (8.5 mm)
Position brake valve in unit and fasten with cap
compressed with 7.25 + 1 lb.
screws. Be sure washer (19, Fig. 2) is between
(32 + 5 N)
mounting structure and brake valve, upper hole.
(3.0 + 0.5 kg)
Tighten cap screw to 85 lb-f1 (115 Nm) (12 kg-m).

Assembly
Connect fines and speed control rod.
Install all new O-rings and backup washers dipped
in HY-GARD oil or its equivalent before assembly. Install brake light switch and bracket.
1
D Install check valve disks, springs and plugs in Bleed brakes. Refer to Group 9025.
housing.
Install right-hand and left-hand console covers.
Install check valve ball, spring and plug with filter
screen.

Install inlet valve nipple (7, Fig. 3) and tighten to 40


lb-ft (54 Nm) (6 kg-m).

Install springs (5). Push plunger into manual brake


piston and place assembly over spring.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Service Brakes 10
TM- 1188 (Jul- 78) Hydraulic System 1060-5

LOW PRESSURE WARNING SWITCH


General Information Removal

A CAUTION: With engine stopped, relieve


hydraulic pressure in system by opening
bleed screws on transmission case and depress-
ing brake pedals or by pumping brake pedals until
no response is felt.

Remove right-hand control console cover from con-


trol console.

Disconnect wiring harness from low pressure warn-


ing switch.

Slowly remove warning switch (Fig. 4) to relieve any


pressure that may be left in accumulator.

Installation
install low pressure warning switch and connect
wiring harness.

Bleed brakes. Refer to Group 9025.

Fig. 4-10~ Pressure Warning Switch Install right-hand control console cover.

The low pressure warning switch is located in pres-


sure tube near brake valve.

The low pressure warning switch will turn on an


indicator light on instrument panel if pressure in brake
circuit drops too low.

Refer to Group 9015 and Group 9025 to test low


pressure warning switch.

Litho in U.S.A.
10 Service Brakes JD670-A and JD672-A Motor Graders
1060-6 Hydra ulic Sys tern TM-l 188 (J&78)

ACCUMULATOR

14 15 16 17

T59939

l-Hydraulic Oil a-O-Ring M-Gas Valve 24-Spring


Accumulator Inlet Port g-Retaining Ring 17-Packing 26-Hydraulic Oil Accumulator
2-Steel Ball 10-Backup Ring lS-Cylinder End Outlet Port
3-tnlet Guide 11-O-Ring 1 g-Special Washer 26-O-Ring
4--Retaining Ring 12-Backup Ring 26-Ball Seat 27-Special Plug
&-Spring %-Piston 21-Gap
6-Backup Ring U-Spring Guide 22-Washer
7-Special Washer 16--Spring 23-Spring

Fig. 5Hydraulic OilAccumulator

General Information Removal


The accumulator is located under the operator’s
platform fastened to the main frame on the right-hand A CAUTION: With engine stopped, relieve
hydraulic pressure in system by opening
side. bleed screws on transmission case and depress-
ing brake pedals or by pumping brake pedals until
The accumulator will retain a reserve of pressure oil no response is felt.
for brake operation in case of pump failure or if the
engine should quit. Remove accumulator pressure lines slowly because
accumulator may still be slightly charged. Cap lines.
The gas end of the accumulator is charged with dry
nitrogen to a pressure of 500 i- 25 psi (34 r 2 bar) (35 Remove cap screws from clamps and remove ac-
1 i 2 kg/cm2). A floating piston in the accumulator keeps cumulator.
m
the dry nitrogen and hydraulic oil from coming in con-
tact with each other. The gas end of the accumulator
can be recharged on the unit through an access hole in
platform.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Service Brakes 10
TM- 1188 (Mar-80) Hydraulic System 1060-7

l-Plug lCl-Back-Up Ring (2 used) Is-Steel Ball (2 used)


2-O-Ring (2 used) 11-O-Ring (2 used) PO-Special Washer
3--Retaining Ring (2 used) 12-Accumulator Cylinder (2 used)
4-Accumulator Cylinder End 13-O-Ring (2 used) 21-Spring
9-Packing 14-Back-Up Ring 22-Spring
GSpecial Washer 16-Retainer Ring 23-Special Plug
7-Valve 16-Special Washer 24-Cylinder Cap
8-Spring 17-Spring 26-Back-Up Ring (2 used)
g-Spring Guide Id-Guide (2 used) 26-Accumulator Piston

Fig. &Accumulator Assembly

Repair Remove gas valve (7, Fig. 6) from accumulator end.

Disassembly
Remove check valve and thermal relief valve from

A CAUTION: Bleed nitrogen gas from accu-


mulator before disassembly. Remove small
cylinder cap (24).

plug in cylinder cod and insert a steel rod through Check accumulator cylinder for pitting or scoring. If
hole to unseat gas valve. scored or pitted, replace it.

.Push accumulator cylinder end (4, Fig. 6) into the Inspect accumulator piston for scoring or other
cylinder (12) and remove retaining ring (3). Pull cap damage. If it is excessively worn or otherwise dam-
with O-ring and back-up ring from the cylinder. aged, replace ‘piston.

Remove accumulator piston (26). Inspect accumulator cap for cracks or other dam-
age. Replace as necessary.
Push cylinder cap (24) into cylinder (12) and remove
other retaining ring (3). Pull end with O-ring and back-
up ring from the cylinder.

Litho in U.S.A.
10 Service Brakes JD670-A and JD672-A Motor Graders
1060-8 Hydraulic Sys tern TM- 1188 (Mar-80)

Check springs for fatigue. Replace as necessary. Pre-Charging Accumulator


IMPORTANT: Use dry nitrogen only to pre-
Gas valve spring (8, Fig. 6)
charge the accumulator. Dry nitrogen does not mix
Free length.. . . . . . . . . 1.lO in. (28 mm)
with oil. It is non-combustible. It will not cause
Test length.. . . . . _. ~. . . 0.59 in. (15 mm)
oxidation or condensation within the accumulator
at 1.5 + 0.2 tbs. force
and is not harmful to the piston seal. Do NOT use
(7 I~I 1 N)
air or any combustible gas as these may cause
oxidation and condensation. Oxidation and con-
Check valve spring (17, Fig. 6)
densation are harmful to the oil piston seal and the
Free length.. . . . . . . . . . .0.41 in. (10.5 mm)
accumulator.
Test length . . . . . . . . . . . .0.22 in. (5.6 mm)
at 1.75 L- 0.2 Ibs. force
NOTE: When pre-charging an accumulator on the
(8 t 1 N)
unit, make sure the oil side of the accumulator’has zero
pressure. Operate brakes for brake accumulator and
Thermal relief valve spring. outer (21, Fig. 6)
turn steering wheel back and forth for steering accu-
Free length.. . . , . . . . .1.20 in. (30.5 mm)
mulator, or slightly open the accumulator outlet line
Test length . . . . . . . . . . i.00 in. (25.4 mm)
throughout the charging operation to make sure piston
at 42 ? 4.2 Ibs. force
goes to the oil end of the accumulator in the event it is
(187 5 18.7 N)
not when the charging operation is started.

Thermal relief valve spr,ing, inner (22, Fig. 6)


NOTE: When measuring the pre-charge of an ac-
Free length . . . , . . . . . . . . . 1.14 in. (29 mm)
cumulator on the unit, make sure the oil side of the
Test length . . . . . . . . . . . . . . .0.85 in. (21.5 mm)
accumulator has zero pressure to assure an accurate
at 6.50 ? 0.7 Ibs. force
reading.
(28.9 + 0.7 N)
Use the D-15041 NU Nitrogen Accumulator Charg-
Assembly
ing Kit to charge the accumulator as follows:
Install gas valve assembly into accumulator end.
NOTE: Use the JD-346 Nitrogen Accumulator Ex-
Dip all O-rings and backing rings in clean hydraulic tension Tube if accumulator is being recharged on unit.
I
oil before assembly.

Install O-ring and back-up ring on end. Install ac- A CAUTION: For safety reasons, pressure
regulator valve and gauge must be ordered
cumulator end in cylinder. Push in far enough to install from your local nitrogen gas supplier.
retaining ring.
1. Remove plug from accumulator cylinder end.
Install back-up rings and O-rings on piston. Install

u
1
piston with small counterbore end toward gas end of
cylinder.

Install back-up ring and O-ring on cap. Install cap in


2. Install the adapter assembly with O-ring washer.

3. Turn needle of gas cock fully,counterclockwise.


Install gas cock on adapter assembly.
cylinder. Push in far enough to install retaining ring.
4. Connect the high pressure hose assembly to the
pressure regulator valve.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Service Brakes 10
TM- 1188 (Mar-80) Hydraulic System 1060-9

5. Turn needle of gas cock clockwise to open gas Installation


valve in accumulator.
Position accumulator.

6. Charge the accumulator to 500 i: 25 psi (34.5 +


Install cap screws, clamps and tighten.
1.7 bar).
Connect lines to accumulator.
7. Turn needle of gas cock fully counterclockwise
so gas valve in accumulator can close
Bleed the brakes. Refer to Group 9025.

8. Slowly, loosen fitting at the pressure regulator


valve to release pressure from hose.

9. Remove gas cock and adapter assembly from


accumulator. Install plug.

NOTE: If the accumulator is overcharged, use gas


cock to release excess pressure.

Litho in U.S.A.
10 Service Brakes JD670-A and JD672-A Motor Graders
1060-10 Hydraulic System TM- 1188 (Mar-80)

I
q

Litho in U.S.A.
JD670-A tind JD672-A Motor Graders Service Brakes 10
TM- 1188 (Jul- 78) Specifications and Special Tools 1099-l

Group 1099
SPECIFICATIONS AND SPECIAL TOOLS
HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES

1 - Pedal bracket to brake


valve housing . . . . . . . . . . . . . . 35 lb-ft
(47 Nm) (5 kg-m)

2 - Pedal bracket to control


mounting structure. . . . . . . . . . 85 lb-ft
(115 Nm) (12 kg-m)

3 - Operating rod spring


Free length 1.062 & 0.005 in. (27 & 0.13 mm)
Test length . . . . .0.885 in. (22.5 mm)
T59447N compressed with 210 ? 21 lb.
(935 zk 93 N) (95 2 10 kg)
Fig. l-Operating Rod Spring and
Pedal Bracket

1 - Inlet valve nipple torque. .. ... 40 lb-ft


(54 Nm) (6 kg-m)
2 - Plunger return spring
Free-length . . .. . . :. . 2.688 in. (68.26 mm)
Test length . . . . . . . 1.688 in. (42.86 mm)
compressed with 43 lb.
(191 N) (20 kg)

Inlet guide spring


Free length . . . . . . . . . . . . .0.41 in. (10.5 mm)
Test length . . . . . . . . . . .0.22 in. (5.6 mm)
compressed with 1.75 5 0.2 lb.
(8 c 1 N) (0.8 + 0.1 kg)

Check valve disk spring


Free length . . . _ . . . . . .1.25 in. (31.5 mm)
%9448N
Test length . . .. . . . .0.88 in. (22.4 mm)
Fig. PBrake Valve
compressed with 0.34 to 0.47 lb.
(1.53 to 2.09 N) (0.16 to 0.22 kg)

5 - Reservoir check valve spring


Free length .. _. . . . . . .2.00 in. (50.8 mm)
Test length . . . . 1.625 in. (41.28 mm)
compressed with 0.19 + 0.06 lb.
(0.8 + 0.3 N) (0.09 k 0.03 kg)
6 - Equalizing valve spring
Free length .. . . .0.50 in. (12.7 mm)
Test length . .... . . . . .0.375 in. (8.5 mm)
compressed with 7.25 -+ 1 lb.
(32 zk 5 N) (3.0 k 0.5 kg)

Litho in U.S.A.
10 Service Brakes JD670-A and JD672-A Motor Graders
1099-2 Specifications and Special Tools TM- 1188 (Jul- 78)
-

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued
1 - Gas valve spring
Free length . . . . . . . . . . 1 .lO in. (28 mm)
Test length . . ... . .. . 0.59 in. (15 mm)
compressed with 1.5 & 0.2 lb.
(7 + 1 N) (0.7 + 0.1 kg)

2 - Check valve spring


Free length . . . . . . . . . .0.41 in. (10.5 mm)
Test length . . . . . . . . . . . . . .0.22 in. (5.6 mm)
compressed with 1.75 + 0.2 lb.
(8 + 1 N) (0.8 k 0.1 kg)

3 - Thermal relief valve spring, outer


a94491 Free length . . . . . . . . .1.20 in. (30.5 mm)
Test length . . . . . 1 .OO in. (25.4 mm)
Fig. 3-Accumulator compressed with 42 -c 4.2 lb.
(187 rtr 18.7 N) (19 t 1.9 kg)

4 - Thermal relief valve spring, inner


Free length . .. .. . . 1.14 in. (29 mm)
Test length . . . . . . . . .0.85 in. (21.5 mm)
compressed with 6.50 ? 0.7 lb.
(28.9 k 3 N) (2.9 t 0.3 kg)

Accumulator precharge. ... . 500 2 25 psi


(34 -c 2 bar) (35 + 2 kg/cm2)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Service Brakes 10
TM- 1188 (Mar-80) Specifications and Special Tools 1099-3

HYDRAULIC SYSTEM
SPECIAL TOOLS

Essential Tools

Tool Tool Number Use

D-15041 NU To charge the accumulator.

A CAUTION: For safety reasons, the pres-


sure regulator valve and gauge must be
ordered from your local nitrogen gas supplier.

l-Gas Cock 3-Adapter Assembly


2-High Pressure 4-O-Ring Washer
Hose Assembly !i-Tru-Seal Nut

Fig. 4-Nitrogen Accumulator


Charging Kit

JD-346 Allows accumulator to be pressure


checked and charged without being
removed from the unit.

Fig. 5-Nitrogen Accumulator


Extension Tube

Litho in U.S.A.
10 Service Brakes JD670-A and JD672-A Motor Graders
1099-4 SDecifica tions and SDecial Tools TM- 1188 (Mar-80)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Parking - Emergency Brakes 11
TM- 1188 (J&78) Active Elements 1111-1

Section 11
PARKING-EMERGENCY BRAKES
CONTENTS OF THIS SECTION
Page Page
GROUP 1111 - ACTIVE ELEMENTS GROUP 1115 - CONTROLS LINKAGE
General Information . .. . .... .. 1111-3 General Information .................. 1115-I
Removal .. .. . .. ...... 1111-3 Removal ............................ 1115-l
Repair Repair .............................. 1115-3
Parking Brake Pinion Shaft Assembly Installation ........................... 1115-3
Disassembly...................... 1111-4 Adjustment
Assembly . . . . . . . . 1111-6 Parking Brake Adjustment. .......... 1115-3
Brake Caliper Assembly
Disassembly...................... 1111-7 GROUP 1199 - SPECIFICATIONS AND
Assembly .. . . . . . 1111-7 SPECIAL TOOLS
Installation . . . .. . . 1111-8 Specifications and Torque Values
Adjustment Active Elements.. . ... ... .. . 1199-1
Parking Brake Adjustment. . . . 1111-8 Controls Linkage ... . .. .. 1199-2

Litho in U.S.A.
.ll Parking-Emergency Brakes JD670-A and JD672-A Motor Graders
;1111-2 Active Elements TM- 1188 (J&78)
!

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Parking-Emergency Brakes 11
TM- 1188 (Jul-78) Active Elements 1111-3

Group 1111
ACTIVE ELEMENTS
GENERAL INFORMATION
The parking brake is a dry disk type, mounted on the
transmission front cover. The brake contains a pinion
shaft connecting the brake disk to the differential ring
gear.

When the brake is applied, pressure from the brake


caliper against the brake disk locks the shaft, which in
turn locks the differential ring gear. When the brake is
released, the shaft and disk are free to rotate with the
differential.

On the JD672-A Motor Grader a brake disk with


teeth is used in conjunction with a sensor to sense rear
tire speed.
(JD670-A Motor Grader)
The brake assembly is lubricated by return oil from
the brake valve and locking pin valve, bleed oil from the
priority valve and differential lock valve, and also by
splash from the differential ring gear.

NOTE: Frequently apply parking brake to check for


proper adjusfment and working order of components.
Adjust parking brake when foot pedal uses over 314
total travel to fully apply brake.

IMPORTANT: After using park brake for an


emergency stop, check adjustment of brake.

REMOVAL
Block rear tandem wheel securely.

Refer to Group 0400 and remove engine. This will


(JD672-A Motor Grader)
provide clearance in removing parking brake elements.
l-Pin 4-Brake Caliper
Remove spring from caliper lever to spring bracket 2-Brake Cable 6-Brake Disk
on engine oil pan. J-Cap Screws 6-Brake Housing
(2 used) 7-Brake Pinion Shaft

Remove pin (1, Fig. 1) from brake cable yoke and


Fig. l-Parking-Emergency Brake
remove cable (2) from caliper lever.

Remove cap screws (3) securing brake caliper (4) to


transmission case top cover and remove brake caliper.

Remove cap screws securing brake disk (5) to brake


housing (6). Remove brake disk.

Litho in U.S.A.
11 Parking-Emergency Brakes JD670-A and JD672-A Motor Graders
1111-4 Active Elements TM- 1188 (J&78)

Disconnect hydraulic lube line from brake housing.

Remove cap screws securing brake housing to


transmission case front cover. Remove parking brake
shaft assembly. Keep respective shim pack with brake
housing.

REPAIR

Parking Brake Pinion Shaft Assembly

Disassembly

Refer to Figure 2 for disassembly of parking brake


pinion shaft.

IMPORTANT: Hold brake pinion shaft securely


in a vise to remove slotted hex nut. Protect gear
area of brake pinion shaft with two blocks of wood
or other suitable material when securing shaft in
vise. Hex nut should only be loosened in assembly T60586N
when assembly is removed from grader, so shaft
can be held tight. l-Cap Screw (2 used) 11-Oil Seal
a--Brake Caliper 12-Bearing Cone
Z&Cap Screw (6 used) 13-Bearing Cup
Remove slotted hex nut (6, Fig. 2) and remove
4-Brake Disk 14-Shim (as required)
assembly from brake pinion shaft. 6-Cotter Pin 1!5-Cap Screw (6 used)
GSpecial Slotted 16-Special Washer (6 used)
Hex Nut 17-Brake Housing
7-Gap Screw 18-Shim (as required)
8-Special Washer 19-Spacer
(as required) 28-Bearing Cup
g--O-Ring 21-Bearing Cone
22-Brake Pinion Shaft .-
l6-Brake Disk Support

Fig. 2-Parking Brake Pinion Shaft Assembly

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Parking - Emergency Brakes 11
TM- I 188 (Jul- 79) Active Elements 1111-5

All parts must be clean to permit effective inspection. Inspect the defective bearing’s housing and shaft for
grooved, burred, or galled conditions that indicate the
All metallic parts (except bearings) should be bearing has been turning in its housing or on its shaft. If
cleaned thoroughly with volatile mineral spirits, or by the damage cannot be repaired with crocus cloth,
the steam-cleaning method. Do not use a caustic soda replace the defective part.
solution for steam cleaning. Gum and varnish deposits
should be removed by allowing the parts to soak in Inspect lip-type oil seals for cuts and hardness.
varnish remover. Replace the oil seals if these defects are found.

Parts should be dried with compressed air. Steam- When replacing lip-type oil seals, make sure the lip
cleaned parts should be oiled immediately after drying. of each seal is toward the oil to be sealed (toward the
inside of the unit). Use a non-hardening sealing com-
After cleaning, examine the parts to make certain pound on the outside of the seal to help prevent oil
they are entirely clean. Reclean them, if necessary. leaks. Coat the inside of the seal with high temperature
grease (AT30408 or equivalent) to protect the seal
Bearings that have been in service should be during shaft installation and to provide lubrication dur-
thoroughly washed in volatile mineral spirits. ing initial operation.

If the bearings are particularly dirty, soak them in the Inspect brake pinion shaft for scuffed, nicked,
spirits before trying to clean them. burred, or broken teeth. If the defect cannot be re-
moved with a soft honing stone, replace the shaft.
Before inspection, oil the bearings with the same
type of oil that will be used in the transmission. Inspect gear teeth for wear that may have destroyed
the original tooth shape. If this condition is found,
1 NOTE: Never spin dry bearings with compressed replace the shaft.
air. Do not rotate bearings while they are not lubricat-
ed. Inspect the thrust faces of gear for scores,
scratches, and burrs. Remove such defects with a soft
Inspect bearings for roughness of rotation. Replace honing stone.
a bearing if its rotation is still rough after cleaning and
oiling.

Inspect bearings for scored, pitted, scratched,


cracked or chipped races, and for indication of exces-
sive wear of rollers or balls. If one of these defects is
found, replace the bearing.

Litho in U.S.A.
11 Parking - Emergency Brakes JD670-A and JD672-A Motor Graders
1111-6 Active Elements TM- 1188 (Jun-83)

Assembly Drive bearing cups (7 and 11, Fig. 3) in brake housing


(8) until cups bottom out.

Install bearing cone (12) on brake pinion shaft (13).

Install brake pinion shaft assembly in brake housing.

Place spacer (10) on shoulder on pinion shaft. Install


bearing cone (6) on pinion shaft next to spacer.

Install brake disk support (4) and O-ring (3).

‘nstall special washer (2) and special slotted hex nut


(1):

Tighten slotted hex nut to 445 lb-ft (603 N.m) (62 kg-
m) with enough shims (9) placed between bearing cone
(6) and spacer (10) to provide 0.001 to 0.003 in. (0.03 to
0.08 mm) end play. Brake pinion shaft must turn freely.

Loosen nut after obtaining proper end play.

Coat sealing lips of oil seal (5) with John Deere Multi-
Purpose Lubricant or an equivalent before installing.

With spring side of oil seal facing away from driver,


191586 press oil seal flush with end of brake housing (8).
l-Special Slotted ‘I--Bearing Cup
Hex Nut E-Brake Housing
Tighten slotted hex nut to 225 to 300 lb-ft (305 to 407
2-Special Washer g--Shim (use as required)
(as required) lo-spacer N.m) (31 to 42 kg-m) where cotter pin (14) can be in-
3-O-Ring 1 l-Bearing Cup stalled.
4--Brake Disk Support 12-Bearing Cone
5-Oil Seal 13-Brake Pinion Shaft IMPORTANT: Hold brake pinion shaft securely in
B-Bearing Cone 14-Cotter Pin
a vise to tighten slotted hex nut. Protect gear area of
I 15-Fixed Shim Pack
brake pinion shaft with two blocks of wood or other
fig, 3-Assembly of Brake Pinion Shaft suitable material when securing shaft in vise. Hex nut
should only be tightened in assembly when assem-
bly is removed from tractor, so shaft can be held
tight.

NOTE: It may be necessary to install a washer (2,


Fig. 3) of different thickness between nut (1) and brake
disk support (4) in order to position cotter pin (14) cor-
rectly, without exceeding the 225 to 300 lb-ft (305 to
407 N.m) (31 to 42 kg-m).

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Parking - Emergency Brakes 11
TM- 1188 (Mar-80) Active Elements 1111-7

Brake Caliper Assembly


Disassembly

T71311

l-Special Nut (009391- ) 4-12 Pt. Hd. Bolt (3 used) 7-Upper Brake Caliper
P-Washer S-Push Pin (2 used) a--Brake Pad (2 used)
3-Cam g--Spring (2 used) O-Lower Brake Caliper
1O-Cotter Pin (009391- 1
1l-Lock Nut ( -009390)

Fig. 4-Brake Caliper Assembly

Remove 12 pt. hd. bolts (4, Fig. 4) fastening upper Assembly


brake caliper (7) to lower brake caliper (9).
Install brake pads (8, Fig. 4) to upper and lower
brake calipers and fasten with springs (6).
Remove springs (6) to remove brake pads (8).
Fasten upper and lower brake caliper (7 and 9) with
Remove cotter pin (10) and special nut (1) to remove
12 pt. hd. bolts (4). Tighten bolts to 125 f 1.5 lb-ft (169
cam (3).
k 20 N.m).

q
Replace brake pads (8) when remaining friction
Install push pins (5) in upper brake caliper down to
material measures less than 0.10 in. (2.5 mm).
brake pad liner.

Inspect upper and lower brake caliper for cracks or


Install cam (3) on threaded stud and fasten with
other damage. Replace entire brake caliper assembly
special washer. (2) and lock nut (1). Tighten nut.
if either part is found damaged.
Install cotter pin (10).
I

Litho in U.S.A.
11 Parking-Emergency Brakes JD670-A and JD672-A Motor Graders
1111-8 Active Elements TM- 1188 (Jun-83)

INSTALLATION ADJUSTMENT
Use 0.034 in. (0.86 mm) fixed shim pack (15, Fig. 3)
between brake housing (8) and transmission front cov-
er.

Shims may then be added or subtracted from shim


pack after running unit for a period of time to obtain the
proper quietness of noise level desired.

Install park brake assembly to transmission case cov-


er and tighten cap screws (15, Fig. 2) to 26 lb-t? (35 N.m).
Then turn cap screws an additional 90’ & 15’ tighter. ---

Make sure lube oil port in brake housing points diag-


onally to the left and forward.

Install brake disk (5, Fig. 1) on brake disk support and


tighten cap screws to 85 lb-f-t (115 Nam). T61263N
TS1263N
Position brake caliper (4) and tighten brake caliper to 1 -Cap Screw B-Caliper Lever
transmission case front cover cap screws (3) against 2-Caliper Assembly I-Top Friction Pad
thread run-out in transmission front cover. 3-Bottom Friction Pad 6-Parking Brake Pedal
4-Brake Disk g--Yoke
I-Lock Nut 10-Locking Pawl
Connect brake cable (2) to outside hole in caliper ~\
lever. Fig. 5-Parking Brake Adjustment

Connect caliper lever return spring in inside hole in Parking Brake Adjustment
caliper lever and to bracket on engine oil pan. To adjust the parking brake, proceed as follows:

1. Disconnect parking brake cable from lever (6, Fig.


5).
2. Adjust cap screw (1) in transmission cover under
caliper (2) until the bottom friction pad (3) just touches
the bottom of the brake disk (4).

3. Adjust lock nut (5) on top of caliper lever (6) until


the top friction pad (7) just touches the brake disk. Move
disk back and forth to check for free motion.

4. With the parking brake pedal (8) in the full raised


position and the caliper lever in the center position, ad-
just the brake cable end yoke. Adjust the yoke (9) at the
caliper, until the holes in the yoke are in alignment with
the outside hole in the caliper lever. Caliper brake should
be tight when locking pawl(l0) reaches first or second
notch on pedal ratchet with 70 + 10 Ibs force (312 + 45
N) applied to brake pedal.
Replace brake pads when remaining friction material
measures less than 0.10 in. (2.5 mm).

Drive unit forward and reverse for a short period of


time and check for drag or heating of brake disk. Read-
just if necessary.

IMPORTANT: After using parking brake for an


emergency stop, check adjustment of brake.
Litho in U.S.A.
JD670-A and JD672-A Motor Graders Parking- Emergency Brakes 11
TM- 1188 (Jul-78) Controls Linkage 1115-1

Group 1115
CONTROLS LINKAGE
GENERAL INFORMATION
The parking brake is actuated by depressing the
pedal located in the lower center of the control panel.

The parking brake is released by depressing the


park brake pedal and pulling the release knob upward
from the control panel.

When the parking brake is on, an interlock linkage


locks the direction selector lever in the neutral position.
This prevents the grader from being driven with the
parking brake on.

IMPORTANT: After using parking brake for an


emergency stop, check adjustment of brake.

REMOVAL
Remove left-hand panel from control console.

Disconnect shifter linkage rod (32, Fig. 2) from shift


linkage arm (33).

Remove cotter pins (5 and 21), pin (28) and remove


link (26) and end yoke (29).

Remove cap screws securing shift linkage arm and


interlock cam (25).

Remove springs (9 and 30) and disconnect park


l-Parking Brake Release Knob brake cable (18) from parking brake pedal (3).
2-Parking Brake Pedal
Remove cable clamp (23) and remove park brake
Fig. l-Parking Brake Controls
cable from control console.

Remove parking brake release knob (7) and cotter

q
pin (5) from the release rod (6). Remove the release
rod.

Remove retaining rings (31) and washers (1) and


remove parking brake pedal (3) and parking brake
locking pawl (4).

Litho in U.S.A.
11 Parking-Emergency Brakes JD670-A and JD672-A Motor Graders
1115-2 Controls Linkage TM- 1188 (J&78)

T612781

l-Washer (2 used) 12-Return Spring Anchor 23-Gable Clamp


P-Bushing (2 used) 13-Spring 24-Gap Screw (2 used)
3-Parking Brake Pedal M-Cap Screw (2 used) 26-Interlock Cam
4-Parking Brake Locking Paw1 16-Park Brake Cable Bracket 26Link
5-Cotter Pin (3 used) Id-Lock Washer (2 used) 27-Jam Nut
&Brake Release Rod l7-Nut (4 used) 28--Pin
7-Parking Brake Release Knob l&Park Brake Cable 29--End Yoke
8-Jam Nut 19-Spacer 30-Spring
9-Pawl Return Spring 20-Washer (2 used) 31-Retaining Ring (2 used)
1 &Pin Ii-Cotter Pin 32-!5hift Linkage Rod
11 --Cotter Pin 22-Pin 33-Shift Linkage Arm
34-Brake Caliper

Fig. Z-Parking Brake Control Linkage

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Parking- Emergency Brakes 11
TM- 1188 (Jul- 79) Controls Linkage 11153

REPAIR ADJUSTMENT
Check all parts for worn or bent condition. Check
pivot points and headed pins for excessive wear.

Check bushing (2, Fig. 2) for worn conditions.

Inspect cable (18) for bent or worn condition. Check


cable to see that it operates freely.

If a high-pressure washer was used in the brake


cable area, the following procedure should be followed
to remove any moisture that may have been forced into ----
the cable to prevent possible freeze-up problems in
cold climates.

Loosen cable at both ends and remove seals. Attach


a dry compressed air line to brake caliper end. Blow
dry air through cable to completely purge all moisture. T61263N
Do not add lubricant, since the cable’s original special
lubricant will be damaged. Reinstall cable, making sure l-Cap Screw g--Caliper Lever
2-Caliper Assembly ~-TOP Friction Pad
all seals are replaced tightly.
3-Bottom Friction Pad a--Parking Brake Pedal
4-Brake Disk g--Yoke
Press bushing (2) flush to 0.06 in. (1.5 mm) below 6-Lock Nut lo-Locking Pawl
outer edge of brake pedal (3).
Fig. 3-Parking Brake Adjustment

If return spring anchor (12) was removed, attach Parking Brake Adjustment
short leg of spring anchor to left-front edge of engine oil
pan, first cap screw to left of engine centerline. To adjust the parking brake, proceed as follows:

1. Disconnect parking brake cable from lever (6,


INSTALLATION Fig. 3).
Install parking brake pedal (3, Fig. 2) and brake 2. Adjust cap screw (1), in transmission cover under
locking pawl (4) and secure with washers (1) and caliper (2), until the bottom friction pad (3) just touches
retaining rings (31). the bottom of the brake disk (4).

Insert release rod (6) through control console and 3. Adjust lock nut (5) on top of caliper lever (6) until 1
install jam nut (8) and release knob (7). Secure release the top friction pad (7) just touches the brake disk.
rod to brake locking pawl. Move disk back and forth to check for free motion. 1

4. With the parking brake pedal (8) in the full raised


Connect park brake cable (18) to parking brake position and the caliper lever in the center position,
pedal and secure with pin (22) and cable clamp (23).

q
adjust the brake cable end yoke. Adjust the yoke (9), at
the caliper, until the holes in the yoke are in alignment
Install springs (9 and 30). with the outside hole in the caliper lever. Caliper brake
should be tight when locking pawl (10) reaches first or
Install interlock cam (25) and shift linkage arm (33). second notch on pedal ratchet with 70 -t 10 Ibs (312 t
45 N) (32 + 5 kg) applied to brake pedal.
Install link (26) with shift linkage rod to linkage arm.
Replace brake pads when remaining friction materi-
Install left-hand panel to control console. al measures less than 0.10 in. (2.5 mm).
Drive unit forward and reversefor a short period of
time and check for drag or heating of brake disk.
Readjust if necessary.
IMPORTANT: After using parking brake for an
emergency stop, check adjustment of brake.

Litho in U.S.A.
11 Parking - Emergency Brakes JD670-A and JD672-A Motor Graders
1115-4 Controls Linkage TM- 1188 (Jul- 79)

m.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Parking - Emergency Brakes 11
TM- 1188 (Jun-83) Specifications and Special Tools 1199-1

Group 1199
SPECIFICATIONS AND SPECIAL TOOLS
ACTIVE ELEMENTS
SPECIFICATIONS AND TORQUE VALUES

1. Brake disk-to-brake support


cap screws . . . . . . . . . . . . . . . . . . . . . . 85 lb-ft
(115 N.m) (12 kg-m)

2. Special slotted hex. nut torque


To establish end play . . . . . . . . . . . . . . . .445 lb-ft
(603 N.m) (62 kg-m)
After end play established . . . 225 to 300 lb-ft
(305 to 407 N.m) (31 to 42‘kg-m)

3. Thickness of washer required to install cotter pin

4. Parking brake shaft


end play . . . . . . . . . . . . . . . . . 0.001 to 0.003 in.
(0.03 to 0.08 mm)

Adjust parking brake shaft end play with slotted hex.


nut tightened to 445 lb-ft (603 Nsm) (62 kg-m).

5. Park brake housing-to-


transmission case front cover . . . . . . . . . . 26 lb-ft
(35 N.m) (4 kg-m)
plus an additional 90’ f 15’ tighter.

‘35’1224 \’ 151224
6. Fixed shim pack . . . . . . , . . . . . . . . . . . . 0.034 in.
(0.86 mm)

Litho in U.S.A.
11 Parking - Emergency Brakes JD670-A and JD672-A Motor Graders
1199-2 Specifications and Special Tools TM- 1188 (Jul- 79)

ACTIVE ELEMENTS
SPECIFICATIONS AND TORQUE VALUES-Continued
1. Replace brake pads when thickness
is less than . . . . . . . . . .. . . . 0.10 in.
(2.5 mm)

NOTE: Refer to page 1111-8 when adjusting park-


ing brake.

T40784N

Fig. Pfarking Brake Pads

CONTROLS LINKAGE
SPECIFICATIONS AND TORQUE VALUES
1. Bushings below outer edge
of brake pedal to ....... .. . . .0.06 in.
(1.5 mm)

Fig. 3-Parking Brake Pedal

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Equipment Attaching 15
TM- 1188 (J&78) Dra wbar 1511-l

Section 15
EQUIPMENT ATTACHING
CONTENTS OF THIS SECTION

Page
GROUP 1511 - DRAWBAR
General Information .... .... . .. . 151 l-3
Removal . . . ......... . . ._...... 1511-3
Repair .... . . ............. ........ 1511-3
Installation. . . . . . . . . . ... ....... 151 l-3

GROUP 1599 - SPECIFICATIONS AND


SPECIAL TOOLS
Specifications and Torque Values . . . . . 1599-l

Litho in U.S.A.
15 Equipment Attaching JD670-A and JD672-A Motor Graders .
1511-2 ‘Drawbar TM- 1188 (J&78)

Litho in U.S.A.
’ JD670-A and JD672-A Motor Graders Equipment Attaching 15
TM- 1188 (J&78) Dra wbar 1511-3

/ Group 1511
‘i,
DRAWBAR
GENERAL INFORMATION TRANSFER

Two drawbar types are possible. If the grader is


equipped with a heavy duty bottom guard, the drawbar
is an integral part of the bottom guard. If the grader is
not equipped with heavy duty bottom guard, the draw-
bar is attached to the transfer housing. Both types of
drawbars are equipped with a pin and pin retainer.

REMOVAL
Attach chain hoist to drawbar. Remove attaching
hardware and lower drawbar to the ground.

REPAIR
l"59127N
Refer to Fig. 1 during disassembly and assembly.
Replace parts as necessary. e-Special Washer (4 used)
l-Cap Screw
a--Machine Bolt 5-Drawbar
3-Machine Bolt (4 used) S-Pin
7-Pin Retainer

Fig. I-Drawbar

INSTALLATION
Position drawbar on transfer housing. Tighten 3/4
in. hardware to 300 lb-ft (407 Nm) (42 kg-m). Tighten
i/2 in. hardware to 85 lb-ft (115 Nm) (12 kg-m).

Litho in U.S.A.
15 Equipment Attaching JD670-A and. JD672-A Motor Graders
1511-4 Dra wbar TM- 1188 (Jul-78)

,
. ’

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Equipment Attaching 15
TM- 1188 (Jul- 78) Specifications and Special Tools 1599-1

Group 1599
SPECIFICATIONS AND SPECIAL TOOLS
Drawbar cap screw torques

1 - 3/4 in. cap screws . .. . .. . 300 lb-ft


(407 Nm)
(42 kg-m)

2 - l/2 in. cap screws . . .. . _ 85 lb-ft


(115 Nm)
(12 kg-m)

P59138N

Fig. 1-Drawbar Cap SCreWS

Litho in U.S.A.
:_
15 Equipment Attaching JD670:A and JD672-A Motor Graders
1599-2 Specificatiotis and Special Tools TM- 1188 (J&78)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1188 (Dee-87) Batteries, Supports and Cables 1671-1

Section 16
ELECTRICAL SYSTEMS
CONTENTS OF THIS SECTION

Page

GROUP 1671 - BATTERIES, SUPPORTS GROUP 1674 - WIRING HARNESS


AND CABLES AND SWITCHES
General Information ................. 1671-3 Fuses and Circuit Breakers
Inspection ........................ 1671-4 General Information . ..... . . . . . . . . . 1674-l
Testing ........................... 1671-4 Repair . . . . . . . . . . . . . . . . . . . . . . ...1674-2
Charging ......................... 1671-6 Start Circuit Relay . . . . . . . . . . . . . . . . . 1674-3
Installation ........................ 1671-7 Accessory Relay . . .. ... .. . . . . . . . . 1674-3
Switches ..... .... .. .... .. . . . . . . . . 1674-4
GROUP 1672 - ALTERNATOR, REGULATOR AND
CHARGING SYSTEM WIRING Connectors
General Information ................. 1672-l Replace Weather Pack’”
42 Amp Alternator .................. 1672-2 Connector . . . . . . . . . . . . . . . . . . . . . 1674-6
Removal ........................ 1672-3 Install Weather Pack’”
Repair ......................... 1672-3 Contact . . . . . . . . . . . . . . . . . . . . . . . 1674-7
Alternator Component Tests ......... 1672-8 Remove Connector Body
Assembly ...................... 1672-l 2 From Blade Terminals . . . . . . . . . . . . 1674-8
Test After Assembly .............. 1672-l 3
Installation ..................... 1672-l 4 GROUP 1675 - SYSTEM CONTROLS
50 Amp Alternator ................. 1672-l 5 Rear Mounted Equipment Switch . . . . . . . 1675-1
Removal ....................... 1672-l 6 Hydraulic Front Wheel Drive
Repair ...................... ..1672-17 Components . . . . . . . . . . . . . . . . . . . . . 1675-2
Component Tests ................ 1672-20
Assembly ...................... 1672-22 GROUP 1676 - INSTRUMENTS AND INDICATORS
Re-establishing Magnetic Field ...... 1672-26 Mechanically Operated Gauges and
Installation ..................... 1672-26 Indicators . . . . . . . . . . . . . . . . . . . . . . . 1676-2
Electrical Sensing Gauges and
GROUP 1673 - LIGHTING SYSTEM Indicators . . . . . . . . . . . . . . . . . . . . . . . 1676-4
General Information ................. 1673-l
Lights .......................... 1673-3 GROUP 1699 - SPECIFICATIONS AND
Light Switches ................... 1673-3 SPECIAL TOOLS
Specifications and Torque Values
Batteries, Supports and Cables . . . . . . . 1699-l
Alternator, Regulator and Charging
System Wiring . . . . . . . . . . . . . . . . . . 1699-l
Lighting., System . . . . . . . . . . . . . . . . . . 1699-5
Wiring Harness and Switches . . . . . . . . 1699-6
System Controls . . . . . . . . . . . . . . . . . . 1699-8
Instruments and Indicators . . . . . . . . . 1699-l 0
Special Tools
Batteries, Supports and Cables . . . . . . 1699-12
Alternator, Regulator and
Charging System Wiring . . . . , . . . . 1699-13

Litho in U.S.A.
16 Electrical Systems JD670-A and JD672-A Motor Graders
1671-2 Batteries, Supports and Cables TM- 1188 (J&78)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Electrical Systems 16
i-M- 1188 (J&78) Batteries, Supports and Cables 1671-3 ’

Group 1671
BATTERIES, SUPPORTS AND CABLES
.
GENERAL INFORMATION There are two important things that must be done m
periodically in order to obtain long life from a battery.

First, the electrolyte must at all times be kept above


the plates and separators. The electrolyte level should
be checked once a week, or after fifty hours of opera-
tion. See “Checking Electrolyte Level” in this group.

Second, be sure the battery is kept nearly charged


at all times. The state of charge should be checked at
frequent intervals by making specific gravity readings
with a battery hydrometer. See “Specific Gravity Cell
Comparison Test” in this group.

For additional information on batteries, refer


ms to “Storage Batteries” in FOS Manual-
ELECTRICAL SYSTEM.
Cl 0

Precautions

l-Negative Terminal 4-Left Battery


A CAUTION: All exposed metal surfaces on
batteries are “alive.” Never lay a metal ob-
P-Battery Hold-Down !&Positive Cable
ject on top of a battery as a short circuit may result.
3-Rear of Bumper Sparks or an open flame must be kept away from
batteries due to the presence of explosive gas in
Fi... I-Left Baffefy and around the batteries while they are being
charged or in use.
The batteries are located at the rear of the motor
grader engine compartment. One battery is on each BATTERY ACID IS HARMFUL ON CONTACT with
side of the unit. To gain access to either battery, swing the skin or materials. If acid spills, here are some
open rear compartment door on either side of grader. first aid tips to minimize the damage:
When replacing a battery, use the John Deere bat-
‘0 tery or its equivalent shown in the following chart: 1. Remove immediately any clothing on which acid
spills.
(2 used)
Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 2. If acid contacts the skin, rinse the affected area
John Deere Part Number. ....... .. AT29160 with running water for 10 to 15 minutes.
BCI Group . . . . . . . . . . . . . . . . . . . . 30H
Cold Cranking Amps (0°F) (-18°C). _ . . . . . . . . 570 3. If acid ever splashes into the eyes, force the lids
(-20°F) (-29°C) . . . . . . . 450 open and flood the eyes with running water for 10 to 15
Reserve Capacity (minutes at 25 amps) . . . . . . 180 minutes. Then see a doctor at once. Don’t use any
medication or eye drops unless prescribed by the
doctor.

Litho in U.S.A.
16 Electrical Systems JD670-A and JD672-A Motor Graders
1671-4 Batteries, Supports and Cables TM- 1188 (Jul-781

4. To neutralize acid spilled on the floor, use one of INSPECTION


the following mixtures:
Cleaning Batteries
a. One pound (0.5 kg) of baking soda in a gallon (4 Wipe batteries with a damp cloth. If terminals are
corroded, use a stiff brush and wash with an ammonia
solution or a solution of baking soda (l/4 pound [O.l:.,
b. One pint (0.4 L) of household ammonia in a kg1 added to a quart [i Ll of water). Keep vent plugs
gallon (4 L) of water. tight while washing. After washing, flush battery and
compartment with clear water. Then coat terminals
5. Acid from the batteries can also damage the with petroleum jelly to protect against corrosion. Be
paint and metal surfaces of the machine. Avoid over- sure vent holes in vent plugs are open.
filling, the battery cells and protect the battery when
necessary. Checking Electrolyte Level
Check electrolyte level in each cell. Proper level is to
REMOVAL
bottom of filler neck. Always add distilled water if
Remove batteries as follows: available. If not, use clean soft water. Avoid hard water.

1. Open right rear compartment door. NEVER ADD ACID TO THE BATTERY unless
electrolyte is lost by spilling.
2. Note carefully the location of the positive (+)
terminal so that battery is installed in the same way. Always wait until after checking specific gravity be-
fore you add water to the battery. This will assure a true
3. Disconnect battery ground cable first. Use only a reading. If level is too low to check specific gravity, add
box end wrench to loosen clamps on terminals. Re- water, operate engine for a few minutes to let water
move clamps using the screw type puller. DO NOT and electrolyte mix, then check.
hammer on the battery posts.
In freezing weather, never add water to the battery
4. Tag and disconnect HFWD wiring at batteries unless it will be operated immediately to allow proper
(JD672-A only). mixing of water with electrolyte.

5. Open left rear compartment door. TESTING


Testing the battery will tell you whether the battery is
6. Disconnect cable at negative terminal of right
usable, requires recharging or should be replaced.
battery.
Regular periodic testing provides a means of antici-
pating battery failure.
7. Disconnect positive cable from both batteries.
If using D-24001 MO battery tester, follow instruc-
8. Remove rear bumper by blocking under bumper
tions given with tester. The battery specifications are
and removing four screws holding bumper to motor
given on page 16-1699-l.
grader.
Specific Gravity Cell
9. Remove battery hold-downs and remove batter-
Comparison Test
ies from rear of unit.
Check the specific gravity of each cell with an accu-
10. Check cables for worn or frayed insulation. Re- rate hydrometer equipped with a thermometer. Hold
place cable clamps or bolts if corroded. the hydrometer vertically and take the reading at eye
level.

Litbo in U.S.A.
JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1188 (J&78) Batteries, Supports and Cables 1671-5

Specific gravity should read from 1.215 to 1.270


(corrected for 80°F [27”Cl electrolyte temperature).

The variation in readings between cells should be no


more than 50 specific gravity points (0.050).
HOLD HYDROMETER
VERTICALLY STRAIGHT
If specific gravity readings show a difference be-
tween the highest and lowest cell of more than 50
\TAKE READING specific gravity points (0.050), the battery is defective
and must be replaced.

If the maximum difference between all readings is


less than 50 specific gravity points (0.050) and the
lowest cell reading is 1.200 or above, the battery is in
good condition and may be returned to service.

If the maximum difference between all readings is


~31402N
less than 50 specific gravity points (0.050) but the
lowest cell reading is below 1.200, the battery is good
Fig. P-Checking Specific Gravity but needs to be charged by the slow method.

True readings are taken at 80°F (27°C) only. To Specific Gravity


Reading (Adjusted) State of Charge
correct a reading, add four gravity points (0.004) for
every 10°F (SC) that the electrolyte temperature is
1.260 100%
above 80°F (27°C). Subtract four gravity points (0.004)
1.230 75%
for every 10°F (SC) that the electrolyte is below 80°F
1.200 50%
(27°C). A hydrometer reading of 1.260 at 0°F (-1 SC)
1.170 25%
is corrected to 1.228.
1.140 Minimal
1.110 Completely

I TEMPERATURE GRAVITY POINTS TO Discharged


OFo;LECTRyL;;: ADD OR SUBTRACT
(I FROM READING
0 (-18) -32 The table above shows the state of charge of a
10 (-12) -28 typical battery at various specific gravity readings.
20 (- 7) -24
High-Rate Discharge Test
To be sure of a battery’s ability to deliver current
under load, give it a high-rate discharge test. This test
shows the internal conditions that might not otherwise
0” i I/l II u be detected.
t 90 I 321 I,
t 4
I I
r-~-
100 ( 38) + 8 IMPORTANT: The following conditions must
110 ( 43) +12
exist before this test is made:
120 ( 49) +I6
130 ( 54) +20
+24
1. Battery specific gravity must not be less than
140 ( 60)
150 ( 66) +28 1.215 at 80°F (27°C). Otherwise, erratic or unreliable
160 ( 71) +32 T3842ON readings will result.

Fig. 3-Correcting Specific Gravity 2. Battery electrolyte temperature must be between


Readings to Allow for Temperatures
70°F (21°C) and 90°F (32°C).

Litho in U.S.A.
16 Electrical Sys terns JD670-A and JD672-A Motor Graders
1671-6 Batteries, Supports and Cables TM- 1188 (Jul-78)

CHARGING THE BATTERY


Batteries can be recharged in two ways:

1. Fast charging.
2. Slow charging.

A battery that is in satisfactory condition but requires


recharging will accept a large amount of charging
current without undesirable effect. This type of battery
may be charged quickly at a high rate with a battery
II ‘WI I I fast charger.

A battery that becomes sulfated, however, will not


accept a high rate of charging current without possible
T330001v
damage. Its sulfated condition provides increased re-
Fig. 4-High-Rate Discharge Battery sistance to current flow within the battery. Flow of a
Tester Connected to Battery high rate of charging creates heat, which can result in
warping of the plates, boiling of electrolyte, and even-
Connect the high-rate discharge tester to the battery tual damage to the separators. Cell caps and covers
and be sure to follow the manufacturer’s instructions and the battery case may be damaged or distorted.
(Fig. 4).
A battery in this condition must be charged over a
long period at a low rate. In this manner, sulfate
The terminal voltage reading should remain above
formation on the,plates will be gradually broken down
9.0 volts.
and the battery returned to its normal charged state.

If the terminal voltage falls below 9.0 volts, the NOTE: When charging batteries be sure to follow
battery is defective or it is not as fully charged as the the manufacturer’s instructions for using the charger.
specific gravity reading indicates in the specific gravity
test. for additional information on charging bat-
ms
teries, refer to “Storage Batteries” in FOS
To be sure of the battery condition, carefully charge 0 Manual 20-ELECTRICAL SYSTEM.
0
it and repeat the test.
John Deere battery chargers can be used as a
Remember these key facts when testing batteries. booster to start the engine.
IMPORTANT: Before hooking up the battery
1. In general, if all cells of a battery test the same,
charger to the batteries in the machine, review the
the battery is good. If all are low, the battery usually
precautions in Group 9015.
only needs recharging.
IMPORTANT: A battery charger should not be
2. If there is a real difference between cells, the used as a booster if a battery has a very low charge
battery generally must be replaced. (1.150 specific gravity reading or lower). A low-
charged battery greatly increases the possibility of
For additional information on “Battery Test- mistakenly connecting the charger to the battery in
ing” refer to “Storage Batteries” in FOS reverse, and it is possible to reverse the charge on
Manual - ELECTRICAL SYSTEMS. a battery. If this is done the alternator diodes or the
wire harness may be damaged.

If the battery has a specific gravity reading of 1.150


or lower, disconnect battery cables and charge until the
specific gravity reading is above 1.150 before using a
battery charger as a booster.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1188 (J&78) Batteries, Supports and Cables 1671-7

INSTALLATION 5. Check for correct polarity of the battery. Connect


the positive cable first. Before connecting the ground
Install batteries as follows:
cable, momentarily touch it against the battery post.
With all switches and accessories off, no spark should
1. Be sure the batteries are fully charged.
occur. If spark does occur, do not connect the ground
cable. Check for reversed battery polarity, improper
2. Clean the battery terminals and cable clamps
alternator connection, defective electrical wire con-
with a wire brush before attaching the clamps. This will
nection, or defective electrical equipment.
assure a good contact.
6. Reconnect HFWD wiring to batteries (JD672-A
3. Set batteries in tray making sure batteries are
only).
resting level.
7. Tighten the clamps on the battery terminals. Use
4. Tighten the battery hold-down nuts evenly until
a box-end wrench carefully to avoid twisting the battery
batteries are secure. Do not overtighten as this will
terminal posts.
distort or crack the battery case.
8. Coat the terminals with petroleum jelly to prevent
corrosion. Never paint the terminal posts.

9. Install rear bumper.

Litho in U.S.A.
16 Electrical Systems JD670-A and JD672-A Motor Graders
1671-8 Batteries, Sumorts and Cables TM- 1188 (Jui-78)

Litho in U.S.A.
JD570-A and JD672-A Mofor Graders Electrical Sysfems 16
TM-1 188 (J&78) Alternator, Regulator and Charging System Wiring 167211

Group 1672
ALTERNATOR, REGULATOR AND
CHARGIN’G SYST.EM WIRING
GENERAL INFORMATION
Two alternators are available for use on the JD670-
A and JD672-A Motor Graders. Generally a 42 amp
alternator is supplied with units without air conditioning
and a 50 amp alternator is supplied for those units with
air conditioning.

Alternator repair stories will be covered in the fol-


lowing pages:

42 Amp Alternator ...................... 1672-2


50 Amp Alternator. .................... 1672-15

l-Output Terminal 3-Voltage Adjust


2-Ground Terminal 4-Relay Terminal

Fig. 2-50 Amp Alternator

l--Regulator 4-Output Terminal


2--Regulator Connector 5-Regulator Terminal
3-Ground Terminal

Fig. l-42 Amp Alternator and Regulator

Litho in U.S.A.
16 Electrical Systems JD670-A and JD672-A Motor Graders
1672-2 Alternator, Regulator and Charging System Wiring TM- 1188 (J&78)

42 AMP ALTERNATOR To convert the a.c. to d.c., diodes are used. Six
diodes are mounted at the slip ring end of the alternator
The alternator assembly consists of an alternator
housing. Three negative diodes are mounted in a heat
and voltage regulator combined as a single unit as

q
sink bolted to the end frame. Three positive diodes are
shown in Fig. 1. It is an open type alternator with
mounted in the heat sink which is insulated from the
’ enclosed brushes and slip rings.
end frame.

It is not necessary to disassemble the alternator to 7


replace brushes or voltage regulator. Such operations a
are usually accomplished with the alternator left intact
on the engine.

The alternator is cooled by an externally mounted


fan. Correct air circulation requires air to be pulled into
the rear of the alternator and expelled through the front
housing.

The alternator can be divided into three main as-


semblies:

1. Rotor Assembly - magnetic field which rotates.


.T56163N

2. Stator Assembly - Conductors which are station-


1-Stator Winding T-Diode Trio
ary. 8-Output Terminal
2-Field Winding
(Rotating) g-Regulator Terminal
3. Rectifier Assembly - diodes which change ac. to 3-Slip Rings lo--Regulator Voltage
d.c. 4-Brushes Sensing Terminal
5-Negative Rectifying 1 l-Regulator
Diodes
The rotor assembly consists of a wire coil wrapped 6-Positive Rectifying
z around an iron core and mounted on a rotating shaft. Diodes
The coil is enclosed between two interlocking soft iron
ii sections. The ends of the coil are connected to two slip Fig. 3-42 Amp Alternafor Circuit
rings mounted on one end of the shaft.
< To understand the diodes, first remember these two
Small brushes ride on the slip rings. One of the points:
brushes is connected to ground. The other is insulated 1. Alternating current flow is produced by the rotor-
and connects to the alternator field terminal. This ter- stator combination. That is, during half the rotor revo-
minal is connected through the regulator and the key lution, current flow in the stator phases is in one
switch to the batteries. direction. In the other half, flow is in opposite direction.

The rotor turns on sealed ball bearings that contain 2. Current flow from the alternator output terminal is
permanent lubrication. always the same direction.
This means that during each phase of a revolution,
The stator assembly is a laminated soft iron ring with two diodes are used to convert a.c. to d.c. - one
three groups of coils or windings in the slots. Each positive and one negative diode.
group is made up of twelve coils.
For additional information on alternators,
One end of each stator winding is connected to a ms refer to “Charging Circuits” in FOS Manual -
positive and negative diode. The other ends of the ELECTRICAL SYSTEMS.
stator windings are wye connected. 0 I3 ..

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1188 (J&78) Alternator, Regulator and Charging System Wiring 1672-3

REMOVAL REPAIR
Refer to Fig. 6 during disassembly and assembly.

Never immerse the alternator in cleaning solution.


Scrape off dirt and grease, then use a stiff brush and
solvent. Dry with compressed air.

Never hammer or jar the diodes as this may damage


them.

Disassembly
Remove regulator from rear housing. To remove
regulator, disconnect three wires from alternator ter-
minals, remove four screws and carefully remove reg-
ulator connector from brush holder assembly.

l-Regulator Wire &Mounting Bracket


Connector Screw
2-Adjusting Strap Screw 5-Output Terminal
3-Fan Belts

fig. 4-Alfernafor Wire Leads and Mounting Bracket

To remove the alternator, disconnect negative bat-


tery strap from grounded battery. Remove connector
from top of regulator and disconnect wire leads from
alternator output terminal.

Loosen adjusting bracket cap screw and mounting


bracket screw and nut. Push alternator toward engine
and remove fan belts from alternator pulley. Remove
adjusting strap cap screw and mounting bracket cap
screw, nut, spacer and washers. Remove alternator.

l-Brush Attaching 3-Brush Holder


Screws 4-Hex. Nuts
2-Through Bolts 54nsulating Washers

Fig. 5-Brush Assembly

Litho in U.S.A.
16 Electrical Sys terns JD670-A and JD672-A Motor Graders
1672-4 Alternator, Regulator and Charging System Wiring TM-1 188 (J&78)

l’S9947N

l-Special Cap Screw g-hxrulating Washer (4 used) M-Special Cap Screw 24-Front Housing
(4 used) 1 G-Rear Bearing Retainer 17-Lock Washer P&Span Spacer
2--Regulator 11-Rear Housing M-Slip Ring Assembly 26Lock Washer
Iasket 12-Insulator Sleeve (2 used) 19-Rear Bearing 27--Machine Screw
4-Drive Screw (2 used) 13-Positive Rectifying Diode PO-Rotor 23-Woodruff Key
g--Brush Holder Negative Rectifying Diode Pl-Sleeve 29-Fan
GThrough Bolt (4 used) 14-Stator 22-Retainer 3g-Pulley
-/-Nut (4 used) 1!5-Diode Trio 23-Front Bearing 31-Lock Washer
%-Lock Washer (4 used) 32-Nut

Fig. B-Alfernafor Assembly

Remove brush holder (3, Fig. 5) and through bolts Removing Rear Housing from
(2) from alternator. Stator and Diodes
Place the open end of the stator on a clean work
Carefully insert two screwdriver blades in opposite
surface, free of metal chips that could damage the
openings between the stator and front housing and
stator windings. Remove hex. nuts (7, Fig. 6) and
separate front housing from rear housing.
insulating washers (9) from the diode terminal studs.

IMPORTANT: Inserting screwdriver blades


Carefully and evenly, tap the diode terminal studs
deeper than l/16” (1.6 mm) may damage stator
out of the rear housing and lift rear housing off the
windings.
studs.

At this time, the rear housing and stator are one


Inspect the rear housing for a cracked or broken
assembly; the front housing and rotor are another
casting, stripped threads or evidence of severe wear in
assembly.
the bearing bore due to a worn rear bearing.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1188 (J&78) Alternator, Regulator and Charging System Wiring 1672-5

l-Rear Housing 2-Rear Bearing Retainer Fig. E-Pulley Removal

fig. 7-Rear l-lousing

If rear housing is to be reused, clean in solvent, dry


with compressed air, and install a new rear bearing
retainer (2, Fig. 7).

Removing Pulley and Woodruff


Key .
The pulley is a slip-fit on the rotor shaft, positioned
with a Woodruff key. To remove the nut and lock
washer from the shaft, clamp the pulley in a vise using
an over-sized belt to protect the pulley from the vise
jaws (Fig. 8).

Remove the nut and lock washer from the rotor shaft
and pull alternator from the pulley. A slight rodking of
the alternator body will loosen a tight pulley.

l-Woodruff Key P-Pulley Nut


I-Screwdriver Blade

Fig. B-Woodruff Key Removal

Remove fan and Woodruff key (Fig. 9).

Inspect the fan for cracked or broken fins and note


condition of the mounting hole. If hole is worn from
running loose, replace the fan to insure balance.

Inspect pulley drive surfaces, key groove and bore


for wear.

Litho in U.S.A.
16 Electrical Systems JD670-A and JD672-A Motor Graders
1672-6 Alternator, Regulator and Charging System Wiring TM- 1188 (J&78)

Removing Front Bearing Retainer Removing and Installing Sleeve


and Front Housing
Figures 12 and 13 show the procedure for removal
and installation of sleeve in front bearing.

1-A-216 Puller 2-A-203 Drive End


Bearing Installation
l-Front Bearing Retainer Screws Tool

Fig. 1O-Front Housing Fig. 7 l-Removing Front Bearing and Sleeve

Remove the three front bearing retainer screws (1,


Fig. 10) and lock washers.

Remove front housing from front bearing by tapping


rotor shaft against a wood block or using A-21 6 Puller.

Inspect front housing for a cracked or broken cast-


ing, stripped threads or evidence of severe wear in the
bearing bore due to a worn rear bearing.

If front housing is to be reused, clean in solvent and


dry with compressed air.

Removing Front Bearing and


Sleeve from Rotor
Place A-203 Drive End Bearing Installation Tool l-A-209 Bearing and Pulley Removal and
over the end of the rotor shaft. Using A-21 6 Puller, pull Installation Tool
front bearing and sleeve from rotor (Fig. 11).
Fig. 12-Pressing Sleeve Out of Front Bearing

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- I 188 (J&78) Alternator, Regulator and Charging System Wiring 1672-7

Removing Slip Rings


Unsolder the rotor leads (1, Fig. 14) from the slip ring
terminals. Carefully unwind the ends of the rotor leads
from the slip ring terminals.

1-A-203 Drive End 2-Front Bearing


Bearing Installation 3-Sleeve
Tool

Fig. 13-Pressing Front Bearing on Sleeve

Position front bearing on two steel blocks as shown


in Fig. 12.
l-Rotor Leads 2-Special Cap Screw
Using A-209 Bearing and Pulley Removal and ln-
Fig. l4-Slip Ring End View of Rotor
stallation Tool (1, Fig. 12), press sleeve out of front
bearing.
Remove special cap screw (2) from end of shaft and
Position sleeve (3, Fig. 13) and front bearing (2) on remove slip rings. If necessary, thread a l/4 x 1-l /2
press bed as shown in Fig. 13. UNF-2A cap screw into the slip ring hub; this will back
the slip ring assembly off the rotor shaft. Do not dam-
Using A-203 Drive End Bearing Installation Tool (1, age rotor leads or small fiber washers.
Fig. 13), press front bearing (2) on sleeve (3) until
bearing bottoms. Removing and Installing
Rear Bearing
Installing Front Bearing Figures 15 and 16 show the procedure for removal
Using a brass drift and a hammer, install front bear- and installation of rear bearing on rotor.
ing with sleeve into front housing until bearing bottoms.
Secure with bearing retainer and attaching screws.

Rotor
Check rotor for stripped threads on shaft, worn key
slot, worn bearing surface, scuffed pole fingers and
worn or dry rear bearing. Replace rotor if necessary.

Check condition of slip rings. If they need cleaning,


polish contact surfaces with No. 00 sandpaper or No.
400 grit silicone carbide paper.

If surfaces are worn beyond repair, replace the slip


ring assembly. l--Rear Bearing 3-A-216 Puller
2-Rotor Leads

Fig. 15-Removing Rear Bearing

Litho in U.S.A.
16 Electrical Systems JD670-A and JD672-A Motor Graders
1672-8 Alternator, Regulator and Charging System Wiring TM- 1188 (J&78)

Using A-216 Puller, remove rear bearing from rotor ALTERNATOR COMPONENT TESTS
shaft. Be careful not to damage rotor leads.
Brushes
First make a visual check of the brushes. If the
brushes are worn down to an exposed length of l/4 in.
(6.4 mm) or less, or are cracked or oil soaked, replace
the entire brush assembly.

1-A-209 Bearing and 2-Rear Bearing


Pulley Removal and 3-A-201 Press Assembly
Installation Tool

fig. 16-Installing Rear Bearing

Support the pulley end of the shaft on the bed of the


A-Field Terminal C&Insulated Brush (Top)
A-201 Press Assembly (3, Fig. 16). Place the new B-Bracket D-Grounded Brush (Bottom)
bearing over the end of the shaft. Position rotor leads
away from the bearing. Using A-209 Bearing and Pul- fig. 77-Brush Test Points
ley Removal and Installation Tool (l), press bearing on
the shaft until inner race contacts the shoulder of the Perform an insulation test on the brushes as follows:
rotor.
1. Connect an ohmmeter or a 24-volt test lamp to
Installing Slip Rings field terminal (A) and bracket (B).

Guide rotor winding leads through the square pas-


2. Resistance should be high (infinite) or test lamp
sage in the slip ring hub (Fig. 14). Hand press the slip
should not light. If resistance is low or test lamp lights,
rings on the shaft while maintaining alignment of
brush assembly is shorted and must be replaced.
winding leads and passage. Install special cap screw
and lock washer (2, Fig. 14) and tighten to 35 lb-in (4
Perform a continuity test on the brushes as follows:
Nm) (0.4 kg-m).
1. Connect ohmmeter or test lamp to field terminal
Wrap leads (1, Fig. 14) around slip ring terminals
(A) and brush (C). Use an alligator clip to assure good
(leads are interchangeable) and solder with rosin core
contact to brush.
solder. DO NOT OVERHEAT. Apply silicone rubber or
a glue to secure wires to the end of the rotor.
IMPORTANT: Be careful not to chip brush.

Retest rotor as instructed under “Rotor Testing” to


2. Resistance reading should be zero or test lamp
insure that short circuit or ground did not develop
should light. Move brush or brush lead wire to make
during repair operation.
certain that the brush lead wire connections are se-
cure. The resistance reading should not vary when
brush and lead wire are moved.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1188 (J&78) Alternator, Regulator and Charging Sys tern Wiring 1672-9

3. Connect ohmmeter to bracket (B) and grounded If the test lamp lights in both directions, the diode is
brush (D). Resistance reading should be zero or test shorted. If the test lamp does not light in either direc-
lamp should light. Move brush and lead wire to make tion, the diode is open.
certain that the brush lead wire connections are se-
cure. Resistance reading should not vary when brush Test the remaining diodes of the assembly in the
and lead wire are moved. same manner. Replace the assembly if one or more of
the diodes is found to be faulty.
Diode Trio
Use the following procedure when using a 1.5 Volt
ohmmeter test:

1. Connect one ohmmeter lead to the diode termi-


nal (1, Fig. 18) and the other lead to the mounting stud
(2).

2. Note the ohmmeter reading.

3. Now reverse the ohmmeter leads and note the


reading.
l-Diode Terminals 2-Mounting Stud
4. A good diode will give a high reading in one
fig. Id-Diode Trio Test Points direction and a lower reading in the other direction.

If a diode tester is used, follow tester manufacturer’s If the high and low readings between the three
testing instructions. If a commercial tester is not avail- diodes are reasonably close, the diodes are good. A
.able, use a DC test lamp. defective diode will have a reading obviously different
from the good diodes.
IMPORTANT: DO NOT USE A 1 lo-VOLT TEST
LAMP. USE A 12-VOLT DC TEST LAMP ONLY, When soldering to a diode terminal, use solder with
OTHERWISE DIODES WILL BE DAMAGED. a melting point of 360°F (182°C) or somewhat higher,
and take care that a good connection is achieved
If using a 12-volt DC test lamp, lamp should light without overheating the diode.’
only when the diode is connected in a forward bias as
given below. If the above tests indicate one or more faulty diodes,
the assembly should be replaced.
Connect one lead of the test lamp to on,e of the diode
terminals (1, Fig. 18) and the other lead to the mount- Always re-test diode assembly after diode replace-
ing stud (2). Reverse the test lamp probes. The test ment or soldering.
lamp should light in one direction but not in I;:? other.
Stator
Examine stator for insulaton failure or defects.
Shorted stator windings are usually discolored and
smell of burned insulation.

If a sensitive ohmmeter is available, use the follow-


ing procedure:

1. Disconnect the stator leads from the diode as-


semblies.

Litho in U.S.A.
16 Electrical Systems JD670-A and JD672-A Motor Graders
1672-10 Alternator, Regulator and Charging System Wiring TM- I 188 (J&78)

2. Check for a grounded winding by connecting an Rectifier Diode ‘Test


ohmmeter to one stator lead and to the stator frame.
A humming or growling sound with considerably low
The ohmmeter reading should be infinite (high).
output (6 to 10 amps) is caused by a shorted diode. If
output is slightly below maximum, a diode may be
3. To check for an open-circuited or short-circuited
open-circuited.
winding, carefully zero the ohmmeter and connect the
ohmmeter leads to A and B (Fig. 19). The meter
If available, use a diode tester and follow the manu-
reading should be approximately 0.6 ohm. An infinite or
facturer’s instructions. Do not use a 11 O-volt test lamp
high reading indicates an open-circuited winding. Now
to check a diode.
touch the remaining A and B leads together several
times. The meter pointer should deflect slightly to zero.
If using a 24-volt test lamp, use the following pro-
If there is no pointer movement, the windings are
cedure:
shorted.

T384.27111

1-Diode Plate 2-Diode Terminals

Fig. PO-Rectifier Diode Test Points

,l. Connect test lamp probes to diode terminal and


to diode plate (See Fig. 20), then reverse test lamp
probes.
4. Check for an open circuit or a short circuit be-
tween A and C and between B and C. 2. The test lamp should light in one direction but not
in the other.
If a sensitive ohmmeter is not available for the above
procedures, carefully disconnect the stator leads AA, 3. If the test lamp lights in both directions, the diode
BB and CC from each other (stator leads may be brittle is shorted.
if they have been overheated or if they are old).
4. If the test lamp does not light in either direction,
Test the stator as instructed in FOS Manual the diode is open.
Fa6 20 - ELECTRICAL SYSTEMS.
r-l 5. Test the remaining diodes of the assembly in the
Lol same manner. Replace entire assembly if one of the
diodes is found to be defective.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1188 (J&78) Alternator, Regulator and Charging System Wiring 1672-l 1

If using a I-l/2-volt ohmmeter use the following Test 1: Continuity and Current Draw
procedure:
This test checks the rotor for shorted or open wind-
ings.
1. Connect one ohmmeter lead to the diode plate
(1, Fig. 20) and the other lead to the diode terminal.
Connect the voltmeter to the slip rings (be sure slip
rings are clean). Then connect an ammeter in series
2. Note the ohmmeter reading.
with a variable resistor to the slip ring and a 12-volt
power source. Set the variable resistor to maximum
3. Reverse the ohmmeter leads and note the read-
resistance. Connect the other slip ring to the power
ing.
source and adjust the resistor to obtain full battery
voltage (Fig. 21).
4. A good diode will give a high and a low reading.
IMPORTANT: Do not remove the rotor leads
5. If the high and low readings between the three
from the slip rings at this time, as it will cause an
diodes are identical, the diodes are good. A slightly
arc, damaging the slip ring surface and requiring
different reading indicates a defective diode.
clean up.

When soldering a diode lead, use a pair of pliers as


Rotor current draw at 70°F to 80°F (21°C to 27°C)
a heat sink. Use solder with melting point of 360°F
should be 0.50 to 1.l.O amps at 10 volts.
(182°C) or higher. Never use an acid-core solder.
Resistance of windings should be 13.4’to 14.6 ohms
If a diode is defective, replace the diode assembly.
at 70°F to 80°F (21°C to 27°C).
Note the insulator locations on the positive diode as-
sembly to aid in correct assembly. The diode connec-
Shorted windings are indicated by excessive current
tions and polarity must be correct. A positive diode
draw, and open windings by no current draw at all.
assembly has a l/4 x 20 terminal stud and a square
hole. A negative diode assembly has two, 10 x 32,
Test 2: Checking Field Coil for Leaka’ge or Shorts
terminal studs.

Rotor Tests

T3842BN

l-Slip Rings 2-Rotor Shaft

L-t- w
3’27641

l-Voltmeter “Variable Resistor


Fig. 22-Test 2 Test Points

2-Rotor Assembly E&Battery


3-Ammeter

Fig. PI-Rotor Current Draw Test Hook-Up

Litho in U.S.A.
16 Electrical Sys terns JD670-A and JD672-A Motor Graders
1672-12 Alternator, Regulator and Charging System Wiring TM- 1188 (Jul-78)

This test checks the field coil for leakage or shorts to Assembling Rectifier Diode
the rotor poles. An ohmmeter or test lamp may be used to Rear Housing
for the test.

Connect ohmmeter or test lamp probe to the slip


rings (1, Fig. 22) and to rotor shaft (2). Ohmmeter
resistance should be high (infinite) or test lamp should
not light. If resistance is not high (infinite) or test lamp
lights, leakage or a short exists between field coil and
rotor.

If rotor assembly fails either of the above tests. it


must be replaced.

ASSEMBLY
Assembling Front Housing
on the Rotor
Position two blocks under rotor. Blocks should be
high enough so slip rings do not touch table. Be careful
not to damage field wire. Place front housing over
shaft. Press on inner race only by using an A-209
Bearing and Pulley Removal and Installation Tool.
Press until inner bearing race contacts shoulder on the
shaft. I-Insulating Washer 3-Slip Ring
a--Brush Assembly

Place spacer over shaft. Install Woodruff key and Fig. 23-Rectifier Diode to Rear Housing
fan. Install pulley, lock washer and nut. Tighten nut to
45 to 50 lb-ft (61 to 68 Nm) (6 to 7 kg-m). Carefully insert rectifier diode terminal studs through
the rear housing. Install insulating washer (1, Fig. 23)
Spin rotor by hand to test freedom of bearing. and hex. nuts. Tighten nuts to 33 to 40 lb-in (3.7 to 4.5
Nm) (0.38 to 0.46 kg-m). Do not tighten output stud.

Assembling Front Housing


to Rear Housing
Lubricate the exposed area of the rear bearing re-
tainer with hydraulic brake fluid to ease assembly over
the rear bearing. DO NOT USE OIL.

Place rear housing over the slip ring end of the rotor
and hand press housings together. Install through bolts
and tighten brush mounting screws to 30 to 35 lb-in
(3.4 to 4.0 Nm) (0.35 to 0.40 kg-m).

Be careful not to damage slip ring.

Spin rotor by hand to test freedom of bearings.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1188 (J&78) Alterna for, Regulator and Charging Sys tern Wiring 1672-13

Installing Brush Assembly TEST AFTER ASSEMBLY


Place the brush assembly in the cavity and tighten
brush mounting screws to 16 to 20 lb-in (1.8 to 2.3 Nm)
(0.18 to 0.23 kg-m).

Installing Regulator

,. -
4 T38431N
B
P l-Brush Terminal 3-24-Volt Power Source
2-Carbon Pile “Ammeter
Resistor !&Voltmeter
@ 6-Jumper Wire

Fig. 25-Alternator Test Connections


1

Mount alternator on electrical services and follow


service instructions. If instructions are not available,
connect alternator as shown in Figure 25. Run alter-
nator at 3000 to 4000 rpm. Momentarily connect a
jumper wire between alternator output terminal and
regulator terminal to excite alternator field. Adiust re-
sister to obtain maximum output.

Open resistor and check regulator operation. If bat-


tery is partially discharged, it may be necessary to
connect a l/4 ohm resistor in series with the ammeter.

l-Regulator Terminal R-Red


2-Output Terminal *Orange
3-Insulating Washer B-Black
4-Ground Terminal

fig. 24 Regulator Connections

Place gasket between regulator and rear housing.


Connect regulator brush lead to brush terminal. Insert
regulator mounting screws. DO NOT tighten.

Place regulator leads on regulator terminal and


ground terminal and under output terminal nut.

Install lock washers and nut for ground and regulator


terminal. Tighten nuts at output terminal to 35 to 40
lb-in (4.0 to 4.5 Nm) (0.40 to 0.46 kg-m). Tighten
regulator mounting screws to 30 to 35 lb-in (3.4 to 4.0
Nm) (0.35 to 0.40 kg-m).

Litho in U.S.A.
16 Electrical Sysfems JD670-A and JD672-A Motor Graders
1672-l 4 Alternator, Regulator and Charging System Wiring TM- 1188 (J&78)

INSTALLATION Mount alternator on mounting bracket with screw,


nut, spacer and washers; do not tighten screw. Install
adjusting strap screw through strap; do not tighten
screw. Place fan belts on alternator pulley.

Adjust alternator-fan belt tension according to in-


structions in Group 9010 and tighten mounting and
adjusting screws.

Connect wires to regulator and alternator output


terminal. Connect battery ground strap.

l-Wire From Regulator 4-Mounting Bracket


Connector to Screw
Alternator Output 5-Wire to Output
Terminal Terminal
2-Adjusting Strap Screw 6-Wire to Output
I-Fan Belts Terminal

Fig. 26-Alternator Mounting

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- I 188 (J&78) Alternator, Regulator and Charging System Wiring 1672-15

50 AMP ALTERNATOR
The alternator consists of an alternator and voltage
regulator combined as a single unit. It is an open type
alternator cooled by an externally mounted fan.

The Niehoff alternator features a brushless rotor, a


self rectifying regulator, a self energized isolated
ground, and is air cooled.

The regulator has a load dump circuit to protect the


alternator and the unit’s electrical system should the
alternator be charging when a battery connection
breaks.

There is no need for an external excitation resistor,


since the residual magnetism induces sufficient current
to turn on the power transistor within the regulator.

This alternator may be divided into four main as-


semblies.

1. Field Coil Assembly - Stationary coils which cur-


rent flows through to induce a voltage in the rotor.

2. Rotor - Laminated iron core that rotates.

3. Stator Assembly - Wye wound stationary con-


ductors.
l-Field Coil Assembly 4A-Regulator Assembly
2-Rotor 4B-Bridge Rectifier
4. Rectifier Assembly - Regulator circuit and Bridge 3-Ctator Assembly Assembly (Diode Heat
rectifier circuit. 4--Rectifier Assembly Sink Assembly)

Fig. 27-50 Amp Alternator with Regulator


The field coil assembly consists of two separately
wound windings. These coils are wound around the
To understand the diodes, first remember these two
innermost core of the alternator.
points:
The rotor rotates between the field coils and the 1. Alternating current flow is produced by the rotor-
stator. The rotor and shaft turn on sealed ball bearings stator combination. That is, during half the rotor revo-
that contain permanent lubrication. lution, current flow in the stator phases is in one
direction. In the other half, flow is in opposite direction.
The stator assembly is a laminated soft iron ring with
2. Current flow from the alternator output terminal is
three groups of coils or winding in the slots. One end of
always the same direction.
each stator winding is connected to a positive and
negative diode. The other ends of the stator windings This means that during each phase of a revolution,
are wye connected. two diodes are used to convert alternating current to
direct current - one positive and one negative diode.
The six rectifier diodes of the full wave bridge recti-
For additional information on alternators,
fier circuit are imbedded in two circular mounting plates
refer to “Charging Circuits” in FOS Manual -
which form a heat sink assembly at the front of the
ELECTRICAL SYSTEMS.
alternator. This provides effective diode heat dissipa-
tion.

Litho in U.S.A.
16 Electrical Systems JD670-A and JD672-A Motor Graders
1672-16 Alternator, Regulator and Charging System Wiring TM- 1188 (J&78)

REMOVAL IMPORTANT: It is necessary to partially dis-


mantle alternator to perform component test. Use
figures in disassembly and assembly procedures
as a guide. Before making any repairs perform all
of the following component tests: stator winding
test, field coil test and diode heat sink test.

Test replacement components before installation.


After reassembling alternator, perform system tests
(Group 9015).

i-Alternator to Relay 4-Relay to Alternator


Wire indicator Wire
2-Adjusting Bracket EL-Alternator Relay
Screw 6-Mounting Bolt
3-Fan Belts 7-Output Terminal Wire

Fig. 28-Alternator Wire Leads and


Mounting Bracket

IMPORTANT: Disconnect battery ground strap


to prevent damage if lead removed from alternator
should be accidentally grounded.

Remove red lead from alternator output terminal.

Loosen adjusting bracket cap screw and mounting


bracket screws and nuts. Push alternator toward en-
gine and remove fan belt from alternator pulley.

Remove mounting bracket screw and adjusting


strap cap screw respectively.

Remove alternator.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Electrical Systems 16
TM-1 188 (J&78) Alternator, Regulator and Charging System Wiring 1672-17

REPAIR

T59949N

l-Pulley Nut 19-Lock Nut 37-Single Flanged Hex Nut


2-Hardened Washer 2GFlanged Hex Nut (3 used) (3 used)
3-Pulley Pl-Spacer (3 used) 38-No. 6 Cap Screw
4-Fan 22-Hardened Washer 39-Gasket
CWoodruff Key 23-Stator and Shell Assembly 40-Voltage Adjust Cover
6-Shaft 24-Rotor 41-Red Insulator
?-Shaft Seal 25---ii.-rdened Washer 42-Dutput Stud
&Front Bearing 26-Ground Lead 43-Rear Housing
9-Gap Screw (4 used) 27-Lock Nut 44-No. 6 Cap Screw
lO-Terminal Lock (4 used) 28-Regulator Assembly 46-Nameplate Cover
ll-Cap Screw (7 used) 29-Spring Washer (4 used) 46White Insulator
12-Heat Sink Assembly BO-Double Chamfered Hex 47-Flat Washer
13-Front Housing and Nut (3 used) 48-Lock Nut
Field Winding Assembly 31-No. 6 Cap Screw (2 used) 49-Rubber Relay Terminal
14-Shorter Stud* 32-No. 10 Cap Screw (2 used) Cap
16-Longer Stud (2 used)* 33-No. 8 Cap Screw
16-Rear Bearing 3kSpring Washer (8 used)
17-Retaining Ring 36-No. 6 Cap Screw (3 used)
18-Flat Washer (2 used) 36lnsulator
*Apply John Deere Low Strength Loctite or equivalent to stud

Fig. 29-50 Amp Alternator Assembly

NOTE: The above figure should be used as general


reference only. Disassemble and assemble alternator
as described in the fool/owing pages.

Litho in U.S.A.
16 Electrical Systems JD670-A and JD672-A Motor Graders
1672-18 Alternator, Regulator and Charging Sys tern Wiring TM- 1188 (J&78)

Disassembly Remove regulator support screw (6) from beneath


nameplate cover.

Remove lock nuts (7) from studs and remove end


housing.

l-Load Dump Retaining 2-Load Dump


l-Ground Terminal &Nameplate Cover Screws Assembly
2-Output Terminal Cap Screws
%-Relay Terminal GRegulator Support Fig. 31-Load Dump Assembly
4-Voltage Adjusting Screw
Screw 7-Lock Nut (3 used) Wipe insulation from all screw heads.

Fig. 30-End Housing Disassembly


Remove 3 screws and spring washers (1, Fig. 31).

Remove output terminal nut (2, Fig. 30) and output


Lift load dump (2) off regulator and turn over.
terminal stud.
Wipe insulation from wire connections.
Remove relay terminal insulator, flat washer and
insulator (3).
Remove screw and spring washer, holding ground
lead (white wire).
Remove voltage adjusting screw (4), and spring
washer.
Remove screw and spring washer, holding wye lead
(brown wire).
Remove nameplate cover and cap screws (5).

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1188 (J&78) Alternator, Regulator and Charging System Wiring 1672-19

l-Regulator 5-Output Lead (Red) l-Rotor Nut


2-Load Dump Assembly GRelay Lead (Brown)
3-Ground Lead (White) -/-Field Lead (White) Fig. 33-Removing Rotor Nut
4-Wye Lead (Brown)
Place alternator in a vise using the pulley as a
Fig. 32-Regulator Disassembly
holding fixture. Use old oversized belt on pulley for
protection of pulley.
Wipe insulation from all screw heads.

Remove pulley nut and hardened steel washer.


Remove screw and spring washer holding output
lead (5, Fig. 32) to output terminal.
Remove alternator from vise and lay alternator on its
side.
Remove screw and spring washer holding relay lead
(6) to relay terminal.

Remove screw and field lead (7) from standoff.

Remove 3 nuts and spring washers from studs.

Lift regulator (1) off studs.

Remove ground lead (3) from stud.

Remove 3 spacers from studs.

l-Rotor Shaft Nut 5-Stator and Shell


2-Hardened Steel Washer Assembly with Front
I-Rotor Housing and Field
4-Hardened Steel Washer 6-Shaft, Fan and
Pulley Assembly

Fig. 34-Removing Rotor

Separate assembly as shown.

Litho in U.S.A.
16 Electrical Systems JD670-A and JD672-A Motor Graders
1672-20 Alternator, Regulator and Charging System Wiring TM- 1188 (J&78)

NOTE: The alternator is now disassembled as far Stator Winding Test


as necessary to perform component test.
Check for open stator windings by connecting ohm-
meter between each successive pair of stator phase
COMPONENT TESTS
terminals (3, Fig. 35). Meter should indicate less than
NOTE: Before making any repairs, perform all of one ohm between each pair of stator phase windings.
the folio wing simple tests: s ta tar winding tests, field coil Connect ohmmeter between each stator phase lead
tests, and diode heat sink test. (3) and the stator frame assembly. No meter needle
movement should be obtained. If a zero (0) ohm read-
Disconnect the 3 phase leads (3, Fig. 35) and the ing is obtained the stator is grounded and must be
output lead (5) from the heat sink assembly. replaced.

If ohmmeter readings differ from those indicated


above, disassemble the alternator to the extent nec-
essary, replace stator and reassemble.

Diode Heat Sink Test


The diode heat sink assembly is normally checked
using a diode tester. If a diode tester is used, refer to
Fig. 35 for proper test equipment connections. The
following procedure is for use when a diode tester is
not available.

1. Make sure all leads are disconnected from the


heat sink assembly before testing diodes for shorts and
opens.

2. Touch one ohmmeter probe to the output termi-


nal (4, Fig. 35), of the top plate of the heat sink
assembly, and the other probe to each stator phase
terminal (2). Observe and record in succession the
ohmmeter readings. All readings should be nearly
alike-i.e., all high or all low.

3. Repeat step 2, except reverse the ohmmeter


probes. All the readings should be opposite of those
recorded in step 2. That is: if the readings were low in
I- em---ALTERNATOR
step 2 they should now be high and vice versa.

I-Diode Heat Sink 5-Output Lead


4. If any reading in step 3 is the same as any
Assembly GAlternator Output reading in step 2, one or more diodes are defective and
P-Diode to Stator Phase Terminal the heat sink assembly must be replaced.
Lead Connections T-Alternator Ground
3-Phase Leads Terminal
5. Repeat step 2 and 3 procedures for the lower
4-Diode Heat Sink
Assembly Output
plate of the heat sink assembly. Touch one ohmmeter
probe to the ground terminal (7) and the other probe to
Fig. 35-Stalor Winding and Diode Test each stator phase terminal (2). Again, if any diode is
defective the heat sink assembly must be replaced.
IMPORTANT: Zero adjust ohmmeter.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1788 (J&78) Alternator, Regulator and Charging System Wiring 1672-21

Field Coil Tests

l-Ground Terminal 3-Output Lead l-Diode Heat Sink Mounting Screws


2-Field Lead
Fig. 37-Removing Diode Heat Sink Assembly
Fig. 36-Field Coil Tesi

Remove 3 screws (1, Fig. 37) holding heat sink


Check field coil resistance by connecting ohmmeter assembly.
across the field lead (2, Fig. 36) and the output lead (3).
Resistance should be 11 ohms + 1 ohm.

If the ohmmeter reads zero ohms or resistance is


excessively high, the winding must be replaced.

Connect one ohmmeter probe to the field lead (2)


and the other probe to the alternator front housing.
There should be no needle movement.

If the ohmmeter needle moves, the front housing


with the field coil must be replaced.
B5995ON.

l-Shaft Seal 4-Rear Bearing


2-Front Bearing 5-Snap Ring
3-Stator and Shell
with Front Housing

Fig. 38-Replacing Bearings

NOTE: Remove bearings and seal only if they are


to be replaced. They need not be removed for stator
replacement.

Remove front bearing and seal with a blind hole


puller.

Litho in U.S.A.
16 Electrical Systems JD670-A and JD672-A Motor Graders
1672-22 Alternator, Regulator and Charging System Wiring TM- 1188 (J&78)

Discard bearing and seal. Check the 3 studs. If their condition warrants, re-
place any that are damaged.
Remove snap ring (5, Fig. 38) from rear of core.
Clean inside of core to remove all old grease.
Support alternator, stator end down and press the
rear bearing out of alternator core. NOTE: Do not soak front housing in solvent. Wipe
with clean cloth.
Discard bearing.
Check field windings for any sign of damage.

Replace whole housing and field winding assembly


if necessary.

ASSEMBLY
NOTE: John Deere Low Strength Loctite or an
equivalent should be used on all cap screws and nuts
as alternator is assembled.

Install 3 studs in outer holes in front housing. Short


threaded end of stud goes into the front housing. Use
two nuts on the long threaded portion of the stud to
tighten stud into front housing. Install short stud in hole
below mounting ear.

Place stator and shell assembly on alternator studs,


1-Stator and Shell 3-Field Lead (White)
Assembly 4-Output Lead (Red) align ground terminal on shell with short stud from front
P-Front Housing and housing, phase leads toward the housing. Refer to Fig.
Field Winding Assembly 39.

Fig. 39-Separaling Siaior and Shell From Front Housing and


Bend end of field lead through field coil terminal and
Field Winding Assembly
solder. Slide sleeving down wire until field coil terminal
is covered.
Remove 3 flanged nuts from studs.

With a 14 in. (356 mm) piece of tape, tape both field


While holding the shell, lightly tap (with a soft faced
leads to field coil.
mallet) the front housing to separate shell from hous-
ing.
Route 3 phase leads and output lead through open-
ing in front housing.
While allowing field lead (3) to slip through space
between stator windings, lift stator and shell 3 in. (76
Slide stator and shell assembly down against hous-
mm) from front housing, thus allowing access to field
winding connections. ing.

Tap the shell with a soft faced mallet until shell


Slip sleeving off field winding terminal and unsolder
seats.
field lead from output lead.

Remove stator and shell assembly completely from


front housing.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1188 (J&78) Alternator, Regulator and Charging Sys tern Wiring 1672-23

Fill front and rear grease reservoir 2/3 full of high


temperature-silicone base grease.

l-Diode Heat Sink 4-Diode Heat Sink


Assembly Assembly Output
2-Diodes to Stator Lead 5-Output Lead
Connection
3-Phase Leads

Fig. 40-Stator Phase Connection l-Front Bearing J-Press Insert l-3/4 inch
P-Press (44 mm)

Connect 3 phase leads and output lead into tabs on Fig. 42-Front Bearing installation
field winding retainers.
Press front bearing into housing as shown in Fig 42.
Install 3 flanged nuts on studs. Leave nuts finger
tight. Lubricate the lip of the new seal as well as filling the
space between the back of the seal and the bearing
Place heat sink assembly on front housing. Attach with high temperature-silicone base grease.
phase leads and output lead as shown in Fig. 40.
Install leads with open end of terminal facing up away In the same manner, press the front bearing seal
from heat sink.
into housing. The seal is inserted with the open side
toward the front bearing and the closed side toward the
Fasten heat sink assembly to front housing with 3 front of the alternator.
screws. Tighten screws to 20 lb-in (2.3 Nm) (0.23
kg-m). Use a l-l /2 inch (38 mm) driver to press rear
bearing into the core. Bearing must be inserted with the
seal side toward the rear of the alternator and the open
side toward the grease reservoir.

l-Shaft Seal 4-Rear Bearing


2-Front Bearing S-Snap Ring
3-Stator and Shell
with Front Housing

Fig. 4 l-Rep/acing Bearing

Litho ir, U.S.A.


16 Electrical Systems JD670-A and JD672-A Motor Graders
1672-24 Alternator, Regulator and Charging System Wiring TM- 1188 (Jul-78)

If necessary press the Woodruff key into the shaft


using a press or a vise with the jaws covered to protect
the shaft.

Using the pulley as a fixture, clamp the pulley in a


vise and set the alternator shaft into the pulley.

Tighten the pulley nut to 70 lb-ft (95 Nm) (9.7 kg-m).

NOTE: Bearing cup must be put on the shaft before


the key is pressed in. The key should be pressed in so
the flaf of the key is parallel to the shaft.

T54111N
Grease the large end of the shaft with high temper-
ature-silicone based grease. Carefully insert the
1-Core 3-Retaining Ring smaller end of the shaft through the seal and into the
2-Rear Searing core. The shaft will seat against the rear bearing.

Fig. 43-Retaining Ring Placement Place the hardened steel washer on the shaft so it
seals against the rear bearing. Place the rotor on the
With snap ring pliers insert the snap ring into the shaft followed by the second hardened steel washer
groove behind the rear bearing. The snap ring is in- and rear lock nut.
serted with the flat side against the bearing and the
tapered side away from the bearing. Tighten the rotor nut to 55 lb-ft (75 Nm) (8 kg-m).

IMPORTANT: Correct rotor to stator clearance


is essential to the operation of the alternator.
Carefully follow the directions given below.

Insert a 1x3 inch (25x76 mm) piece of 0.008 inch


(0.2 mm) shim stock between each pole of the rotor
and adjacent poles of the stator. BE SURE ADJACENT
SHIMS DO NOT OVERLAP. Extra length of shims
should project from the alternator. Move stator in shell
for best freedom of movement of shims.

Tighten all stud nuts to 30 lb-in (3.4 Nm) (0.35 kg-m)


to secure stator position.

Pull out shims. If shims resist removal, turn rotor to


dislodge.

T'59951N Check with a feeler gauge for a minimum 0.005 inch


(0.13 mm) air gap between all rotor poles and adjacent
l-Pulley Nut GShaft
stator poles.
2-Hardened Washer 7-Hardened Washer
3-Pulley B-Rotor
4-Fan g-Hardened Washer
5-Woodruff Key 1 O-Rotor Nut

Fig. 44-Rotor Assembly

Assemble rotor assembly as shown in Fig. 44.

_Litho in U.S.A.
JD670-A and JD672-A Motor Graders Electrical Systems 16
TM-1 188 (Mar-80) Alternator, Regulator and Charuinu Svstem Wirins 1672-25

p6 (?.pp;1.

159952N I I 1 -Regulator 4-Wye Lead (Brown)


1 -Stud 6-Regulator 2-Load Dump Aesem bly 6-Output Leab (Redj
2-Flanged Hex Nut (3 used) 6-Spring Washer (3 used) 3-Ground Lead 6-Relay Lead (Brown)
a--Spacer (3 used) 7-Double Chamfered (White) ‘I-Field Lead (White)
““round Lead Nut (3 used)
(Only one used) Fig. 46-Regulator and Load Dump Assembly

fig. 45-Regulator Mounting Hardware Attach field lead (7, Fig. 46) to regulator standoff.
Tighten screw to 8 to 10 lb-in (0.9 to 1.1 Nm) (0.09 to
Place 3 spacers on alternator studs. 0.12 kg-m).

Place ground wire on longer stud on alternator’s Attach output lead (5) to output terminal standoff
right side. with spring washer and screw. Tighten to 20 lb-in (2.3
Nm) (0.23 kg-m).
Place regulator assembly on alternator studs. With
ear above voltage adjust standoffs to top of alternator. Attach relay lead (6) to relay terminal standoff with
spring washer and screw. Tighten to 20 lb-in (2.3 Nm)
Fasten regulator assembly with 3 spring washers (0.23 kg-m).
and 3 double chamfered nuts. Tighten nuts to 25 to 30
lb-in (2.8 to 3.4 Nm) (0.29 to 0.35 kg-m). Attach ground lead (3) to load dump assembly using
spring washer and screw. Tighten to 10 to 15 lb-in (1 .I
to 1.7 Nm) (0.12 to 0.17 kg-m).

Attach wye lead (4) to load dump assembly with


spring washer and screw. Tighten to 8 to 10 lb-in (0.9
to 1.1 Nm) (0.09 to 0.12 kg-m).

Coat all connections with silicone rubber.

Turn load dump over and install on regulator. Attach


with 3 spring washers and 3 screws. Tighten to 8 to 10
lb-in (0.9 to 1.1 Nm) (0.09 to 0.12 kg-m).

Coat these screw heads with silicone rubber.

Litho in U.S.A.
16 Electrical Systems JD670-A and JD672-A Motor Graders
1672-26 Alternator, Regulator and Charging Sys tern Wiring TM- 1188 (Mar-SO)

NOTE: If rotor and stator were removed from alter-


nator during repair, conduct REESTABLISHING
MAGNETIC FIELD procedure.

Install alternator on unit.

REESTABLISHING MAGNETIC FIELD

STRIP
-INSULATION l/16"

l-Ground Terminal 5--Nameplate Cover


2-Output Terminal Cap Screws
3-Relay Terminal 6--Regulator Support Fig. 4SEstablishing Magnetic Field
4-Voltage Adjusting Screw
Screw 7-Lock Nut (3 used)
After reassembly of alternator, it is necessary to
Fig. 47-End Housing Assembly energize the field coil to establish the magnetic field
properties of the alternator.
Place end housing on alternator studs. Short step of
end housing goes on short alternator stud. Connect alternator to battery supply, (battery posi-
tive to alternator output, battery negative to alternator
Place 3 flanged lock nuts (7, Fig. 47) on studs and ground).
tighten to 45 lb-in (5.1 N.m) (0.52 kg-m).
Attach a jumper wire to the alternator ground stud as
Insert voltage adjust screw with spring washer in shown in Fig.‘48. Insert the other end of this wire
voltage adjust terminal. momentarily into the hole in end housing.

NOTE: Refer to Group 9015 for voltage adjustment. NOTE: This is a momentary connection and should
be held for only a few seconds.
Insert regulator support screw and spring washer.
INSTALLATION
Fasten cover plate to end housing. Refer to Fig. 28 to install alternator.

Place flat washer, nut and cover on the relay termi- Place alternator on mounting bracket and loosely
nal. fasten with mounting bracket screw.

Insert output terminal stud. Push alternator towards engine to replace alternator
belt.

To adjust fan belt tension, see Group 9010.

Tighten alternator adjusting strap cap screw to 6 +


0.9 or - 2.5 lb-ft (8 + 1 or - 3 N.m) (0.8 + 0.1 or - 0.3
kg-m).

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1188 (J&78) Lighting System 1673-1

Group 1673
LIGHTING SYSTEM
GENERAL INFORMATION

There are various lights and light options available Figures 1 and 2 show locations of the lights and
on the Motor Grader. These lights are controlled by a which switches are used to control the lights.
set of switches. A flasher is used with the turn lights.
Refer to Group 9015 for testing of the lighting cir-
cuits.

T40790W

I-Tail, Turn, Brake Lights 6-Front Turn Lights A-Work Light Switch
Z-Rear Work Lights 7-Main Frame Work Lights B-Drive Light Switch
3-Rear Turn Lights &-Gauge Lights (6 used) C-Dimmer Switch
4-Under Platform Work Lights g-Dome Light (controlled D-Turn Light Switch
6-Driving Lights by switch on light) E-Stop Light Switch
F-Turn Light Flasher

(Letters on illustration indicate which switch or switches control lights)

Fig. I-Lights and Light Options on Grader With Cab

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16 Electrical Systems JD670-A and JD672-A Motor Graders
1673-2 Lighting System TM- 1188 (J&78)

T40791N

I-Tail, Turn, Brake Lights 4-Main Frame Work Lights A-Work Light Switch D-Turn Light Switch
2-Rear Work Lights 5-Driving Lights B-Drive Light Switch E-Stop Light Switch
34Jnder Platform Work GFront Turn Lights &Dimmer Switch F-Turn Light Flasher
Lights 7-Gauge Lights (6 used)

(Letters on illustration indicate which switch or switches control lights)

Fig. P-Lights and Light Options on Grader Without Cab

The drive light switch is on the left side of the The turn light switch is controlled by a lever near the
instrument panel. With the switch lever in the down steering column. When the lever is down the left turn
position the lights are off, with the switch lever in the up lights flash, when the lever is in the first up position the
position the drive lights are on. The dimmer switch is right turn lights flash, when the lever is all the way up all
located on the bottom left floor plate. By pressing on warning lights flash and when the lever is in the ‘IN”
the switch button the driving lights change from high position no lights will flash.
beam to low beam or low to high.

The work light switch is located on the right side of


the instrument panel. With the switch lever in up or “F”
position the front work lights are on, with the lever in
the down or “F-R” position, the front and rear work
lights are on, and with the switch in the center or “OFF”
position the work lights are off.

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JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1188 (Mar-80) Lighting System 1673-3

LIGHTS If one light will not work, a burned out bulb or sealed
beam is probably the cause.
Removal
If lights go off and on, a wire lead is shorted and
To remove the sealed beam lamps from the rear
circuit breaker trips and resets itself.
turn, brake and taillights, rear work lights, under plat-
form work lights and driving lights, use a screwdriver
If all lights on one switch will not operate, the cause
and pry between the rubber seal and the lamp and pull
could be a defective switch, tripped circuit breaker or
out lamp.
an open or short in the wiring.

To remove the rear cab or canopy mounted turn light


Check to see if light body is properly grounded.
bulb, remove two screws from front of light lens, re-
move lens, and pull out bulb.
Whenever a light bulb or sealed beam is replaced or
the light is disassembled, check light internal surfaces
To remove dome light bulb, press both sides of lens,
for corrosion or damage. Repair or replace as neces-
remove lens and pull out bulb.
sary.

The light bulb in the front turn lights mounted on cab


Installation
or canopy can be removed by removing screws from
front of lens, removing lens and turning bulbs until Follow removal procedures in reverse order.
released from socket.
LIGHT SWITCHES
The gauge lights may be removed by removing
instrument panel mounting screws, pulling out panel, Removal
pulling gauge light socket from back of gauge and
removing bulb from socket.

Repair
The following chart lists the lights and light options
and the replacement trade number for bulb or sealed
beam.

Light Trade No.

Front turn light with


cab or canopy 1683
Front turn light’without
cab or canopy 1683
Rear turn light with
cab or canopy 1683
Driving light with cab
or canopy 4579
Driving light without
cab or canopy 4579
Main frame work light 4578
Under platform work
light John Deere Part No. AT48364 l-Drive Light Switch 3-Turn Light Switch
Dome light with cab or a--Work Light Switch

canopy 1309 Fig. 3-Light Switches


Gauge light 1864
Rear taillight and turn light (early units) 4579R
(later units) 1662

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16 Electrical Systems JO670-A and JD672-A Motor Graders
1673-4 Lighting System TM- 1188 (Mar-80)

To remove work or drive light switches, remove four The stop light switch is located above the brake
instrument panel mounting screws and pull panel out, pedals. To remove the switch, disconnect wires, de-
remove switch hex. nut on front of instrument panel, press brake pedal, remove attaching hardware and
pull out switch from back of panel, disconnect.wires remove switch.
and remove switch.
The flasher is located outside the operator’s station
To remove the turn light switch, remove the bottom under the front console cover. To remove the flasher,
left console cover. Loosen set screw holding switch remove front console cover, disconnect wires from
handle to switch. Pull up on switch handle until handle flasher, remove attaching hardware and remove
is off switch. Loosen hex. nut from front of switch, flasher.
disconnect switch harness connector and pull switch
back and down. Remove switch with wires and har- Repair
ness connector.
The switches and flasher cannot be repaired. If
defective, the switches or flasher must be replaced.
The dimmer switch is located in the left front floor
panel. To remove the switch, remove floor mat (if
If switches are not operating properly wire connec-
equipped) from area of switch button, pull off top boot
tions may be loose or dirty. Check connections before
and remove two screws. Open left front window (if
replacing switch.
equipped), remove small left front floor plate, reach
under floor, disconnect wires and pull down on switch
Installation
to remove.
Follow removal procedures in reverse order.

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JD670-A and JD672-A Motor Graders Nectrical Systems 16
TM- 1188 (Jul- 78) Wiring Harness and Switches 1674-1

Group 1674
WIRING HARNESS AND SWITCHES
FUSES AND CIRCUIT BREAKERS
GENERAL INFORMATION The cab has a fuse block (Fig. 2) on the upper front
ceiling panel near the wiper switch.
The JD670-A and JD672-A Motor Graders use
fuses throughout the entire electrical system to protect
the various electrical functions and components from
overload.

A main fuse block (Fig. 1) is located on the left side


of the control console. For fuse replacement, see chart
on next page.

Fig. P-Cab Fuse Block

Two circuit breakers are used to protect the grader


lighting system. A IO amp circuit breaker is used to
protect the drive lights. A 10 or 15 amp circuit breaker
is used to protect the work lights (the 15 amp circuit
breaker is used when under platform work lights are
used in the work light system). The drive light and work
light circuit breakers are mounted on the back of the
transmission oil temperature gauge.

Fig. l-Main Fuse Block

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16 Qectrical Systems JD670-A and JD672-A Motor Graders
1674-2 Wiring Harness and Switches TM- 1188 (Jul-78)

FUSE! Location Size

Ignition Main Fuse Block 10 amp


Hydraulic Front Wheel Drive Main Fuse Block 5 amp
Turn Signal Flasher Main Fuse Block 10 amp
Stop Lights Main Fuse Block 10 amp
Horn Main Fuse Block 10 amp
Gauges Main Fuse Block 5 amp
Defrost Fan Cab Fuse Block 3 amp
Front Wiper Cab Fuse Block 3 amp
Rear Wiper Cab Fuse Block 3 amp
Dome Light (w/o A/C) Cab Fuse Block 3 amp
Dome Light and Air Conditioning Cab Fuse Block 15 amp
Auxiliary Controls Auxiliary Control Box 5 amp
Hydraulic Front Wheel Drive HFWD Control Box 1 amp - 8 AG
Hydraulic Front Wheel Drive HFWD Control Box 1 amp - 8 AG
Small Floor Heater In-Line 5 amp
Large Floor Heater In-Line 10 amp
Reverse Warning Alarm In-Line 3 amp

REPAIR
Replace any blown fuse.

IMPORTANT: Always replace a blown fuse with


one of the same size. It is imperative that only 1
amp 8 AG fuses be used in the HFWD control box.

Store extra HFWD fuses in the inside of the HFWD


control box in clips provided.

The circuit breakers will reset themselves. If the


circuit breaker trips, it will reset when the temperature
at the breaker decreases.

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JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1188 (Jul- 79) Wiring Harness and Switches 1674-3

RELAYS
START CIRCUIT RELAY ACCESSORY RELAY

General Information

Fig. 4-Accessory Relay

Fig. 3-Start Circuit Relay The accessory relay is activated with the key switch
on “ACC” or “IGN”. The relay then will pass voltage to
The start circuit relay is located on the left side of the the various accessories on the unit.
engine in back of the starting motor (Fig. 3). The relay
allows full battery voltage to flow to the starting motor Removal
when starting the engine.
Disconnect battery ground strap.

Disconnect and tag wires. Remove the attaching


hardware and then remove relay.

Repair
The relays cannot be repaired. Test as described in
Group 9015.

Installation
Mount relay with attaching hardware. Connect wires.

Connect battery ground strap.

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16 Electrical Sys ten-is JD670-A and JD672-A Motor Graders
1674-4 Wiring Harness and Switches TM- 1188 (Jun-83)

SWITCHES
GENERAL INFORMATION Neutral Start and Reverse Warning
Switches
Key Switch
The key switch is a one-piece sealed switch.

The accessory relay is wired to the key switch “ACC”


terminal.

When the key is straight up and down in the switch, it


is in the “OFF” position. When the key is turned to the
left, the “ACC” terminal is energized and when the key
is turned to the right, the “IGN” and “ACC” terminals
are energized.

Start Switch
The start switch is a push button switch. When the
start switch button is depressed with the key switch in
the “IGN” position and the transmission in neutral, cur-
rent flows through the start switch to the starting circuit
relay, to the neutral start switch to ground.

l-Neutral Start Switch 2--Reverse Warning Switch


‘(Early units-l used) (JD670-A)
(Later units-2 used) 3--Reverse Warning Switch
(JD672-A)

fig. 5Neutral Start and Reverse Warning


Switches

The neutral start switch is located on the transmis-


sion control valve. It is activated by a cam on the control
valve.

The reverse warning switch on the JD670-A is locat-


ed on the transmission control valve. It is a mechanical
switch that is activated by a cam in the control valve.

The reverse warning switch on the JD672-A is locat-


ed in the B, transmission control line. It is a pressure
sensing switch activated by B, transmission control
pressure.

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JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1188 (Jun-83) Wiring Harness and Switches 1674-5

REMOVAL INSTALLATION
To remove the switches located in the instrument Follow removal in reverse order.
panel, remove four screws from panel and pull out panel.
Disconnect wiring to switch and remove switch attach- Neutral Start Switch Adjustment
ing hardware. (units with one neutral start switch)
NOTE: On units with two switches, no adjustment is
To remove neutral start or reverse warning switches,
required.
tag and disconnect wires to switch. Unscrew switch.

Place gear selector lever in neutral position. Insure


that shift linkage is adjusted correctly.

Adjust the switch by adding shims one by one until


switch continuity is lost. Remove one shim.

NOTE: Tighten the switch to 20 io 25 ib-ft (27 to 34


N.m) (2.8 to 3.5 kg-m) EACH TIME a washer is added or
removed during the adjustment procedure.

Operate selector lever and verify that the unit will start
in neutral only.

Reverse Warning Switch Adjustment I


Adjust the reverse warning switch on the JD670-A by
placing the F-R selector lever in the reverse position.
Insure that the shift linkage is adjusted correctly.

Add shims under switch until switch continuity is lost.


Remove two shims.

NOTE: Tighten the switch to 20 to 25 Ib-ft (27 to 34


N.m) (2.8 to 3.5 kg-m) EACH TIME a washer is added or
removed during the adjustment procedure.

Operate the shuttle lever and verify that the reverse


warning alarm will sound in reverse only.

NOTE: No adjustment of the reverse warning pres-


sure switch on the JD672-A is required.

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1674-6 Wiring Harness and Switches TM-1 188 (Dee-87)

REPLACE WEATHER PACKTM CONNECTOR

IMPORTANT: Identify wire color locations with connec-


tor terminal letters.

1. Open connector body (A).

WEATHER PACK is trademark of PACKARD ELECTRIC

2. insert JDG-364 Extraction Tool over terminal contact in


connector body.

3. Hold extractor tool fully seated and pull wire from l,‘+; ,-‘,

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JD670-A and JD672-A Motor Graders Electrical Systems
TM- 1188 (Dee-87) Wiring Harness and Switches

IMPORTANT: Carefully spread contact lances to assure


good seating in connector body.

NOTE: Connector bodies are “keyep for proper contact


mating. Be sure contacts are in proper alignment.

4. Push contact into new connector body until fully seated.

5. Pull on wire slightly to be certain contact is locked in


place.

6. Transfer remaining wires to correct terminal in new


connector.

7. Close connector body.

INSTALL WEATHER PACK CONTACT

NOTE: Cable seals are color coded for three sizes of wire:
a) Green - 18 to 20 gauge wire
b) Gray - 14 to 16 gauge wire
c) Blue - 10 to 12 gauge wire

1. Slip correct size cable seal on wire.

2. Strip insulation from wire to expose 6 mm (1/4in.) and align


cable seal with edge of insulation.

NOTE: Contacts have numbered indentification for two


sizes of wire:
a) #15 for 14 to 16 gauge wire
b) # 19 for 18 to 20 gauge wire

3. Place proper size contact on wire and use JDG-144


Terminal Applicator to crimp contact in place with a “W” type
crimp.

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16 Electrical Systems JD670-A and JD672-A Motor Graders
1674-6 Wirina Harness and Switches TM- 1188 (Dee-871

4. Use JDG-144 Terminal Applicator to secure cable seal


to contact as shown.

IMPORTANT: Proper contact installation for “sleeve”


(A) and “pin” (B) is shown.

REMOVE CONNECTOR BODY FROM BLADE


TERMINALS

1. Use a small screw drive; to depress locking tang (A) on


terminal. Slide connector body off.

2. Be sure to bend locking tang back to its original position


(B) before installing connector body.

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JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1188 (Mar-80) Sys tern Controls 1675-1

Group 1675

GENERAL INFORMATION
SYSTEM CONTROLS
REMOVAL
.
q
The rear mounted equipment switch is located on Disconnect battery ground strap.
the console. It is a momentary rocker switch to control
the rear mounted equipment. Remove direction lever knob, direction lever cover
and bottom left control console panel. Remove two
bolts through the control box and pull control box away
from console. Remove screws, tag and remove wires
from switch and remove switch.

REPAIR
Test switch as a part of the electrical system (See
Group 9015).

Switch cannot be repaired; if defective, switch must


be replaced.

INSTALLATION
Follow removal procedure in reverse order.

Fig. l-Rear Mounted Equipment Switch

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16 Electrical Systems JD670-A and JD672-A Motor Graders
1675-2 System Controls TM- 1188 (Dee-87)

HYDRAULIC FRONT WHEEL DRIVE COMPONENTS


(JD672-A ONLY)
GENERAL INFORMATION Thread sensor through bracket until end touches a
tip of the brake disc. Rotate sensor counterclockwise
For individual component function and HFWD
one full turn and tighten jam nut to 10 to 12 lb-ft (14
system theory of operation, see Group 9016.
to 16 N-m).

REMOVAL/INSTALLATION
IMPORTANT: Overtightening will result in sensor
damage. Rotate brake disk by hand to insure sensor
Rear Sensor
and disc have a clearance of 0.045 f 0.025 in. (1.14
AI 0.63 mm).

Front Sensor

Fig. P-Rear Sensor


Fig. 3-Front Sensor (Early Units)

Turn unit off. Make sure key switch is in “OFF ”


IMPORTANT: The front sensor and wiring to sensor
position.
are serviced as one part. If wire breaks, it will be
necessary to also replace sensor. During removal
The rear sensor is located to the right of the
and installation, be sure to turn wire with sensor.
parking brake disc.
Also, it is important not to disconnect protective
hose from cover.
To remove, disconnect wiring harness to rear
sensor.
To remove front sensor, carefully disconnect
harness at frame. Remove sensor cover. Loosen jam
Loosen jam nut from sensor and remove sensor
nut. Unscrew sensor, turning harness with cover to
from bracket.
prevent twisting of the sensor wire.

IMPORTANT: Front and rear sensors are sensitive.


To reinstall sensor, install jam nut with nylon insert
Caution should be exercised at all times to insure
toward wheel. Turn harness with cover while screwing
that the sensor and lead wiring are not damaged.
in sensor to prevent twisting of the sensor wire.

To reinstall rear sensor, thread sensor into bracket.


Turn sensor and wire in until it contacts sensor
Insure that the sensor bracket is adjusted so the
plate. Rotate sensor counterclockwise 270 degrees
sensor is centered on the thickness of the brake disc
and tighten jam nut to lo-12 lb-ft (14-16 N-m).
and perpendicular to the top surface of the disc.
Reinstall cover and connect harness.
Install jam nut on the sensor after sensor is
threaded into bracket.

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JD670-A and JD672-A Motor Graders Electrical Sys terns 16
TM- 1188 (Jun-83) Sys tern Controls 1675-3

Fig. 3A-Front Sensor (Later Units)

Adjust lock nut (A, Fig. 3A) fully toward wire end of
sensor.

Install sensor into manifold until it meets resistance


(stops).
Check clearance between lock nut and manifold. Use
feeler gauge if necessary. If there is clearance, go to
“IMPORTANT” below.

If lock nut contacts manifold, remove sensor and


grind lock nut approximately 0.030 in. (0.080 mm) to
reduce nut thickness.
l-C:, Pressure Switch 4-l - 4 Cam Switch
Repeat first two paragraphs above to install sensor P-Reverse Warning Switch B-Forward Cam Switch
and lock nut. If lock nut still contacts manifold, grind it 3-B,, Pressure Switch B-Reverse Cam Switch
again. Grind nut as necessary to get clearance between
it and manifold. Fig. 4Control Switches

IMPORTANT: Overtightening lock nut will cause 1 - 4 Cam Switch - closed in 1 to 4 gears only.
sensor damage. Forward Cam Switch - closed in forward only.
Turn sensor out three quarters of a turn (270’). Hold Reverse Cam Switch - closed in reverse only.
sensor and tighten lock nut to (14 to 16 N.m) 10 to 12 Ib-
ft. Adjust by moving the respective control lever to a
position to close the switch to be adjusted. Insure that
1 - 4 Cam Switch, ,Forward Cam Switch, shift linkages are adjusted correctly.
Reverse Cam Switch, C, Pressure Add shims one by one until switch continuity is lost.
Switch, B, Pressure Switch Then remove two shims.
To remove any switch, tag and disconnect wiring and Tighten switch to 20 to 25 lb-ft (27 to 34 N.m) (2.8 to
unscrew switch. Mark and note shim stock on cam 3.5 kg-m).
switches to eliminate switch adjustment on reinstalla-
tion. Operate the respective control lever and insure that
the switch closes as indicated above.
To reinstall C, or B, pressure switches screw switch
into tee and connect wiring. NOTE: C, and B3 pressure switches do not require
adjustment.
Reinstall 1 - 4 cam switch, forward cam or reverse
cam switch with shims in transmission control valve Connect wiring. The wiring may be interchanged to
cover. either terminal of any particular switch, but must be
installed on the correct switch. Compare numbers on
Adjust switches to function as follows: wiring leads to electrical schematic (Group 9016).

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16 Electrical Systems JD670-A and JD672-A Motor Graders
1675-4 System Controls TM- 1188 (J&78)

Clutch Pressure Switch HFWD Fuse

Fig. 5-C/f&h Pressure Switch

To remove switch, disconnect wiring and unscrew


switch. Fig. 7-HFWD Fuse

Electra-Hydraulic Actuator The HFWD fuse located in the main fuse block is
rated at 5 amps. Replace with a fuse of 5 amps only.

Solenoid Manifold

Fig. 6-Electra-Hydraulic Actuator

To remove, unscrew clamp securing wiring protector


and remove protector. Tag and disconnect wiring.
Remove nut, internal lock washer and spacer
washer from displacement control valve lever shaft and
remove lever. Remove three nuts on pump actuator
mounting bracket cap screws and remove actuator.
To reinstall, reverse procedure. Be sure displace-
ment control valve lever is fifteen degrees back from a l-Forward Solenoids 3-Diodes
straight up position. Align actuator so that output rod is 2-Reverse Solenoid
perpendicular to displacement control valve lever.
Fig. E-Solenoid Manifold

To service solenoids, see Group 2160.

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JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1188 (Dee-87) System Controls 1675-S

Control Box To remove control box, disconnect three harness


connectors at bottom of box.

Remove four cap screws from outside cab securing


control box to cab.

The only serviceable items in the control box are


the fuses and the On/Off and aggressiveness
switches. To remove switches, tag and disconnect
wiring and remove attaching hardware.

IMPORTANT: To avoid control circuit damage, use


1 amp 8 AG fuses only.

To adjust aggressiveness control, see “Front


Wheel Speed Adjustment” in Group 9016.

l--Spare 1 Amp 4-Potentiometer


Fuses (3) (8 AG Only) S-On/Ott Switch
P-Circuit Board 6-Aggressiveness Switch
3-l Amp Fuses (2) 7--Mounting Screws
(8 AG Only)

Fig. S-Control Box

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16 Electrical Systems JD6?0-A and JD672-A Motor Graders
1675-6 System Controls TM- 1188 (Jul-78)

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JD670-A and JD672-A Motor Graders Electrical Systems 16
TM-1 188 (Dee-87) Instruments and Indicators 1676-1

Group 1676
INSTRUMENTS AND INDICATORS
GENERAL INFORMATION

1-Lett Turn Indicator g--Right Turn Indicator 17-Air Cleaner Restriction


a--Brake Pressure indicator lo--Start Switch Indicator
3-Engine Coolant Temperature Gauge 11 -Work Light Switch 18-Fuel Gauge
4-Rear Steer Indicator 12-Transmission Oil Pressure 19-Alternator Indicator
5-High Beam Indicator Gauge PO-Drive Light Switch
B-Locking Pin Indicator 13-Transmission Lube Pressure Il-Start Aid Switch
P-Transmission Oil Temperature Gauge 22-Horn Switch
Gauge 14-Key Switch 23-Cigar Lighter
6-Transmission Filter Restriction 15-Engine Oil Pressure Gauge 24-Ripper Control Box
Indicator 16-Turn Signal Switch 25--Dimmer Switch

Fig. l-Instruments and Indicators (JD670-A shown)

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16 Electrical Systems JD670-A and JD672-A Motor Graders
1676-2 instruments and indicators TM- 1188 (Jul-78)

The JD670-A and JD672-A Motor Graders have MECHANICALLY OPERATED


both mechanical and electrical sensing gauges and GAUGES AND INDICATORS
indicators (see Fig. 1).
General Information
The mechanically operated gauges and indicators
are the transmission lube pressure gauge, transmis- Transmission Lube Pressure Gauge
sion oil pressure gauge, air restriction indicator, service
meter, rear steer indicator, and HFWD charge pres- The transmission lube pressure gauge (13, Fig. 1)
sure gauge (JD672-A only). measures the pressure of the oil which cools and
lubricates the transmission.
The electrically operated gauges and indicators are
the engine coolant temperature gauge, engine oil
pressure gauge, fuel gauge, transmission oil tempera-
ture gauge, left and right turn indicators, brake pres-
sure indicator, high beam indicator, locking pin indica-
tor, transmission filter restriction indicator alternator
indicator, and HFWD return filter restriction indicator
(JD672-A only).

NOTE: HFWD gauge and indicator may be found


on 16-1676-8.

T38464N

14 PSI (0.3 bar) (0.3 kg/cm*) 3--Red-Orange


2-14 PSI (1 bar) (1 kglcmz) 4-Light Green

Fig. Z-Transmission Lube Pressure Gauge

The gauge registers from 0 to 60 psi (0 to 4 bar) (0 to


4 kg/cm”). When the engine is idling the gauge should
register in the striped zone (4 to 14 psi LO.3 to 1 bar]
LO.3 to 1 kg/cm*]). Under normal operating conditions
the gauge should register in the light green zone (14 to
60 psi Cl to 4 bar] [i to 4 kg/cm?).

IMPORTANT: Do not operate the grader if indi-


cator falls into the red-orange zone.

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JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1188 (Mar-801 Instruments and Indicators 1676-3

Transmission Oil Pressure Gauge Service Meter

The transmission oil pressure gauge (12, Fig. 1) The service meter (Fig. 4) is located on the engine
measures the transmission operating pressure. tachometer drive housing.

l-Red-Orange 3-Light Green


2-163 PSI (1124 kPa) 4-187 PSI (1290 kPa)
(11 bar) (13 bar) Fig. 4-Service Meter
6--Sending Line

Fig. 3-Transmission Oil Pressure Gauge The meter reads engine revolutions and converts it
into a figure which represents the number of hours the
The gauge registers from 90 to 250 psi (621 to 1724 engine has operated.
kPa) (6 to 17 bar). Normal operating range is in the
light green zone (163 to 187 psi [1124 to 1290 kPa1 [11 Removal
to 13 bar]). To remove the transmission lube or oil pressure
gauges, remove four screws from instrument panel,
IMPORTANT: Do not operate grader if the indi- pull out panel and disconnect oil tube from back of
cator falls into the lower red-orange zone. gauge.

NOTE: Gauge will not indicate with clutch pushed To remove the air restriction indicator, remove left
in. hand instrument panel console cover, disconnect air
hose, remove attaching hardware and remove indica-
Air Restriction Indicator tor.
The air restriction indicator (17, Fig. 1) will show red
when the air intake system is excessively restricted. To remove the service meter, loosen hex nut and
pull up on meter.
Rear Steer Indicator
To remove the rear steer indicator, remove front
The optional rear steer indicator may be located valve cover, disconnect cable and pivot near instru-
directly above the instrument panel vandal cover ment panel and remove linkage from grader pivot area.
opening.

The indicator will show the operator whether the rear


of the unit is in line with or pivoted to the right or the left
in relation to the front of the unit.

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16 Electrical Systems JD670-A and JD672-A Motor Graders
1676-4 Instruments and Indicators TM- 1188 (Mar-80)

Repair High Beam Indicator

The transmission oil and lube pressure gauges, the The high beam indicator (4, Fig. 1) is controlled by
air restriction indicator or the service meter cannot be the high beam switch. When the driving lights are on
repaired. high beam the indicator will light.

Test the transmission oil and lube pressures (see


Group 9025) and compare with gauge readings.

Test the restriction indicator as described in Group


9010.
T38469N
On rear steer indicator make sure indicator linkage
Fig. &High Beam Indicator
is not damaged and moves freely. Adjust indicator and
linkage as described in Group 9030.
Brake Pressure Indicator

Installation The brake pressure indicator (2, Fig. 1) will light


when pressure in the system falls below approximately
Follow removal procedure in reverse order.
1350 psi (9308 kPa) (93 bar).

NOTE: Insert oil pressure tube in union and tighten


nut on union one full turn after finger tight.

Install linkage and rear steer indicator in reverse of


removal sequence. Adjust indicator and linkage as
described in Group 9030.

ELECTRICAL SENSING GAUGES


AND INDICATORS c/
T60352NY

General Information l-Brake Pressure ~-LOW Brake Pressure


Indicator
Turn Indicator
Fig. 7-Brake Pressure Indicator
There are two turn indicators (1 and 8, Fig. 1)
activated by the turn signal switch. The left indicator
will flash for a left turn, the right indicator will flash for a
right turn and both will flash when the turn signal switch
is in the emergency position.

T38467N

Fig. 5-Turn Indicator

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JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1188 (J&78) Instruments and Indicators 1676-5

Locking Pin Indicator Transmission Filter Restriction Indicator

The locking pin indicator (6, Fig. 1) will light when- The transmission filter restriction indicator (8, Fig. 1)

.
ever the locking pin is not fully engaged. will light whenever there is a pressure differential in the
transmission filter of more than 61 psi (4 bar) (4.3
kg/cm2) indicating a restriction in the filter. q
I *
1cl
0”
T60353NY

l-Locking Pin Indicator 2-Locking Pin Switch

Fig. d-Locking Pin Indicator 2-Transmission Filter


l-Transmission Filter
Indicator Pressure Switch
Alternator Indicator
Fig. 7 i-Transmission Filter Restriction
The alternator indicator (19, Fig. 1) glows red when indicator
the alternator is not charging.
An engine oil pressure switch will turn on the indi-
cator with the key switch on and engine not running.

Fig. O-Alternator Indicator

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1676-6 Instruments and Indicators TM- 1188 (J&78)

Engine Coolant Temperature Gauge Engine Oil Pressure Gauge

The engine coolant temperature gauge (3, Fig. 1) The engine oil pressure gauge (15, Fig. 1) measures
indicates the coolant temperature in-the cooling sys- the oil pressure in the engine.
tern.

1 -Red-Orange 3-25 PSI (2 bar)


l-l OO’F (38°C) 6-224°F (107°C) 2-10 PSI (0.7 bar) (2 kglcmz)
P-Black GRed-Orange (0.7 kg/cm*) 4-Light Green
3-160°F (71°C) 7-280°F (138°C) !&Sending Unit
4-Light Green 8-Gauge Sending Unit
Fig. 13-Engine Oil Pressure Gauge
Fig. 12-Engine Coolant Temperature Gauge
The gauge indicates pressure from 0 to 80 psi (0 to 6
The gauge indicates temperatures from 100” to bar) (0 to 6 kg/cm2).
300°F (38” to 149°C).
The normal operating range is 25 to 80 psi (2 to 6
Normal operating temperature is indicated by the bar) (2 to 6 kg/cm2).
light green zone (160” to 224°F 171” to 107”Cl).

The sending unit is located on the cylinder head.

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JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1188 (J&78) Instruments and Indicators 1676-7

Fuel Gauge Transmission Oil Temperature Gauge


The fuel gauge (18, Fig. 1) is used to determine the The transmission oil temperature gauge (7, Fig. 1)
amount of fuel in the fuel tank. measures the temperature of the oil in the transmis-
sion.
.
m
The operatina range of the gauge
- - is 0” to 300°F
1-18” to 1496 ‘I’ -

The normal operating range is the light green zone


(0” to 222°F [-18” to 105”C]).

T38475N
l-Light Green 3--Red-Orange
1 -Orange 2-Light Green 2-222°F (106°C) 4--Sending Unit

Fig. 14-Fuel Gauge Fig. 15-Transmission Oil Temperature Gauge

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16 Electrical Systems JD670-A and JD672-A Motor Graders
1676-8 Instruments and Indicators TM- 1188 (Dee-87)

HFWD Charge Pressure Gauge The HFWD return filter indicator will light with a
(JD672-A only) pressure differential of 13 to 17 psi (90 to 117 kPa)
(0.9 to 1 bar) in the filter indicating a restricted filter.

The light will also light with the key switch on and
engine not running as an indicator check. This is
accomplished with a pressure switch in the engine
oil pressure circuit.

Hour Meter
(Later Units)

l-Red-Orange 4-240 (414 kPa)


2-120 PSI (827 kPa) PSI (17 bar)
(8 bar) 5-Light Green
3-130 PSI (896 kPa) B-Sending Tube
(9 bar)

Fig. 16-HFWD Charge Pressure Gauge

The gauge indicates the charge pressure of the


hydraulic front wheel drive system.

The gauge indicates from 0 to 300 psi (o-2067


kPa) (0 to 21 bar).

HFWD Return Filter Indicator


(JD672-A Only)
T43770N

Fig. 78-Hour Meter

The hour meter is an electrically energized clock


which records the number of hours the engine has
operated. Starting and stopping of the clock is
controlled by the key switch “IGN” terminal.

A pressure switch in the engine oil filter base


grounds the hour meter circuit only when the engine
is running.

l-Indicator P-Pressure Switch

Fig. 17-HFWD Return Filter Indicator

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JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1188 (Jul- 79) instruments and Indicators 1676-9

Removal To replace the bulbs in the various indicator lights,


remove socket from indicator lens and turn bulb to
To remove any gauge or indicator from instrument
remove from socket.
panel, remove four screws from panel, pull out panel,
disconnect wires from gauge or indicator to be re-
Use the follcwing chart for indicator light bulb re-
moved and remove attaching hardware.
placement:

Repair indicator Light Bulb


Color Trade No.
The gauges cannot be repaired. Test according to
instructions in Group 9015. Replace any defective
Locking Pin Red 456R
gauge.
Brake Pressure Red 456R
Transmission Filter Red 456R
If the HFWD return filter and transmission filter re-
Alternator Red 456R
striction indicators do not operate properly, the pres-
High Beam Blue 1829 1
sure switches, located on the engine block, may be
Right Turn Green 4566
defective.
Left Turn Green 4566
HFWD Filter Red 456R

Installation
Follow removal procedure in reverse order.

When installing engine oil pressure gauge tube,


insert tube in connector and tighten nut on connector
one full turn past finger tight.

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1676-10 Instruments and Indicators TM- 1188 (Jul- 79)

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JD670-A and JD672-A Motor Graders Electrical Systems 16
TM-1188 (J&78) Specifications and Special Tools 1699-1

Group 1699
SPECIFICATIONS AND SPECIAL TOOLS
c
BATTERIES, SUPPORTS AND CABLES rm
SPECIFICATIONS AND TORQUE VALUES

Battery ground .............................................................................. Negative


Full charge specific gravity (corrected for 80°F [27”Cl electrode temperature) ......................... 1.260
Maximum variation between cells during specific gravity test (specific gravity points) .................. 0.050
High-rate discharge test (minimum reading per cell). ............................................ .9.0 volts

When replacing the batteries use the John Deere battery or its equivalent shown in the following chart:

cold
Cranking Reserve
AMPS Capacity
John Deere BCI -20°F (Minutes at
Part Number Volts Group (-CC, (-29°C) 25 amps)

AT29 160
(2 used) 12 30H 570 450 180

ALTERNATOR, REGULATOR AND CHARGING SYSTEM WIRING


SPECIFICATIONS AND TORQUE VALUES

42 Amp Alternator Stator winding. . . . . . . . . . . . Wye


Brush minimum length . . . . . . ;‘/i-~GI ‘(ii.b mm)
Field current draw at 70” to 80°F
(21” to 27°C). . . . . . . . . 0.50 to 1.10 amps
Field resistance at 70” to 80°F
(21” to 27°C). . . . _ . . . . . . 13.4 to 14.6 ohms

1 - Alternator pulley nut . . . . . 4.5 to 50 lb-ft


(61 to 68 Nm) (6 to 7 kg-m)

Fig. l-Alternator Pulley Nut

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1699-2 Specifications and Special Tools TM-1 188 (J&78)

ALTERNATOR, REGULATOR AND CHARGING SYSTEM WIRING


SPECIFICATIONS AND TORQUE VALUES-Continued

1 - Brush holder screws . . . I _. . . 16 to 20 lb-in


(1.8 to 2.3 Nm) (0.18 to 0.23 kg-m)

Fig. 2-Brush Holder Screws

1 - Regulator mounting
screws ..... .. ... ... . . . . . 30 to 35 lb-in
(3.4 to 4 Nm) (0.35 to 0.40 kg-m)
2- Ground and regulator
terminal nuts.. ... ..... . . . . 35 to 45 lb-in
(4 to 5.1 Nm) (0.40 to 0.52 kg-m)
3- Alternator through
bolts . . . ..... .... . . 30 to 35 lb-in
(3.4 to 4 Nm) (0.35 to 0.40 kg-m)
4- Rectifier diode terminal
nuts.. . . . . . . . . . . . ... . . . . 33 to 40 lb-in
(3.7 to 4.5 Nm) (0.38 to 0.46 kg-m)

Fig. 3-Rear View of Alternator

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JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1188 (Jul-78) Specifications and Special Tools 1699-3

ALTERNATOR, REGULATOR AND CHARGING


SYSTEM WIRING
SPECIFICATIONS AND TORQUE VALUES-Continued

50 Amp Alternator Rating

50Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 volt
Ground . . . . . . . . ... . . Negative
Stator Winding . . .... .. .. . . . Wye

1 - Stud
2 - Flanged Hex Nut . . .... 65 lb-in (7.3 Nm)
(0.75 kg-m)

Prior to tightening flanged hex nut, obtain minimum


rotorlstator clearance of 0.005 in. (0.13 mm).

3- Spacer
4- Ground Lead
5- Regulator
6 - Spring Washer
7- Double Chamfered Nut. . . . . . . . . 25 to 30 lb-in

4 (2.8 to 3.4 Nm) (0.29 to 0.35 kg-m)

Fig. 4-Stator and Regulator


Hold Down Nut Specifications

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16 Electrical Systems JD670-A and JD672-A Motor Graders
1699-4 Specifications and Special Tools TM- 1188 (Jul-78)

ALTERNATOR, REGULATOR AND CHARGING


SYSTEM WIRING
SPECIFICATIONS AND TORQUE VALUES-Continued

259977N

No. Part Description Torque Specification

1 .. Pulley Nut ............................................................. 70 lb-it (95 Nm) (10 kg-m)


2 .. Heat Sink Cap Screw ................................................ 25 lb-in (2.8 Nm) (0.29 kg-m)
3 .. Phase Lead Cap Screw .............................................. 20 lb-in (2.3 Nm) (0.23 kg-m)
4 .. Ground Stud Nut* ................................. 60 to 70 lb-in (6.8 to 7.9 Nm) (0.69 to 0.81 kg-m)
5 .. Stator Hold Down Nut*. .............................................. 65 lb-in (7.3 Nm) (0.75 kg-m)

6 .. Rotor Nut ............................................................... 55 lb-ft (75 Nm) (8 kg-m)


7 .. Regulator Hold Down Nut* ......................... 25 to 30 lb-in (2.8 to 3.4 Nm) (0.29 to 0.35 kg-m)
8 .. Regulator Terminal Cap Screw. ...................... 8 to 10 lb-in (0.9 to 1.1 Nm) (0.09 to 0.12 kg-m)
9 .. Regulator Terminal Cap Screw ........................................ 20 lb-in (2.3 Nm) (0.23 kg-m)

10 Load Dump Terminal Screw ........................ 10 to 15 lb-in (1.1 to 1.7 Nm) (0.12 to 0.17 kg-m)
11 Load Dump Mounting Screw. ........................ 8 to 10 lb-in (0.9 to 1.1 Nm) (0.09 to 0.12 kg-m)
12 End Housing Flanged Nut* ........................................... 45 lb-in (5.1 Nm) (0.52 kg-m)
*Apply John Deere Low Strength Loctite or equivalent to stud.

Fig. 5-50 Amp Alternator Torque Values

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JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1188 (Mar-80) Specifications and Special Tools 1699-S

LIGHTING SYSTEM
SPECIFICATIONS AND TORQUE VALUES

Use the following chart for replacement of sealed


beams and light bulbs:

Light Trade No.


Front turn light with
cab or canopy 1683
Front turn light without
cab or canopy 1683
Rear turn light with
cab or canopy 1683
Driving light with cab
or canopy 4579
Driving light without
cab or canopy 4579
Main frame work light 4578
Under platform work
light John Deere Part No. AT48364
Dome light with cab or
canopy 1309
Gauge light 1864
Rear taillight and turn light (early units) 4579 R
(later units) 1662

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16 Electrical Systems JD670-A and JD672-A Motor Graders
1699-6 Specifications and Special Tools TM- 1188 (Mar-80)

WIRING HARNESS AND SWITCHES


SPECIFICATIONS AND TORQUE VALUES

Fuses

FUSe Location

Ignition Main Fuse Block 10 amp


Hydraulic Front Wheel Drive Main Fuse Block 5 amp
Turn Signal Flasher Main Fuse Block 10 amp
Stop Lights Main Fuse Block 10 amp
Horn Main Fuse Block 10 amp
Gauges Main Fuse Block 5 amp
Defrost Fan Cab Fuse Block 3 amp
Front Wiper Cab Fuse Block 3 amp
Rear Wiper Cab Fuse Block 3 amp
Dome Light (w/o A/C) Cab Fuse Block 3 amp
Dome Light and Air Conditioning Cab Fuse Block 15 amp
Auxiliary Controls Auxiliary Control Box 5 amp
Hydraulic Front Wheel Drive HFWD Control Box 1 amp - 8AG
Hydraulic Front Wheel Drive HFWD Control Box 1 amp - 8AG
Small Floor Heater In-Line 5 amp
Large Floor Heater In-Line 10 amp
Reverse Warning Alarm In-Line 3 amp

Circuit Breakers

Use Size
Work Light (without under platform
work lights) 10 amp
Work Light (with under platform
work lights) 15 amp
Drive Light 10 amp

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JD670-A and JD672-A Motor Graders Electrical Sys terns 16
TM- 1188 (Jun-83) Specifications and Special Tools 1699-7

WIRING HARNESS AND SWITCHES


SPECIFICATIONS AND TORQUE VALUES-Continued

Neutral Start and Reverse Warning


Switches

l* - Adjust neutral start switch with shims


until unit will start in neutral ONLY.
Tighten to . . . . . . . . . . . . . . . . . 20 to 25 lb-ft
(27 to 34 N.m) (2.8 to 3.5 kg-m)

NOTE: On units with two switches, no adjustment is


required.

2* - (JD670-A)
Adjust reverse warning switch with
shims until switch is closed in
reverse only.
Tighten to . . . . . . . . . . . . . . . . . 20 to 25 lb-ft
(27 to 34 N.m) (2.8 to 3.5 kg-m)

3 - (JD672-A)
Not Adjustable

*NOTE: See Group 1674 for proper adjustment proce-


dure.

Fig. &Neutral Start and Reverse Warning Switches

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16 Electrical Systems JD670-A and JD672-A Motor Graders
1699-6 Specifications and Special Tools TM- 1188 (Dee-87)

SYSTEM CONTROLS
SPECIFICATIONS AND TORQUE VALUES-Continued

Rear Sensor

Rear Sensor - Thread sensor through bracket until


end touches a tip of the brake disc. Rotate sensor
counterclockwise one full turn.

Sensor clearance . . . . . , . . , . , . .0.045 + 0.025 in.


(1 .14 5 0.63 mm)

Tightenjamnutto ..~ . . . . . . . . . . . . lOto20Ib-ft*


(14 to 16 N+m)

*NOTE: Overtightening will cause sensor damage.

Fig. 7-Rear Sensor

Front Sensor
Front Sensor - Turn sensor and harness in until it
contacts sensor gear. Rotate sensor counterclock-
wise 270 degrees.

Tightenjamnutto . . . . . . . . . . . . . . . lOto12lb-ft*
(14 to 16 N.m)

*NOTE: Overtightening will cause sensor damage.

Fig. d-front Sensor (Early Units)

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JD670-A and JD672-A Motor Graders Electrical Sys terns 16
TM- 1188 (Jun-83) Specifications and Special Tools 1699-9

, SYSTEM CONTROLS
SPECIFICATIONS AND TORQUE VALUES-Continued

Front Sensor - Install sensor until it


meets resistance (stops). Rotate sensor
counterclockwise 270 degrees.
Hold sensor and tighten
jam nut to . . . . . . . . . . . . . . . . . . . . 10 to 12 lb-ft*
(14 to 16 N.m)

*NOTE: Overtorquing will cause sensor damage.

Fig. 8A-Front Sensor (Later Units)

1 - 4 Cam Switch, Forward Cam Switch,


Reverse Cam Switch
(JD672-A Only)

l* - Adjust 1 - 4 cam switch with shims


so that switch is closed in gears
1 to 4 only.
Tighten to ...... . . . . . . . . 20 to 30 lb-ft
(27 to 41 N.m) (2.8 to 4.1 kg-m)

2* - Adjust forward cam switch with


shims so that switch is closed
in forward only.
Tighten to , . . . ... ... . 20 to 30 lb-ft
(27 to 41 N.m) (2.8 to 4.1 kg-m)

3* - Adjust reverse cam switch with


shims so that switch is closed
in referse only.
Tighten to . . . . . . . . . . . . . . . 20 to 30 lb-ft
(27 to 41 N.m) (2.8 to 4.1 kg-m)

*NOTE: See Group 1675 for proper adjustment


procedure.

Fig. 9-HFWD Switches

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16 Electrical Systems JD670-A and JD672-A Motor Graders
1699-10 Specifications and Special Tools TM- 1188 (J&78)

INSTRUMENTS AND INDICATORS


SPECIFICATIONS AND TORQUE VALUES

Transmission Lube Pressure Gauge


Gauge operating range. . . . . . . .O to 60 psi
(0 to 4 bar) (0 to 4 kg/cm2)
Gauge range during engine idling . . . .4 to 14 psi
(0.3 to 1 bar) (0.3 to 1 kg/cm2)
Normal operating range . . . . . . . .14 to 60 psi
(1 to 4 bar) (1 to 4 kg/cm2)
Transmission Oil Pressure Gauge
Gauge operating range.. . . . . . . . 90 to 250 psi
(6 to 17 bar) (6 to 18 kg/cm2)
Normal operating range . . . . . . . . . . . 163 to 187 psi
(11 to 13 bar) (12 to 13 kg/cm2)
Brake Pressure Indicator Light
Indicator will light when pressure
drops below . _ .. ... ...... . 1350 psi
(93 bar) (95 kg/cm2)
Transmission Filter Restriction Indicator Light
Indicator will light with pressure
differential of more than. . . . . . . . . . 61 psi
(4.2 bar) (4.3 kg/cm*)
Engine Water Temperature Gauge
Gauge operating range. . . . . . . 100” to 300°F
(38' to 149°C)
Normal operating range . . . . . . . . . . 160” to 224°F
(71” to 107°C)
Engine Oil Pressure Gauge
Gauge operating range.. . . . . . . . . . . .O to 80 psi
(0 to 5.5 bar) (0 to 6 kg/cm2)
Normal operating range . . . . . . . . . . . . .25 to 80 psi
(1.7 to 5.5 bar) (2 to 6 kg/cm2)
Transmission Oil Temperature Gauge
Gauge operating range. _. . . . . . . . . . . . 0 to 300°F
(0 to 149°C)
Normal operating range . . . . . . . . . . . . . 0 to 222°F
(0 to 105°C)

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JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1188 (Mar-80) Instruments and Indicators 1699-l 1

INSTRUMENTS AND INDICATORS

a.
SPECIFICATIONS AND TORQUE VALUES-Continued

HFWD Charge Pressure Gauge


(JD672-A only)

Gauge operating range . . . . . . .O to 300 psi


(0 to 2069 kPa) (0 to 21 bar)
I
HFWD Return Filter Indicator
(JD672-A Only)

Indicator will light when pressure


differential in filter is . . . . . . . . . . .13 to 17 psi
(90 to 117 kPa) (0.9 to 1 bar) ’

Indicator Light Bulb Replaceme*nt Chart

Indicator Light Bulb


Trade No.
Locking Pin Red 456R
Brake Pressure Red 456R
Transmission Filter Red 456R
Alternator Red 456R
High Beam Blue 1829
Right Turn Green 4566
Left Turn Green 4566
HFWD Filter Red 456R

Engine Oil Pressure Gauge. . . . . . . . . . . . . . Tighten


nut on union one full
turn past finger tight.

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16 Electrical Sys terns JD670-A and JD672-A Motor Graders
1699-12 Specifications and Special Tools TM- 1188 (Mar-801

BATTERIES, SUPPORTS AND CABLES


SPECIAL TOOLS

Ica
l Convenience Tools
Tool Tool Number Use

TY-1337 (10 amp) Charge battery and


TY-5104 (15 amp) booster to start
TY-5105 (30 amp) engine.
TY-5106 (100 amp)

Fig. 1O-Battery Charger


(100 amp shown)
..... .. .. . .. Hydrometer - to check
specific gravity.

T70047
Fig. 1 l-Hydrometer

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JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1188 (J&78) Specifications and Special Tools 1699-13

BATTERIES, SUPPORT AND CABLES


SPECIAL TOOLS-Continued

Convenience Tools-Continued

Too! Tool No.

D-24001 MD Battery Tester - To check battery


internal condition

l5728ON
Fig. ISBattery Tester

ALTERNATOR, REGULATOR AND CHARGING


SYSTEM WIRING
SPECIAL TOOLS

Convenience Tools

Tool Tool No. Use

Alternator Diode Tester - To test


diodes.

Fig. 13-Alternator Diode Tester

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16 Electrical Systems JD670-A and JD672-A Motor Graders
1699-14 Specifications and Special Tools TM- 1188 (J&78)

ALTERNATOR, REGULATOR AND CHARGING


SYSTEM WIRING
SPECIAL TOOLS-Continued
.
RI Convenience Tools-Continued

D-19001 TT Ohmmeter - To test diodes,


brushes. rotor and stator.

fig. 14-Volt-, Ohm-, Ammeter

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JD670-A and JD672-A Motor Graders Electrical Systems 16
TM- 1188 (J&78) Specifications and Spe&l Tools 1699-15

ALTERNATOR, REGULATOR AND CHARGING


SYSTEM WIRING
SPECIAL TOOLS-Continued

Convenience Tools-Continued

Tool Number Use

Fig. 15-A2OOJD * Alferna tar Service Tool Set

1 - A-203” Remove front bearing and sleeve


Press front bearing on sleeve
2 - A-208* Press front housing on rotor
3 - A-216* Remove front bearing and sleeve
Remove rear bearing
4 - A-201 * Install rear bearing
5 - A-209* Press sleeve out of front bearing
Install rear bearing
Press front housing on rotor
6 - A-205” Press front housing on rotor

*Tools are part of APOOJD Alternator Service Tool Set


and cannot be purchased individually.

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1699-16 Specifications and Special Tools TM- 1188 (J&78)

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JD670-A and JD672-A Motor Graders Frame, Chassis or Supporting Structure 17
TM- 1188 (J&78) Frame Installation 1740-l

Section 17
FRAME, CHASSIS OR SUPPORTING
STRUCTURE
CONTENTS OF THIS SECTION

Page Page
q
GROUP 1740 - FRAME INSTALLATION GROUP 1746 - BOTTOM GUARDS
Engine Frame. ....................... 1740-3 General Information .................. 1746-l
General Information ................ 1740-3 Removal ............................ 1746-l
Removal .......................... 1740-3 Repair .............................. 1746-1
Separating of Engine and Installation ........................... 1746-l
Equipment Frames ............. 1740-3
Separating Power Unit From GROUP 1747 - VEHICLE BUMPERS
Engine Frame ................. 1740-4 Rear Panels and Bumper ............. 1747-l
Repair ............................ 1740-5 General Information ................ 1747-1
Installation. ........................ 1740-5 Removal .......................... 1747-l
Joining Engine and Equipment Repair ............................ 1747-1
Frames.. ..................... 1740-5 Installation ......................... 1747-2
Joining Power Unit and Engine
Frame.. ...................... 1740-5 GROUP 1799 - SPECIFICATIONS AND
Equipment Frame .................... 1740-6 SPECIAL TOOLS
General Information ................ 1740-6 Specifications and Torque Values
Removal .......................... 1740-6 Equipment Frame . . 1799-l
Repair ............................ 1740-6 Special Tools
Installation. ........................ 1740-6 Equipment Frame . . .. 1799-2

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1740-2 Frame lnstalla lion TM- 1188 (J&78)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Frame, Chassis or Supporting Structure 17
TM- 1188 (J&78) Frame Installation 1740-3

Group 1740
FRAME INSTALLATION
ENGINE FRAME Disconnect transmission pressure gauge lines, air

q
cleaner restriction indicator line, transmission lube
General Information
pressure gauge lines, park brake lube hose and front
The engine frame is a welded assembly which sup- wheel drive charge pressure gauge line if equipped.
ports the engine and related components. It connects
the power train to the frame steer at the final drive and Disconnect heater hoses, brake and differential lock
transmission. hoses, electrical harness, and all hoses between en-
gine frame and main frame.
Removal
Tag hoses for correct assembly.
Separation of Engine and Equipment Frames
Drive motor grader straight ahead and stop with Upper and lower rear panels can be removed if
blade centered perpendicular to forward direction of desired (not necessary). Remove bumper and service
unit and in horizontal position on the ground. Relieve housing (see Group 1910). Install support bar on en-
hydraulic pressure in hydraulic system. gine frame (see Fig. 3, Group 1799) to keep power unit
from rotating on tandem axles.
Disconnect steering cylinders at rod end as shown in
Fig. 1. Refer to Group 0960 for information on removal.

l-Steering Cylinder Pin P-Steering Cylinder

Fig. 1-Disconnecting Steering Cylinders

Disconnect wiring harnesses at bulkhead.

Disconnect throttle cable, clutch cable, speed se-


lector cable, direction selector cable, park brake cable
and cold weather disconnect cable if equipped.

l-Upper Pivot Pin 2-Lower Pivot Pin


3-Pin Retainer

Fig. P-Pivot fins

Remove upper and lower pivot pins (1 and 2, Fig. 2).

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17 Frame, Chassis or Supporting Structure JD670-A and JD672-A Motor Graders
1740-4 Frame Installation TM- 1188 (J&78)

Separating Power Unit From Engine Frame Disconnect all hydraulic hoses between engine
frame and main frame.
For servicing major areas of the power unit, the
power unit may be separated from the engine frame
Disconnect healer hoses if equipped.
and roiled away from the vehicle, or the power unit may
be left in the engine frame and the engine final drive
Remove rear steer cylinder pin with retaining hard-
assemblies and transfer drive removed separately as
ware from final drive housing (see Fig. 1).
required. If shop space is limited, roll only the power
unit into the shop for repair.
Disconnect hydraulic pump-to-priority valve line
from hydraulic pump.
NOTE: Once separation is made, the power unit
can on/y be moved in a straight line. Therefore, be sure
Attach hoist (5-ton [4500 kg] capacity) to main
motor grader is positioned correctly before making
frame.
separation.
Install transfer case support bar on rear of tandem
NOTE: Remove any rear mounted options such as
housings (on steps). Install i/2 inch pins (6 inches
ripper, bottom guard or snow wing support.
[152 mm] long) in each mounting pad to prevent sup-
port bar from moving during its use. See Group 1799
Use the following procedure to separate the power
(Fig. 3) for directions on making support bar.
unit from the engine frame.

NOTE: Position the blade centered perpendicular to


forward direction of unit and horizontal with the unit so
A CAUTION: The transfer case support bar
prevents the transmission and transfer
case from oscillating around the final drives once
the blade can stabilize the main frame.
the connecting pins are removed. Be sure support
bar is snug against transfer housing.
Remove muffler, pre-cleaner, hood and service
housing as directed in Group 1910.
Remove cap screws retaining engine frame to final
drive housing and transmission case.
Disconnect battery ground strap, starter cable, and
fuel lines.
NOTE: On rear joint on/y of final drive housing to
engine frame, drive hollow dowel through after cap
Unhook main wire harness at bulkhead connector
screw removal.
on inside of left engine frame channel.
Use hoist (Non E4500 kg] capacity) to lift main
Break hydraulic line connections at clamp on front of
frame and engine frame as a unit. Roll power unit out
engine frame. Tag all connections for installation.
from under the engine frame.

Disconnect park brake cable, speed selector cable,


Install engine frame support bar on rear of engine
direction selector cable, clutch cable, throttle cable,
frame. See Group 1799 (Fig. 2) for directions on mak-
and cold weather disconnect cable (if equipped).
ing engine frame support bar.

Disconnect gauge lines from control panel at power


unit, rather than at console.

Disconnect air cleaner restriction indicator tube.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Frame, Chassis or Supporting Structure 17
TM- 1188 (Dee-87) Frame Installation 1740-S

Repair Installation
Refer to Fig. 3 during disassembly and assembly Joining Engine and Equipment Frames
of engine frame. Inspect bushings for wear. Replace
Use reverse of removal procedure to join engine
parts as necessary.
and main frames.

When connecting wiring harness, be sure con-


nectors are installed at the proper terminals.

Joining Power Unit and Engine Frame

Position main frame so engine frame clears axle.

Roll power unit into position inside engine frame.

Use reverse of removal procedure to install all


hardware, lines, and cables.

l-Cap Screw (4 used) 6-Cap Screw (4 used) IMPORTANT: Tighten lower pivot pin (2, Fig. 2),
l--Washer (6 used) 7-Washer (4 used)
nut, and strike pin with a lead hammer to properly
3-Upper Pivot Bushing 6-Nut (4 used)
4-Lower Pivot Bushing g--Grease Fitting seat pin. Loosen nut to zero torque and re-tighten
B-Engine Frame lo-spacers (2 used) until it is just snug. Install cotter pin through nut and
1 l-Shim (8 used) (505455- ) hole in lower pivot pin.

Fig. 3-Engine Frame Connect wiring harness. Be sure connectors are


attached to proper terminals.

Litho in U.S.A.
17 Frame, Chassis or Supporting Structure JD670-A and JD672-A Motor Graders
1740-6 Frame Installation TM- 1188 (J&78)

EQUIPMENT FRAME

General Information Remove front axle as directed in Group 0230.

The main frame is a welded assembly which serves Remove scarifier as directed in Group 4240.
as a mounting area for cab, lift arms, draft frame, front
axle and scarifier. Repair
Use Fig. 1 as a guide during disassembly and as-
Removal
sembly. Inspect bushing (5) and pivot pins (20 and 25)
Refer to Engine Frame, this Group, for separation of for excessive wear. Replace parts as necessary.
frames.
Installation
If necessary, remove the following:
Use reverse of removal procedure to join frames and
Remove cab as directed in Group 1810.
reinstall major components on main frame.
Remove lift arms and draft frame as directed in
IMPORTANT: Tighten lower pivot pin nut (17,
Group 3440.
Fig. 1) and strike pin with A lead hammer to prop-
erly seat pin. Loosen nut to zero torque and re-
tighten until it is just snug. Install cotter pin
through nut and hole in lower pivot pin.

TS9909N

l-Cotter Pin 12-Isolator 23-Cover Plate (2 used)


l-Nut $3~Isolator 24-Valve Cqver (2 used)
3-Special Washer M-isolator 26-Washer (8 used)
4-Lower Boom Pivot Pin X--Cap Screw (2 used) 26-Gap Screw (8 used)
S-Pin Retainer 16-Washer (14 used) 27-Gap Screw (2 used)
g--Washer (2 used) 17-Upper Panel 28-Isolator (2 used)
7-Gap Screw (2 used) l&Bushing (2 used) 29-Special Nut (2 used)
8-Special Lock Nut 19-Bushing (2 used) to-Rear Steer Cylinder Pin
g-Upper Boom Pivot Pin 20-Bushing (2 used) (2 used)
lo-Grease Fitting (3 used) 21-Main frame With Bushings 31-Cap Screw (2 used)
11 -Cap Screw 22-Clamp (2 used) 32-Special Washers (2 used)

fig. 4-Main Frame

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Frame, Chassis or Supporfing Structure 17
TM- 1188 (J&78) Bottom Guards 1746-1

Group 1746
BOTTOM GUARDS
GENERAL INFORMATION
The motor grader may be equipped with a bottom
guard if not equipped with ripper. The bottom guard
protects transmission and engine components from
contamination and damage from rocks,

REMOVAL
Support bottom guard with moveable jacks.
TS9910N

Remove retaining cap screws. Lower bottom guard l-Bottom Guard 3-Washer
and slide from under rear of engine frame. P-Cap Screw 4-Lock Washer

Fig. l-Bottom Guard


REPAIR
Refer to Fig. 1 during disassembly and assembly. INSTALLATION
Replace parts as necessary.
Use reverse of removal procedure to install bottom
guard.

Litho in U.S.A.
17 Frame, Chassis or Supporting Structure JD670-A and JD672-A Motor Graders
1746-2 Bottom Guards TM- I 188 (J&78)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Frame, Chassis or Supporting Structure 17
TM- I188 (J&78) Vehicle Bumpers 1747-1

Group 1747
VEHICLE BUMPERS
REAR PANELS AND BUMPER

General Information
The rear panels and bumper enclose the rear of unit
and protect components from damage.
The service housing, mounted to the rear of the
engine frame, supports the rear panels, bumper, fuel
tank and batteries.

T’59911N

i-Service Housing 7-Cap Screw (8 used)


2-Upper Rear Panel 8-Washer (8 used)
3-Lower Rear Panel B-Cap Screw (4 used)
4-Bumper lo-Lock Washer (4 used)
%-Washer (4 used) 11-Cap Screw (2 used)
8-Cap Screw (4 used) 12-Washer (2 used)

Fig, Z-Rear Panels and Bumper

l-Upper Rear Panel 3-Bumper


Repair
2-Lower Rear Panel 4-Service Housing
Refer to Fig. 2 during disassembly and assembly.
Fig. l-Rear of Motor Grader
Replace parts as necessary.
Removal
NOTE: Service housing (I, Fig. 2) can be removed
with or without service doors (3, Fig. 3) attached.

Remove retaining hardware (7 and 8, Fig. 2) from


upper and lower rear panels. Disconnect light wiring
and lift panels out and away from service housing.

Remove cap screws (6) and washers (5) retaining


bumper to service housing. Lower bumper to the
ground.
Remove batteries and fuel tank (see Groups 1671
and 0560).
Remove service housing-to-engine frame cap
screws (9 and 11). Lower service housing to the
ground.

Litho in U.S.A.
17 Frame, Chassis or Supporting Structure JD670-A and JD672-A Moior Graders
1747-2 Vehicle Bumpers TM- 1188 (J&78)

P59912N

l-Cylinder Lock (2 used) 4-Washer (2 used)


2-Bracket With Handle 5-Spring (2 used)
(2 used) GLatch Rod (2 used)
3-Service Door 7-Cotter Pin (4 used)
(L.H. Shown)

Fig. 3-Service Door

Installation
Use reverse of removal procedure to install rear
panels and bumper.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Frame, Chassis or Supporting Structure 17
TM- 1188 (J&78) Specifications and Special Tools 1799-1

Group 1799
SPECIFICATIONS AND SPECIAL TOOLS
EQUIPMENT FRAME
SPECIFICATIONS AND TORQUE VALUES

1 - Installing Lower
pivot pin. ... .Tighten lower pivot pin nut
and strike pin with lead ham-
mer to seat pin. Loosen nut to
zero torque and retighten
until it is just snug. Secure nut
with cotter pin.

fig. I-Installing Lower Pivot Pin

Litho in U.S.A.
17 Frame, Chassis or Supporting Structure JD670-A and JD672-A Motor Graders
1799-2 Specifications and Special Tools TM- 1188 (Jul-78)

ENGINE FRAME
SPECIAL TOOLS

Essential Tools Tool Use

Support Bar To support engine frame when


power unit is removed from
grader.
6 -
6
7 ’ t 3 Use quarter-inch angle iron to make support bar.
c Cut iron using dimensions 1, 8 and 9. Drill holes to

i
49 accomodate 518” cap screws.

1 t
Weld pieces of angle iron together.

:,i

937873h

l-73 in. (1 854 mm) 5-4 in. (102 mm)


2-36.5 in. (927 mm) 6-l 1.25 in. (285.75 mm)
3-15 in. (381 mm) 7-13 in. (330 mm)
4-33 in. (838 mm) 840.5 in. (1 028.7 mm)
9-46 in. (1 218.8 mm)

FI& P-Support Bar

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Frame, Chassis or Supporting Sfructure 17
TM- 1188 (Jul-78) Specifications and Special Tools 1799-3

SPECIAL TOOLS-Continued

Essential Tools-Continued

g/!gp/e
_I aa.,,,,i
2 inches
(51 mm)
(127 mm)

4 in

4 inches (51 mm)


(102 mm)

Fig. 3-Transfer Case Support Bar

l- l/4 x 3 x 4 inch channel iron 7-l /4 inches (184 7 - i/4 x 2 x 2 inch channel iron 8 inches (203 mm
mm) long (2 used). long (2 used).

2- 1/4 x 7-l/2 x 5 inch plate (4 used). Drill i/2 inch 8 - l/4 x 3 x 4 inch channel iron 52-l/2 inches (1 33,
holes as shown. mm) long.

3 - l/4 x 6-l/4 x 5 inch plate (4 used). Use quarter-inch plate steel and channel iron t,
make transfer case support bar.
4 - l/4 x 2 x 2 inch channel iron 12 inches (305 mm)
long. Weld pieces together as shown in assembly view

5- l/4 x 4 x 4 inch gusset (2 used).

6- 1/4 x 2 x 3 inch gusset (4 used).

Litho in U.S.A.
17 Frame, Chassis or Supporting Structure JD670-A and JD67.?-A Motor Graders
1799-4 Specifications and Special Tools TM- 1188 (J&78)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Operator’s Station 18
TM- 1188 (Dee-87) Operator Enclosure 1810-l

Section 18
OPERATOR’S STATION
CONTENTS OF THIS SECTION

Page Page
GROUP 1810 - OPERATOR ENCLOSURE GROUP 1830 - HEATING AND AIR
Cab ........................... ..1810- 3 CONDITIONING-Continued
General Information ............... 181 O-3 Checking and Adding Compressor Oil.1 830-l 6
Removal ........................ 1810-3 When Servicing Compressor ....... 1830-I 7
Repair ......................... 1810-3 When Servicing System Components
Installation ..................... 1810-l 1 Other Than Compressor ........... 1830-l 7
Control Mounting Structures ......... 181 O-12 Leak Testing Compressor .......... 1830-18
Front Windshield Wiper ............. 181 O-13 Installation ..................... 1830-20
Rear Wiper ...................... 1810-14 Condenser, Receiver-Dryer and Evaporator
Defroster Fan ..................... 1810-14 Condenser
General Information ............. 1830-21
GROUP 1821 - SEAT AND SEAT BELT Removal ..................... 1830-21
General Information ................. 1821-l Repair ....................... 1830-22
Suspension Seat ................... 1821-l Installation .................... 1830-24
Removal ........................ 1821-l Receiver-Dryer
Repair ......................... 1821-l General Information ............. 1830-24
installation ...................... 1821-2 Removal ..................... 1830-25
Bench Seat ....................... 1821-3 Repair ....................... 1830-25
Removal ........................ 1821-3 Installation .................... 1830-25
Repair ....................... ..1821- 3 Heater/Evaporator Core
.lnstallation ...................... 1821-4 General Information ............. 1830-26
Removal ..................... 1830-26
GROUP 1822 - STEPS AND HANDHOLDS Repair ....................... 1830-26
General Information ................. 1822-l Installation .................... 1830-26
Removal ......................... 1822-l Regulatory Controls
Repair ........................... 1822-l Expansion Valve
Installation ........................ 1822-1 General Information ............. 1830-28
Removal ..................... 1830-28
GROUP 1830 - HEATING AND AIR Repair.. ..................... 1830-28
CONDITIONING Installation .................... 1830-28
Heating System Thermostatic Temperature Control Switch
General Information .... . . . . . .. . . . 1830-l General Information ............. 1830-29
Removal . . . . . . . . . . . . . . . . . . *. . . . 1830-l Removal ..................... 1830-29
Repair . . . . . . . . . . . . . . . . . . . .. . . . 1830-2 Repair.. ..................... 1830-30
Installation ... .... .... . . . . . .. . . . 1830-2 Installation .................... 1830-30
Air Conditioning System Compressor Relief Valve
Compressor General Information ............. 1830-30
General Information ... . ... .. . . . . . 1830-5 Removal ..................... 1830-30
Removal . . . . . . . . . . . . . .... . . . . . . 1830-7 Repair.......................1830-3 0
Repair . . . . . . . . . . . . . . ... .. . . . . . 1830-8 Installation .................... 1830-30

Contents continued on next page

Litho in U.S.A.
18 Operator’s Station JD670-A and JD672-A Motor Graders
1810-2 Operator Enclosure TM- 1188 (Mar-80)

CONTENTS OF THIS SECTION-Continued

Page
GROUP 1830 - HEATING AND AIR
CONDITIONING-Continued
Thermal Fuse and Super Heat
Shut-Off Switch
General Information . .. ... .. 1830-31
Test............................... 1830-31
Removal ... ............ ... .. 1830-31
Repair . . . . . . .... ... .. 1830-32
Installation. . . ; . . . . . .. 1830-32
Pressurizer Motor
General Information . . . . . . . . . . .. 1830-32
Repair .. .... ..... .. . ... 1830-32

GROUP 1899 - SPECIFICATIONS AND


SPECIAL TOOLS
Specifications and Torque Values
Operator Enclosure, ... . . . . . . . . . 1899-1
Heating and Air Conditioning . ... 1899-2
Special Tools
Heating and Air Conditioning . . . . . . . . . 1899-4

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Operator’s Station 18
TM- I 188 (Jul- 79) Operator Enclosure 1810-3

Group 1810
OPERATOR ENCLOSURE
CAB NOTE: Lift cab assembly straight up to avoid dam-
aging door tracks.
General Information
The cab is designed
and access to controls.
for optimum operator safety A CAUTION: Use care when lifting cab to
avoid tipping the assembly over back-
wards.
A Personal Posture” seat or bench seat is available
with the cab. Repair
A cab door release lever is also available. Refer to Figs. 1 through 9 during disassembly and
assembly of the cab.
Removal
Tighten special cap screw (28, Fig. 1) to 300 lb-ft
NOTE: A minimum clearance of 170 inches (4.5 m)
(407 Nm) (42 kg-m) and stake hex nut (18) to cap
(180 inches [4.6 ml on units with air conditioning) is
screw.
necessary for cab removal. Do not attempt to remove
cab without minimum clearance.
Note the following during assembly of door.

A CAUTION: On units equipped


conditioning, discharge
with air
the system as Insert spring (25, Fig. 9) into end of catch release
directed in Group 9031 before removing the cab. rod (26) to stop. Install one special screw (22) into
Failure to discharge the air conditioning system as larger hole of release rod support so that other leg of
directed can result in bodily injury from boiling support is next to cap screw head.
refrigerant.
Insert rod end with spring into smaller hole of sup-
Disconnect air conditioning as directed in Group
port. Extend rod over cap screw head through slot in
1830.
door.
Disconnect cab wiring harness from main harness at
connector under front L. H. area of platform. Position latch cover with inside handle assembl!
and door rod on door.
Remove floor mat and R. H. and L. H. foot rests.
Remove foot throttle linkage.
Align and insert cap screw with support into cove
Close heater shut-off cocks on the engine and dis- and door. Insert remaining cap screws into cover.
connect heater hoses from heater. Disconnect heater
wire lead under platform. Place catch (20, Fig. 5) in door so catch extend:
beyond rear of door. Insert pin from outside of doo
Remove bench seat (if equipped).
through door and catch. Secure with cotter pin (21)
Remove seat support-to-platform cap screws and Place clip (6, Fig. 9) and rear catch rod into remainin!
leave seat and seat support attached to rear of cab. hole of catch. Secure clip.

Disconnect cold weather clutch cable from control


It may be necessary to adjust the washer up or dowl
lever and cab at L. H. rear area of cab (if equipped).
between the two center track rollers to retain the roller
Attach chain hoist to cab. on the track. Adjust so there is 0.04 to 0.06 inch (1 .O tl
1.5 mm) from the top of the washer keeper to the top c
On units after Ser. No. xxxxx, remove button plugs
the track. Cab doors should move without interfereno
(16, Fig. 4). Attach eyebolts through holes in roof into
between washer and cab rail.
weld nuts in cab.
Attach chain hoist to eyebolts.

Remove two rear attaching bolts, four front attaching


bolts and four platform-to-cab bolts at the side.

Litho in U.S.A.
18 Operator’s Station JD670-A and JD672-A Motor Graders
1810-4 Operator Enclosure TM- 1188 (Jul- 79)

118 17
T59852N

l-Button Plug (Without Rear Wiper) 16-Isolator 21-Nut


2-Gab 11 -Seal 22-Lock Washer
3-Button Plug (2 used) (Without Front 12-Left Side Seal 23-Cleai
Wiper) 13-Main Frame Filler 24-Button Plug (2 used) (Without Air
4-Button Plug (Without Front Wiper) U-Washer (6 used) Conditioner)
6-Gap Screw (4 used) 16-Special Cap Screw (6 used) 26-Button Plug (5 used)
g-Special Washer (6 used) %---Right Side Seal 26-Button Plug
7-Hex Nut (4 used) 17-Special Screw (4 used) 27-Screw Spacer (2 used)
8-Button Plug (2 used) (Without Cold 18-Hex Nut (2 used) 28-Special Screw (2 used)
Weather Disconnect) 19-Button Plug (Without Cold Weather 29-Rear Panel Foam
g--Button Plug (2 used) (Without Cold Disconnect)
Weather Disconnect) 28-Cap Screw (4 used)

Fig. 1-Cab Assembly

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Operator 3 Station 18
TM- 1188 (Jul- 79) Operator Enclosure 1810-5

T’59853N

l-Floor Plate &Nut (2 used) M-Washer (7 used)


Z-Saddle Pin Valve Guard g--Bonded Bushing 17-Cap Screw (7 used)
3-Pin 16-Rear Bonded Bushing (2 used) 18-Nut
4-Cotter Pin 11-Mounting Bracket (2 used) 18-Cap Screw
6-Sealing Strip (2 used) 12-Cap Screw (2 used) 26--Plug
6-Cap Screw (4 used) 13-Shield (R. H. Shown) 21-Grommet
7-Washer (4 used) 14-Machine Screw (4 used) 22-Throttle Linkage Seal
16-Footrest (Ft. H. Shown)

Fig. Z-P/a tform

Litho in U.S.A.
18 JD670-A and JD672-A Motor Graders Grading Device
1810-8 TM- 1188 (Dee-87) Grading Device Frames

T6713AA 8--W'-

l-Cap Screw (2 used) 5-Nut (4 used) I-Cap Screw (4 used)


2-Spacer (2 used) B-Angle 8-Isolator (2 used)
&Nut (8 used) 7A-Channel (2 used) lo-Bracket
4-Cap Screw (4 used) 7B-Bracket (2 used) 1%Nut (4 used)

Fig. &Platform Without Cab

Litho in U.S.A.
Opera for’s Station JD670-A and JD672-A Motor Graders 18
Opera for Enclosure TM- 1188 (Dee-87) 1810-7

l-Slotted Screw (4 used) 5-Nut (6 used) lo-Receptacle (2 used)


(Without Turn Signal Lights) 6-Special Screw (2 used) 1 l-Face
P-Cover (2 used) (Without Turn ‘I-Special Washer (2 used) 12-Headliner
Signal Lights) 6-Fuse Cover 13-Molding (2 used)
t--Special Screw (2 used) g--Button Plug (w/o Front 14-Cab Roof
4-Special Screw (6 used) Wiper) l6-Spring Nut (4 used)

Fig. 4-Cab Roof (without air conditioning)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Operator’s Station
1810-8 TM- 1188 (Dee-87) Op’erator Enclosure

l-Slotted Screw (4 ured) 5-Nut (6 used) lo--Receptacle (2 used)


(Without Turn Signal Lights) B-Special Screw (2 ured) 11-Face
P-Cover (2 used) (Without Turn ‘I-Special Washer (2 used) 12-Headliner
Signal Lights) S-Fuse Cover 13-Molding (2 used)
%--Special Screw (2 used) S-Button Plug (w/o Front 14-Cab Roof
4-Special Screw (6 used) Wiper) lEGSpring Nut (4 used)
16-Button Plug (4 used)

Fig. 5-&b Roof (with air conditioning)

bitho in U.S.A.
Operator’s Station JD670-A and JD672-A Motor Graders 18
Operator Enclosure TM- 1188 (Dee-87) 1810-9

26
l’59412N
Li”59413N 15-L
l-Door Rear Seal ll-Special Bolt (4 used)
2-Cab Door 16-Plug (2 used) l-Window Latch 13--Machine Screw
3-Roller (4 used) 17-Lock Nut (2 used) (2 used) 14-Lower Front Glass
4-Roller Support 18-Washer (2 used) l-Lock Nut 15-Glass Seal
B-Cap Screw (2 used) 19-Pin (2 used) 3-Gasket 1 B-Bracket
B-Special Nut (14 used) 20-Right Catch 4-Bracket 17-Washer
T-Molding (4 used) Pl-Cotter Pin 5-Window Regulator 16-Stop Nut
6-Door Glass (4 used) 22-Catch Seal (6 used) 6-Nut Is-Spring Washer
O-Rod Bearing (2 used) 23-Quarter Panel Seal ‘I-Washer PO-Headed Pin
lo--Spacer (2 used) 24-Washer (2 used) 0-Cap Screw 21-Nut
il-Weatherstrip 26-Washer (4 used) g-Grommet PP-Washer
12-Bushing (6 used) 26-Lock Nut (2 used) lo--Hinge 23-Cotter Pin
13-Roller Mount 27-Door Catch Holes 1 l-Bushing 24-Special Screw
Channel Seal 1 P-Cap Screw
14-Pin (2 used) 26-Door Latch Seal
Fig. 7-Cab Lower Front Glass
Fig. B-Cab Door
NOTE: Window latch (1, Fig. 7) can be mounted on
either hole in bracket (16). Install the window latch(es)
in whichever hole provides best window sealing.

Position of window latch pin can also be adjusted


to improve sealing. Loosen nut on window latch pin
and move window latch pin to desired position for
proper sealing.

Litho in U.S.A.
18 JD670-A and JD672-A Motor Graders Operator’s Station
1810-10 TM- 1188 (Dee-87) Operator Enclosure

T5941.58

l-Lock Nut ‘I-Special Hex Nut


2-Washer 8-Window Frame
&-Male Adjusting Arm g-weatherstrip
4-Female Adjusting Arm lo-Window Glass
S--Knob 1 l-Offset Molding
8-Special Screw 12-Locking Spring Pin

@(@
13-Washer

Fig. g-Cab Front Window


\ ’
1312

T’59414jN

l-Upper Track g--Nut


P-Nut lo-Machine Screw
3-Spin Lock Screw 1 l--Washer
4-Washer li-Nut
5-Rear Track Assembly 13-Washer
8-Lower Track 14-Cap Screw
‘I-Cap Screw 1 S-Cap Screw
8-Rubber Bumper 18-Nut

Fig. .&Cab Door Tracks

NOTE: Lower door track (6, fig. 8) is adjustable.


Track mounting holes are slotted for vertical
adjustment, Use washers between track mounting
brackets and cab for horizontal adjustment. Adjust
track so roller (9, Fig. 6) travels down the center of
the track.

Litho in U.S.A.
Operafor’s Station JD670-A and JD672-A Motor Graders 18
Operator Enclosure TM- 1188 (Dee-87) 1810-11

63-8

RELEASE
T59416N I/----- ASSEMBLY

1-Cap Screw l&T-Handle Lock Bushing 16-Latch Cover


2-Latch Pivot Pin Mount ll-Spring 19-Cap Screw
3-Spring 12-Spacer PO--Knob
4-Latch Pin 13-Door Handle With Escutcheon 2l-Jam Nut
S-Inside Door Handle 14-Lock Nut 22-Cap Screw
6-Clip 15-Pin 23-Clip
7--Rod 16-Cotter Pin 24-Release Rod Support
6-Jam Nut V-End Yoke 25-Plated Spring
O-Bushing Is-Catch Release Rod

Fig. IO-Cab Door Handle and Linkage (Left-Hand lhstrated)

Installation
Reverse removal procedure to install cab.

Lifho in U.S.A.
18 JD670-A and JD672-A Motor Graders Operator’s Station
1810-12 TM-l 188 (Dee-87) Operator Enclosure

CONTROL MOUNTING STRUCTURES

1-Special Cap Screw O-Washer (2 used)


(16 used) lo-Special Lock Nut
l--Special Screw (4 used) ll-Jam Nut
3-Directional Lever Cover 12-Set Screw
4-Special Washer (2 used) 13-R. H. Front Cover
5--Special Cap Screw 14-Console Cover
T’5988631’ (2 used) %-Edging
6-L. H. Console Front Cover 16-R. H. Console Cover
l-Cap Screw 12-Control Mounting ‘I-Seal 17-Shift Lever Cover
l-Fuse Mount Link Structure B-Crown Nut 18-Nut (2 used)
3--Resistor Support 13-Cap Screw (2 used) 19-L. H. Console Cover
4-Cap Screw 14-Washer (2 used) 20-L. H. Front Cover
B-Nut (9 used) 15-Nut (2 used)
6-Console Filler 16-Console
Fig. 12-Control Panel Covers
7-Steering Valve Mount 17-Jam Nut (2 used)
6-Cap Screw (4 used) 16-Washer (2 used)
g--Washer (8 used) 19-Cap Screw (2 used)
lo--Cap Screw (2 used) PO-Console Support
ll-Control Mounting Pl-Button Plug (4 used)
Structure Support 22-Lock Washer

Fig. 11 -Control Mounting Structures

Litho in U.S.A.
Operator’s Station JD670-A and JD672-A Motor Graders 18
Operator Enclosure TM- 1188 (Dee-87) 1810-13

FRONT WINDSHIELD WIPER

25

T59419N

l-Wiper Motor 12-Gasket 23-Lock Washer


P-Bowed Washer 13-Pivot 24-Wiper Blade
3-Drive Arm Assembly 14-Cap Screw (2 used) 25--Wiper Arm Assembly
4-Nut and Lock Washer 15-Leather Washer 26-Screw and Washer (2 used)
B-Connecting Link Is-Special Washer 27-Lock Washer
B-Special Washer (2 used) 17-Special Nut 28-Nut
7-Spring Clip (2 used) 18-Rain Shield Cap 29-Adapter Kit
8-Crank Pin Is-Nut SO-Special Nut
g--Screw and Lock Washer (3 used) 20-Washer 31-Special Screw
lo-Bracket Pl-Cap Nut 32-Spacer
li-Shalt and Pivot Assembly 22-Cap Nut

Fig. 13-Front Windshield Wiper

Removal Note the following during assembly:

Remove cab face. (11, Fig. 4).


Install bowed washer (2) between wiper motor and
drive arm.
Disconnect wiper motor lead.
Install one special washer (6) at each end of drive
Remove hardware attaching wiper motor to bracket.
arm.
Remove shaft and pivot assembly (11, Fig. 13) and
wiper arm assembly (25) if necessary.
Installation
Repair Use reverse of removal procedure to install front
windshield wiper.
Refer to Fig. 13 during disassembly and assembly.

Litho in U.S.A.
18 JD670-A and JD672-A Motor Graders Operator’s Station
1810-14 TM- 1188 (Dee-87) Operator Enclosure

REAR WIPER DEFROSTER FAN

l2 1 ifs-3 -4

d%L ’ 5

w
l--L3
r------l
-17
8 94 R
r8

0
T'5942ON

l-Wiper Arm 6-Nut


P-Special Nut 7-Wiper Motor
3-Outer Spacer 6-Drive Screw
4-Gasket g--Wiper Blade
1A
Z-Spacer T59421N
-7

Fig. 14-Rear Wiper l-Switch 1 l-Motor Clamp


P-Lamp Bulb 12-Nut (2 used)
Removal a--Nut (2 used) 13-Fan Blade
4-Lock Washer 14-Fan Guard
Diconnect wiring lead from wiper motor. 5-Fan Base l!i-Clip (6 used)
B-Defroster Motor 16-Lock Washer
Remove hardware attaching wiper motor to cab ‘I-Washer (2 used) ll-Machlne Screw (3 used)
6-Swivel Rod 16-Nut (With Lock Washer)
and wiper arm.
O-Cap Screw
lo-Swivel Clamp
Remove wiper arm and blade.
Fig. l&Defroster Fan
Repair
Refer to Fig. 14 during disasssembly and assembly. Removal
Replace parts as necessary. Disconnect wiring lead from defroster motor (6,
Fig. 15).
Installation
Use reverse of removal procedure to install rear Remove hardware connecting fan base (5) to cab.
wiper.
Repair
Refer to Fig. 15 during disassembly and assembly.
Replace parts as necessary.

Installation
Use reverse of removal procedure to install
defroster fan.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Operator’s Station 18
TM- 1188 (Jui- 78) Seat and Seat Belt 1821-l

Group 1821
SEAT AND SEAT BELT
GENERAL INFORMATION
The Motor Grader can be equipped with either a
suspension seat or bench seat.

The seat cushion on the bench seat tips back verti-


cally to allow the operator to stand during operation.

SUSPENSION SEAT

T59406N s 6

l-Push-on Fastener !%Seat Rear Bracket


(4 used) 8-Nut (7 used)
2-Seat Suspension 7-Gap Screw (4 used)
3-Washer (10 used) &Screw (2 used)
4-Cap Screw (3 used) 9-Spacer (4 used)

Fig. P-Seaf Suspension


11594051

l-Left Armrest 6Right Armrest To remove seat without total disassembly, remove
2-Seat Cushion 7-Gap Screw (8 used) hardware securing seat suspension (2, Fig. 2) to sea
3-Washer (4 used) &Lock Washer (8 used) rear bracket (5) and lift seat assembly out of cab.
4-Cap Screw (4 used) g-Seat Backrest
5-Nut (8 used)
Repair
Fig. l-Seat Cushions
Refer to Figs. 1, 2 and 3 during disassembly.
Removal
Examine parts for damage and replace as neces
Refer to Figs. 1, 2 and 3 during removal and disas- sary.
sembly of seat suspension.

Litho in U.S.A.
18 Operator’s Station JD670-A and JD672-A Motor Graders
1821-2 Seat and Seat Belt TM- 1188 (Dee-87)

l-Seat Support lo--Bolt (4 used) 20- Nut (4 used) (007471- )


2-Nut (8 used) 11-R. H. Seat Adjuster ( -007470) 21-Lever (00747% )
3-Washer (4 used) 12-Nut (2 used) al--Cable (007471. )
4-L. H. Seat Adjuster ( -007470) 13-Seat Belt Bar 23-Lock Nut (2 used) (007471- )
S-Spacer 14-Lock Washer (2 used) 24-Lever (00747% )
B-Seat Lett Track Bracket M-Cap Screw (2 used) 2%Cap Screw (4 used)
7-Seat Suspension Cover 16LNut (4 used) 28-Lock Washer (4 used)
I-Seat Right Track Bracket 17-Cap Screw (2 used) (007471. ) 27-Spring
g-Lock Washer (4 used) 18-Washer (8 used) (007471- ) 28-Grip
19-Adjuster (2 used) (007471- )

Fig. 3-Seat Support

Installation
Reverse removal procedure to install suspension
seat.

NOTE: Install cap screws (7, Fig. 2) with head up


and hex nut on the bottom. F/at washer must also be
under head of cap screw. Suspension will not function
properly if nut is installed on fop.

Litho in U.S.A.
Operator’s Station 18
JD670-A and JD672-A Motor Graders
Seat and Seat Belt 1821-3
TM- 1188 (J&78)

BENCH SEAT

23

8
9

l&-Bolt (2 used) 19-Adjuster Lever Pivot


l-Pitch Adjuster Pin (2 used)
11-Hex. Nut (4 used) 29-Cotter Pin
2-Retaining Ring (2 used)
12-Seat Cushion Pi-Seat Adjuster Lever
3-Quick Lock Pin (2 used)
13-Seat Left Bracket 22-Knob
4-Gap Screw (5 used)
M-Front Link 23-Washer (4 used)
!i-Seat Back Cushion
15-Seat Right Bracket 24-Spring
9-Gap Screw (4 used)
E-Washer 2’Nut
‘I-Back Rest Support
17-Gap Screw (2 used) 26Was her
&Bolt
1 a--Was her 27-Rear Link
O-Washer (2 used)

Fig. 4-Bench Seat and Supporfs

Removal Repair

Remove hardware attaching seat brackets to plat- Refer to Figs. 4 and 5 during disassembly and
form. assembly.

Litho in U.S.A.
18 Operator’s Station JD670-A and JD672-A Motor Graders
1821-4 Seat and Seat Belt TM- 1188 (Jul- 78)

T59409N

l-Stop Nut (4 used) g-Seat Adjuster (2 used) 17-Lock Washer (4 used)


2-Cotter Pin (2 used) 1tbSpring (2 used) 18-Nut (8 used)
3-Seat Adjuster Lever 11-Seat Adjuster Rod lg-Seat Belt Anchor
4-Machine Screw (4 used) 12-Yoke 28-Washer (4 used)
g-Seat Support K&-Nut Il-Lock Washer (8 used)
8-Lock Washer (4 used) M-Seat Adjuster Arm 22-Gap Screw (4 used)
7-Washer (2 used) H-Washer (4 used) 23-Nut (4 used)
8-Washer (4 used) l8-Cap Screw (4 used) 24-Rod End Pin

Fig. BBench Seat Supports and Adjusters

Installation
Use reverse of removal procedure to install bench
seat.

Litho in U.S.A.
JD670-A and JD67.CA Motor Graders Opera tar’s Station 18
TM- 1188 (Jul- 78) Steps and Handholds 1822-1

Group 1822
STEPSANDHANDHOLDS
GENERAL INFORMATION
Steps for entering the cab are located at the front of
left and right tandem housing. The steps can be placed

:
in a vertical or horizontal position.

REMOVAL
Remove three spring locking pins (1, Fig. 1) from
q
each pin (2). Remove pin and step (3).

REPAIR
Examine parts for damage and straighten, weld or
replace parts as necessary.
l's97021

l--Spring Locking Pin 2-Pin (4 used)


(16 used) 3-Tandem Step (2 used)

Fig. 1-Steps

INSTALLATION
Reverse removal procedure to install steps.

Litho in U.S.A.
18 Operator's Sfation JD670-A and JD672-A Motor Graders
1822-2 Steps and Handholds TM- 1188 (J&78)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Operator’s Station 18
TM- 1188 (J&78) Heating and Air Conditioning 1830-l

Group 1830
HEATING AND AIR CONDITIONING
HEATING SYSTEM
GENERAL INFORMATION REMOVAL
Two floor mounted cab heaters are available to Disconnect heater lead.
increase operator comfort. The smaller floor mounted
heater may be used when the unit is equipped with Close heater shut-off cocks on engine. Disconnect
either the bench style or Personal PostureTM suspen- hoses (1 and 8, Fig. 1) from heater. Remove heater
sion seat. The large floor mounted heater may only be mounting hardware.
installed when unit is equipped with the Personal Pos-
tureTM suspension seat.

T58777F

l--Met Hose 4-Grommet (2 used) 6-Fan Guard


2-Clamps (4 used) 6-Pipe Bushing T-Plastic Band (6 used)
3-Heater Shut-off Cocks (2 used) (2 used) 8-Outlet Hose

F@ 1-Small Heater Assembly

Litho in U.S.A.
18 Operator’s Station JD670-A and JD672-A Motor Graders
1830-2 Heating and Air Conditioning TM- 1188 (Jul- 78)

REPAIR INSTALLATION
Refer to Figs. 1 through 4 for disassembly and Install heater using reverse order of removal. Check
assembly of heater. engine coolant level. Fill if necessary.

Check hoses for blockage, holes or cracks. Replace


parts as necessary.

Note the following during assembly: Before attach-


ing motor (1, Fig. 2), assemble ground lead of motor to
lower stud and install washer (9) on upper stud.

1 -Heater Motor 4-Heater Core ‘I-Nut (2 used)


P-Fan Blade wore Baffle E-Nut (2 used)
3-Back Casing GSpecial Screw (2 used) %-Washer

Fig. PSmall Healer Assembly

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Operator’s Station 18
TM- 1188 (Mar-80) Heating and Air Conditioning 1830-3

TO THERMOSTAT
HOUSING

I
\
P
,l I

TO WATE
PUMP

T72452

l-Edging 8-Heater Shut-off Cock 15-Formed Hose (2 used)


Z-Heater Control Panel O-Pipe Bushing (2 used) 1 g--Grille
Z&Special Nut (5 used) 1 II-Outlet Hose 17-T&e Connector
4-Washer (8 used) ll-Plastic Band (6 used) 18-Heater
5-Cap Screw (6 used) 12-Inlet Hose 19-Nut (4 used)
B-Heater Control Valve 13-Grommet (2 used) PO-Cap Screw (4 used)
7-Clamp (8 used) 14-Heater Valve 21-Knob

Fig. 3-40.000 BTU Heater Assembly

Litho in U.S.A.
18 Operator’s Station JD670-A and JD672-A Motor Graders
1830-4 Heating and Air Conditioning TM- 1188 (Mar-80)

T59041F

I-Seal 6-Gap Screw (9 used) if&Tube Connector (4 used)


P-Heater Core 7-Formed Hose (4 used) l&-Grommet (2 used)
3-Washer &-Clamp (10 used) 12-Band (use as required)
4-Gap Screw (3 used) 9-Control Valve to Heater M-Heater Valve
S--Heater Mounting Baffle Inlet Hose

Fig. 4-Heater Assembly Supplied With Air Conditioning

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Operator’s Station 18
TM- 1188 (Mar-80) Heating and Air Conditioning 1830-5

AIR CONDITIONING SYSTEM


COMPRESSOR

T65955N 08

l-Shaft Seal 4-Dust Cover 8-Oil Pick-Up Tube


2-Ceramic Seal Seat O-Ring 5-Hub and Drive Plate Assembly g---Relief Valve
3-Pulley Bearing 8-Pulley lo-superheat Shut-Off Switch
7-Clutch Coil

fig. 5-Cross Section of Compressor

General Information The compressor is fitted with a high pressure relief


valve which opens whenever the compressor dis-
The compressor is a horizontal 3-piston, double-
charge pressure exceeds 440 psi (3033 kPa) (30 bar).
acting type (Fig. 5), and is belt-driven from the engine
crankshaft. The superheat switch (10, Fig. 5) and relief valve (9)
in the rear of the compressor and the clutch assembly
Pistons are mounted axially around the compressor
(Fig. 6) can be serviced separately. The basic com-
shaft and driven by a swashplate.
pressor should not be disassembled for service as it is
Reed-type suction and discharge valves are serviceable only as a complete unit.
mounted in valve plates between the cylinder assem-
The compressor clutch assembly (Fig. 6) is a heavy
bly and the head at each end of the compressor. The
duty unit with special dust protection seals and covers.
heads are connected by gas-tight passageways which
It is specially designed for construction and forestry
direct refrigerant gas to a common outlet.
applications. Use only heavy duty service parts. DO
An oil pump mounted at the rear of the compressor NOT USE automotive service parts.
picks up oil from the bottom of the compressor oil sump
If the clutch assembly is serviced, replace all dust
and pumps the oil to the internal working parts of the
protection seals and shields with new ones.
compressor.

Operation of the compressor is controlled by the


temperature control switch, which electrically controls
the magnetic clutch on the compressor.

Litho in U.S.A.
18 Opera tar’s Station JD67U-A and JD672-A Motor Graders
1830-6 Heating and Air Conditioning TM- 1188 (Mar-80)

lW306N

l-Shaft Seal 4-Hub and Drive Plate Assembly 7-Pulley Bearing


2--Seal Seat 5-Felt Seal &Coil and Coil Housing
3-Pulley GPulley Bearing Front Shield Assembly
%-Retainer Ring

Fig. d-cross Section of Compressor Clutch Assembly

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Operator’s Station 18
TM- 1188 (Mar-80) Heating and Air Conditioning 1830-7

Removal

T60038N

l-Compressor Manifold Plate 3-Suction Line (Larger Line) Clhermal Fuse


2-High Pressure Line (Smaller Line) 4-Compressor Wiring Harness 6-Adjusting Strap

Fig. 7-Compressor Removal

If the compressor is operable, operate for 10 min- IMPORTANT: Cover compressor openings im-
utes by running engine at 2000 rpm with temperature mediately with manifold plate to protect O-rings
control set for maximum cooling and blower speed on and prevent entry of moisture and dirt into com-
high position, before removing compressor. This pressor. Plug or cap openings in refrigerant lines.
allows the refrigerant oil to be circulated in the system
and more nearly gives the correct quantity of oil in the Disconnect compressor clutch coil wires and re-
compressor. move the compressor drive belt.

If the system is down due to an internal compressor Disconnect wiring from thermal fuse and superheat
malfunction, discharge, flush and purge the system as switch.
described in Group 9031.
Remove compressor from the mounting bracket.
Remove compressor manifold plate (1, Fig. 7) and Drain and measure oil from compressor.
remove refrigerant lines.
IMPORTANT: Do not impact clutch face or set

A CAUTION: High pressure may still exist at


the discharge fitting. If this pressure is re-
compressor on clutch face. Clutch hub and drive
plate assembly can be bent causing the clutch to
leased too rapidly, there may be a considerable overheat.
discharge of refrigerant and oil.

Litho in U.S.A.
18 Operator’s Station JD670-A and JD672-A Motor Graders
1830-8 Heating and Air Conditioning TM- 1188 (Mar-80)

Repair
The compressor should be tested for leaks before
starting disassembly. Refer to LEAK TESTING COM-
PRESSOR, page 1830-l 8.

A compressor that has an internal leak (discharge to


suction side), will require replacement.

:
Compressor Hub and Drive

rn
Plate Assembly

Removal

l-9/16 Inch Thin 2-D-05280ST Clutch


Wall Socket Holding Wrench
I

Fig. 9-Removing Lock Nut

Using the clutch holding wrench (D-05280ST), hold 1


the clutch hub while removing the hub and drive plate
lock nut from the compressor shaft (Fig. 9).

I
i-D-01006AA Bench
Holding Fixture
2-Dust Cover
3-Compressor

Fig b-compressor Dust Cover

Mount compressor vertically in a D-01 006AA Bench


Holding Fixture (Fig. 8) or any other suitable fixture.
Remove the three dust cover attaching screws, and
pull off dust cover.
IMPORTANT: Do not impact clutch face or set

I
compressor on clutch face. Clutch hub and drive
plate can be bent causing the clutch to overheat. l-AC-454 Threaded Hub Puller

Fig. lo-Removing
2-Hub and Drive Plate

Hub and Drive Plate


I

Using a AC-454 Threaded Hub Puller (part of D-


05278ST) remove the hub and drive plate assembly I
(Fig. 10). Remove the hub pulling tool.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Opera tar ‘s Station 18
TM- 1188 (Mar-80) Heating and Air Conditioning 1830-9

Align hub and drive plate assembly (with key) in


shaft. Position assembly in compressor front end
casting.

IMPORTANT: Do not drive or pound on hub of


drive plate assembly or on end of compressor
shaft. Use the proper tools to prevent possible
shifting of swashplate position (keyed to main
shaft), which might cause compressor damage.

l-Retaining Ring 2-Spacer

Fig. 1 l-Retaining Ring and Spacer

Remove hub and drive plate retainer ring and spacer


(Fig. 11). Remove hub drive key from shaft.

installation
Place drive key in hub drive plate. Position key so
that it will protrude about 3116 in. (4.76 mm) from
shoulder of compressor shaft when installed (Fig. 12).

l-AC-458A Hub Installing Tool 2-Hub and Drive Plate 1

Fig. 13-installing Hub and Drive P/ate

Screw AC-458A (part of D-05278ST) Installing Tool )


(Fig. 13) onto threaded end of compressor shaft ap-
proximately 3 full turns.

Press hub, and drive plate on compressor shaft by


holding hex. end of tool with a wrench in one hand and
using a wrench in the other hand to turn the hex. nut.
Continue to press hub and drive plate until there is
0.032 in. (0.81 mm) clearance between the drive plate
l-Compressor Shaft Shoulder 3-Key and pulley. Use the 0.032 in. (0.81 mm) AC-423 feeler
2-Bearing Front Shield
gauge (part of ‘D-05278ST). t
Fig. 12-Drive Key Position

Litho in U.S.A.
18 Operator’s Station JD670-A and JD672-A Motor Graders
1830-l 0 Heating and Air Conditioning TM- 1188 (Mar-80)

Remove the AC-458A Installation Tool. Make cer- Compressor Shaft Seal
tain the key has remained in place by looking into drive
plate hub. Removal

Make sure the system is depressurized before at-


Install hub spacer washer (Fig. 11). Secure spacer
tempting to replace the shaft seal assembly. Follow
with retainer ring (fiat side of ring facing spacer).
instructions given in DISCHARGING THE SYSTEM,
Group 9031.
Install a new retaining nut on compressor shaft with

:I
the thin side of nut next to the spacer. Tighten nut to 15
Remove the hub and drive plate assembly (Fig. 10).

q
lb-ft (20 N.m) (2 kg-m). Use the D-05280ST Clutch
Holding Wrench to hold clutch from turning while tight-
Remove the pulley bearing front shield (Fig. 12).
ening nut.

Check the gap between the drive plate and pulley for
specified clearance of 0.022 to 0.057 in. (0.56 to 1.45
mm).

After compressor has been installed on unit and


system has been evacuated and charged, cycle the
clutch off and on at least 20 times to seat the mating
parts of the clutch. This can be done by operating
engine and turning the temperature control switch off
and on at 1 second intervals.

l-Felt Seal 2-Bearing Rear Shield

Fig. 14-Bearing Rear Shield

Carefully pry out bearing rear shield (Fig. 14) and


discard. Remove the felt seal.

IMPORTANT: Thoroughly clean inside of com-


pressor neck with compressed air before continu-
ing to disassemble.

Remove the shaft seal seat retainer ring from inside


the compressor neck.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Operator’s Station 18
TM- 1188 (Mar-80) Heating and Air Conditioning 1830-11

Engage tabs on compressor shaft seal assembly


with locking tangs on the AC-41 5 (part of D-05276ST) I
Seal Installation and Removal Tool. Press down on
tool and twist clockwise to engage shaft seal. Remove
shaft seal assembly by pulling straight out from shaft
(Fig. 16).

Remove the ceramic seal seat O-ring from the inte-


rior of the compressor neck by using the AC-412 (part I
of D-05276ST) O-Ring Removal Tool.

Installation
:
q
Be sure interior of compressor neck is clean before
reassembling parts.

l-D-05284ST Seal Seat Remover 2-Ceramic Seal Seat

Fig. 75-Removing Shaft Sea/ Seat

l-O-Ring 2-Washers

Fig. 17-installing Seal Seat O-Ring

Coat seal seat O-ring with clean compressor oil and


place over shaft of AC-460 Tool between the two
washers. Pull O-ring tight and hold against tool (Fig.
17). Insert tool into compressor neck, and push down
firmly with a rocking motion to allow O-ring to snap into
groove.
i-AC-415 Seal Removal Tool 2-Shaft Seal Assembly

Fig. Id-Removing Shaft Seal Assembly

Remove the ceramic seal seat (Fig. 15), using the


D-05284ST Removal Tool.

Litho in U.S.A.
18 Operator’s Station JD670-A and JD672-A Motor Graders
1830-12 Heatina and Air Conditionina TM- 1188 (Mar-80)

l-AC-415 Seal Installation Tool 3-Seal Shaft Assembly


2-D-05285ST Seal Protector

Fig. l&installing Seal Shaft Assembly

I Place D-05285ST Seal Protector over end of com-


l-Driver 3-Bearing Rear Shield
pressor shaft (with thumb screw removed). Coat new P-Installation Tool
O-ring and face of seal assembly with clean compres-
sor oil and install seal using AC-415 (part of D- Fig. 794nstalling Bearing Rear Shield
05285ST) Tool (Fig. 18). Make sure seal is properly
positioned by having the flats of seal assembly aligned Install a new felt seal by rolling the material into a
with flats on compressor shaft. Release AC-415 (part cylinder, overlapping the ends, and placing seal in the
of D-05285ST) Tool from seal assembly by twisting interior of compressor neck. Carefully position seal so
tool slightly counterclockwise. that the ends butt together.

Place thumb screw in end of seal protector, and turn With felt seal properly positioned, insert a new pulley
screw in to remove seal protector from shaft. bearing rear shield into bore of compressor neck.
Using JDST-26-4B Installation Tool and Driver (Fig.
Coat face and outside edge of new seal seat with 19), drive shield in until it bottoms on outside end of
clean compressor oil, and install seal seat, using neck.
D-05284ST Tool. Make sure that seal seat O-ring is
not dislodged, and that seal seat is making good Note that the outer face of the rear shield which
contact with the O-ring. contacts the front shield has a Teflon coating. There-
fore, no lubricant of any kind should be used on these
Install seal seat retainer ring with flat side against surfaces.
the seal seat. Place retainer ring in bore of compressor
neck with snap ring pliers, and complete installation by
I using AC-462 (part of D-05276ST) Tool to help force
the retainer ring into the groove.

Remove excess oil from inside the compressor neck


with a clean cloth.

Before installing the remaining parts, the compres-


sor should be tested for leakage of refrigerant. See
LEAK TESTING COMPRESSOR on page 1830-18.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Opera for’s Station 18
TM- 1188 (Mar-801 Heating and Air Conditioning 1830-i3

l-JDST-26.4A Tool 2-Bearing Front Shield

Fig. Zl-Front Shield and Installation Tool

l-D-01203AA Puller P-Front Shield


Installation Tool Install hub and drive plate assembly. See page
1830-g. Then install dust cover (Fig. 8).
Fig. 20-Installing Bearing Front Shield
After the compressor has been completely assem-
Place a new bearing front shield over the pulley bled, it is ready to be installed on the unit. Evacuate
bearing bore. Press in shield until it bottoms against and charge refrigeration system. Perform operational
the bearing using the JDST-26-4A Installation Tool test. See INSTALLATION (Group 1830) EVACUA-
and a conventional D-01203AA puller as shown in Fig. TION AND CHARGING, and OPERATIONAL TEST,
20. respectively (Group 9031).

If the front shield cocks to one side as its outer edge


starts to enter the bearing cone, lightly tap the “high”
side of the installation tool with a soft hammer to
square up the shield. Fig. 21 shows the front shield
installed.

Litho in U.S.A.
18 Operator’s Station JD670-A and JD672-A Motor Graders
1830-14 Heating and Air Conditioning TM- 1788 (Mar-80)

Compressor Pulley and Bearing

Removal

Remove the hub and drive plate assembly (Fig. 10).

Remove the pulley bearing front shield (Fig. 21).

Carefully pry out bearing rear shield (Fig. 14), and


discard.

: Remove the pulley assembly retainer ring (Fig. 22).


PI

I Using the D-05277ST Puller Assembly as shown in


Fig. 23, remove the pulley and bearing from the com-
pressor neck.

IMPORTANT: Never use the D-05277ST Puller


Assembly directly against the drilled end of the
compressor shaft, or compressor internal damage
may result. Always place the AC-455 (part of D-
05277ST) Pilot over the drilled end of the com-
l-D-05277ST Puller Assembly
pressor shaft before removing the pulley.
Fig. 23-Removing Pulley and Bearing
Remove bearing using D-05279ST Driver.

IMPORTANT: If bearing is to be replaced, be


sure to use a John Deere bearing or equivalent.
This bearing has a special seal to keep out dust
and- dirt.

i-Retaining Ring 2-Pulley Bearing

Fig. 22-Pulley Bearing and Retaining Ring

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Operator’s Station 18
TM- 1188 (Mar-80) Heatina and Air Conditionina 1830-15

Installation Clutch Coil and Housing


If installing the same pulley and hub-drive plate
Removal
assembly, be sure to clean the contact faces of each
unit. Check surfaces for warpage caused by overheat- Remove hub and drive plate assembly (Fig. 10).
ing. Replace those parts that show evidence of war- Remove the pulley bearing shield (front and rear).
page, or are badly worn. See Fig. 12 and 14.
Remove the pulley and bearing assembly (Fig. 22
and 23).

l-Felt Seal %--Retaining Ring


l-D45279ST Installing Tool P-Coil Housing

I Fig. 24-Installing Pulley and Bearing Assembly Fig. 25-Removing Coil Housing Felt Seal
and Retaining Ring

I Installing
Carefully install
Tool.
bearing in pulley, using D-05279ST

Drive pulley and bearing assembly onto compressor


1 neck using the D-05279ST Installing Tool (Fig. 24).

Check pulley for free rotation.

Install pulley snap ring retainer.

Install pulley bearing rear and front shields (Fig. 19


and 20).

Install hub and drive plate assembly. See page


1830-g. Then install dust cover (Fig. 8).

After the compressor has been completely assem-


bled, it is ready to be installed on unit. Evacuate and
charge refrigeration system. Perform operational test.
See INSTALLATION (Group 1830), EVACUATION l-Dowel 3-Rubber Gasket
AND CHARGING, and OPERATIONAL TEST, re- P-Coil Housing
spectively (Group 9031).
Fig. 26-Removing Coil Housing

Litho in U.S.A.
18 Operator’s Station JD670-A and JD672-A Motor Graders
1830-l 6 Heating and Air Conditioning TM- I 188 (Mar-80)

Remove the felt seal and coil retaining ring (Fig. 25). Checking and Adding
A cross-sectional view of these parts installed is shown Compressor Oil
in Fig. 6.
General Informatioq
Note position of wiring terminals on coil housing in
The compressor oil flows throughout the system with
relation to compressor body. Mark location on com-
the refrigerant when the system is operating to lubri-
pressor body, if desired, to insure correct installation.
cate the compressor parts.

Remove coil housing assembly and rubber gasket


In general, it is not necessary to question the oil level 1
(Fig. 26).
in the system unless there is evidence of a significant
loss of refrigerant (hence, a significant loss of oil) from:
installation

1. Broken hose
IMPORTANT: If coil is being replaced, be sure to
use 24 volt coil.
2. Severe leak at hose fitting

Check rubber gasket condition, and replace, if not in


3. Leaking compressor seals
good condition. Install gasket on compressor.
4. Collision or upset damage to system components
Position clutch coil on compressor head casting so
the electrical terminals correspond with the mark made
If the compressor or one of the other major system
previously on the compressor body.
components (condenser or evaporator) has been re-
moved for servicing, the oil level should be checked.
IMPORTANT: Be sure clutch coil is correctly
Refer to page 1830-17.
seated on dowels.
To check the oil level in the system, the compressor
Replace the coil retainer ring with the flat side of ring
has to be removed from the unit. When oil is required,
facing coil.
pour 525 viscosity oil into the oil drain tube of com-
pressor.
Install felt seal next to coil retainer ring (Figs. 6 and
25).
NOTE: The compressor takes a special 525 vis-
cosity oil that has “special additives ” which give better
Install pulley and bearing assembly (Fig. 24). Then
compressor life. The part number is R49856.
install pulley bearing front shield (see Fig. 20 and 21).

Install hub and drive plate assembly as previously


instructed (Fig. 13) using the AC-458A (part of D-
05278ST) Installing Tool. Do not pound or drive on the
hub assembly.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Opera tar’s Station 18
TM- 1188 (Mar-80) Heating and Air Conditioning 1830-17

When Servicing Compressor 3. If the amount of oil drained is more than 1-l/2
fluid oz. (44 mL) and the system showed no signs of a
If the air conditioning system was placed in opera-
major teak, add this same amount of new oil to the
tion just prior to removal of the compressor as de-
compressor.
scribed in REMOVAL, and the same compressor is to
be placed back on the unit, check the oil level before
4. When the amount drained is less than 1-l 12 oz.
installing. Proceed as follows:
(44 mL) and the system appears to have lost an
excessive amount of oil, add 6 fluid oz. (178 mL) of
1. Place compressor in a horizontal position with
new oil to the compressor.
the drain plug downward.

2. Drain the compressor. Measure the oil in a bottle


or container that is graduated in fluid ounces (or milli-
When installing a new or rebuilt compressor that has
a full charge of oil (10 fluid oz. 1296 mLl), drain the oil
and save it. Place the required amount of oil that was
q :

litres). Discard the oil.


saved back into the compressor in the amount in-
structed in steps 3 and 4.
3. If more than 4 fluid oz. (118 mL) was drained
from the compressor, place that same amount of new
When installing a compressor that has been over-
oil back into the compressor.
hauled (and has not been filled with a full charge of oil),
add 1 extra ounce (30 mL) to the amount given in steps
4. If 4 fluid oz. (118 mL) or less was drained, add 6
3 and 4.
fluid oz. (178 mL) of new oil to the compressor.

5. Install compressor (see INSTALLATION, page


When installing a new or rebuilt compressor that has
1830-20). I
a full charge of oil (10 fluid oz. [296 mLl), drain the oil
and save it. Place the required amount of oil that was
When Servicing System Components
saved back into the compressor in the amount in-
Other Than Compressor
structed in steps 3 and 4.
When replacing other system components, the
When installing a compressor that has been over- compressor will also have to be removed. Follow in-
hauled (and has not been filled with a full charge of oil), structions given above for checking compressor oil and
add 1 extra ounce (30 mL) to the amount given in steps add the following amounts of oil for each listed com-
3 and 4. ponent being serviced:
Evaporator-4 fluid oz. (118 mL)
IMPORTANT: Do not add any more oil than Condenser-2 fluid oz. (59 mL)
necessary, or maximum cooling will be reduced. Receiver-Dryer-i /2 fluid oz. (15 mL)

5. Install compressor (see INSTALLATION, page NOTE: If complete system was flushed to remove
1830-20). contamination, the full charge of oil (11 fluid oz. [326
mL1) should be added to the system.
If the air conditioning system was not placed in
operation (or the compressor was not operable just
prior to removal), and the same compressor is to be
placed back on unit, check the oil level before install-
ing. Proceed as follows:

1. Place compressor in a horizontaf position with


the drain plug downward.

2. Drain the compressor. Measure the oil in a bottle


or container that is graduated in fluid ounces (or milli-
litres). Discard the oil.

Litho in U.S.A.
18 Operator’s Station JD670-A and JD672-A Motor Graders
1830-18 Heating and Air Conditioning TM- 1188 (Mar-80)

LEAK TESTING COMPRESSOR Mount the compressor in a vise with the oil reservoir

A compressor that has been removed from the unit up.


should be tested for internal and external refrigerant
Remove the dust cover (2, Fig. 8).
leakage before making repairs on compressor. See
REPAIR, page 1830-a.
Turn the clutch hub by hand with the suction and
discharge ports open. If it can be turned, proceed with
Perform the following Volumetric Efficiency Test to
the test. If it cannot be turned (internal failure), replace
determine if the compressor is serviceable. If the
the compressor.
compressor fails the volumetric efficiency test, it need
not be tested further, and must be ieplaced.
Install D-l8032KD Test Plate (3, Fig. 27).
Volumetric Efficiency Test
Connect the low side valve (1, Fig. 27) to the left
hand test plate fitting and the high side valve (2) to the
right hand fitting.

The center hose must be left “open” to the atmo-


sphere. Refer to Fig. 27.

NOTE: The low pressure gauge how is connected


to the discharge adapter so that the prt we reading
during the test can be more easily reac

Turn the compressor (clockwise) approximately 25


times with hand valves (1 and 2, Fig. 27) open.
lx529211

2-High Side Valve (Open)


Close the low side valve (1). High side valve (2)
l-Low Side Valve
(Closed) 3-D-18032KD lest Plate must be open.

Fig. P7-Volumetric Efficiency


Test Hook-Up

IMPORTANT: There must be a minimum of one


ounce (30 mL) of oil in the compressor to perform
this test. If all the compressor oil was lost during
discharging the system, pour a minimum of one
ounce (30 mL) of oil into the compressor reservoir.

Litbo in U.S.A.
JD670-A and JD672-A Motor Graders Operator’s Station 18
TM- 1188 (Mar-go) Heating and Air Conditioning 1830-19

Shaft Seal Leak Test

u-3
T43797N

l-Low Pressure Gauge 3-D-18032KD Test Plate


T69832 Valve (Open) 4--Refrigerant Con-
2-High Pressure Gauge tainer
l-Speed Handle ~-LOW Side Gauge Valve (Closed)
P-Clutch Hub ~-LOW Side Hand Valve
Fig. 29-Testing for External Leaks
Fig. 28-Volumetric Efficiency Test

1. Install D-18032KD Test Plate on rear head of


Use a speed handle (1, Fig. 28) to rotate the com-
compressor (Fig. 29).
pressor clutch hub ten revolutions at a rate of one
revolution per second.
2. Connect pressure gauges and hoses to test
NOTE: The proper rate of compressor shaft revo-
plate. Both gauge valves must be closed.
lutions is important. An incorrect rate can give an
improper pressure reading.
3. Connect the yellow hose to center outlet on
If correct rate of compressor shaft revolution is not
pressure gauge manifold, and to a refrigerant supply
achieved, depressurize compressor by opening hand
container.
valve (4) until both gauges read 0 psi.
Repeat test until correct rate of revolutions is
4. Open refrigerant container valve and LOW pres-
achieved. Check gauge (3) reading.
sure gauge valve. Charge compressor to container
1 - Before model number 1131111 and all remanu-
pressure (container at room temperature).
factured TY6601 or TY6602 compressors:
l If gauge (3) registers 40 psi (275 kPa) (2.8 bar)
5. Test area around shaft seal assembly for leaks
or more, compressor is serviceable. Perform
using D-05232ST Electronic Leak Detector. If a leak is
shaft seal leak test.
detected, try turning the compressor shaft a few turns.
l If gauge (3) registers less than 40 psi (275 kPa)
Again, test for leaks. If a leak persists, it may be
(2.8 bar), replace compressor.
necessary to replace the shaft seal assembly.
2 - Model 1131111 and after:
l If gauge (3) registers 60 psi (410 kPa) (4.1 bar)
6. Close the low pressure gauge valve, and the
or more, compressor is serviceable. Perform
refrigerant container valve. Slowly disconnect the yel-
shaft seal leak test.
low hose from. the refrigerant container. Cover con-
l If gauge (3) registers less than 60 psi (410 kPa)
nection with a cloth to protect yourself from escaping
(4.1 bar), replace compressor.
refrigerant.
Open hand valve (4) until gauge (3) reads 0 psi.
Drain oil from compressor.
IMPORTANT: Seal compressor openings by ei-
ther capping test plate fittings or removing test
plate and installing cover plate.

Litho in U.S.A.
18 Operator’s Station JD670-A and JD672-A Motor Graders
1830-20 Heating and Air Conditioning TM- 1188 (Mar-80)

7. Slowly open gauge valves to discharge the re- 5. Remove pressure gauges, hoses, and D-
frigerant from compressor. 18032KD Test Plate.

6. install cover plate on compressor to keep out


8. Remove pressure gauges, hoses, and D-
moisture and contamination.
18032KD Test Plate.

Installation
9. Install cover plate on compressor to keep out
moisture and contamination. Before installing compressor, be sure the compres-
sor contains the correct amount of oil. See the infor-
Discharge to Suction Side Leak Test mation given in CHECKING AND ADDING COM-
PRESSOR OIL, page 1830-16.

Be sure to flush and purge the complete system if


compressor failed internally due to broken parts or
seizure. Refer to FLUSHING THE SYSTEM, Group
9031.

NOTE: Before installing compressor, turn the com-


pressor shaft 4 or 5 times. This permits proper lubri-
cation of compressor seal over all its surface. Be sure
to remove all excess oil from the outside surface of the
compressor to prevent oil being thrown onto the mag-
netic clutch.

Install compressor on unit and connect the magnetic

LJ-3
T43797N
clutch control wiring.

Connect thermal fuse and superheat switch wiring.

l-Low Pressure Gauge 3-D-18032KD Test Plate Install compressor drive belt and tighten new belt to
Valve (Closed) 4-Refrigerant Con- 130 to 140 Ibs. force (578 to 623 N) or used belt to a
2-High Pressure Gauge tainer minimum of 90 Ibs. force (400 N) strand tension.
Valve (Open)
A suitable alternate belt adjustment procedure is to
Fig. 30-Testing for Internal Leaks obtain l/4 inch (6 mm) belt defiection with 17 Ibs. force
(76 N) applied midway between the pulleys.
1. Follow steps 1, 2 and 3 as given under ‘Shaft
IMPORTANT: Compressors kept on hand for
Seal Leak Test.” Refer to Fig. 30.
stock purposes should be charged with refriger-
ant, whenever the refrigerant charge is lost. Keep
2. Open container valve and HIGH pressure gauge
compressor openings capped until installation, to
valve. Charge compressor to container pressure. If
prevent moisture and foreign material from enter-
pressure is immediately observed on the low pressure
ing compressor.
gauge, it indicates there is an internal leak. Replace
the compressor. IMPORTANT: New compressors are charged
with a mixture of nitrogen, Refrigerant-12, and !O
3. Close the high pressure gauge valve. Slowly fluid oz. (296 mL) of 525 viscosity oil. If the cover
disconnect the yellow hose from the refrigerant con- plate is removed too rapidly, oil will be blown out
tainer. Cover connection with a cloth to protect yourself with the sudden release of pressure.
from escaping refrigerant.
When installing an exchange or remanufactured
compressor, SLOWLY remove the cover plate from the
4. Slowly open gauge valves to discharge the re-
compressor valve fittings to bleed off any pressure that
frigerant from compressor.
may,exist in the compressor.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Operator k Station 18
TM- 1188 (Mar-so) Heating and Air Conditioning 1830-21

Coat the compressor manifold O-ring packings with


compressor oil and install refrigerant lines on com-
pressor. Tighten cap screw (6, Fig. 31) to 35 lb-ft (47
N.m) (5 kg-m).

IMPORTANT: Prevent dirt or moisture from en-


tering the compressor manifold assembly. Gauge
port caps should be in place.

Evacuate and charge the system (Group 9031).

Perform operational test (Group 9031).

l-Mounting Cap Screws 4-Pressure Line (Smaller)


a--Adjusting Screw 6-Wire to Superheat
3-Suction Line (Larger) Switch
B-Cap Screw

Fig. 3 1-Compressor hstalla tion

CONDENSER, RECEIVER-DRYER AND EVAPORATOR


CONDENSER The condenser is located in front of the engine
cooling system radiator.
General Information
Air is drawn in through the condenser core by the
fan, permitting heat exchange to take place.

Be sure that the condenser core is not plugged with


dirt or trash, or excessive heat and pressure may
result, causing system to not function properly.

Removal
Depressurize the system as described in DIS-
CHARGING THE SYSTEM, Group 9031.

Disconnect inlet and outlet openings. Cap all open-


ings. Remove condenser from mounting track by re-
moving cap screws.

IMPORTANT: Install caps on lines to prevent


entry of moisture or contaminants.

Fig. 32-Condenser Location

Litho in U.S.A.
18 Operator’s Station JD670-A and JD672-A Motor Graders
1830-22 Heating and Air Conditioning TM- 1188 (Mar-80)

Drain oil from condenser and discard. Caustics attack copper and if not properly controlled,
cause irreparable damage to the core.
Repair
Welding represents an easy and effective method
Remove the plugs or caps from openings. If con- for repairing damage to the relatively heavy tank, con-
tamination is evident in condenser, flush all system nection, or bracket areas. Use the tungsten inert gas
I components (Group 9031). (heli-Arc) welding process. With a little practice, even
the leading edges of the tube can be repaired by this
Examine condenser core for possible restrictions or welding process. All parts of the core are weldable
sources of trouble. The fins should be straight and free using 4043 welding rod.
of dirt or trash.
Epoxy adhesive is the best way of repairing leaks in
Check condenser core for leaks. Cap the outlet the core section. See manufacturer’s instructions with
connection and install a Schrader type service valve in adhesive kits for mixing and curing times.
the inlet opening. Place refrigerant container in a pail of
water warmed to a maximum of 125°F (52°C) which Squeeze equal lengths of epoxy and hardener on a
gives a pressure of 167.5 psi (1155 kPa) (11.5 bar). discardable surface. Mix the two ribbons thoroughly
Connect refrigerant supply to the Schrader valve. with a putty knife or spatula and immediately apply to
Open refrigerant container valve and test condenser the damaged area.
for leaks with a leak detector (see LEAK TESTING). If
the aluminum condenser core leaks, repair as follows: Repair a small puncture, such as created by a nail,
by patching the hole with the adhesive. If the puncture
Four general methods of repairing aluminum heat is larger,. use a combination of adhesive and sheet
exchangers are welding, brazing, soldering, and the metal screw. When the simple patch method is used,
se of epoxy adhesives. Brazing and soldering are force the adhesive into the hole (Fig. 35), allowing it to
generally too complex for field use. Welding and epoxy spread internally so that it forms a plug or adhesive
adhesives are recommended for field repair. rivet. Then cover the area above and around the hole
with a generous coating of epoxy. Where a screw is to
NOTE: The repair story which follows is valid for be used, first apply adhesive to the hole, drive in a
most aluminum heat exchangers. short sheet metal screw, and then completely cover the
repair and the screw head with adhesive (Fig. 36).

Fig. 33-Removing Fig. 3.4 Forcing


Contaminants Fluid Through
From Outside

The first step in making any repair is to properly Fig. 35-Forcing Fig. 36-Covering
Adhesive Into Hole Area Around Hole
clean the damaged area. Remove all paint, oil, grease
and dirt from the area. Use a pen-knife (Fig. 33) file,
emery paper, or wire wheel, and solvent to remove the
contaminants to bare the surface. Flush internally with
a hydrocarbon solvent such as trichlorethyene or
chlorothene nu to degrease the internal surfaces (Fig.
34). For this limited work, naphtha paint thinner or
chlorothene nu are acceptable solvents.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Opera tork Station 18
TM- 1188 (Mar-80) Heating and Air Conditioning 1830-23

Should the damage occur to the sidewall of the tube,


a plug technique can be used. First clean the area;
then plug the back of the air fin convolution with paper,
gum or modeling clay. To complete the repair, fill the
entire air fin convolution with adhesive and allow to
harden (Fig. 37). Be sure to pack the adhesive into the
area to avoid bubbles and potential leaks caused by air
entrapments (Fig. 38).

Fig. 39-Removing Fig. 40-Applying


Air Fins Prime Coat of Epoxy

For repair of large areas, use the bandage tech-


nique. First, remove the air fins adjacent to the dam-
aged area by driving a sharp wood chisel (Fig. 39)
down the side wall of the tube. Prepare a bandage
which will cover the entire area to be repaired, using
expanded aluminum or copper, aluminum screening,
or heavy-duty aluminum foil with some perforations.
This bandage will act as a bridge for the epoxy and add
to the strength of the repair.
Fig. 37-Filling Air Fin Convolution
After cleaning the repair area, apply a prime coat of
epoxy (Fig. 40), then lay the prepared bandage over
the area (Fig. 41). To hold this bandage in place, wrap
string, wire, or hairpin clips twisted on the back around
the tube. Using several strands of wire or several
hairpins in a row will add to the structural strength of
the repair. Then, completely cover bandage with ad-
hesive (Fig. 42).

To improve appearance, straighten any bent fins


with a duck bill pliers and spray the repaired area with a
paint that matches the remainder of the core. To re-
place a removed fin for appearance purposes, form the
fin from a strap of light. gauge aluminum folded be-
tween wooden strips of the right size. Bond in place
with a fresh batch of adhesive.
Fig. 38-Packing Adhesive to Avoid Bubbles

Litho in U.S.A.
18 Operator’s Station JD670-A and JD672-A Motor Graders
1830-24 Heating and Air Conditioning TM-l 188 (Mar-80)

RECEIVER-DRYER
General Information
The receiver-dryer .has a two-fold function. First, it
receives the high-pressure liquid refrigerant from the
condenser and stores the liquid until needed by the
evaporator. Second, the unit removes harmful mois-
ture (and acids), and filters out solid contaminants.

The sight glass is built into the outlet side of the


receiver-dryer unit and should be used for checking
Fig. 4 1-Laying Fig. 42-Covering
system operation.
Bandage Over Area Bandage with Adhesive
Replace receiver-dryer whenever the air condition-
Remember, adhesives have a limited pot life. Do not ing system has been discharged or when it cannot
mix the materials until you are ready to use and only absorb further moisture. Diagnosis of moisture in the
mix enough for one repair. Also, always allow sufficient system is difficult. Therefore if all checks are “NOR-
time for the adhesive to cure. Curing times are slower MAL” and the operator complains of lack of cooling
when the temperature is under 65°F (18%). Warming below 80°F (27”C), there probably is moisture in the
the repair area with a 100 watt light bulb can speed up system and the receiver-dryer should be replaced.
the cure time.

IMPORTANT: Do not let the materials harden on


tools which you intend to reuse. Once the adhesive
has set, it is practically impossible to remove.
Clean your tools immediately after a repair.

Installation
1 Flush and purge the core. See Group 9031.

Reverse the removal steps. Use the torque chart


(Group 1899, this section) as a guide for tightening
connections on pipes and hoses.

NOTE: If the condenser was repaired or replaced


with a new one, pour 2 fluid oz. (59 mL) of oil into
condenser. If there were any major leaks in the system,
refer to CHECKING AND ADDlNG COMPRESSOR
OIL, (page 1830- 16).

Remove old receiver-dryer and replace with new.


See receiver-dryer Removal, page 1830-25.

Evacuate and charge the system.

I Perform operational test (Group 9031).

Litho in U.S.A.
JD670-A and JD672-A Motoi Graders Opera tar’s Station 18
TM- 1188 (Mar-80) Heating and Air Conditioning 1830-25

Removal Installation
Add i/2 fluid oz. (15 mL) of refrigerant oil to new
receiver-dryer.

Reverse the removal procedure for installing unit.

Refer to torque chart in Group 1899 for tightening


refrigerant pipes. To improve sealing, coat all fittings
with refrigerant oil.

Evacuate and charge system (Group 9031.)

Perform operational test (Group 9031).

Fig. 43-Receiver-Dryer Location

Depressurize the system as instructed in DIS-


CHARGING THE SYSTEM, Group 9031.

Disconnect the inlet and outlet fittings on receiver-


dryer (Fig. 43).

IMPORTANT: install caps on lines to prevent


entry of moisture or contaminants.

Remove the receiver-dryer clamp and remove as-


sembly. Cap or plug openings.

Repair
The receiver-dryer assembly is not repairable.

To service a malfunctioning unit, replace with a new


one.

IMPORTANT: Always install other system com-


ponents before installing a new receiver-dryer.
This will help keep the receiver-dryer from ab-
sorbing additional moisture prior to evacuation.

IMPORTANT: Keep caps on receiver-dryer until


just before the lines are to be connected.

IMPORTANT: Whenever the air conditioning


system is opened up for service, a new receiver-
dryer must be installed.

Litho in U.S.A.
18 Operator’s Station JD670-A and JD672-A Motor Graders
1830-26 Heating and Air Conditioning TM- 1188 (Mar-80)

HEATER/EVAPORATOR CORE

General Information Remove thermostatic switch sensing tube from


heater/evaporator core.
The heater core and the air conditioning evaporator
are incorporated into one assembly.
Remove heater/evaporator core mounting screws
and lift out core. Cap openings. Note amount of oil that
The heater/evaporator core is constructed of alumi-
drains from the core.
num and greatly resembles an ordinary cooling system
radiator. Refrigerant travels through tubes located
Repair
within the core.
If contamination is evident in system, flush and
To obtain maximum cooling efficiency, the refriger- purge the entire system (Group 9031).
ant must remain in the evaporator for a sufficient length
Accessible minor leaks may be repaired, but the
of time to completely vaporize. Too little or too much
evaporator should be replaced if there is a restriction or
refrigerant entering the evaporator will limit refrigerant
a major leak in the core. The core should be tested with
capacity to absorb heat. The regulatory controls for the
at least 5O’psi (345 kPa) (3 bar) when testing for leaks.
evaporator are the expansion valve and the thermo-
static temperature control switch.
Installation
The expansion valve sensing bulb is wrapped w,ith Flush and purge the core (evaporator section) as
an insulating compound. This compound insulates the directed in Group 9031.
bulb from the surrounding air and allows sensing of
temperature of refrigerant leaving the evaporator. Before installing evaporator, check the condensate
drain tray to make sure that it is clean and that the drain
Removal outlets on both ends are not plugged.

Depressurize the system as explained in DIS-


Remove caps from evaporator core openings and
CHARGING THE SYSTEM, Group 9031.
reverse the removal instructions. Refer to Fig. 44. Be
sure to thoroughly wrap expansion valve, sensing bulb,
Remove front panel on air conditioning unit. Remove
and adjoining section of refrigerant pipe with insulation
and cap heater hoses.
tape (R57003) to get desired expansion valve control.

A CAUTION: Lines may still contain some


refrigerant; see precautions Group 9031.
Refer to page 1830-28 for installation
valve sensing bulb.
of expansion

IMPORTANT: Install caps on lines to prevent


Use care when tightening parts. Refer to the torque
entry of moisture or contaminants.
chart in Group 1899 when necessary.

IMPORTANT: The tube connecting the bulb to


NOTE: If the evaporator was repaired or replaced
the expansion valve contains a low pressure gas.
with a new one, pour 4 fluid oz. (118 mL) of refrigerant
To avoid improper valve action, do not kink or
oil into the evaporator. If there were any ma/or leaks in
pinch the tube, or dent the bulb.
the system, refer to CHECKING AND ADDING COM-
PRESSOR OIL (page 1830-16).
Disconnect sensing bulb, evaporator inlet and outlet
fittings and expansion valve equalizer line.fitting and
Change receiver-dryer, page 1830-25.
cap fittings.

Evacuate and charge system (Group 9031).

Perform the operational test (Group 9031).

Litho in U.S.A.
Operator’s Station 18
JD670-A and JD672-A Motor Graders
Heating and Air Conditioning 1830-27
TM- 1188 (Mar-80)

moo4 2N

7-lube 13-Right-Hand Bracket


l--Seal (4 used)
E-Expansion Valve IAlUbe
2-Evaporator
3-Bracket g--Hose X-Spring Clip
W-Grommet 16-O-Ring
4-Screw (8 used)
11-Grommet 17-O-Ring
5--O-Ring
6-O-Ring 12-Hose 18-O-Ring

Fig. 44-Evaporator

Litho in U.S.A.
=I8 Operator’s Station JD670-A and JD672-A Motor Graders
1830-28 Heating and Air Conditioning TM- 1188 (Mar-80)

REGULATORY CONTROLS
EXPANSION VALVE

General information Depressurize the system as instructed in DIS-


CHARGING THE SYSTEM, Group 9031.
Liquid refrigerant under high pressure is piped to the
expansion valve from the receiver-dryer. The function Remove forward air conditioning panel.
of the expansion valve is to regulate the amount of
Remove the insulation from sensing bulb and ex-
liquid refrigerant entering the evaporator (now under
pansion valve.
low pressure), depending upon the desired inside
temperature. Sensing action which regulates valve Disconnect sensing bulb, expansion valve inlet and
action takes place in the temperature sensing bulb. outlet fittings, and equalizer line fittings.

Plug or cap openings after r.emoving valve and bulb.


Removal
IMPORTANT: Install caps on lines to prevent
entry of moisture or contaminants. I

IMPORTANT: If valve seems to have been


operating properly, be careful not to kink or pinch
the tube connecting the sensing bulb to the valve
body when removing the unit.

Repair
Since there are no external adjustments, an im-
properly working expansion valve must be replaced.

Installation
Before installing valve, remove the caps from open-
ings and check screen in valve inlet for foreign materi-
al. If foreign material is present, remove the screen and
clean. Do not allow contamination to enter valve. Fie-
verse the removal steps.

T59826N Thoroughly clean both the sensing bulb and the


adjacent portion of the refrigerant line with a solvent
l-Temperature Sensing ~-LOW Pressure ,Liquid
and steel wool before fastening the sensing bulb to the
Bulb and Tube Line
G-High Pressure Liquid 4-Equalizer Line
pipe. The sensing bulb must be mounted on the evap-
Line !&Diaphragm orator outlet manifold in the 9 o’clock position. There

i
must be good contact between the manifold and the full
Fig. 45Expansion Valve length of the bulb.

Thoroughly wrap insulation tape around valve,


sensing bulb, and adjacent portion of refrigerant pipe to
get desired expansion valve control. Be careful not to
lift the sensing bulb from the evaporator outlet manifold
when wrapping with tape.

Make sure the expansion valve makes a good con-


tact with the evaporator outlet.

NOTE: If there were any major leaks within the


system, it will be necessary to remove the compressor,
drain the oil and add the correct amount of oil as
instructed on page 1830-16.

bitho in U.S.A.
JD670-A and JD672-A Motor Graders Operator’s Station 18
TM- 1188 (Mar-so) Heating and Air Conditioning 1830-29

THERMOSTATIC TEMPERATURE CONTROL SWITCH

T43802N

I-Temperature Control Switch P-Sensing Tube

Fig. 46-Temperature Control Switch

General Information Turning the control knob all the way to the left
(counterclockwise) manually opens the contact points
The purpose of the temperature control switch (Fig. in the switch housing, stopping compressor operation.
46) is to regulate the temperature of the refrigerant in
the evaporator corresponding to the control knob set- Removal
ting selected by the operator.
Remove sensing tube from evaporator core (Fig.
The switch consists of a set of contact points which 46).
receives its power from the blower switch whenever
the blower switch is on. The current flows from the Remove 4 screws on air conditioning control panel.
temperature switch to the compressor clutch.
Disconnect wiring and remove switch from instru-
The contact points in the temperature switch are ment panel.
controlled by a gas-filled temperature sensing tube
having a spring bellows or diaphragm on one end Note the routing and shaping of the sensing tube so
making contact with the point operating mechanism. that it can be reinstalled and shaped the same way as
The other end of the sensing tube is inserted into the removed.
core of the evaporator.

When the control knob is turned on (clockwise), the


contact points close, thereby activating the compres-
sor. However, the compressor will not operate unless
the blower switch is turned on. As the temperature in
the evaporator reaches its specified lower limit, the
contact points are allowed to open, which in turn shuts
off the compressor. The compressor will remain off
until the temperature in the evaporator reaches its
specified upper limit. When that limit is reached, the
contact points close and the compressor starts
operating. In this manner, the compressor turns off and
on automatically to satisfy the demands of the evapo-
rator.

Litho in U.S.A.
18 Opera tar’s Station JD670-A and JD672-A Motor Graders
1830-30 Heating and Air Conditioning TM- 1188 (Mar-80)

Repair Installation
The temperature control switch is not designed to be Route and shape the sensing tube the same as
repaired as such. However, it should be tested for removal.
proper operation. To test the switch, place the end of
the sensing tube in a cup or similar container filled with Insert the tube through the evaporator core in the
a mixture of ice and water. Insert a thermometer into center below the second row of horizontal tubes. Then
the water. Observe the contact point operation based route the tube half way back through the core.
upon the temperature of the liquid. The switch should
open and close within the range of 29” to 38°F (-2’ to IMPORTANT: Do not pinch or kink the sensing
3°C). If the switch does not operate properly, replace tube. If necessary to reshape tube to fit into core,
with a new one. avoid making too sharp a bend.

Switches are preset to correctly regulate the tem- Install switch into instrument panel.
perature in the evaporator.

COMPRESSOR RELIEF VALVE

General Information Repair


I The compressor relief valve (9, Fig. 5) is a pressure The valve is not designed to be repaired. If the valve
regulating control. If the system discharge pressure does not operate properly or has been damaged, re-
’ exceeds 440 psi (3033 kPa) (30 bar), the valve will place with a new one.
1 open and stay open until the pressure decreases. The
valve will then close automatically. Before replacing valve, make sure that there is not a
malfunction somewhere else in the system.
If the relief valve opens, a loud popping noise will be
heard. In addition, some oil may be ejected through the Installation
valve. CORRECT ANY CONDITION THAT WOULD
Install valve on compressor.
CAUSE THIS VALVE TO OPEN.

Evacuate and charge the system, Group 9031. 1


Removal
Depressurize the system as instructed under DIS- Perform operational test Group 9031.
CHARGING THE SYSTEM, Group 9031.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Operator’s Station 18
TM- 1188 (Mar-80) Heating and Air Conditioning 1830-31

THERMAL FUSE AND SUPERHEAT SHUT-OFF SWITCH

General Information The thermal fuse contains a heat sensitive fuse and
heater element. Use an ohmmeter to determine if fuse
The purpose of the superheat switch located on the
is blown. See Fig. 47 below.
rear end of the compressor is to stop compressor
action when the refrigerant level is low. This prevents
damage to compressor from a lack of lubrication.

The switch senses refrigerant pressure and tem-


perature at the suction inlet to the compressor. When a
partial or complete loss of refrigerant occurs, the switch
closes and a path to ground is provided for the thermal
fuse.

The thermal fuse located on the rear of the com-


pressor mounting bracket contains a heat sensitive
fuse and heater element. If a combination of low pres-
sure and high temperature occurs in the suction inlet of
the compressor, the superheat switch closes. Current
in the thermal fuse is then routed through a heater
element in the thermal element to ground. The heat
melts the “fuse” and electrical power is removed from
the compressor. The compressor then is no longer
driven by the engine.

The thermal fuse has a built-in time delay. A blister


or bulge on the outer surface, next to the mounting ear, Fig. 47-Testing Thermal Fuse
usually indicates a blown, or ready to fail thermal fuse.
Removal
The “S” on the thermal fuse stands for superheat
switch to which this terminal connects. The “B” stands The thermal fuse is pressed into a locking termin
for battery which is the power supply for the fuse. The connector. Do not jerk connection. Move locking te
“C” stands for compressor clutch to which this terminal minal ears away from tabs and pull connections apar
connects.
Before removing superheat switch, discharge sy
Test tern, Group 9031. Remove compressor with inlet ar
outlet hoses still attached. Do not allow weight
The superheat switch does not need to be removed compressor to pull on the hoses.
to test. The thermal fuse does need to be removed for
testing. As a safety precaution always wear protecti
gloves and safety glasses when removing superhc
Make a continuity test. Check for an open between switch.
the compressor frame and superheat switch terminal.
Remove retainer, superheat switch and O-ring.

Litho in U.S.A.
18 Opera tar’s Station JD670-A and JD672-A Motor Graders
1830-32 Heating and Air Conditioning TM- 1188 (Mar-80)

Repair
The thermal fuse and superheat switch are not
repairable. Replace if found defective.

Installation
If the superheat switch is replaced, check compres-
sor oil level, page 1830-16.

Reverse the removal steps.

PRESSURIZER MOTOR
General Information Repair
The pressurizer motor draws in either outside air or The pressurizer motor is not repairable. Test as
recirculated cab air. The air flow is through the air described in Group 9015 and replace if defective.
conditioner evaporator core.

T59378F

l-Retainer (8 used) 4-Blower Casing Front Half 6-Clip (4 used)


2-Blower Casing Rear Half 5-Self Tapping Screws (14 used) 7-Motor
3-Impeller (2 used)
8-Filter

I Fig. 48-Pressurizer Assembly

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Operator’s Station 18
TM- 1188 (Mar-80) Specifications and Special Tools 1899-l

Group 1899
SPECIFICATIONS AND SPECIAL TOOLS
OPERATOR ENCLOSURE
SPECIFICATIONS AND TORQUE VALUES

1 - Cab Mounting Cap Screw . . Tighten to 300 lb-ft


(407 Nsm) (42 kg-m)
and stake nut
(2) to cap screw (1)

.?59700N

l-Special Cap Screws 2-Hex Nut

Fig. l-Cab Mounting Cap Screw Torque

1 - Washer-to-Track -p.. . . . 0.04 to 0.06 inch


(1 to 1.5 mm)

T59701N

Fig. BCenter Track Roller Adjustment

Litho in U.S.A.
18 Operator’s Station JD670-A and JD672-A Motor Graders
1899-2 Specifications and Special Tools TM- 1188 (Mar-80)

HEATING AND AIR CONDITIONING


SPECIFICATIONS AND TORQUE VALUES

Compressor High Pressure Relief Valve


Will open at . . . . .. . . . . .440 psi
(3033 kPa) (30 bar)
Tighten to . . . . . . . . . . .10 to 14 lb-ft
(14 to 19 N.m)
1 - Compressor drive plate lock
nut torque . . . . . . . . _. 15 lb-ft
(20 N.m) (2 kg-m)
2 - Gap between drive plate and
pulley.. . . . . . . . . . . . . 0.022 - 0.057 in.
(0.56 - 1.45 mm)

Fig. 3-Compressor Drive P/ate Installation

Compressor Oil . . . . . . . . . . . . . . . . . 525 viscosity


Amount to be added when
replacing components
Compressor (new or
rebuilt) . . . . . . . . . . . . . 10 fluid oz. (296 mL) 1
Evaporator . . . . . . . . . . . .4 fluid oz. (118 mL)
Condenser . . . _. . . . . . .2 fluid oz. (59 mL)
Receiver Dryer.. . . . . . . . 0.5 fluid oz. (15 mL)

NOTE: Total system capacity is 11 fluid oz. (326


mL).
1 - Compressor drive belt _ . . . _. 130 to 140 lb.
(578 to 623 N)
Strand tension, after 3 minutes of operation
should be 90 lb. (400 N) minimum strand ten-
sion
2 - Compressor manifold plate cap screw
torque. . . . . . . . . . . . ... . . . 35 lb-ft
(47 N.m)
Clutch coil
Voltage Range. . . . . . . . . . . 24 to 28 volts
Current Draw . . . . . . . . . . 2.0 to 2.5 amps
Resistance .... . .. 11.5 ohms at
80°F (27%)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Operator’s Station 18
TM- 1188 (Mar-80) Specifications and Special Tools 1899-3

HEATING AND AIR CONDITIONING


SPECIFICATIONS AND TORQUE VALUES-Continued

Hose and Tubing O-Ring Connection Torques

Metal Tube Thread and


Outside Diameter Fitting Size Torque
inches inches lb-ft

:
(N-d (kg-m)

l/4
3/a
l/2
7/16
5/a
314
lo-15
lo-15
24-29
(14-20)
(14-20)
(33-39)
(l-2)
(l-2)
(3-4)
q
5/a 7/a 26-31 (35-42) (3.5-4)
314 l-1/16 30-35 (41-47) (4-5)

IMPORTANT: Care must be taken when tighten- NOTE: Air conditioning hoses in the engine frame
ing connections to evaporator core. should be routed away from the battery and clutch
housings. Use heavy-duty tie bands to fasten the
NOTE: Dip O-ring or female flare portion in refrig- hoses away from housings.
erant oil prior to assembly.

Litho in U.S.A.
1B Operator’s Station JD670-A and JD67.CA Motor Graders
1899-4 Specifications and Special Tools TM- 1188 (Mar-80)

HEATING AND AIR CONDITIONING


SPECIAL TOOLS :
Essential Tools
Tool Tool Number Use

AIR CONDITIONER TEST EQUIPMENT SET NO. D-18018KD


Manifold Pressure Gauge Set D-l 8019KD Testing system pressures
Safety Goggles D-l 8020KD Protecting eyes
Air Conditioning Wrench D-l 8021 KD Adjusting service valves
Pocket Thermometer D-l 8022KD Measuring outlet air temperature
Refrigerant Can Dispensing Valve D-l 8023KD Using pressurized refrigerant cans
Anti-blowback Valve D-l 8024KD Prevents system pressure blowback
Test Plate D-l 8032KD Connecting test gauge set to
compressor

AIR CONDITIONER COMPRESSOR SERVICE TOOL KIT NO. D-05273ST (Was D-1801 1 KD)
Seal Kit D-05276ST Remove and replace compressor seal and
(Was DY18012KD) O-rings
“0” Ring Remover AC-41 2 Remove seal seat “0” ring
Seal Seat Remover AC-41 4 Not used
Seal Remover-installer AC-41 5 Remove and install shaft seal
“0” Ring Installer AC-460 Install “0” ring
Seal Seat Installer AC-462 Install seal seat
Universal Pulley Puller D-05277ST Removing compressor pulley
(Was D-18013KD)
Puller Arbor AC-45 1 AC-451, AC-452 and AC-457 are an
Pulley Removal Jaws AC-452 assembly used with AC-455 and AC-456
Puller Body AC-457 to remove pulley
Pulley Removal Pilot AC-455 Remove compressor pulley
Pulley Hub Removal Pilot AC-456 Remove compressor pulley
Universal Clutch Service Kit D-05278ST Remove and install clutch hub
(Was D-l 8014KD)
Clutch Remover AC-454 Remove clutch
Clutch Installer AC-458A Install clutch
Screw (5/B x 1-l/2 inch) AC-440 Not used
Screw (5/B x 2-l/2 inch) AC-441 Not used
Screw (5/B x 2-l/2-inch) AC-442 Not used
Universal Bearing Service Set D-05279ST Remove and install pulley bearing
(Was D-l 8015KD)
Clutch Holding Wrench D-05280ST Removing hub and drive plate
(Was D-l 8016KD)
Snap Ring Pliers Set D-0528 1ST Removing retainer rings
(Was D-l 8017KD)
Internal Snap Ring Pliers AC-425 Remove and install snap rings during
External Snap Ring Pliers AC-426 compressor repair.
Ceramic Seal Seat Remover D-05284ST Remove and install ceramic
and Installer (Was D-18027KD) seal seat
Seal Sleeve Protector D-05285ST Installing shaft seal
(Was D-l 8028KD) assembly
Expansion Valve Screen Remover D-05286ST To remove expansion valve
(Was D-l 8029KD) inlet screen

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Opera to& Station 18
TM- 1188 (Mar-80) Specifications and Special Tools 1899-S

HEATING AND AIR CONDITIONING


SPECIAL TOOLS-Continued

Essential Tools-Continued

Tool Tool Number Use

Portable Vacuum Pump D-05267ST Evacuating system


(Was D-l 8003KD)
Electronic Leak Detector D-05232ST Detecting refrigerant leaks
Shield Installation Tool JDST-26-4-A Installing front (rotating) portion
of pulley bearing front shield
Shield Installation Tool JDST-26-4-B Installing rear (stationary) portion
of pulley bearing front shield
Volt-Ohm-Amp Meter D-19001TT To check electrical system
Fixture D-01 006AA To hold compressor during disassembly
and assembly
A/C Service Fitting Kit D-l 5038NU For flushing, purging and leak testing
system components

3/4 Tube Tee Assembly w/1/4


Tube Tee 2632
Tube Test Plug Assembly 2633
3/8 Tube to l/4 SAE m Adapter
Assembly 2634
7/8 Tube to 7/l 6 x 20 SAE m
Adapter Assembly 2635
Tube to SAE Adapter
Subassembly 2637
SAE Tee to Internal SAE
Union Assembly 2636
Reducer, 5/8-18F SAE x
7/16-20 m SAE 6887
Reducer, 3/4-16F SAE x
7/16-20 m SAE 6888
Reducer, 90” elbow, 3/4-16 m
SAE x 5/a-l a m SAE 7432
Reducer, l/2 Tube x 7/16-20 M
SAE 7436
90” Elbow, l/2 Tube x 7/16 Tube 7426
Adapter, 7/16-20 m SAE x 5/a-20 m
SAE 7427
Reducer, 7116-20 m SAE x 5/8-18F
SAE 7439
Cap, 7/16 x 20 SAE 7447
Adapter, 7/a-14 UNF m SAE
7/16-m UNF SAE 7509
Reducer, 7/a-14 UNF SAE x 7116-20
UNF m SAE 7510
Tee, 3/4-16F SAE Swivel x
7/16-20 m SAE x 7/16-20 m SAE 7511

Litho in U.S.A.
18 Operator’s Station JD670-A and JD672-A Motor Graders
1899-6 Specifications and Special Tools TM- 1188 (Mar-80)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Sheet Metal 19
TM- 1188 (J&78) Hood or Engine Enclosures 1910-l

Section 19
SHEET METAL
CONTENTS OF THIS SECTION

Page Page

GROUP 1910 - HOOD OR ENGINE ENCLOSURES GROUP 1921 - GRILLE AND GRILLE HOUSING
Engine Shields Removal .............................. 1921-l
General Information .................. 1910-3 Repair ................................ 1921-t
Removal ............................ 191 O-3 Installation .............................
Repair .............................. 191 O-3
Installation. .......................... 191 O-4
Hood
General Information . . 1910-5
Removal . . . .. . 1910-5
Repair . . . . .. . 1910-5
Installation. .. . . 1910-5
Rear Panels and Bumper
General Information . 1910-6
Removal . ... . 1910-6
Repair . . . 1910-6
Installation. . .. . . 1910-6

GROUP 1913 - MISCELLANEOUS SHIELDS


Heavy-Duty Bottom Guard . . . . . . 1913-1
Front Wheel Drive Port Block Cover
(JD672-A only) . . . . 1913-2
Shift Valve Cover . . . . . _. _. . . . _. 1913-3

Litho in U.S.A.
19 Sheet Metal JD670-A and JD672-A Motor Graders
1910-2 Hood or Engine Enclosures TM-l 188 (J&78)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Sheet Metal 19
TM- 1188 (Mar-801 Hood or Engine Enclosures 1910-3

Group 1910
HOOD OR ENGINE ENCLOSURES
ENGINE SHIELDS
General Information Repair
The engine side shields and service doors give easy Refer to Fig. 2 or 3 during disassembly and assem-
access to engine components. Key lock provides op- bly.
timum vandal protection.

T58813N

l-Latch (2 used) 12-Washer (2 used)


P-Engine Side Shield P-Washer (4 used) 13-Center Stop (2 used)
l-Service Door
d-Pin (2 used) 14-Locking Rod (2 used)
4-Yoke (2 used) 15-Cotter Pin (8 used)
F;g, l-Service Door and Side Shield
5-Spring (2 used) Is-Bracket with Handle
6-Engine Shield (2 used)
Removal 7-Washer (8 used) 17-Screw (2 used)
I-Bolt (8 used) 18-Special Nut (4 used)
Open engine side shield.
9-Cylinder Lock (2 used) Is-Washer (4 used)
IO-Nut (8 used) 20-Spring (2 used)
On engine side shield, disconnect spring (20, Fig. 2 l&-Cap Screw (2 used) 21-Cotter Pin (4 used)
or 21, Fig. 3) from screw (17, Fig. 2 or 19, Fig. 3) using
screwdriver to ease lower hook of spring off screw. Fig. Z-Side Shield
( -007620)

Remove hinge hardware and lower side shield from


the unit.

Litho in U.S.A.
19 Sheet Metal JD670-A and JD672-A Motor Graders
1910-4 Hood or Engine Enclosures TM- 1188 (Mar-80)

Installation
Use reverse of removal procedure to install service
doors or side shields.

Note the following during installation of side shields:

Install hinge pins with long legs of pins facing each


other.

Install hinge-to-hood bolt (8, Fig. 2 or 11, Fig. 3) so


head is between plates of hinge.

For units ( -007620) to increase engagement


T70708 of locking rod (14, Fig. 2), remove washers (2) as
needed.
l-Spring 12-Washer (8 used)
2-Latch (2 used) 13-Cotter Pin (4 used)
3-Cotter Pin (2 used) la--Nut (8 used)
4-Washer (4 used) 15-Gap Screw (2 used)
!5-Pin (2 used) Is-Washer (4 used)
B-Yoke (2 used) 1‘/-Center Stop
7-Engine Side Shield 18-Nut (2 used)
(+-Cylinder Lock (2 used) IS-Screw (2 used)
9-Bivet (8 used) 26-Washer (2 used)
19-Lock (2 used) Pl-Spring (2 used)
11-Bolt (8 used)

Fig. 3-Engine Side Shield


(007621- )

Note the following during assembly of side shields:

Install cylinder lock (9, Fig. 2 or 8, Fig. 3) or lock (10,


ig. 3) so arc of travel is opposite from the bracket (16,
ig. 2).

Adjust center stop to engine frame so door is tight


gainst stop and flush with outside of engine frame
fhen locking and engages center stop.

Install handle with bracket (16, Fig. 2) ( -


107620) onto locking rod so cut-out on bracket is
oward cylinder lock.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Sheet Metal 19
TM- 1188 (J&78) Hood or Engine Enclosures 1910-5

- HOOD
General Information Remove side shields or disconnect spring (20, Fig.
2) from screw (17) if shields are left attached to hood
The hood assembly features a two-piece design
assembly.
(see Fig. 3). The sides may be removed separately or
together if desired.
Attach chain to handles on right and left hoods. Lift
hood assembly from the unit.

NOTE: The right and left hood may also be re-


moved separately.

Loosen eyebolts to service housing and cap screws


to grille housing to relieve tension on attaching screws
(6, Fig. 3). Remove screws (6) and eyebolts (19). Lift
each side of the hood from the unit.

Repair
Refer to Fig. 3 during disassembly and assembly of
lb
T59183N the hood. Replace parts as necessary.
l-Lock (2 used) 11-Lock Nut (4 used)
2-Clip (4 used) 12-Jam Nut (2 used)
Note the following during assembly.
3-Cover 13-Cushion (2 used)
4-Cushion (2 used) - M-Cap Screw (4 used)
6-Pin (2 used) 16-Washer (4 used) Trim hood cushions (4 and 13) even with 90” bend
B-Screw (7 used) 16Right Hood on bottom of hood and start of offset area where left
7-Left Hood 17-Handle (2 used) and right hoods attach. ”
E-Cover 18-Washer (4 used)
O-Cap Screw (2 used) 19-Eyebolt (2 used)
lo-Washer (2 used)
Apply on right and left hoods with’suitable adhesive.

Fig. 3-Hood Install eyebolts (19) and cap screws through slotted
retainer on inside of hood with thread,downward. Eye-
Removal bolt is retained in slot by outside diameter of eye.
Remove the air cleaner and muffler stack extension. Secure with washers (18) and lock nuts (11).

Open engine side shields and remove eyebolts (19, Installation


Fig. 3) to service housing and cap screws to grille Use reverse of removal procedure to install hood.
housing.

Litho in U.S.A.
19 Sheet Metal JD670-A and JD672-A Motor Graders
1910-6 Hood or Engine Enclosures TM- 1188 (Jut- 78)

REAR PANELS AND BUMPER


General Information Repair
The rear panels and bumper enclose the rear of unit Refer to Fig. 5 during disassembly and assembly.
and protect components from damage. Replace parts as necessary.

The service housing, mounted to the rear of the


engine frame, supports the rear panels, bumper, fuel
tank and batteries.

l-Service Housing 7-Gap Screw (8 used)


P-Upper Rear Panel a-Washer (8 used)
3-Lower Rear Panel g-Cap Screw (4 used)
4-Bumper IO-Lock Washer (4 used)
5-Washer (4 used) lb-Cap Screw (2 used)
l-Upper Rear Panel 3-Bumper &Cap Screw (4 used) 12-Washer (2 used)
Z-Lower Rear Panel 4-Service Housing
Fig. 5-Rear Panels and Bumper
Fig. #-Rear of Motor Grader
Installation
Removal
Use reverse of removal procedure to install rear
Remove retaining hardware (‘7 and 8, Fig. 5) from panels and bumper.
upper and lower rear panels. Disconnect light wiring
and lift panels out and away from service housing.

Remove cap screws (6) and washers (5) retaining


bumper to service housing. Lower bumper to the
ground.

Remove batteries and fuel tank (see Groups 1671


and 0560).

Remove service housing-to-engine frame cap


screws (9 and 11). Lower service housing to the
ground.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Sheet Metal 19
TM- 1188 (J&78) Miscellaneous Shields 1913-1

Group 1913
MISCELLANEOUS SHIELDS
HEAVY DUTY BOTTOM GUARD

General Information Repair


The JD670-A and JD672-A are equipped with sev- Disassemble guard as necessary to repair.
eral covers. All covers must be used when unit is in
operation. Paint as necessary.

Replace all parts removed.

Installation
Place bottom guard on jack.

Raise bottom guard and position under the grader

Install front hardware.

Install rear hardware.

Fig. l-Heavy Duty Bottom Guard

Removal
Position jack under bottom guard.

Remove rear attaching hardware.

Remove front attaching hardware.

Lower jack with bottom guard slowly.

Pull bottom guard away from unit.

i
bitho in U.S.A.
19 Sheet Metal JD670-A and JD672-A Motor Graders
1913-2 Miscellaneous Shields TM- 1188 (Jul-78)

FRONT WHEEL DRIVE PORT BLOCK COVER (JD672-A Only)


Installation
Position cover on frame.

Move cover down and rearward.

Tighten cap screws.

Fig. a-front Wheel Drive Port Block Cover

Removal
Loosen cap screws.

Move cover forward and up.

Lift cover off.

Repair
Repair or replace cover as necessary.

Paint cover as necessary.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Sheet Metal 19
TM- 1188 (Jul-78) Miscellaneous Shields 1913-3

SHIFT VALVE COVER


The shift valve cover is located on the left side of the Repair
grader, Fig. 3.
Remove dents and straighten guard as necessary.

Paint as necessary.

Installation
Position cover. Install cap screws

IMPORTANT: It is very important to install all


protective covers.

F@ 3-Shift Valve Cover

Removal
Remove heavy duty bottom guard left side panel.

Remove cap screws holding shift valve cover on


(Fig. 3).

Litho in U.S.A.
19 Sheet Metal JD670-A and JD672-A Motor Graders
1913-4 Miscellaneous Sheilds TM- 1188 (Jul-78)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Sheet Metal 19
TM- 1 I88 (Jul- 78) Grille and Grille Housing 1921-1

Group 1921
GRILLE AND GRILLE HOUSING
REMOVAL
To remove grille housing:

Remove hood as directed in Section 19, Group


1910.

Remove cap screws (4, Fig. 1) and washers (3) and


lower grille from the unit.

Remove grille.

Attach chain hoist to grille housing. Tapped holes T59184N


are provided on top surface for eye bolts.
l-Grille Housing 4-Cap Screw (6 used)
P-Grille 6-Cap Screw (4 used)
Remove cap screws (5) and washers (6) attaching d-washer (6 used) g-Washer (4 used)
grille housing to engine frame.
Fig. I-Grille and Grille Housing
Lift grille housing from the unit, moving housing
forward to clear radiator and baffles. INSTALLATION
Use reverse of removal procedure to install grille
REPAIR and grille housing.
Refer to Fig. 1 during disassembly and assembly.
Replace parts as necessary.

Litho in U.S.A.
19 Sheet Metal JD670-A and JD672-A Motor Graders
1921-2 Grille and Grille Housing TM-1 188 (Jul-78)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Safety, Convenience and Miscellaneous 20
TM- 1188 (Jwl-78) Mirror 2002-l

Section 20
SAFETY, CONVENIENCE AND
MISCELLANEOUS
CONTENTS OF THIS SECTION

GROUP 2002 - MIRRORS


General information .................... 2002-3
Removal .............................. 2002-3
Repair ................................ 2002-3
Installation. ............................ 2002-3

GROUP 2003 - FIRE EXTINGUISHER


General Information .................... 2003-l
Repair ................................ 2003-2
Installation. ............................ 2003-2

GROUP 2004 - HORN


General Information .. . . .... 2004-l
Removal . . . . 2004-2
Repair . . .. .. . . . . . . . 2004-2
Installation.. . .. . .. .. 2004-2

GROUP 2006 - CIGAR LIGHTER


General Information .................... 2006-l
Removal .............................. 2006-2
Repair ................................. 2006-3
Installation ............................. 2006-4

Litho in U.S.A.
20 Safety, Convenience and Miscellaneous JD670-A and JD672-A Motor Graders
2002-2 Mirror TM- 1188 IJul-78)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Safety, Convenience and Miscellaneous 20
TM- 1188 (Jul- 78) Mirror 2002-3

Group 2002
MIRRORS
GENERAL INFORMATION
The mirror(s) are located on the left side of the
operators station. Optional mirror(s), can be installed
on the right side of the operators station (Fig. 1).

T59224N

l-Mirror 7-Half Clamp


2-Half Clamp &Slop Nut
3-Washer g--Bow Arm
4-Nut lo-Half Clamp
6-Gap Screw 11-Fiber Washer
6--Mounting Angle 12-Gap Screw
13-Self Tapping Screw t

Fig. P-Mirror and Bow

IQ. 1-Mirrors INSTALLATION


REMOVAL Position bow on cab corner post.

Remove screws holding mirror bow arm to side of Install metal tapping screws.
cab.

REPAIR
The mirrors are not repairable. Replace as neces-
sary.

Use Fig. 2 when assembling bow and mirror.

Litho in U.S.A.
20 Safety Convenience and Miscellaneous JD670-A and JD672-A Motor Graders
2002-4 Mirror TM- 7 188 (J&78)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Safety, Convenience and Miscellaneous 20
TM- 1188 (J&78) Fire Extinguisher 2003-l

Group 2003
FIRE EXTINGUISHER
GENERAL INFORMATION
The fire extinguisher is a field installed option. It will
be located on the right side of the operators station.

Two red plastic indicators and a gauge are your


at-a-glance assurance that the fire extinguishers are in
working condition (Fig. 1 and 2).

Fig. Z-Canister Gauge

Fig. 1-Red Plastic Indicators


The red plastic indicators are located on the head
unit (Fig. 1). The gauge is located on the bottom of the
canister (Fig. 2). Inspect the fire extinguisher; if either
red plastic indicator is missing, replace canister. Re-
place canister if gauge needle is in the red area.

IMPORTANT: To be effective, fire extinguisher


canister must be replaced after ANY use, regard-
less of duration. Once the canister seal is broken,
the valve will only hold pressure for a short period
of time. After using, replace with a new canister
immediately.

A CAUTION: Never incinerate an extin-


guisher or canister. When discarding, re-
member it is a pressure vessel that could explode
if incinerated. Discharge fully. Remove caps and
valves. Dispose of safely.

Litho in U.S.A.
20 Safety, Convenience and Miscellaneous JD670-A and JD672-A Motor Graders
2003-2 fire Extinguisher TM- I 188 (Jul-78)

REPAIR

A CAUTION: If the fire extinguisher shows


signs of usage (red plastic indicator miss-
ing from trigger or gauge indicator in red), squeeze
trigger to vent pressure.

l-Puncture Pin 3-Shut-off Valve


1 -Head Unit a-Canister 2-O-Ring

Fig. 3-Head Unit and Canister Separated Fig. 5-Underside of Head Unit

Unscrew head unit (1, Fig. 3) from canister (2). The A malfunction by any of the head unit parts could
red plastic indicator pops off when the head unit is cause the fire extinguisher to be inoperative.
unscrewed about one turn.
Remove dry chemical from shut-off valve, O-ring,
and puncture pin and any dry chemical remaining in
control head. Examine nozzle opening for obstructions.

If any damaged parts are noted, replace complete


head unit.

To assemble the canister and head unit, first insert a


new red plastic indicator into the trigger slot.

Screw the canister firmly into the head unit. Insert


red plastic indicator into slot at base of head unit.

INSTALLATION
Replace fire extinguisher in its mounting bracket.
Notice that a prong at the top of the bracket fits into a
l-Nozzle 2-Trigger
hole in the side of the trigger. This locks the trigger and
prevents accidental discharge of the fire extinguisher.
Fig. 4-Head Unit

Check trigger (2, Fig. 4) and nozzle (1). Check


puncture pin (1, Fig. 5), O-ring (2), and shut-off valve
(3). Verify that they are functional and in good working
condition.

bitho in U.S.A.
JD670-A and JD672-A Motor Graders Safety,. Convenience and Miscellaneous 20
TM- 1188 (Dee-87) Horn 2004-l

Group 2004
HORN
GENERAL INFORMATION
The safety equipment items covered in this group
are the horns, horn switch, reverse warning horn and
reverse warning horn switch.

The horns are located under the left side of the


operator’s station. The horns are controlled by the
horn switch. When the horn button is depressed the
horns will sound.

Fig. 2-Horn Switch

The reverse warning horn is located at the rear of the


grader in the rear engine compartment. The reverse
warning horn is controlled by the reverse warning
horn switch. The reverse warning horn switch is
located in the transmission shift valve. When the
grader is shifted to reverse, the reverse warning horn
will sound. The volume of the reverse warning horn
can be adjusted to either high or low depending on
the position of the switch located on the horn.

T6708AI

l-Horn (Low-Note) ( -405835) 4-Horn (405836- ) B-Bracket (405836- )


P-Nut ( -405835) 5-Cap Screw (405636- ) ‘I-Nut (405836- )
3-Horn (High-Note) ( -405835)

Fig. 3-Horn Components

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20 Safety, Convenience and Miscellaneous JD670-A and JD672-A Motor Graders
2004-2 Horn TM- 1188 (J&78)

REMOVAL REPAIR
To remove the regular horns or reverse warning The switches or horns cannot be repaired.
horn, disconnect wires and remove attaching hard-
ware. Test as described in Group 9015, Section 90.

To remove the horn switch, remove front control Replace if damaged or defective.
console panel, disconnect wires, and remove attaching
hardware. INSTALLATION
Follow removal procedure in reverse order.
To remove the reverse warning horn switch, dis-
connect wires from switch and unscrew switch from
transmission shift valve.

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JD670-A and JD672-A Motor Graders Safety, Convenience and Miscellaneous 20
TM- 1188 (Jul- 78) Cigar Lighter 2006-l

Group 2006
CIGAR LIGHTER
GENERAL INFORMATION REPAIR
The cigar lighter (if so equipped) is located on the
lower left side of the instrument panel (Fig. 1). The
motor grader is equipped with a 24V DC system. A
small resistor must be used in series with the cigar
lighter so the applied voltage to the cigar lighter is
lowered.

Fig. PResetting Cigar Lighter Circuit Breaker

If cigar lighter doesn’t function, reset circuit breaker.


Remove dash and insert wire in small hole at rear of
lighter as shown in Fig. 2.

Check element for conductivity.

Check resistor for conductivity. A slight resistance


(1.5 Ohms) should be indicated.

Power for the cigar lighter comes from the horn


Fig. I-Cigar Lighter switch. Check the connections.

REMOVAL If cigar lighter or resistor is defective, replace as


Disconnect negative battery cable. necessary.

Refer to Section 9015 Testing Miscellaneous com-


Remove cigar lighter element.
ponents for further testing.
Remove panel as needed to expose the cigar lighter
wiring.
INSTALLATION
Install cigar lighter housing and clamping shell.
Disconnect cigar lighter lead.
Connect wires.
Trace lead to resistor.
Replace panel.
Remove resistor.
Install cigar lighter element.
The cigar lighter is protected from overload by a ten
amp fuse, and a circuit breaker. Connect battery (-) cable.

Litho in U.S.A.
20 Safety, Convenience and Miscellaneous JD670-A and JD672-A Motor Graders
2006-2 Cigar Lighter TM- I 188 (J&78)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM- 1188 (Dee-87) Hydraulic System 2160-I

Section 21
MAIN HYDRAULIC SYSTEM
CONTENTS OF THIS SECTION

Page Page
GROUP 2160 - HYDRAULIC SYSTEM GROUP 2160 - HYDRAULIC SYSTEM
Main Hydraulic Pump -Continued
Removal ........................ 2160-3 Flow Divider* . . . . . . . . . . . . . . . . . . . 2160-53
Installation ...................... 2160-3 Solenoid Valve* . . . . . . . . . . . . . . . . . 2160-55
Pump Drive Assembly ............... 2160-4 Lube Line Check Valve ~ . . . . . . . . . . 2160-58
Hydraulic Noise Attenuator ........... 2160-6 HFWD Filters* . . . . . . . . . . . . . . . . . . 2160-59
Pressure Control Valve .............. 2160-7 Hydraulic Fitting Installation
Oil Cooler Assembly ................ 2160-9 and Service Recommendations . . . 2160-60
Check Valve Tee* ................. 2160-l 1
Function Return Filter .............. 2160-l 2 GROUP 2199 - SPECIFICATIONS AND
JD672-A HFWD Pump* SPECIAL TOOLS
Cleanliness. .................... 2160-14 Specifications and Torque Values . . . . 2199-1
Replacement Parts ............... 2160-l 4 Special Tools
Removal ....................... 2160-l 4 Essential Tools . . . . . . . . . . . . . . . . 2199-12
Repair ........................ 2160-l 5 Convenience Tools. . . . . . . . . . . . 2199-14
Disassembly .................. 2160-l 5
Inspection .................... 2160-25
Assembly .................... 2160-31
Installation ..................... 2160-40
Displacement Control Valve* ....... 2160-41
Charge Pump* .................. 2160-45
Electra-Hydraulic Actuator* ........ 2160-47
HFWD Pump Case Relief Valve ..... 2160-48
High Pressure and Charge Relief
Manifold Assembly* ............ 2160-49

*JD672-A Motor Grader Only

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21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2160-2 Vehicle Hydraulics TM- 1188 (Jut- 79)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM- 1188 (Dee-87) Hydraulic System 2160-3

Group 2160
HYDRAULIC SYSTEM
MAIN HYDRAULIC PUMP
JOHN DEERE RADIAL PISTON PUMP- Remove grille housing from the unit.
USE CTM-7
Remove baffle panels from front lower edge of
radiator.

Disconnect and plug hydraulic lines, Tag lines to


aid in assembly.

Discharge and remove hydraulic accumulat& from


main pump.

Attach an overhead hoist to the pump.

Remove cap screws securing pump drive shaft to


pump shaft. Remove cap screws securing pump to
Fig. l-CTM Manual pump support and remove pump from the unit.

For complete repair information on the John Deere INSTALLATION


Radial Piston Hydraulic Pump CTM-7 is also required. Locate pump shaft in pump drive shaft and tighten
pump to pump support cap screws to 85 lb-ft (115
Use components manual in combination with this N.m) (12 kg-m).
machine manual.
Put two or three drops of T43513 John Deere
REMOVAL Loctite Thread Lock and Sealer (High Strength) or an

A CAUTION: Escaping fluid under pressure equivalent on cap screws (7, Fig. 5).
can have sufficient force to penetrate the
skin, causing serious personal injury. Before dis- Tighten drive shaft retaining cap screws (7) to 30
connecting lines, be sure to relieve all pressure. lb-ft (41 N-m) (4 kg-m) using “X” pattern.
Before applying pressure to system, be sure all
connections are tight and that lines, pipes and hoses Connect hydraulic lines. Refer to Hydraulic Fitting
are not damaged. Fluid escaping from a very small Installation and Service Recommendations, this group.
hole can be almost invisible. Use a piece of card-
board or wood, rather than hands, to search for Install hydraulic accumulator. Charge as described
suspected leaks. under Hydraulic Accumulaotr, this group.

If injured by escaping fluid, see a doctor at once. Install baffle panels onto front lower edge of
Serious infection or reaction can develop if proper radiator.
medical treatment is not administered immediately.
Install grille screen.

Check standby pressure as described in Group


9025.

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21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2160-4 Hydraulic System TM- 1188 (Dee-87)

PUMP DRIVE ASSEMBLY


(Serial No. -010039)

l-Special Nut (2 used) 7-Cap Screw (4 used) 13-Washer (as required)


P-Coupler Hal! (2 used) a-Pump Support 14-Cap Screw (4 used)
3-Special Screw (2 used) O-Lock Washer (4 used) 15-Lock Washer (4 used)
4-Bushing (4 used) lo--Cap Screw (2 used) 16-Dowel Pin (2 used)
&Special Screw (2 used) 11-Cap Screw (2 used) l7-Cap Screw (2 used)
B-Drive Shaft 12-Bracket

Fig. 5-Pump Support and Drive Assembly

PUMP DRIVE ASSEMBLY


(Serial No. 010040-405856)

T6713AF

l-Support 7-Cap Screw (4 used) 12-Isolator


2-Washer (4 used) I-Lock Washer (4 used) 13-Cap Screw (2 used)
d-Cap Screw (2 used) g--Dowel Pin (2 used) 14-Coupling
4-Cap Screw (2 used) lo--Cap Screw (6 used) E-Shaft
S-Bracket 1 l-Coupling 16-Kit
6-Washer (AR)

Fig. Sa-Pump Support and Drive Assembly

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Main Hydraulic Sys tern 21
TM- 1188 (Dee-87) Hydraulic System 2160-5

PUMP DRIVE ASSEMBLY


(Serial No. 405857- )

12
T6713AG

l-Support 6-Washer (AR) 11-Coupling


2-Washer (4 used) ‘I-Cap Screw (4 used) 12-Cushion
3-Cap Screw (2 used) 6-Lock Washer (4 used) 13-Shaft
4-Cap Screw (2 used) g--Dowel Pin (2 used) 14-Coupling
I-Bracket lo--Cap Screw (2 used) %-Screw (2 used)

Fig. Bb-Pump Support and Drive Assembly

REMOVAL Loosely, install hydraulic pump on pump support


(8) and position pump drive shaft (6) on pump shaft.
Remove main hydraulic pump from the unit (see
Tighten pump to pump support cap screws to 85 lb-
hydraulic pump removal, this group).
ft (115 N.m) (12 kg-m).

Refer to Fig. 5 and disassemble drive shaft.


Install coupler halves (2) on bushings.

REPAIR
Adjust drive shaft to relieve any axial strain on
inspect all parts for wear or damage. Replace bushings.
parts as necessary.
IMPORTANT: There must be a minimum clearance
INSTALLATION of 0.06 in. (2.03 mm) between the ends of the special
screws (3 and 5).
If support (8, Fig. 5) is removed, install on unit and
tighten cap screws (14) to 85 lb-ft (115 N.m) (12
Tighten coupler cap screws (17) to 30 lb-ft (41
kg-m).
N-m) (4 kg-m). Check and tighten cap screws in
same sequence until all cap screws can hold 30
Install the bushings (4) on the special screws (3
lb-ft.
and 5).
Hold cap screws (17) and tighten special nuts (1)
Put two or three drops of T43513 John Deere
to 30 lb-ft (41 N-m) (4 kg-m).
Loctite Thread Lock and Sealer (High Strength) or an
equivalent on special screws (3). Tighten screws
Put two or three drops of T43513 John Deere
into engine pulley to 75 lb-ft (102 N.m).
Loctite Thread Lock and Sealer (High Strength) or an
equivalent on driveshaft clamping cap screws (7).
Put two or three drops of T43513 John Deere
Tighten in a “X” pattern until all cap screws hold 30
Loctite Thread Lock and Sealer (High Strength) or an
lb-ft (41 N.m) (4 kg-m).
equivalent on special screws (5). Tighten screws
into drive shaft to 35 lb-ft (47.5 N.m).

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21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2160-6 Hydraulic System TM- 1188 (Dee-87)

HYDRAULIC NOISE ATTENUATOR


GENERAL INFORMATION

Fig. &Hydraulic Noise Attenuator


(JD672-A Shown)

The hydraulic noise attenuator (Fig. 6) has no


precharge. Hydraulic oil is admitted into the attenuator
.T64158N
and collapses the bladder until the pressure behind
the bladder equals main pump standby pressure.
Fig. 7-Attenuator

The attenuator acts as a buffer to greatly reduce


sound level peaks. REPAIR
There are no service parts on this attenuator.
The attenuator is located next to the main hydraulic Replace complete attenuator.
pump. It is connected between the main hydraulic
pump outlet port and the hydraulic pump pressure INSTALLATION
hose.
Install attenuator (Fig. 6) so that it fully contacts
support bracket.
REMOVAL
With engine off, operate steering valve and brake Connect hose.
valve to relieve the hydraulic pressure.

Remover attenuator from unit.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM- 1188 (Dee-87) Hydraulic System 2160-7

PRESSURE CONTROL VALVE


REMOVAL
A CAUTION: Escaping fluid under pressure
can have sufficient force to penetrate the
skin, causing serious personal injury. Before dis-
connecting lines, be sure to relieve all pressure.
Before applying pressure to the system, be sure all
connections are tight and that lines, pipes and hoses
are not damaged. Fluid escaping from a very small
hole can almost be invisible. Use a piece of card-
board or wood, rather than hands, to search for
suspected leaks.

If injured by escaping fluid, see a doctor at once.


Serious infection or reaction can develop if proper
medical treatment is not administered immediately.

Relieve hydraulic system pressure by actuating


the steering valve and brakes with the engine stopped.

Disconnect and mark all lines for easier installation.


Cap all lines to prevent dust from entering hydraulic
system.

Remove valve from unit.


l-Lift Arm Locking Pin 4-10 Function Control
Valve Valve
~-TO Brake Accumulator B-Pressure Control Valve
~-TO Rear Mounted ~-TO Lift Arm
Equipment Control Locking Pin
Valve ‘I-From Main Pump
8-To Steering Valve

Fig. &Pressure Control Valve Location

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21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2160-8 Hydraulic System TM- 1188 (Dee-87)

1-Valve Body 4-Washer


2-Orifice S-Shim (as required)
3-Pressure Control Valve B-Spring

Fig. g-Pressure Control Valve Assembly

REPAIR The valve spring (6, Fig. 9) should have a free


length of 4.61 in. (117.1 mm) and its test length
Refer to Fig. 9 for identification of parts and
should be 3.5 in. (88.9 mm) when compressed with
sequence of assembly. Also note the following
50 III 5 lb (223 & 22 N) (23 i 2 kg).
specific instructions
Assembly
Disassembly
Use the same number of shims (5, Fig. 9) as were
Note the number of shims (5, Fig. 9) removed
removed, to obtain correct spring pressure setting.
during disassembly. It will be necessary to use the
same number when assembling to obtain the correct
Assemble orifice (2) (pointed end first), washer (4)
pressure setting.
shims (5), and spring (6) into valve (3) before valve is
installed into valve body (1).
Inspection
Check the inside diameter of the pressure control Install tee in end of control valve.
valve bore in the valve body (1, Fig. 9). The front of
the bore should be 0.7508 to 0.7518 in. (19.07 to INSTALLATION
19.10 mm). The rear should be 0.7268 to 0.7278 in.
Install valve on unit and connect lines. Refer to
(18.46 to 18.49 mm).
Hydraulic Fitting Installation and Service Recommen-
dations, this group.
Check the outside diameter of the pressure control
valve (3, Fig. 9). The front of the valve should be
Check the pressure setting as described in Group
0.7497 to 0.7503 in. (19.04 to 19.06 mm). The rear
9025.
should be 0.7257 to 0.7263 in. (18.43 to 18.45 mm).

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM-1 188 (Dee-87) Hydraulic System 2160-9

OIL COOLER ASSEMBLY


GENERAL INFORMATION The bypass valve is equipped with two spring
loaded valves. The small center valve opens when
pressure in the inlet tank of the oil cooler reaches
approximately 35 psi (2 bar) (2 kg/cm*), allowing oil
to bypass the cooler and flow directly to the main
hydraulic pump.

REMOVAL

Oil Cooler
Remove grille screen.

Disconnect all oil lines to the oil cooler and cap so


dirt will not enter system.

Remove all cap screws connecting oil cooler to


radiator and remove from unit.

Bypass Valve
l-Oil Cooler l-Bypass Valve Remove gille screen, disconnect hoses, and
remove bypass valve from oil cooler.
Fig. 1 O-Oil Cooler and Bypass Valve
(Radiator Removed From Unit) REPAIR

The oil cooler is of the air-to-oil-type, controlling Oil Cooler


transmission lubrication oil temperature and is located
Clean oil cooler thoroughly.
at the front of the radiator.

In addition, the cooler provides cooled oil for the Inspect oil cooler for leaks, cracks and bent fins.
hydraulic system through the main hydraulic pump.
NOTE: Cooler should be cleaned and repaired
The oil cooler bypass valve is located externally only by an experienced radiator technician.
on a bypass line between the two tanks of the cooler.

Litho in U.S.A.
21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2160-10 Hydraulic System TM- 1188 (Dee-87)

Bypass Valve

P61023N

l-Housing 5-Spring (I-Spring


2-Pin 6-Washer g--Spring Guide
3-Special Washer 74tetaining Ring 10-O-Ring
+-Bypass Valve 1 l-Cap

Fig. 1 T-Oil Cooler Bypass Valve

Check bypass valve opening pressure (22 to 35 INSTALLATION


psi [2 bar] [2 kg/cm*]) with a hydraulic hand pump.
Oil Cooler
Disassemble bypass valve and check springs to
Install oil cooler and secure in place.
specifications.
Connect all lines to cooler and hydraulic pump.
Spring (5, Fig. 11) free length is 2.25 in. (57.2 mm)
and test length is 1.75 in. (44.5 mm) when compressed
Install grille screen.
with 7.2 to 8.8 lbs (32 to 39 N) (3.3 to 4.0 kg).
Bypass Valve
Spring (8) free length is 2.50 in. (63.5 mm) and test
length is 1.875 in. (47.63 mm) when compressed with Connect hoses to bypass valve and install grille
0.25 + 0.06 Ibs (1.1 * 0.27 N) (.l 1 + 0.03 kg) of force. screen.

Check bypass valve (4) for flatness. It should be


within 0.002 in. (0.05 mm).

Check special washer (3) for flatness. It should be


within 0.002 in. (0.05 mm).

Inspect all other parts and replace as necessary.


Assemble ground faces of bypass valve (4) and
special washer (3) toward each other.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM-1 188 (Dee-87) Hydraulic System 2160-l 1

CHECK VALVE TEE


(JD672-A Only)
REPAIR

Disconnect the hoses from the check valve tee.

Remove special connector (2, Fig. 13).

Replace O-ring (3).

Inspect seating area of check valve (5) and check


valve body (4).
8
-m
0
l’61025N

l-To Main Hydraulic Pump S-Check Valve


l-special Connector B-From Oil Cooler
3-O-Ring ~--TO HFWD Charge Pump
4-Check Valve Body 6-Spring

Fig. 73-Check Valve Tee Assembly

Inspect spring (8) for the following:

Free length . . . . . . . . . . . . . . . 1.29 in. (32.8 mm)


Test length . . . . . . . . . . . . . . . . 0.83 in. (21.1 mm)
when compressed with 1.20 i 0.12 lb.
(5.3 + 0.5 N) (0.5 rk 0.05 kg)

Reassemble check valve.

Install check valve tee as shown (Fig. 13).

IMPORTANT: The special connector (2, Fig. 13)


Fig. 72-CheckValve Tee
(JD672-A Only) must face the main pump. If check valve is installed
backwards the main pump and HFWD charge pump
will be starved.

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21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2160-12 Hydraulic System TM- 1188 (Dee-87)

FUNCTION RETURN FILTER


GENERAL INFORMATION The hydraulic return filter relief valve is a pressure
differential valve. As long as differential pressures
are no more than 100 psi (7 bar) (7kg/cm*) no oil will
go to sump. If the difference in pressure increases to
100 psi (7 bar) (7 kg/cm*) due to plugged filter
element or cold oil, the hydraulic filter relief valve will
open allowing hydraulic return oil to go to sump.

REMOVAL
Remove the special cap screw (1, Fig. 15) and
drain the filter assembly.

Remove filter from transmission housing.

REPAIR
Disassemble using Fig. 15 as a reference.

l-Hydraulic Return Filter

Fig. 14-Hydraulic Return Filter Location

The hydraulic return filter is located on the right-


hand side of the transmission housing.

It filters all the oil returning from the steering valve


and all function valves.

Should the filter element become plugged due to


dirty oil or cold weather operation, hydraulic return
oil would be bypassed to sump by the hydraulic
return filter relief valve.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM-1 188 (Dee-87) Hydraulic System 2160-13

T61526N

l-Special Cap Screw g--Washer 11-Cap Screw (2 used) 16-Bypass Valve


2-O-Ring (2 used) 7--Retainer 12-Lock Washer (2 used) Spring
3-Hydraulic Oil Filter 6-Packing 13-Hydraulic Oil Filter 17-Special Washer
Cover g--Retaining Ring Valve Housing 18-Retaining Ring
4-Packing lo-Oil Filter Element 14-Bypass Valve 19-O. Ring
5-Spring 15-O-Ring

Fig. 15-Hydraulic Return Filter Assembly

Visually inspect hydraulic return filter relief valve Tighten special cap screw (1) to 15 to 20 lb-ft (20
for damage. Replace filter element and any other to 27 N.m) (2 to 3 kg-m) of torque.
parts as needed.
Start engine and check for leaks.
ASSEMBLY
Assemble parts (14 to 18, Fig. 15) into valve housing
(13).

Install valve housing into the transmission housing


and tighten cap screws (11).

Slip special cap screw (1) through O-ring (2) and


cover (3) and assemble parts (4 to 11, Fig. 15).

INSTALLATION
Dip packing (4, Fig. 15) in oil and install packing
on hydraulic oil filter cover (3).

Install filter assembly to unit making sure filter is


square with unit.

Litho in U.S.A.
21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2160-l 4 Hydraulic System TM- 1188 (Dee-87)

JD672-A HFWD PUMP


Cleanliness
IMPORTANT: When removing the pump, be certain
to clean the outside of the pump thoroughly. Either
steam clean or wash with solvent. Also, clean
surrounding area so dirt will not get into system
when hoses are disconnected.

If internal service work is to be performed, keep


the work bench, tools, and equipment clean.
Cleanliness is very important on this unit.

Replacement Parts
When servicing the pump, always install new O-
rings, gaskets, and seals. This will provide a tight
seal for mating parts when pump is assembled.

If it is necessary to replace a check valve assembly


in the pump, replace both check valve assemblies.
This will insure even wear on the check valves and
proper flow of oil through the pump.
1-Clevis and Pin 4-Battery Clamps
REMOVAL P-HFWD Pump B-Blocks
3-Cap Screws
Remove rear panel and bumper.
Fig. l&Removal of HFWD Pump
Cover batteries to prevent oil contamination of the
batteries. Install clevis and pin (1) in the lifting eye of the
pump. Attach to the overhead hoist.
Remove actuator and mount from HFWD pump.
Remove retaining cap screws and carefully slide
Disconnect and plug or cap all lines and hoses pump rearward until the front of the pump can also
from HFWD pump. be attached to an overhead hoist with a sling.

Place two long cap screws (3, Fig. 16) in trunnions Remove pump from unit.
to assist in removal of pump.

Block up battery clamps. Use as guides for pump


removal.

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JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM-1 188 (Dee-87) Hvdraulic Svstem 2160-15

REPAIR

Disassembly
IMPORTANT: Protect all highly finished (lapped)
surfaces with soft clean paper towels to avoid nicks
and scratches. Also, be certain two lapped surfaces
do not slide against each other. After wrapping
these parts with clean paper towels, set to one side
so they will not be bumped by other parts during
service. Use tools made from wooden dowels to
protect lapped surfaces from damage when removing
or installing parts.

Fig. lb-Removing Stationary Seal with Retainer

Remove stationary seal with retainer (Fig. 18). Be


careful not to lose the eight small springs which are
between stationary seal and retainer.

l--Snap Ring 3-Control Lever Arm


l--Seal Retainer

Fig. 17-Removing Snap Ring

Remove snap ring (1, Fig. 17) which holds seal


retainer (2) in housing.

IMPORTANT: Do NOT set pump on control lever


arm (3).

l-Rotating Seal I-Seal Retainer


2-Stationary Seal

Fig. 19-Removing Rotating Seal

Remove rotating seal (1, Fig. 19).

IMPORTANT: Do NOT mark or damage inner


surface of shaft rotating seal or outer surface of
stationary seal.

Wrap rotating seal and stationary seal separately


in soft clean paper towels to protect lapped surfaces.

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21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2160-l 6 Hydraulic System TM- 1188 (Dee-87)

l--Do Not Remove These a--Charge Pump


Two Bolts t-Wooden Block

Fig. PO-Removing Charge Pump Bolts

Remove charge pump (2, Fig. 20) and gasket.


Remove only four bolts as shown. Other two bolts (1)
hold sections of pump together. l-Charge Pump 4-Charge Pump Gasket
2-Spread Pin 5-Charge Pump Bolts
When removing charge pump (1, Fig. 21) it is 3-Idler ShaH and Plug B-Charge Pump Drive Shaft
necessary to overcome friction of spread pin (2) in
pump housing. Do NOT pry charge pump to loosen. fig. Pl-Removing Charge Pump
Tap with a plastic hammer if necessary. When lifting
charge pump, be certain idler shaft and shaft plug (3)
remain in charge pump. Remove charge pump and
gasket (4).

NOTE: If charge pump requires servicing, order


replacement.

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JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM-1 188 (Dee-87) Hydraulic System 2160-17

l-Check Valve 2-Socket Screwdriver

l-Check Valves P-End Cap Fig. 23-Replacing Check Valves

Fig. 22-Oil on Check Valves in End Cap Check valves (1) are replaced as a complete unit.
Remove with a wide blade screwdriver or socket
Clean and inspect check valves (1, Fig. 22) in end screwdriver. When installing new check valve, tighten
cap (2) of main pump. Apply a light coat of hydraulic to 35 to 40 lb-ft (47 to 54 N.m) (5 to 6 kg-m) torque.
fluid to slotted end of check valve. Hydraulic fluid
should not flow through the check valve. If hydraulic
fluid flows through check valve, replace it. However,
if there is no oil on a check valve, it is leaking and
should be replaced.

NOTE: If one check valve is to be replaced, be


certain to replace both check valves. This will provide
uniform operation of check valves.

l-End Cap P-End Cap Screws

Fig. 24-Removing End Cap Screws

Remove six cap screws (2, Fig. 24) leaving two


across from each other. Loosen the last two equally
to keep the end cap (1) from cocking.

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21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2160-l 8 Hydraulic System TM-1 188 (Dee-87)

l--End Cap 4-Bearing Plate


P-Valve Plate 5-Gasket
3-Bearing Plate Pilot 6-O-Ring

Fig. 26-End Cap, Valve and Bearing Plates,


Gasket and O-Ring Removed
l-End Cap 4-O-Ring
P-Valve Plate 5-Bearing Plate
3-Gasket Remove brass bearing plate (4, Fig. 26). If neces-
sary, pry up at edge of plate only at dowel pin
Fig.25Removing End Cap and Valve Plafe groove. Be very careful not to mark surfaces. Remove
gasket (5) and O-ring (6).
Very carefully, raise end cap (1, Fig. 25) and if
valve plate (2) is stuck to end cap, hold plate with NOTE: Wrap valve p/ate and bearing plate in soft
fingers to be certain it will not drop away from end clean paper towels separately and set to one side.
cap. Remove valve plate from end cap and wrap
valve plate in soft clean paper towels. Also protect
finish surface of end cap. If necessary to pry valve
plate loose from end cap, pry only at dowel pin
groove.

If valve plate does not come off with end cap,


separate valve plate from bearing plate (5) by first
spraying diesel fuel between plates and then sepa-
rating plates by hand. The diesel fuel cuts through
the oil suction created by the extremely flat plates.
Surfaces of plate must be protected to prevent
marking or scratching.

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JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM- 1188 (Dee-87) Hydraulic System 2160-19

l-Puller 3-Rear Bearing l--Spring Guide P-Rear Searing Removed


l-Steel Ball
Fig. 28-Removing Sleeve
Fig. 27-Removing Rear Bearing
Remove spring guide (1, Fig. 28) from shaft.
IMPORTANT: Cut out a piece of cardboard and
place between puller and cylinder block. Be careful
not to score surface of cylinder block.

Remove rear bearing (3, Fig. 27) from end of shaft


with a JDG-96 Bearing Puller (1). Use a small block
or ball (2) between shaft and ram of puller to avoid
damage to slot in end of shaft.

l-Cylinder Block Assembly l-Pistons

Fig. 29-Removing Cylinder Block Assembly

Carefully lay pump on its side and hold splined


end of drive shaft so shaft will not slide during
removal of cylinder block. Remove cylinder block (1,
Fig. 29), ball guide, pistons (2) and slipper retainer
from pump housing. Be sure to note how slipper
retainer is installed.

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2160-20 Hvdraulic Svstem TM- 1188 (Dee-871

l-Springs (6 used) 3-Pistons with Retainer


Z-Cylinder Block 4-Ball Guide

Fig. 30-Parts of Cylinder Block Assembly l-Front Cover 3-Drive Shatt


2-Gasket
If pistons do not come out with cylinder block (2,
Fig. 30), remove as follows: Fig. 37-Removal of Front Cover

Remove bail guide (4). It is necessary to align Remove front cover (1, Fig. 31) and gasket (2).
missing tooth in guide with missing tooth on shaft to
remove ball guide. Remove shaft (3) from front cover.

Remove piston assembly (nine pistons) (3) with NOTE: In most cases, it will not be necessary to
retainer. It is necessary to reach in housing with both disassemble the pump any further. However, the
hands to remove all pistons and retainer. Protect remaining disassembly procedure should be used if
face surface of slippers. Wrap piston assembly in it is necessary to disassemble the servo cylinders,
soft clean paper towels. con trot valve, or s washpla te.

Remove thrust plate (26, Fig. 39) from swashplate Remove the nine cap screws which secure the
with fingers. Protect surface of plate after removal by pump displacement control valve. Pull the control
wrapping in soft clean paper towels. It may be valve away from the pump housing. Disengage the
necessary to spray diesel fuel between thrust plate pin on the control link from the mating hole in the
and swashplate. small link attached to the swashplate, by moving the
control valve sideways.

If displacement control valve requires servicing


see the displacement control valve repair, this group.

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JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM- 1188 (Dee-87) Hydraulic System 2160-21

Insert cap screw into threaded hole in center of


trunnion to aid in removal.

Remove both trunnions with trunnion bearings (6,


Fig. 33). The bearings on the trunnions are a “slip-
fit.” If they are to be removed, do not use a puller or a
pry bar. Keep shims (2) with each trunnion.

1-Trunnion P-Swashplaie

Fig. 32-Scribing Trunnions and Pump Housing

Scribe a line on both trunnions (1, Fig. 32) and


pump housing and mark trunnions and housing to
facilitate correct assembly of trunnions after servicing l-Pin 3-Swashplate
2--Retaining Rings
pump.

Fig. 34-Removal of Swashplate

Remove retaining rings (2, Fig. 34) and pins (1)


which hold swashplate (3) to servo pistons.

Remove swashplate from pump body.

l--Scribe Line 4-Trunnions


2-Shims 5-O-Ring
3-Swashplate 6:Bearing

Fig. 33-Removal of Trunnions

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21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2160-22 Hydraulic System TM-1 188 (Dee-87)

l--Servo Piston 3--Retaining Ring


a--Pin 4-Swashplate
l--Mark Servo Cylinders P-Scribe Lines
Fig. Xi-Removal of Swashplate and Housing 3-Servo Retainer

Remove remaining retaining ring and pin and lift Fig. 36-Marking and Scribing Servo Cylinders

swashplate from pump housing.


Remove servo retainer (3, Fig. 36) on each servo
NOTE: Swashplate can be removed without cylinder.
removing the servo cylinders.
IMPORTANT: Cylinders must NOT be interchanged.

Number each servo cylinder (1) and pump housing


to facilitate reassembly.

Mark each servo cylinder and pump housing with


horizontal and vertical scribe lines (2).

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JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM- 1188 (Dee-87) Hydraulic System 2160-23

Remove servo cylinders (1, Fig. 37) and pistons (2).

IMPORTANT: Keep each piston with its respective


cylinder.

Remove servo pistons with links.

Protect finished surfaces of cylinders and pistons


with soft clean paper towels.
;, “.

l-JDG-37-1 Servo P-Servo Cylinder


Cylinder Socket (2 used)

Fig. 36a-Remove Servo Cylinders

IMPORTANT: Record the exact number of turns


needed to remove each servo cylinder. Servo cylin- l-Piston 4-Washer
ders must be installed to exact depth for transmission P-Spring B-Cap Screw
pump to have a neutral position. 3-Spring Guide

Use JDG-37-1 Servo Cylinder Socket (1, Fig. 36a) Fig. 38-Exploded View of Servo Piston
to remove servo cylinders (2). Record exact number
of turns needed to remove each servo cylinder. If servo piston (1, Fig. 38) must be disassembled
due to wear or damage, use a long l/4 inch socket
to reach cap screw (5) inside spring guide (3).
Removing this cap screw will permit disassembly of
piston (Fig. 38).

I-Servo Cylinder g--Servo Retainer


2-Servo Piston with Link

Fig. 37-Removal of Servo Cylinders and Pistons

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21 Main Hydraulic Sys tern JD670-A and JD672-A Motor Graders
2160-24 Hydraulic System TM- 1188 (Dee-87)

T61033N

l-Check Valve (2 used) 14-Drive Shaft 27-Swashplate 38-Servo Retainer (2 used)


P-O-Ring (2 used) W-Spiral Lock Ring 28-Connecting Link 39-Gasket
3-End Cap 16-Spring Retainer SQ-Servo Piston Link 40-Front Bearing
4-Gasket 17-Spring Guide (2 used) 41-Front Cover
L-Shim (as required) 18-Spring 30-Pin (4 used) 42-O-Ring (2 used)
B--Rear Bearing lQ-Spring Seat 3l-Retaining Ring 43-Rotating Seal
7-Valve Plate 20-Cylinder Block (8 used) 44-Stationary Seal
8-Bearing Plate 21-Spring (8 used) 32-Servo Piston (2 used) 45-O-Ring
Q-Bearing Plate Pilot 22-Ball Guide 33-Spring (2 used) 46-Spring (8 used)
lo-lrunnion (2 used) 23-Piston Retainer 34-Spring Guide (2 used) 47-Seal Retainer
1 l-Shim (use as required) 24-Piston Assembly (9 used) 35-O-Ring (2 used) 48-Snap Ring
12-O-Ring (2 used) 25-Pump Housing 36-O-Ring (2 used) 49-O-Ring
13-Trunnion Bearing (2 used) 28-Thrust Plate 37-Servo Cylinder (2 used) SO-Rotating Group

Fig. 39-Exploded View of HFWD Pump

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JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM- 1188 (Dee-87) Hydraulic System 2160-25

Inspection The balance land (1, Fig. 40) balances the 5000 psi
(345 bar) (352 kg/cm2) system pressure, against the
Wash all parts in diesel fuel and dry thoroughly.
case pressure. Scoring of both lands (4) and (5)
Coat all parts with clean hydraulic oil.
would indicate fine contamination over a long period
of time. Deep scoring of one land would indicate the
IMPORTANT: Be very careful when handling these
presence of large contaminants in the system.
parts during washing, drying and inspection.
Bearing plates may be encountered where the
NOTE: To dry parts after washing in diesel fuel,
balance land (1) appears good, but the outer foot (2,
shake off excess liquid and blow dry with clean
Fig. 40) is scored. This condition could arise from
compressed air. DO NOT dry with rags or paper
either a lack of lubrication or from a lubricant
to we/s.
breakdown. This condition would not indicate the
presence of contaminants in the system.
Inspect all surfaces for excessive wear, nicks,
scratches, or scoring.
NOTE: Failure of a bearing plate can be caused by
any one or a combination of the following:
Refer to Fig. 40 to familiarize yourself with the
various parts of a valve or bearing plate.
1. Cavitation (caused by air in the system oil).
2. Contamination (from either within the system or
from outside the system).
3. Water (indicated when oil in the reservoir is
white, milky, or light yellow in color).

l-Balance Land 4-Outer Land


2-Outer Foot S-Inner Land
G-Kidney

Fig. 40-Parts of a Valve or Bearing Plate

NOTE: Replace bearing plate, valve plate or ball


guide if a scratch or groove can be detected with a
lead pencil.

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21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2160-26 Hydraulic System TM- 1188 (Dee-87)

Examples of Scored
Bearing Plates and Valve Plates

Fig. 42-Example of Deeply Scored Bearing Plate

Fig, 41-Example of Scored Bearing Plate This bearing plate (Fig. 42) shows deep scoring
only through the area on the balance land between
This bearing plate (Fig. 41) shows complete inter- the kidneys. This deep scoring indicates solid par-
face (bearing plate to valve plate) scoring due to fine ticles of contamination within the system.
abrasive contamination (dust or dirt) suspended in
the hydraulic fluid. This example (Fig. 41) could also
indicate early stages of water contamination. When
water is present in the system, the oil in the reservoir
is white, milky, or light yellow in color.

NOTE: Replace bearing plate, valve plate, or ball


guide if a scratch or groove can be detected with a
fingernail or lead pencil.

Fig. 43-Example of Scored Valve Plate

This valve plate (Fig. 43) shows scoring between


valve plate kidney, indicating solid particle contami-
nation within the system, such as brass particles.

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JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM- 1188 (Dee-87) Hydraulic System 2160-27

Examples of Eroded Bearing Plates

Fig. 45-Example of Eroded Area


Fig. 44-Example of Eroded Areas on a Bearing Plate in Bearing Plate Kidney

This bearing plate (Fig. 44) shows eroded areas on This bearing plate (Fig. 45) shows erosion in the
the balance land. This erosion is characteristic of bearing plate kidney. This erosion is characteristic of
cavitation. Cavitation is usually caused by air in the cavitation. See Fig. 44 for another example.
system. This can be caused by loose hose or line
connections or by a hole in the suction hose. See
Fig. 45 for another example.

NOTE: Erosion that cannot be felt but seen on the


cylinder block side of the bearing plate and the
lapped surface of the cylinder block can cause
excessive leakage.

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21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2160-28 Hydraulic System TM-l 188 (Dee-87)

Examples of Smeared Bearing Plates

l-Bearing Plate 3-Cylinder Block


2-Block Litt (Block lilt)

Fig. 47-Block Lift (Block Tilt)

‘* “.7”?
,>a* , .sr Block lift (2, Fig. 47) sometimes referred to as
l-Outer Foot P-Balance Land block tilt, occurs when the cylinder block (3) and the
bearing plate (1) separate, which is caused by
Fig. 46-Example of Smearing of Outer Edge of Outer Foot and overspeeding.
of the inner Edge of the
Balance Land on a Bearing Plate

This bearing plate (Fig. 46) shows smearing of the


outer edge of the outer foot (1, Fig. 46) and of the
inner edge of the balance land (2). This smeared
condition indicates that cylinder block lift or block tilt
has occurred.

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JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM- 1188 (Dee-87) Hydraulic System 2160-29

Fig. &?-Example of Smearing of Balance Land Fig. 49-Example of Partial Smearing of


on a Bearing f/ate Balance Land on a Bearing Plate

This bearing plate (Fig. 48) shows smearing on This bearing plate (Fig. 49) unlike (Fig. 48), shows
most of the balance land due to water contamination. partial smearing at the outer edges of the balance
This plate shows the dull yellow or gold coloration land, due to water contamination. This plate also
and the darker oxidation tarnish characteristic of shows the dull yellow or gold coloration and the
water contamination. When water is present in the darker oxidation tarnish characteristic of water
system, the oil in the reservoir is white, milky, or light contamination.
yellow in color.
NOTE: Fig. 48 shows more advanced deterioration
NOTE: The dark (tarnished) areas are exposed to by smearing than does Fig. 49.
case pressure, where the dull yellow or gold area is
the balance land and is exposed to high pressure.

The smearing at the outer edge of the balance


land occurs because this area is in contact with the
valve plate and is not receiving the lubrication of the
system high pressure fluid.

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21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2160-30 Hydraulic System TM- 1188 (Dee-87)

Piston and Piston Slipper Damage Bearing races in swashplate should be inspected
for wear or brinnelling.
Inspect piston slippers for scoring across their
balance lands. The balance land is the second land
Be certain all bearings rotate freely and there is no
in from the outside edge. Scoring, to some degree,
roughness.
may be seen across the inner lands. When inspecting
slippers, also check to be certain the oil hole in each
IMPORTANT: Use only JD bearings ordered by
slipper is open.
specific part number as they are selected for close
tolerances. Bearing manufacturer’s numbers may be
Replace pistons if pieces of the filler break off.
the same but not matched to the necessary close
tolerances.
Check for piston to piston slipper play. Play of
more than 0.005 in. (0.13 mm) is excessive. Replace
piston assembly.

Rotating Seal Damage

l--Spring Retainer 3-Spring


2-Spiral Lock Ring 4-Spring Seat
(Beveled)

Fig. 51-Spring in Cylinder Block

IMPORTANT: Be sure not to damage surface of


cylinder block.

If it is necessary to replace spring (3, Fig. 51) at


rear of cylinder block, use a press to facilitate removal
Fig. BO-Example of Nicked Rotating Seal of spiral lock ring (2). Replace spring and reinstall
remaining parts. Be certain to install beveled spring
This rotating seal (Fig. 50) shows several nicks at seat (4) with beveled side toward splined end of
the edges. These nicks were probably caused by block. Install spring retainer (1) with shoulder toward
contamination from outside the system, such as dirt. open end of block.
Such contaminants can damage the seal during
start-ups. The light scoring on the surface of the seal Inspect splines of cylinder block and shaft for
land was probably caused by fine abrasive contami- wear and galling.
nants suspended in the hydrostatic system fluid.

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JD670-A and JD672-A Motor Graders Main Hydraulic Sys tern 21
TM- 1188 (Dee-87) Hydraulic System 2160-31

Assembly

NOTE: Be certain to install new O-rings and gaskets


when assembling pump.

Have a small can of clean hydraulic fluid and a


container of petroleum jelly available. Apply a light
coat of hydraulic fluid to each surface prior to
assembly. Apply a light coat of petroleum jelly to all
O-rings prior to assembly.

Refer to Figure 39 (exploded view) and if any of the


parts listed below have been replaced, it will be
necessary to check drive shaft end play before
completely assembling the pump.

These parts are:

3-End Cap 25-Pump Housing l-Links 5--Connecting Link


P-Servo Piston 6-Swashplate
4-Gasket 40-Front Bearing
%--Retaining Ring 7-Be Certain Both Links
6-Rear Bearing 41 -Front Cover I-Pin Have Bends Toward
14-Drive Shaft Center of Housing

To check end play, assemble the above parts Fig. 524nstalling Servo Pistons and Swashplate
(including front cover gasket [39]), being certain
bearing races are down to shaft shoulders and Cover servo pistons (2, Fig. 52) with hydraulic oil
bearing cups are properly seated. Tighten bolts to 36 and install pistons with links (1) in pump housing
to 38 lb-ft (49 to 52 N.m) (5.0 to 5.3 kg-m); then check (Fig. 52). Be certain each link on pistons is set with
drive shaft end play. bend toward center of housing. Be careful not to
mark or scratch surface of piston.
End play of the pump drive shaft must be 0.006 to
0.016 inches (0.15 to 0.41 mm). If the end play is less
than 0.006 inch (0.15 mm), use two end cap gaskets
(4) under the end cap.

If end play of the drive shaft exceeds 0.016 inch


(0.41 mm), use one shim (5) under the cup of the rear
bearing in the end cap. Each shim is 0.010 inch (0.25
mm) thick.

Once the correct end play has been obtained,


disassemble these pieces and proceed with the
complete assembly of the pump as follows.

NOTE: End play can be checked with the swash-


plate and servo cylinders installed.

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21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2160-32 Hydraulic System TM- 1188 (Dee-87)

Install swashplate in pump housing (Fig. 53). Be


certain connecting link (2) on swashplate comes
through hole in pump housing before installing pins
in swashplate and piston links. Secure pins with
retaining rings.
,),,:_,.,‘,,’
__

,,_,
l-Scribe Line 4-Pins with Retaining
L-Connecting Link Ring
3-Trunnions S-Swashplate

Fig. 5%Swashplate Installed


l-Retainers 4-Thrust Plate and
2-Servo Cylinder Swashplate
Apply a light coat of hydraulic oil on trunnion 3-Scribe Lines S-Depth Micrometer
bearings. Install two trunnion assemblies (3, Fig. 53)
with new O-rings in pump housing (Fig. 33). Be Fig. 54-Installing Servo Cylinders
certain to install correct trunnion on correct side of and Setting Swashplate in Neutral
housing. Align scribe marks (1, Fig. 53) and be certain
shims are installed correctly. Tighten trunnion cap NOTE: If a new swashplate, new servo pistons, or
screws to 36 to 38 lb-ft (49 to 52 N.m) (5.0 to 5.3 cylinders are installed, it will be necessary to use a
kg-m). depth micrometer (5, Fig. 54) to obtain the neutral
position of the swashplate. Install thrust plate on
After installing trunnions, check movement of swashplate. Locate micrometer on both sides of thrust
swashplate (5). A force of 4 to 7 pounds (18 to 31 N) plate (by each servo cylinder) in a line parallel to the
will be required to move swashplate. shaft. Adjust servo cylinders in as evenly as possible
so all play in the swashplate is eliminated. Tighten
Apply a light coat of hydraulic oil to the inside of servo cylinders until they just touch spring guide.
servo cylinders (2, Fig. 54). Use JDG-37-1 Servo Excessive tightening will cause spring to bottom and
Cylinder Socket to install cylinders in pump housing. servos will be inoperative. Then adjust for neutral by
Tighten cylinders the same number of turns counted tightening one cylinder a small amount (l/8 to l/4
during removal. Align scribe lines (3) on cylinders turn) and loosening the other cylinder a like amount
and pump body very closely. Correct alignment of until both micrometer readings are within 0.001 in.
scribe lines is necessary to place the swashplate in (.025 mm) of being the same and there is no play in
neutral. the swashplate.

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JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM- 1188 (Dee-87) Hydraulic System 2160-33

Install new gasket for pump displacement control


valve.

Install three new O-rings (2, Fig. 56) on displace-


ment control valve.

Insert displacement control valve lever pin into


swashplate controlling link.

l-Servo Retainer

Fig. 55-Servo Cylinder Retainers Installed

Install servo retainers (1, Fig. 55) with socket head


set screws previously removed. Use a screwdriver to
set retainer into slot (2) in cylinder to prevent servo
cylinder rotation.
l-Displacement Control Vahre P-O-Ring (3 used)

NOTE: If it was necessary to relocate servo


Fig. 56-Displacement Control Valve
cylinders, flatten previous set in servo retainer before and O-Rings
installing retainer. Reset in new position.
Attach control valve to pump body. Tighten nine
bolts to 10 to 11 lb-ft (14 to 15 N-m) (1.4 to 1.6 kg-m)
torque.

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2160-34 Hydraulic System TM- 1188 (Dee-87)

1 -Front Cover 3-Drive Shaft


l--Gasket 4-Front Bearing

Fig. 57-lnslalling Front Cover,


Drive Shaft and Gasket

Install drive shaft (3, Fig. 57) through front cover (1) l-Thrust Plate 2-Swashplate
end of pump housing.
Fig. 594nstallation of Thrust P/ate

Place pump on wood blocks. Install thrust plate (1,


Fig. 59) in swashplate (2) with smooth surface out.
Beveled side of thrust plate fits into swashplate.

l-Drive Shatt l-Front Cover l-Piston Retainer 4-Springs


2-Align Missing Teeth !&Ball Guide
Fig. 58-Front Cover with Shaft Installed 3-Cylinder Block B-Piston
I-Piston Bore

Install new front cover gasket; then install front


cover (2, Fig. 58). Tighten twelve bolts to 36 to 38 Fig. 60-Assembling Pistons and Ball Guide
in Cylinder Block
lb-ft (49 to 52 N.m) (5.0 to 5.3 kg-m) torque.

Assemble six springs (4, Fig. 60) in cylinder block


(3) then install ball guide (5). Align missing tooth (2)
in guide with half tooth in cylinder block (Fig. 61).

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JD670-A and JD672-A Motor Graders Main Hydraulic Sys tern 21
TM-l 188 (Dee-87) Hydraulic System 2160-35

1-Bhaft Missing Tooth 2-Ball Guide Missing Tooth

Fig. 624nstalling Cylinder Block Assembly

Align half tooth in cylinder block and missing tooth


l-Ball Guide 3-Half Tooth in ball guide (2) with missing tooth on shaft in pump
P-Missing Tooth 4-Cylinder Block (1, Fig. 62). When cylinder block is completely
installed, end of block should be even or slightly
fig. Bl-Aligning Missing Tooth and Half Tooth below surfaces of pump housing.

Install nine pistons with slippers in piston retainer. Be careful not to bump shaft, causing it to move up
Apply a light coat of oil to pistons and retainer and out of ball guide.
install pistons with retainer in cylinder block (Fig. 62).

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21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2160-36 Hydraulic System TM- 1188 (Dee-87)

l--Spring Guide 3-Lapped Surface of


a--Rear Bearing Removed Cylinder. .Wpck

Fig. 63-Installing Spring Guide l-Bearing Press J-Spring Guide


l-special Tool, JDG-96-2 4-Bearing

install spring guide (1, Fig. 63) on shaft and into


cylinder block. Fig. 64-Pressing Rear Bearing on Shaf!

Press rear bearing (4, Fig. 64) on shaft until bearing


is flush with shoulder on shaft. Outer surface of
bearing should be nearly even with end of shaft
when completely installed.

IMPORTANT: Do not damage slot in end of shaft.


Use special tool, JDG-96-2 (2) to protect end of
shaft (Fig. 64).

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JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM-7 788 {Dee-87) Hydraulic System 2160-37

Fig. &J-End Cap installed

Turn end cap over carefully and set on pump body


1-Valve Plate 4-Gasket (Fig. 66).
l-End Cap 5-O-Ring
3-Bearing Plate IMPORTANT: Do not let valve plate fall away from
end cap. Tighten opposite bolts to be certain end
Fig. 65Installing End Cap, Valve Plate, cap sets properly. Tighten bolts to 36 to 38 lb-ft (49
Bearing P/ate, Gasket, and O-Ring to 52 N-m) (5.0 to 5.3 kg-m) torque.

Install bearing plate (brass) (3, Fig. 65) and pilot on Install both check valves and tighten to 35 to 40
cylinder block. Dowel pin in block locates bearing lb-ft (47 to 54 N.m) (5 to 6 kg-m) torque.
plate. Coat all surfaces liberally with oil.

NOTE: Install pilot with bearing plate.

Coat valve plate (1) with a light coat of petroleum


jelly between valve plate and end cap and install on
end cap (2). Plate is located by dowel pin and outer
race of rear bearing. Coat gasket (4) and O-ring (5)
with petroleum jelly and install on pump housing.

IMPORTANT: Use extreme care when assembling


plates to avoid dropping, marking or scratching
plates, end of cylinder block, or face of end cap. If
any of the above-mentioned parts are damaged,
they will have to be replaced with new parts.

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21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2160-36 Hydraulic System TM-1 188 (Dee-87)

Fig. 66-Charge Pump Installed

Align tang on pump shaft with slot in drive shaft.


Install charge pump. Be certain spacer for idler gear
shaft does not fall out when installing charge pump.
Tighten four bolts to 10 to 11 lb-ft (14 to 15 N.m) (1 to
l-Charge Pump 4-Charge Pump
2 kg-m) torque (Fig. 68).
2-Spread Pin Gasket
3-Idler Shaft and S-Charge Pump Bolts
Plug B-Charge Pump Drive
Shaft

Fig. 674nstalling Charge Pump

IMPORTANT: Be certain slot in gasket is over slot


for relief valve in charge pump. Notch in gasket
should align-with notch alongside of pump.

Install new gasket on charge pump (Fig. 67).

1-Shatt Rotating Seal 5-O-Ring


l-springs B-Front Stationary Seal
3-Seal Retainer 7-O-Ring
4-Snap Ring 6-Control Lever

Fig. 69-Front Seal Parts

Set pump so control lever (8, Fig. 69) does not rest
on work bench. Lay out front seal parts (Fig. 69).

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JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM- 1188 (Dee-87) Hydraulic System 2160-39

l-Stationary Seal 4-Springs (6 used)


2-Align Slot with Pin 5-Retainer
3-O-Ring

Fig. 77-Stationary Sea/ with Retainer


l-Rotating Seal a--O-Ring
Install new O-ring (3, Fig. 71) on stationary seal (1).
Fig. 70-Installing Rotating Sea/ Be certain six springs (4) are in place between
stationary seal (1) and seal retainer (5). Locate seal
Install new O-ring (2, Fig. 70) on drive rotating seal in seal retainer by aligning notch in seal with pin (2)
(1) and install seal on drive shaft being careful not to in retainer.
drag seal across splines of shaft. Seat seal firmly on
drive shaft, using special tool, JD-356 (see “Special Install stationary seal with retainer and new O-ring
Tool” this section). and secure with snap ring. Snap ring should be
installed with the chamfered side of the snap ring
facing out.

Rotate shaft of pump, being careful not to damage


splines. There should be a drag on the shaft, but
shaft should rotate without binding.

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21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2160-40 Hydraulic System TM- 1188 (Dee-87)

INSTALLATION
Install HFWD pump on motor grader.

Connect hoses and lines. Tighten as outlined in


Hydraulic Fitting installation and Service Recommen-
dations, this group.

Fill the HFWD pump cas with clean oil of the type
recommended in “Lubricants” Section I, Group V.

Install actuator and link.

IMPORTANT: Do not start engine at this time.


Perform Start Up Procedure as described in Group
9016.
Fig. 72-HFWD Pump Installed
See Actuator To Displacement Control Valve Lever
Neutral Adjustment, Group 9016.

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JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM- 1188 (Dee-87) Hydraulic System 2160-41

DISPLACEMENT CONTROL
VALVE (JD672-A Only)
REMOVAL Support rear of fuel tank with jacks or blocks.

The displacement control valve can be removed


Remove rear fuel tank support (3, Fig. 73).
from the HFWD pump without removing the entire
HFWD pump from the motor grader.
Remove the nine displacement control valve
mounting cap screws.
IMPORTANT: Before removing the control valve,
clean the control valve and the surrounding areas so
Lift valve and gently move it to the right40 disen-
dirt will not enter the system during removal. Either
gage the valve’s pin from the swashplate control link.
steam clean or wash with solvent. If internal service
work is to be performed, keep the work bench, tools
Remove the displacement control valve from the
and equipment clean.
unit.

Disconnect control linkage (2, Fig. 73) from lever


IMPORTANT: Cover opening of HFWD pump to
arm on pump. ensure no dirt will enter the case.

l-Displacement Control P-Linkage


Valve 3-Fuel Tank Support

Fig. 734lisplacement Control Valve

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21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2160-42 Hydraulic System TM- 1188 (Dee-87)

33

Q
CD

461042N

l-Spring Pin lo-O-Ring Is-Gasket 26-Spool


2-Acluator 1 l-Control Shaft Bushing 20-O-Ring (3 used) 29-Sleeve
3-Spring 12-O-Ring 21-Connector Link 30-Centering Spring
4-Sleeve 13-Spacer 22-Control Valve Link 31-O-Ring
5--Retaining Ring 14-Control Handle 23-Plug (2 used) BP-Adjusting Screw
B-Stop 1I-Washer 24-O-Ring (2 used) 33-Jam Nut
P-Control Shatt Link 16-Lock Washer 25-Locking Nut 34-Cover
I-Retaining Ring 17-Jam Nut 26-O-Ring 35-Retaining Ring
9-Control Shatt 16-Valve Housing 27-Centering Spring 36-Washer (2 used)
Housing

Fig. 74-Displacement Control Valve Assembly

Remove control shaft bushing (11, Fig. 74) from Remove l/8-inch pipe plug in end of valve and
housing. The control shaft assembly can now be drive out spring pin (1) which fastens actuator to
moved over so the connector link (21) will be out of control shaft.
the way. Rotate spool (28) and remove link (22).
Remove control shaft (9) linkage, spring, and
To remove spool (28) from valve body, remove actuator from valve body. Do not disassemble
cover (34) loosen lock nut (25) next to body and linkages unless necessary.
screw centering spring housing (27), lock nut, and
jam nut (33) out as a unit. Spool will come out with
housing.

To remove spool from centering spring housing,


loosen outer hex jam nut and, using a screwdriver,
remove centering spring screw (32) from housing.
Spool can then be removed through center end of
housing.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Main Hydraulic Sys tern 21
TM- 1188 (Dee-87) Hydraulic System 2160-43

lnpsection Place new O-ring (10, Fig. 74) on shaft and place
entire assembly into valve body (18) and slide end of
Wash all parts in clean solvent and dry thoroughly.
shaft into the recess in the valve body.

Inspect parts for excessive wear or scoring.


Rotate spool (28) and insert link (22). Insert link so
Replace all worn or damaged parts.
that the two pins. facing the same direction, are up.
Rotate the link and spool to the normal position and
Carefully inspect O-rings (20). A damaged O-ring
slide the shaft assembly back in place, attaching it to
in this area of the control valve can cause the spool
the middle pin on link.
to direct insufficient oil to the servo cylinders and
pistons. This insufficient flow of oil could cause the
Place new O-ring (12) on bushing (11). Slide
grader not to move in either direction.
bushing on control shaft and into valve body.

IMPORTANT: Check all new O-rings before they


Install plugs (23) with new O-rings (24) in valve
are installed, to be certain they are still elastic.
body.

Assembly Install O-rings (20) in valve body.


If valve spool (28, Fig. 74) has been disassembled,
assemble washers (36), centering spring (30), and
sleeve (29) on spool and secure with one retaining
ring (35).

Insert assembled spool into the outer end of the


centering spring housing (27). Screw centering spring
screw (32) with new O-ring (31) on screw, into the
end of the housing only until it comes in contact with
the centering spring. Install jam nut (33), new O-ring
(26), and lock nut (25) on housing (27).

Insert assembled spool with centering spring


housing into valve body (18). Tighten housing only
finger tight.

Place stop (6) with connector link (21) through


control shaft link (7) and secure with retaining ring.
Place retaining ring (5) in center groove on shaft and
then slide control shaft link (7) on shaft.

Slide sleeve (4) and spring (3) on shaft. Be certain


both ends of spring are correctly wound around stop
(6).

Slide actuator (2) on shaft and secure with spring


pin (1). Refer to Fig. 75 for relationship of parts.

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21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2160-44 Hydraulic System TM- 1188 (Dee-87)

INSTALLATION
Make sure O-rings (10, Fig. 75) are in valve housing.

Install new gasket (5) on valve housing. Install


displacement control valve on unit making sure pin
in control valve link is connected to swashplate
controlling link.

IMPORTANT: Make sure pin in control valve link


(3) is connected to the swashplate control link.

Tighten cap screws to 10 to 11 lb-ft (14 to 15 N.m)


(1.4 to 1.6 kg-m).

l-Actuator 9-Control Shaft


p-stop lo-O-Ring (3 used) 1-bsplacement Control 2-Linkage
3-Control Valve Link 1 l-Cover Valve 3-Fuel Tank Support
4-Connector Link 1 a-Spool
B-Gasket 13-Control Shaff Link
6-Control Handle 14-Spring fig. 76Displacement Control Valve Installed
7-Washer 15-Spring Pin
6-Jam Nut Install spacer (13, Fig. 74), control handle (14),
washer (15) lock washer (16) and nut (17).
Fig. 75-Displacement Control Valve
Position control handle (6, Fig. 75) perpendicular
to the actuator rod as shown in Fig. 76. This position
is 15 degrees back from straight up.

IMPORTANT: Do not start engine at this time.


Refer to Start Up Procedure, Group 9016.

Perform Actuator to Pump Displacement Control


Valve Lever Neutral Adjustment and Displacement
Control Valve Neutral Adjustment, Group 9016.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM- 1188 (Dee-87) Hydraulic System 2160;45

CHARGE PUMP
(JD672-A Only)
REMOVAL A large container should be available to catch any
oil that drains from the pump when the charge pump
is removed. Do not save drained oil.

Remove four bolts (1, Fig. 77). Other two bolts hold
pump sections together. These sections can not be
separated. Remove the charge pump and gasket.

NOTE: When removing charge pump it is necessary


to overcome friction of spread pin in main pump
housing. Do NOT pry charge pump to loosen. Tap
with a plastic hammer if necessary. When removing
pump, be certain idler shaft and shaft plug remain in
charge pump.

After removing charge pump, cover open side of


end cap to keep dirt out of main pump.
l-Remove These Cap 2-Neutral Charge Relief
Screws Only Valve
L&Charge Pump

Fig. 77-Charge Pump

The charge pump may be removed from the HFWD


pump without removing the pump from the grader.

IMPORTANT: When removing the charge pump,


be certain to clean the outside of the pump
thoroughly. Either steam clean or wash with diesel
fuel. Also, clean surrounding area so dirt will not get
into system when hoses are disconnected.

Cover batteries to avoid contamination.

Disconnect inlet hose from charge pump. Plug


end of hose.

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21 Main Hydrtiulic System JD670-A and JD672-A Motor Graders
2160:46 Hydraulic System TM- 1188 (Dee-87)

REPAIR INSTALLATION
Install new gasket (6, Fig. 78) on charge pump.

IMPORTANT: Make sure slots in charge pump line


up with slots in gasket. When gasket is installed
6 correctly, relief valve hole in gasket will line up with
0
relief valve hole in pump housing.
0

0
When installing charge pump be sure idler shaft
0 plug does not fall out.
O 0

0
0
Install charge pump. Tighten cap screws to 10 to
8
11 lb-ft (14 to 15 N.m) (1.4 to 1.5 kg-m).

Fill the charge pump with clean oil of the type


P61045N
recommended in “Lubricants” Section I, Group V.
1 -Plug S-Relief Valve
P-O-Ring B-Gasket Connect inlet hose. Refer to Hydraulic Fitting Instal-
3-Shim (as required) ~--DO Not Remove These lation and Service Recommendations, this group.
4-Spring Cap Screws
E-Charge Pump
IMPORTANT: Do not start engine at this time.
Refer to the Start Up Procedure, Group 9016.
Fig. 78-Charge Pump Repair

Refer to Group 9016 for adjustment of the neutral


Remove plug (1, Fig. 78). Do not lose shims (3) that charge relief valve.
are in plug. Remove spring (4) and relief valve (5).

IMPORTANT: Charge pump can not be separated


for inspection or repair. If charge pump is inoperative
replace the entire pump.

Clean parts in solvent.

Inspect spring, relief valve, and relief valve seating


area in charge pump for damage. Replace parts if
necessary.

Install relief valve and spring. Install all shims that


were removed into plug.

Place new O-ring on plug and install.

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JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM- 1188 (Dee-87) Hydraulic System 216047

ELECTRO-HYDRAULIC ACTUATOR
(JD672-A Only)
REPAIR

l-Cap 4-Filter 6-Actuator


2-O-Ring 5-Seal 7-Force Motor
d-spring

Fig. 79-Electra-Hydraulic Actuator

Disconnect wiring from actuator. Install new seal (5), filter, spring, new O-ring (2)
and cap into actuator.
Disconnect hoses from actuator.
IMPORTANT: Note location of small nylon ball
Remove actuator from unit. behind set screw. Take care that this ball is reinstalled
before set screw.
Remove cap (1) spring (3), filter (4) and seal (5).
Replace O-ring (2) and seal (5). Remove force motor (7) if it is to be replaced by
first removing set screw on left of actuator. Screw
Inspect spring as follows: force motor out of actuator.
#
Free length .. . . . . . . . . . 1.75 in. (44.45 mm) Install force motor into actuator but do not tighten
set screw until force motor is adjusted as described
Test length . . . . . . . . . . . . . . 0.85 in. (21.6 mm) under Actuator Neutral Adjustment, Group 9016.
when compressed with 21.6 + 2.2 lb.
96&10N(9.7+1 kg) Install actuator on actuator bracket and connect
hoses and wiring.

Adjust Actuator Neutral and Actuator To Pump


Displacement Control Valve Lever Neutral as
described in Group 9016.

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21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2160-48 Hydra&c System TM-1 188 (Dee-87)

HFWD PUMP CASE RELIEF VALVE

(JD672-A Only)

REPAIR

l-Check Valve S-Washer


P-Valve Body 6-Spring
3-O-Ring 7-Shim (as required)
4-Special Connector 6-O-Ring

l-Case Relief Valve


Fig. U-Case Relief Valve

Fig. 80-HFWD Pump Case Relief Valve


Remove case relief valve (1, Fig. 80).

Remove special connector (4, Fig. 81). Remove


remaining components.

inspect seating area of check valve (1) and valve


body (2).

Check spring (6) for the following:

Free length . . . . . . . . . . . . . . . . 1.5 in. (38 mm)

Assemble valve using the same number of washers


(5) as were removed.

If necessary shim valve to open at 80 zt 5 psi (5.5


+ 0.35 bar) (552 f 35 kPa).

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TM- 1188 (Dee-87) Hydraulic System 2160-49

HIGH PRESSURE AND CHARGE RELIEF


MANIFOLD ASSEMBLY (JD672-A Only)
REMOVAL

Fig. BP-HFWD Port Block Cover


l-Cap Screw (6 used) 3-Port Block
Remove HFWD part block cover (Fig. 82). Z-Valve Housing

IMPORTANT: Before removing the valve housing, Fig. 83-HFWD Vaalve Housing

clean the housing and surrounding area with diesel


fuel or steam. If internal work is to be performed
keep the work bench, tools and equipment clean.

Remove the cap screws (1, Fig. 83) securing the


valve housing (2) to the port block (3).

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2160-50 Hydra&c System- TM- 1188 (Dee-87)

REPAIR

l-Forward High Pressure Relief Valve 4-Charge Relief Valve


2-Shuttle Valve S-Reverse High Pressure Relief Valve
3-Valve Housing

Fig. 84-HFWD Relief Valves

Remove valves (1, 2, 4, 5, Fig. 84) from valve Do not lose shims (3, Fig. 86) in charge relief valve
housing (3). plug.

l-Plug (2 used) 4-Washer (2 used)


l-O-Ring (2 used) B-Shuttle Valve Spool
3--Spring (2 used)

Fig. 85-Shuttle Spool Removed l-Charge Relief Valve Piston 4-O-Ring


l--Spring 5-Plug
3-Shim (as required)

Fig. 86-Charge Relief Valve Removed

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JD670-A and JD672-A Motor Graders Main. Hydraulic System 21
TM- 1188 (Dee-87) Hydraulic System 2160-61

l--Backup Ring (2 used) 4-Relief Valve Assembly ‘I-Shim (as required)


2-O-Ring S-Relief Valve Cone I--q-Ring
3-O-Ring g--Spring g--Cap

Fig. 87-High Pressure Relief Valve Removed

The high pressure relief valve may be disassembled


for cleaning purposes and to adjust the pressure
setting. There are shims inside the O-ring cap (9, Fig.
87).

INSPECTION
Clean all parts in diesel fuel and dry thoroughly
with compressed air.

Check all parts for excessive wear or scoring.


Replace parts as necessary.

Clean orifice (1, Fig. 88) in the high pressure relief


valves.

1-Orifice

Fig. 88-High Pressure Relief Valve Orifice

NOTE: If high pressure relief valve is defective, it


must be replaced. The plug shims (7, Fig. 87) are the
only service part of this valve. The relief valve can be
reshimmed to correct pressure setting.

Install new O-rings and backup washers on plugs


and relief valves before assembly.

If shuttle valve spool (5, Fig. 85) needs to be


replaced, the valve housing (3, Fig. 84) must also be
replaced.

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21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2160-52 Hvdraulic Svstem TM- 1188 (Dee-87)

Assembly INSTALLATION
Install high pressure relief valves in valve housing.
Tighten to 20 to 30 lb-ft (27 to 41 N-m) (3 to 4 kg-m).

Install charge relief valve piston (1, Fig. 86), spring


(2) and plug (5) with O-ring. Tighten plug securely.

Install shuttle valve spool (5, Fig. 85), washers (4)


springs (3), and plugs (1) with O-rings. Tighten plugs
securely.

IMPORTANT: Shims are used with the charge


relief valves. Make sure shims are installed in plugs
used with relief valves.

2610518
3
l-Plug S-Backup Washer (2 used)
2-0-Ring g--O-Ring (2 used)
3-Port Block 7-Valve Housing
4-O-Ring S-Cap Screw (6 used)

Fig. BQ-installing Valve Housing

Install new O-rings (4 and 6, Fig. 89) in face of


valve housing manifold. Install two backup washers
(5) (flat side out) on top of O-rings (6) in two main
ports of valve housing. Backup washers should be
against face of port block when valve housing is
installed.

Attach valve housing to port block. Tighten six cap


screws.

IMPORTANT: Do not start engine at this time.


Refer to Start Up Procedure, Group 9016.

See Group 9016, for adjustment of valves.

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JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM- 1188 (Dee-87) Hydraulic System 2160-53

FLOW DIVIDER
(JD672-A Only)
REMOVAL REPAIR
Remove the end plates (2, Fig. 91) by removing
cap screws (1).

Remove plug (5). Remove spring (6) and orifice


plates (7).

Carefully pull spools (13) and spring (14) from the


flow divider body (15).

IMPORTANT: Keep spools with their respective


sleeves. They are matched sets.

l--Port Block P-Flow Divider


Carefully remove sleeves (10). Do not scratch the
inner surface of the sleeve.
Fig. 90-Flow Divider Location

Remove pipe plug (18) from flow divider body to


Disconnect lines from flow divider (2, Fig. 90). allow cleaning of the orifice. Do not remove orifice. It
is not a service item.
Remove flow divider from unit.
Clean all parts in clean solvent.
Cap the lines.
Replace worn or damaged parts.

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21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2160-54 Hydraulic System TM- 1188 (Dee-87)

l-Cap Screw (8 used) 7-Orifice Plate (2 used) 13-Spool (2 used)


l-End Plate (2 used) B-Backup Ring (4 used) 14-Bpring
3-Backup Ring (2 used) 9-O-Ring (2 used) 15-Flow Divider Body
4-O-Ring (2 used) lo-Sleeve (2 used) 1 B-Plug
5-Plug (2 used) ll-Backup Ring (4 used) 1 ‘I-0-Ring
8-Spring (2 used) 12-O-Ring (2 used) 18-Pipe Plug

Fig. 9140~ Divider

Replace all O-rings and backup rings. INSTALLATION


Install flow divider on unit.
Install clean parts as shown in Fig. 91 with spools
(13) hooked together.
Connect the forward drive lines to the flow divider.
Refer to Hydraulic Fitting Installation and Service
Tighten cap screws (1) to 20 to 25 lb-ft (27 to 34
Recommendations, this group.
N.m) (3 to 4 kg-m).

IMPORTANT: Do not start engine at this time.


Tighten pipe plug to 6 to 8 lb-ft (8 to 11 N-m) (0.8 to
Refer to Start Up Procedure, Group 9016.
1 kg-m).

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JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM- 1188 (Dee-87) Hydraulic System 216045

SOLENOID VALVE
(JD672-A Only)
REMOVAL REPAIR

1-Q
2-F) -5
8
3A8 p-2

T61055N

l-Plug (2 used) ‘I-Connector (2 used)


2-O-Ring (4 used) E-O-Ring (5 used)
3-Seat (2 used) 9-Connector (2 used)
4-Ball (2 used) lo-Elbow (3 used)
5-Connector 11-Pipe Plug (6 used)
6-Valve Body 12--Solenoid Cartridge
l-Cap Screws and Washers (3 used)
P-Solenoid Valve

Fig. 93-Solenoid Valve


Fig. 92-Solenoid Valve

Mark, disconnect, and cap all hoses from the Remove plugs (1, Fig. 93). Inspect balls (4) and
solenoid valve (2, Fig. 92). seats (3). Replace if necessary.

Mark and disconnect the solenoid wires. Apply John Deere Loctite Thread Lock and Sealant,
Low Strength, or an equivalent to plugs (1) and
Remove solenoid valve by removing cap screws tighten to 20 z!z5 lb-ft (27.1 + 6.8 N.m).

(1).
Remove solenoid cartridges (12) using JD-305
special tool.

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21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2160-56 Hydraulic System TM- 1188 (Dee-87)

T60316N

l--Sleeve and Valve 7-Spring Pin 13-Nut (2 used)


l-Backup Ring 8-O-Ring 14-O-Ring
&O-Ring g-Backup Ring 1 C--Tube
4-Backup Ring lo--Plunger 1 B-Coil
5-O-Ring 1 l-Brass Washer 17-Lock Washer
I-Retaining Ring 12-Spring 1 G-Nut

Fig. 94-Solenoid Cartridge

bitho in U.S.A.
JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM- 1188 (Dee-871 Hydraulic System 216047

Refer to Fig. 94 during disassembly and assembly INSTALLATION


of the solenoid cartridge.

Check spring (12) for a free length of 0.652 in.


(16.56 mm) and a test length of 0.512 in. (13.00 mm)
at 5.75 + 0.25 lb. (25.6 IL 1 N) (2.6 = 0.1 kg).

Check parts for wear and damage and replace as


necessary. The difference between sleeve I.D. and
valve O.D. measurements should be 0.0002 to 0.0005
in. (0.0051 to 0.0127 mm). If proper clearance is not
obtained, replace valve and sleeve.

Replace old O-rings and backup rings with new.

Clean valve body and solenoid cartridges


thoroughly before installing solenoid cartridges.

lY1056N

l-To Drain Hose B-Forward Solenoid


~-TO Lett Wheel Drain ~--TO Right Brake Hose
~-TO Lefl Forward 6-Reverse Solenoid
Pressure Hose 9-To Right Reverse
~--TO Lett Brake Hose Pressure Tube
S-To Right Forward lo-Forward Solenoid
Pressure Hose 11-To Right Wheel Drain

Fig. 95-Solenoid Valve Hose Connections

Install valve on unit. Connect hoses as shown in


Fig. 95. Connect wiring.

IMPORTANT: Do not start unit at this time. Refer to


Start Up Procedure, Group 9016.

Litho in U.S.A.
21 Main Hydraulic System JD670-A and JD672-A Motor Graders
216046 Hydraulic System TM- 1188 (Dee-87)

LUBE LINE CHECK VALVE


GENERAL INFORMATION REPAIR
The lube line check valve is located on the top Remove check valve from unit.
rear of the transmission in the return to lube line from
the main hydraulic pump. On the JD672-A the HFWD Drive check ball retaining pin from check valve
return filter outlet is also connected to this check housing to remove the ball.
valve.
Check the seat and ball for wear.

Replace as necessary.

Fig. 96-Lube Line Check Valve

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM- 1188 (Dee-87j Hydraulic System 216049

HFWD FILTERS
(JD672-A Only)
GENERAL INFORMATION REPAIR
There are two return filters in the HFWD system. The HFWD front axle return filter consists of a
The HFWD return filter (2, Fig. 97) filters oil from the base and element. Replace as necessary.
HFWD pump case. Filtered oil is then routed to the
transmission lube circuit. The HFWD return filter consists of a base with
switch and a spin-on filter.
The HFWD front axle return filter (1) filters drain oil
from the front wheel motors, brake cavity, and ‘When replacing spin-on filter also replace O-ring
solenoid valve. Filtered oil is then routed to the between filter and base.
transmission charge pump inlet.
Check switch piston and O-ring in base by
removing the switch plug.

Check switch spring for:

Free length . . . . . . . . . . . . . . . 0.5 in. (12.7 mm)

Test length . . . . . . . . . . . . . . . 0.2 in. (5.08 mm)


when compressed to 4.8 AI 0.5 lb.
(21.4 + 2.23 N) (2.2 I!I 0.2 kg)

l-HFWD Front Axle P-HFWD Return Filter


Return Filter

Fig. 97- HFWD Filters

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21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2160-60 Hydraulic System TM-1 188 (Dee-87)

HYDRAULIC FITTING INSTALLATION AND


SERVICE RECOMMENDATIONS
GENERAL INFORMATION Lubricate the correct O-ring with hydraulic fluid,
petroleum jelly, or soap. Install a thimble over the
Hydraulic fittings leak because the parts are
fitting threads to protect the O-ring from nicks. Slide
damaged or because they are improperly installed,
the O-ring over the thimble into the turned down
assuming proper manufacture.
section of the fitting. Remove thimble.

Adherence to the following instructions will insure


On angle fittings, back the lock nut off until the
leak-free hydraulic connections.
washer bottoms, then proceed as above.

Hydraulic fittings are threaded, and like all threaded


Screw the fitting by hand into the boss until the
joints some relaxation of new parts can be expected
backup washer, or washer face if a straight fitting,
to occur. Re-torquing may be necessary.
bottoms on the boss face and the O-ring is squeezed
into its’seat.
O-RING BOSS FITTINGS
Inspect boss O-ring seat. It must be free of dirt and Position angle fittings by unscrewing the fitting no
defects. If repeated leaks occur, inspect for defects more than one turn.
with a magnifying glass. Some raised defects can be
removed with a slip stone. Tighten straight fitting to the torque value shown in
the table. On angle fittings, tighten the lock nut to the
Occasionally a lower durometer O-ring will seal value shown in the table while holding the body of
against a rough seat. If neither of these solutions the fitting with a wrench.
work, the component must be replaced.

STRAIGHT FITTINGS OR LOCK NUTS


Tube Size Torque’ (N-m) (kg-m) Number of Flats*
3116 5.5 lb-ft 7 N-m 0.8 kg-m 2
l/4 7 lb-ft 10 N.m 1.0 kg-m 2
5/16 9 lb-ft 12 N-m 1.2 kg-m 2
318 11 lb-ft 15 N.m 2 kg-m 2
l/2 19 lb-t? 26 N.m 3 kg-m 2
5/8 30 lb-ft 41 N.m 4 kg-m 1.5
3/4 44 lb-ft 60 N.m 6 kg-m 1
7/8 51 lb-ft 69 N-m 7 kg-m 1
1 57 lb-ft 77 N-m 8 kg-m .75

1. Tolerance * 10%. These torques may be ex- 2. To be used if a torque wrench or adequate
ceeded by 25% in steel and gray iron ports if O-ring clearance for a torque wrench is not available.
shows evidence of nibbling. Check pressure setting
first. Tighten fitting or lock nut snug. Mark hex and port
with a line then tighten the number of flats shown.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM- 1188 (Dee-87) Hvdraulic Svstem 2160-61

TUBE AND HOSE FITTINGS, Align the tube with the fitting before attempting to
37’ FLARE start the nut. Failure to do so can cause a deformed
flare and subsequent leaks. Install hoses without
Inspect the flare and the flare seat. They must be
twists. A twisted hose attempts to straighten out
free of dirt and defects. If repeated leaks occur,
when pressure is applied. This exerts a torque on
inspect for defects with a magnifying glass. If burrs
the connection, eventually causing failure.
and raised nicks on the connector body cannot be
removed with a slip stone, replace the connector.
Lubricate the connection with hydraulic fluid,
petroleum jelly or soap. Tighten the swivel nut by
Defects in the tube flare cannot be repaired.
hand until it is snug.
Replace the tube. Overtightening a defective flared
fitting will not stop leaks.
Mark a line across the nut and connector body.
This line will serve as a visual indicator as to whether
As a field expedient, a ductile truncated cone
the nut has been tightened and by how much.
shaped washer can be used between the tube flare
and connector body. These washers are soft enough
Using two wrenches, one on the connector body
to fill defects in the seat and flare. They will also seal
and a torque wrench on the nut, tighten the nut to the
the connection. Ductile washers are available from
torque value shown in the table. In the case of a
industrial supply houses.
hose, it may be necessary to use three wrenches to
prevent twisting.

37O FLARE TORQUE


Original Assembly & Reassembly &
Tube Size Torque lb-ftl (N-m) (kg-m) Number of Flats2 Number of Flats3

3/16 6 lb-ft 8 N.m 0.8 kg-m 2.5 1


l/4 a lb-ft 11 N.m 1.1 kg-m 2.5 1
5116 11 lb-ft 15 N.m 1.5 kg-m 2.5 1
3/a 18 lb-ft 24 N.m 2.5 kg-m 2 1
l/2 30 lb-ft 41 N.m 4 kg-m 2 1
518 60 lb-ft al N.m 8 kg-m 1.5 1
3/4 100 lb-f? 136 N.m 14 kg-m 1 .75
7/a 120 lb-ft 163 N.m 17 kg-m 1 .75
1 130 lb-ft 176 N.m 18 kg-m .75 .75

1. Tolerance + 10%. 3. Flare connections seal by deforming or


squeezing the tube between the nut and the con-
2. To be used if torque wrench or adequate nector. More deformation is possible with new parts
clearance for a torque wrench is not available. than with old. Therefore if a torque wrench is not
used for re-assembly Ihe values in this column must
be used to prevent damage.

Litho in U.S.A.
21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2160-62 Hydraulic System TM- 1188 (Dee-87)

SAE SPLIT FLANGE FITTING Be sure the line is centrally located and perpen-
dicular to the port. Be sure the O-ring is not pinched.
Inspect the sealing surfaces for nicks or scratches,
Be sure the split flange halves are not tipped. Use
roughness or out-of-flat condition. Scratches cause
feeler gauges if necessary to insure that the split
leaks. Roughness causes seal wear. Out-of-flat
flange halves are seated evenly. Failure to do this
causes seal extrusion. If these defects cannot be
will lead to bent flanges, bolts and leaks.
polished out, replace the component.
Uniformly tighten the screws to the torque value in
Install the correct O-ring (and backup washer if
the table using several passes. Uniform screw torque
required) into the groove using petroleum jelly to
on properly seated flanges is critical to the success
hold it in place.
of this hydraulic connection.

Loosely assemble one split flange half to the com-


Do not use air wrenches. Do not tighten one screw
ponent. Hook the line into the groove in the first
fully before tightening the others. Do not over tighten.
flanae half then loosely assemble the second split
flange half. While holding the line in the center of the
split flanges and perpendicular to the port, hand
tighten the flange screws.

SPLIT FLANGE SCREW TORQUE


Nominal Flange Size Screw Size1 Torques lb4 (N-m) (kg-m)

1 I2 5/16- 18 17 lb-ft 23 N.m 2 kg-m


314 3/8 - 16 27 lb-ft 37 N.m 3.7 kg-m
1 3/8 - 16 32 lb-ft 43 N.m 4.4 kg-m
l-114 7/16- 14 42 lb-ft 57 N.m 6 kg-m
l-1/2 l/2 - 13 53 lb-ft 72 N.m 7 kg-m
2 l/2 - 13 64 lb-ft 87 N.m 9 kg-m
2-l I2 l/2 - 13 84 lb-ft 114 N-m 12 kg-m
3 5/8 - 11 120 lb-ft 163 N-m 17 kg-m
3-l I2 518 - 11 120 lb-ft 163 N.m 17 kg-m
4 S/8 - 11 120 lb-ft 163 N.m 17 kg-m
5 518 - 11 120 lb-ft 163 N.m 17 kg-m

1. SAE Grade 5 or better screws with phosphate 2. Tolerance k 70%. The torques given are enough
and oil finish. for the given size connection with the recommended
working pressure. Torques can be increased to the
maximum shown for each screw size if desired.
Increasing screw torque beyond this maximum will
result in flange and screw bending and connection
failures.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM- 1188 (Jul-78) Specifications and Special Tools 2199-l

Group 2199
SPECIFICATIONS AND SPECIAL TOOLS
HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES

4.00 Cubic-Inch (66 cm3) Hydraulic 1 - I.D. at pump shaft quad ring. . 1.3945 to 1.3965
Pump in. (35.421 to 35.471 mm)
2 - I.D. at pump shaft oil seal.. . 2.0110 to 2.0210
in. (51.079 to 51.333 mm)
3 - I.D. at pump shaft bearings.. . 3.3745 to 3.3755
in. (85.712 to 85.738 mm)
4 - I.D. of inlet valve bore . 0.9995 to 1.0005 in.
(25.387 to 25.413 mm)
5 - I.D. of discharge valve seat bore . . 0.6245 to
0.6255 in. (15.862 to 15.888 mm)
6- I.D. of piston bore . . . 0.9637 to 0.9643 in.
(24.478 to 24.493 mm)

T’27816N

Fig. I-Pump Housing

1 - O.D. of pump piston ., 0.9630 to 0.9634 in.


(24.460 to 24.470 mm)

T27817N
Fig. P-Pump Piston

Litho in U.S.A.
21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2199-2 Specifications and Special Tools TM- 1188 (J&78)

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

4.00 Cubic-Inch (66 cm3) Hydraulic


Pump-Continued

1 - O.D. of pump shaft cam . . 1.7442 to 1.7448 in.


(44.303 to 44.318 mm)

T27818N

Fig. d-Pump Shaft Cam

1 - I.D. of needle bearing


race.. . . . . . . _. . . . . . . . 2.2457 to 2.2465 in.
(57.041 to 57.061 mm)

T27
Fig. 4-Needle Searing Race

1 - Inlet valve lift . . . . . . . . . . . 0.1100 to 0.1300 in.


(2.794 to 3.302 mm)
2- O.D. of inlet valve
assembly . . . . . _. . , . . . . . . 1.0015 to 1.0025 in.
(25.44 to 24.46 mm)

Fig. S-Valve Assembly

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Main Hydraulic Sys tern 21
TM- 1188 (Mar-80) Specifications and Special Tools 2199-3

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

4.00 Cubic-Inch (66 cm3) Hydraulic


Pump-Continued
1 - Piston springs, test length at
47 to 53 Ibs. force (209 to
236 N) , . . . . . _. . . . . . . . _. _. . . 1.78 in. (45 mm)
2 - Piston springs, free length. . . . 2.74 in. (70 mm)

IMPORTANT: The maximum difference of force


permissible between the springs in a set is 1.5 Ibs.
(6.7 N). If the difference is more than the specifica-
tion, install new springs as a set. All springs must
be of the same color code.

FQ. 6-Piston Spring

1 - I.D. of stroke control valve


sleeve bore . . . . . . . . . 0.7485 to 0.7495 in.
(19.012 to 19.037 mm)
2 - I.D. of crankcase outlet
sleeve bore . _. . . . . . . . _. . . 0.7485 to 0.7495 in.
(19.012 to 19.037 mm)

T27822
Fig. 7-Stroke Control Valve Sleeve Sore

1 - Housing stirfaces flat within 0.0030 in. (0.076 mm)

427823N
Fig. b-Housing Surface

Litho in U.S.A.
21 Ma in Hydraulic Sys tern JD670-A and JD672-A Motor Graders
2199-4 Soecifications and SDecial Tools TM- 1188 (Mar-80)

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

4.00 Cubic-Inch (66 cm3) Hydraulic


Pump-Continued

1 I.D. of stroke control valve sleeve (lower end)


0.4080 to 0.4120 in. (10.363 to 10.465 mm)
2 O.D. of stroke control valve sleeve 0.7481 to
0.7485 in. (19.002 to 19.012 mm)

l’27825N

Fig. g-stroke Gmtrol Valve .Sleeve

1 - O.D. of crankcase outlet sleeve . . . 0.7481 to


0.7485 in. (19.002 to 19.012 mm)

T27826N
Fig. 1O-Crankcase Outlet Sleeve

/ 1 - Stroke control valve spring, test


/ length . . . . _. . . . _. . . . . . . . . . 2.95 in. (75 mm)
// when compressed with 180 to 220 Ibs. force (801
I
to 977 N)
2 - Stroke control valve spring, free
length . __ . _. . . . . . . . _. . . . . . .3.54 in.
(89.9 mm)

\ ./ /’
i61534N

Fig. 1 I-Stroke Control Valve Spring

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM- 1188 (Mar-801 Specifications and Special Tools 2199-5

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

4.00 Cubic-Inch (66 cm3) Hydraulic


Pump-Continued

1 - O.D. of stroke control


valve.. . . . . . . . . ... 0.2661 to 0.2665 in.
/’ (6.759 to 6.770 mm)
1

127824N

Fig. 12-Stroke Control Valve

1 - Distance from pump housing surface


to discharge valve seat shoulder . . . . . .0.870 in.

Fig. 13-Housing Surface to Discharge ValveClearance

1 - Inlet valve plug torque . . . . . . . , . . . . . 100 lb-ft


(136 Nm) (14 kg-m)
2- Piston plug torque.. . . . . . . . . . . . _. . 100 lb-ft
(136 Nm) (14 kg-m)
3 3- Stroke control valve housing to main
pump cap screw torque . . . . . . . . _. . . 85 lb-ft
(115 Nm) (12 kg-m)

T61535N

Fig. 14-Torque Values

Litho in U.S.A.
21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2199-6 Specifications and Special Tools TM- 1 I88 (Mar-80)

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

Pump Drive Assembly 1 - Coupler cap screw lock nuts


torque..............................
(41 N.m)
2 - Special screws in engine pulley
torque.............................. 75 lb-ft
(102 N.m) ( ;O kg-m)
3 - Special screws in drive shaft
torque.................,............ I 35 lb-ft
(47 N+m) (5 kg-m)
4 - Drive shaft retaining cap screw
l’E1536N
toraue.............................. 30 lb-ft
Fig. 15-Pump Support and Drive Assembly (41 Nsm) (4 kg-m)
5 - Hydraulic pump to support cap screw
torque. . . _. . . . . . . . . . . . . . . . . 8.5 lb-ft
(115 N.m) (12 kg-m)
6 - Support to engine block cap screw
torque. ..... .. .......... . . . . 85 lb-ft
(115 Nam) (12 kg-m)
7 - Coupler cap screw torque . . . . . . . . 30 lb-ft
(41 N+m) (4 kg-m)

NOTE: Put two or three drops of T43513 John


Deere Loctite Thread Lock and Sealer (High Strength)
or an equivalent on the threads of special screws and
cap screws for the drive shaft.

Hydraulic Noise Attenuator No Precharge

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Main Hydraulic Sys tern 21
TM- 1188 (J&78) Specifications and Special Tools 2199-7

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

Pressure Control Valve

1 - I.D. of housing bore


(rear). . . . . 0.7268 to 0.7278 in.
(18.461 to 18.486 mm)
2 - I.D. of housing bore
(front) . . 0.7508 to 0.7518 in.
(19.070 to 19.096 mm)

Fig. 16-Pressure Control Valve Housing

1 - Pressure control valve spring


free length., _. . _. _. . _. . .4.61 in.

q
(117.1 mm)
2 - Pressure control valve spring
test length ... . . . 3.5 in.
(88.9 mm) when compressed with 50 c 5 lb.
(223 -t 22 N) (23 _t 2 kg) of force
3 - O.D. of valve (rear) 0.7257 to 0.7263 in.
(18.433 to 18.448 mm)
T61143N 4 - O.D. of valve (front) . 0.7497 to 0.7503 in.
Fig, 17-Pressure Control Valve Spring and Valve (19.04 to 19.058 mm)

Litho in U.S.A.
21 Main Hydraulic Sys tern JD670-A and JD672-A Motor Graders
2199-8 Specifications and Special Tools TM- 1188 (Jul-78)

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

Oil Cooler Bypass Valve

Bypass valve opening pressure .


.22 to 35 psi
(2 bar) (2 kg/cm*)
1 - Bypass valve flatness within . .‘. 1 .., 0.002 in:
(0.05 mm)
2 - Spring free length .. . . . . . 2.25 in.
(57.2 mm)
3 - Spring test length . . . . 1.75 in. (44.5 mm)
when compressed with 7.2
to 8.8 Ibs. (32 to 39 N) (3.3 to 4.0 kg)
of force
4 - Spring free length .. . .2.50 in.

1
(63.5 mm)
5 - Spring test length .. 1.875 in. (47.63 mm)
when compressed with 0.25 + 0.06 lb.
(1.1 t 0.27 N) (0.11 + 0.03 kg)
Special washer flatness
within . . . . .0.002 in.
(0.05 mm)

T61144N

Fig. l&Oil Cooler Bypass Valve

Check Valve Tee

1 - Spring free length . . . . 1.29 in. (32.8 mm)

Spring test length . . . . . .0.83 in. (21.1 mm)


when compressed with 1.20 + 0.12 lb.
(5.3 + 0.5 N) (0.5 k 0.05 kg)

161145N
6
1

Fig. Y9-Check Valve Tee (JD672-A Only)

Litbo in U.S.A.
JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM- 1188 (Jul- 79) Specifications and Special Tools -2199-9

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

Function Return Filter

1 - Special cap screw


torque. ... . ... . .15 to 20 lb-ft
(20 to 27 Nm)
(2 to 3 kg-m)

1
2’61537N
2 - Bypass valve opening pressure . . 100 psi
(7 bar)
(7 kg/cm’)

Fig. 20-Function Return Filter Assembly

JD672-A HFWD Pump


1 - Check valve torque ...

2 - End cap cap screw torque . . .36 to 38 lb-ft


(49 to 52 Nm)
(5.0 to 5.3 kg-m)

3 - Trunnion cap screw torque .36 to 38 lb-ft


(49 to 52 Nm)
(5.0 to 5.3 kg-m)

Pump shaft end play.. 0.006 to 0.016 in.


(0.15 to 0.41 mm)

Pounds of force to
move swashplate .. . 4 to 7 lb.
(18 to 31 N)
(2 to 3 kg)

Front cover cap screw torque. . .36 to 38 lb-ft


Fig. 27-Check Valves (49 to 52 Nm)
(5.0 to 5.3 kg-m)

Litho in U.S.A.
21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2199-10 Specifications and Special Tools TM- 1188 (Jun-83)

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

Pump Displacement Control Valve Displacement control valve


(JD672-A Only) mounting cap screw torque. . . . . . . . . . 10 to 11 lb-ft
(14 to 15 N.m)
(1 to 2. kg-m)

Charge Pump (JD672-A Only) Charge pump mounting


cap screw torque. . . . . . . . . . . . . . . . 10 to 11 lb-ft
(14 to 15 N.m)
(1 to 2 kg-m)

Electra-Hydraulic Actuator (JD672-A Only) Filter spring:


Free length. . . . . . . . . . . . . . 1.75 in. (44.45 mm)

Test length.. . ~. . . . . . . . .0.85 in. (21.6 mm)


when co\mpressed with 21.6 + 2.2 lb.
(96 + 10 N) (9.7 +- 1 kg)

HFWD Case Relief Valve (JD672-A Only) Spring Free length . , . . . . . . . . . . . . 2.32 in. (59 mm)
Spring test length , . . . . . . . . . . . . 1.34 in. (34 mm)
when compressed with 23 r 2.3 lb.
(102 r 10 N) (10 k 1 kg)

Opening pressure setting . . . . . . . . . . . 80 rt 5 psi


(552 + 35 kPa) (5.5 + 0.35 bar)

High Pressure and Charge Relief High pressure relief valve torque. . . 20 to 30 lb-ft
‘Manifold Assembly (JD672-A Only) (27 to 41 Nm)
(3 to 4 kg-m)

Flow Divider (JD672-A Only) End plate cap screw torque . . . . . . . 20 to 30 lb-ft
(27 to 41 N.m)
(3 to 4 kg-m)

Pipe plug torque . . . . . . _ . . . . . . . . . . . . . 6 to 8 lb-ft


(8 to 11 N.m)
(0.8 to 1 kg-m)

HFWD Return Filter (JD672-A Only) Restriction switch spring:


Free length. . . . . . . . . . . . . . . . 0.5 in. (12.7 mm)

Test length. . . . . . . . . . . . 0.2 in. (5.08 mm)


when compressed with 4.8 & 0.5 lb.
(21.4 -t 2.23 N) (2.2 -I- 0.2 kg)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Ma in Hydra ulic Sys tern 21
TM- 1188 (Mar-80) Specifications and Special Tools 2199-11

HYDRAULlC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

Solenoid Valve (JD672-A Only)

1 - Sleeve I.D.

2 - Valve O.D.
Clearance between sleeve I.D. and valve O.D. of
0.0002 to 0.0005 in. (0.0051 to 0.0127 mm)

3 - Spring free length . . . . . . 0.652 in. (16.56 mm)

4 - Spring test length . . . . . . . 0.512 in. (13 mm)


at 5.75 F 0.25 Ibs. force (25.6 t 1 NI

‘p51323

fig. 22-Solenoid Cartridge

1 - Plug torque . . . . . . . . . . . . . . . .20 + 5 lb-ft


(27.1 2 6.8 N-m)
(use AT52853 John Deere Loctite Thread Lock
and Sealant, Low Strength, or equivalent)

T65058N

Fig. 23-Solenoid Valve

Litho in U.S.A.
21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2199-12 Specifications and Special Tools TM- 1188 (Mar-80)

HYDRAULIC SYSTEM
SPECIAL TOO&S

Essential Tools

Tool Tool Number Use

JDH-18 To install seal into bore of hydraulic


pump.

Fig. 24-Pump Seal Driver

1 - JDH-40 To remove outlet valve seats from


pump housing.

2 - JDH-39A To install outlet valve seats to the


correct depth in pump housing.

fig. 25-Out/et Valve Replacement Tools

JDHl9 or
JDHlSB* To adjust crankcase outlet valve.

*Shown

Fig. 26-Crankcase Outlet Valve Adjusting Tool

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM- 1188 (Dee-87) Specifications and Special Tools 2199-13

HYDRAULIC SYSTEM
SPECIAL TOOLS-Continued

Essential Tools-Continued

Tool Tool Number Use

JDG-96 To remove pump rear bearing.

Fig. 27-HFWD Pump Rear Bearing Puller

MTD-H16* To press on rear bearing.

Fig. 28-HFWD Pump Rear Bearing Press Tool *Midwest Tool Specialties,
P.O. Box 776, Silvis, Illinois 61282

Litho in U.S.A.
21 Main Hydraulic System JD670-A and JD672-A Motor Graders
2199-14 Specifications and Special Tools TM- 1188 (Dee-87)

HYDRAULIC SYSTEM
SPECIAL TOOLS-Continued

Essential Tools-Continued
Tool Tool Number Use

JDG-37-1 To remove and install servo cylin-


ders in pump.

T6718AM

Tool

JD-356 To install rotating seal.

Convenience Tools
Tool Tool Number Use

JDH-21 Parts tray for pump pistons, inlet


valves, discharge valves and
plugs.

Fig. 29-Pump Parts Tray

Removal of inlet valve assembly.

T.25015
l

l-Grind Off Chamfer 3-R27157 Guide


l--Driver Rod

Fig. 304nlet Valve Removal Tool

*Make in dealer’s shop.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Main Hydraulic System 21
TM- 1188 (Mar-80) Specifications and Special Tools 2199-15

HYDRAULIC SYSTEM
SPECIAL TOOLS-Continued

Convenience Tools-Continued

Tool Tool Number US0

JDH-26 When attached to a hoist, permits


lifting radial-piston (closed-center)
hydraulic pump from tractor frame,
and reinstalling it as well.

Fig. 31-Hydraulic Pump Lifting Device

JD-305 Remove and install HFWD solenoid

@i
6Y
cartridges.
6

2'518801
Fig. 32-Solenoid Tool

Litho in U.S.A.
21 Main Hydraulic Sys tern JD670-A and JD672-A Motor Graders
2199-16 Specifications and Special Tools TM- 1188 (Mar:80)

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JD670-A and JD672-A Motor Graders Grading Device 34
TM- 7 188 (Dee-87) Blade 3401-l

Section 34
GRADING DEVICE
CONTENTS OF THIS SECTION

Page Page
GROUP 3401 - BLADE GROUP 3440 - GRADING DEVICE
General Information ................. 3401-3 FRAMES-Continued
Removal ......................... 3401-3 Circle and Blade Tilt Assemblies:
Repair ........................... 3401-3 General Information ............... 3440-6
Installation ........................ 3401-4 Removal ........................ 3440-6
Repair ......................... 3440-6
GROUP 3415 - CONTROLS LINKAGE Installation ...................... 3440-7
Blade Lift: Circle Adjustment ................. 3440-7
General Information ............... 3415-l
Removal ........................ 3415-l GROUP 3450 - CIRCLE GEARBOX
Repair ......................... 3415-2 General Information ................. 3450-l
Installation ...................... 3415-2 Removal/Repair .................... 3450- 1
Rear Steering: Installation ........................ 3450-2
General Information ............... 3415-2
Removal ........................ 3415-2 GROUP 3460 - HYDRAULIC SYSTEM
Repair ......................... 3415-2 Function Control Valves:
Installation ...................... 3415-2 General Information ............... 3460-l
Blade Rotation and Blade Side-Shift: Removal ........................ 3460-2
General Information ............... 3415-4 Repair ......................... 3460-3
Removal ........................ 3415-4 Installation ...................... 3460-7
Repair ......................... 3415-4 Circle Drive Motor:
Installation ...................... 3415-4 General Information ............... 3460-8
Circle Side-Shift: Removal ........................ 3460-8
General Information ............... 3415-5 Repair ......................... 3460-8
Removal ........................ 3415-5 Assembly ...................... 3460-l 0
Repair ......................... 3415-5 Installation ..................... 3460-l 2
Installation ...................... 3415-5 Lift Arm Locking Valve
Blade Tilt: General Information .............. 3460-l 3
General Information ............... 3415-6 Removal ....................... 3460-l 3
Removal ........................ 3415-6 Repair ........................ 3460-l 3
Repair ......................... 3415-6 Installation ..................... 3460-l 4
Installation ...................... 3415-6 Lift Arm Locking Pin
General Information .............. 3460-l 5
GROUP 3440 - GRADING DEVICE FRAMES Removal ....................... 3460-l 5
Lift Arm Assembly: Repair ........................ 3460-l 5
General Information ............... 3440-l Installation ..................... 3460-I 8
Removal ........................ 3440-l
Repair ......................... 3440-l Contents continued on next page
Installation ...................... 3440-3
Draft Frame:
General Information ............... 3440-5
Removal ........................ 3440-5
Repair ......................... 3440-5
Installation ...................... 3440-6

Litho in U.S.A.
34 Grading Device JD670-A and JD672-A Motor Graders
3401-2 Blade TM- 1188 (Dee-87)

Page
GROUP 3460 - HYDRAULIC SYSTEM-
Continued
Rotary Manifold:
General information .............. 3460-19
Removal ....................... 3460-19
Repair ........................ 3460-l 9
Installation ..................... 3460-20
Crossover Relief Valve:
General Information .............. 3460-21
Removal ....................... 3460-21
Repair ........................ 3460-21
Installation ..................... 3460-22
Cylinders:
General Information .............. 3460-23
Removal ....................... 3460-23
Blade Lift Cylinder .............. 3460-23
Circle Side-Shift Cylinder ........ 3460-23
Blade Tilt Cylinder .............. 3460-24
Blade Side-Shift Cylinder. ........ 3460-24
Repair ........................ 3460-25
Installation ..................... 3460-29
Blade Side-Shift Cylinder. ........ 3460-31
Disassembly ................ 3460-32
Assembly ................... 3460-32
Installation .................. 3460-33

GROUP 3499 - SPECIFICATIONS AND


SPECIAL TOOLS
Specifications and Torque Values:
Grading Device Frames . . . . . . . . . . . . 3499-l
Circle Gearbox . . . . . . , . . . . . . . . , . . . 3499-3
Hydraulic System . . . . . . . . e . . . . . . . . 3499-4
Special Tools:
Grading Device Frames . . . . . . . . . . . 3499-l 4

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Grading Device 34
JD670-A and JD672-A Motor Graders Blade 3401-3
TM- 1188 (J&78)

Group 3401
BLADE
Disconnect and plug hydraulic hoses from blade
GENERAL INFORMATION
side shift cylinder.
The motor grader can be equipped with either a 12
foot (366 cm), 13 foot (396 cm) or 14 foot (427 cm) Remove blade by tipping top edge down and sliding
blade. A two-piece cutting edge is used. forward.

Blade extensions are also available to extend blade REPAIR


length by two feet (61 cm).
Refer to Figs. 1, 2 and 3 during disassembly and
assembly. Replace parts as necessary.
REMOVAL
Place blocks under cutting edge.

Extend tilt cylinder. Supporting upper edge of blade,


remove upper blade retainers from blade tilt frame.

7-Pin (2 used)
4-Lock Washer (24 used)
l-End Bit (2 used) &Spacer (2 used)
&Nut (24 used)
2-Gutting Edge (2 used) g--Washer (2 used)
6-Blade
3--Plow Bolt (24 used) IO-Cap Screw (2 used)

Fig. l-Blade and Cutting Edge

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34 Grading De vice JD670-A and JD672-A Motor Graders
3401-4 Blade TM- 1188 (J&78)

I-Plow Bolt (8 used) 4-Washer 7-Cutting Edge


2-Upper Stiffener +-Lock Washer (9 used) 8-Lower Stiffener
a--Cap Screw 6-Nut (9 used) g-Blade Extension

Fig. P-Blade Extension

INSTALLATION
Use reverse of removal procedure to install blade
assembly.

Install top stiffener (2, Fig. 3) in the second set of


holes from the top using only two holes to attach

q
stiffeners to blade and blade extensions.
4
NOTE: If the top stiffener is assembled in the top
set of holes or in an upside-down position, the stiffener
will hit the blade pitch cylinder when side shifting the
blade, causing damage to the cylinder. Cap screw (3,
Fig. 2) serves to stabilize the blade extension.

l-Cap Screw Cl-Plow Boll Nuts


~-TOP Stiffener S--Bottom Stiffener
3-Plow Bolts B-Blade Extension

Fig. 3-Blade Extension Assembled

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JD670-A and JD672-A Motor Graders Grading Device 34
TM- 1188 (J&78) Controls Linkage 3415-l

Group 3415
CONTROLS LINKAGE
BLADE LIFT CONTROL VALVE LINKAGE

General Information
The blade lift control valves are located on the right
side of the nine section main control valve (8, Fig. 1)
They are activated by lever and linkage (Fig. 2).

l--Rod End L.H. Lift 5-Control Valve Outlet


Cylinder 6-Control Valve Inlet
2-Rod End R.H. Lift jr--Main Control Valve T59776N
Cylinder Il-Blade Lift Control
3-Piston End R.H. Lift Valves g--Link Coupler (2 used)
l-Knob
Cylinder 6-Pin
P-Bushing
4-Piston End L.H. Lift 7-Lock Washer
3-Right Blade Lift Lever
Cylinder g--Cap Screw
With Bushing
4-Left Blade Lift Lever
Fig. i-Function Control Valve
With Bushing

Fig. Z-Blade Lift Linkage

Removal
Unfasten link couplers (5, Fig. 2).

Remove cap screw (8), lock washer (7) and pin (6).

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34 Grading Device JD670-A and JD672-A Motor Graders
3415-2 Controls Linkage TM- 1188 (J&78)

Lift out lever assemblies (3 and 4, Fig. 2). Installation


Slide pin (6, Fig. 2) through lever assemblies (3 and
4, Fig. 2).
Inspect parts for wear and replace as necessary.
Align pin (6) on control console and install lock
washer (7) and cap screw (8).

REAR STEERING CONTROL VALVE LINKAGE


Removal
Remove steering wheel emblem (1, Fig. 4).

Loosen special nut (3).

Use wheel puller and remove steering wheel (5).

Remove right side of control console.

Unfasten coupler link (15).

Remove cotter pin (21) and slide rear steer rod from
pivot plate (22).

Rotate rear steer control (12) 90” to right and re-


l--Rod End R.H. Cylinder 3=-Control Valve
Outlet
move.
Piston End L.H. Cylinder
Rear Steer 4-Control Valve Inlet
2-Rod End L.H. Cylinder 5-Main Control Valve Repair
Piston End R.H. Cylinder 6-Rear Steer Control
Rear Steer Valve Inspect parts for wear or damage and replace as
necessary.
Fig. 3-Rear Steer Control Valve
Installation
General Information
Install using reverse of the removal procedure.
The rear steer control valve is located on the nine
section main control valve (Fig. 3). It is activated by
lever and linkaae (Fin. 4).

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Grading Device 34
TM- 1188 (J&78) Controls Linkage 3415-3

\‘\ /’ 8

T59777N

l-Steering Wheel Emblem 7-Snap Ring 13-Flange Assembly Tube 19-Ball Joint
2-O-Ring S-Retaining Ring 1Aain Control Valve 20-Nut
3-Special Nut %-Bearing 15-Coupler Link al-Cotter Pin
4-Lock Washer lo-Bushing (2 used) 16-Gap Screw 22-Pivot Plate
!&Steering Wheel ii-Control Knob (2 used) 17-Rear Steer Rod 23-Bushing
GSteering Shaft 12-Rear Steering Control 18-Special Washer 24-Nut

F&c 4-Rear Steering Linkage

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34 Grading Device JD670-A and JD672-A Motor Graders
3415-4 Controls Linkage TM- 1188 (Dee-87)

BLADE ROTATION AND BLADE SIDE-SHIFT CONTROL VALVE LINKAGE

l-Rod End R.H. Blade B--Main Control Valve


Side-Shin Cylinder Assembly
2-Rod End L.H. Blade 7-Blade Rotation Left
Side-Shift Cylinder 6-Blade Rotation
3-Blade Rotation Right Control Valve
4-Control Valve Outlet g-Blade Side-Shin
5-Control Valve Inlet Control Valve

Fig. 543lade Side-Shift and Blade Rofation Control


Valves Location

General Information
The blade rotation and side-shift control valves
are located next to each other on nine section main
control valve assembly (6, Fig. 5). These valves are
controlled by linkage (Fig. 6).

Removal
Remove linkage using Fig. 6.

Repair
l-Pin (2 used) O-Circle Blade
Check bell crank, side-shift rod, and rotate rod for l--Cotter Pin (2 used) Control Handle
wear or damage. 3-Yoke (2 used) 1 O-Pivot
4-Nut (2 used) 11 -Washer
J-Side-Shift Rod 12-Snap Ring
Check pivot and circle blade control handle for
6-Nut (2 used) 13-Rotate Rod
wear. 7-Ball Joint (2 used) 14-Bell Crank (2 used)
I-Snap Ring lS-Snap Ring (4 used)
Replace worn or damaged parts. 16-Coupler Link (2 used)

Fig. B-Blade Rotation and Side-Shift


Control Valve Linkage

Installation

Install linkage following Fig. 6.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Grading De vice 34
TM-l 188 IJul-78) Controls Linkage 3415-5

CIRCLE SIDE-SHIFT CONTROL VALVE LINKAGE

l-Piston End Circle 5-Rod End Circle Side-


Side-Shift Cylinder Shift Cylinder
P-Control Valve Outlet Circle Side-Shift
3-Control Valve Inlet Control Valve
4-Main Control Valve
Assembly (9 section) P59773N

fig. 7-Circle Side-Shift Control Valve Location l-Connecting Pin (2 used) 5-Circle Side-Shift
P-Cotter Pin (2 used) Lever with Bushings
General Information 3-Gap Screw (5116” x 2” 6-Knob
x l/4”) ‘I-Spacer
The circle side-shift control valve is located on the 4-Bushing (2 used) &Nut
nine section main control valve (Fig. 7). It is controlled 9-Link (2 used)
by lever (5, Fig. 8) and linkage.
fig. d-circle Side-Shift Control Valve Linkage

Removal Installation
Remove linkage by following Fig. 8.
Install following Fig. 8.

Repair
Check bushings (4, Fig. 8) for wear or damage.

Check linkage for ease of operation. Replace parts


as necessary.

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34’ Grading Device JD670-A and JD672-A Motor Graders
34156 Controls linkage TM- 1188 (Dee-87)

BLADE TILT CONTROL VALVE LINKAGE

l-Piston End Blade 4-Main Control Valve


Tilt Cylinder Assembly (nine
P-Control Valve sections)
Outlet 5-Rod End Blade 2'597801 -
3-Control Valve Tilt Cylinder
B-Blade Tilt Control l-Bushing 4-Pin
Inlet
Valve 2-Blade Tilt Lever &Lock Washer
With Linkage I-Cap Screw
3-Knob 7-Coupler Link
Fig. O-Blade Tilt Control Valve Location

Fig. IO-Blade Tilt Control Valve Linkage


General Information
The blade tilt control valve is located on the nine Installation
section main control valve assembly. It is controlled
Install according to Fig. 10.
by lever (2, Fig. 10) and linkage.

Removal
Remove linkage by following Fig. IO.

Repair
Check bushing (1, Fig. 10) for wear or damage.

Check linkage for ease of operation. Replace parts


as necessary.

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JD670-A and JD672-A Motor Graders Grading Device 34
TM- 1188 (Jun-83) Grading Device Frames 3440-l

Group 3440
GRADING DEVICE FRAMES
LIFT ARM ASSEMBLY
General Information Remove indicator (2, Fig. 1). Remove indicator plate
(1) and front and rear stub shafts (6) connecting lift arms
The lift arm assembly, with related hydraulic cylin-
to main frame.
ders, controls the lifting and side-shifting of the blade.
Lift lift arms from the main frame.
Removal
Repair
Refer to Fig. 3 during disassembly and assembly.
Inspect bushings for wear. Replace parts as necessary.

Shims are placed between the front saddle ear (34,


Fig. 3) and main frame to make stub shaft axes parallel
to each other and the main frame. If saddle ear must be
changed and if equipment for measuring parallelism of
the front and rear ears is not available, use the factory
installed shim pack to install saddle ears till parallelism
can be measured.

Tighten the saddle ear cap screws (32, Fig. 3) by one


of the following methods:

NOTE: Method # 7 for tightening cap screws is pre-


ferred. lfyou do not have the necessary tools, use Meth-
od # 2.
1 -indicator PIate B-Crossbar Pin
2-Indicator 6-Stub Shaft
IMPORTANT: All four cap screws MUST be tight-
3-Lift Arm 7-Locking Crossbar
4-Cap Screw B-Hydraulic Tube ened equal.

Fig, l-Lift Arm Method #l:


Lower blade to the ground and relieve hydraulic pres-
sure.
1. Remove any nicks or burrs from the mating surfaces.
Clean the mating surfaces with solvent to remove
any dirt, grease, oil, and paint. Also clean the cap
q
,

Support both lift arms with chain hoist. Support screws (32, Fig. 3) and holes. Cap screws must be
crossbar with blocks or moveable jacks. clean, dry, and free of all oil and grease before instal-
lation
Refer to Section 34, Group 3460, for removal of lift
cylinders. 2. Using D-05125ST Torque Multiplier (or an equiv-
alent) and a large torque wrench, evenly tighten the
Disconnect side-shift cylinder at the rod end. saddle ear cap screws (32, Fig. 3) to 1665 ft-lb (2330
N.m) (229 kg-m).
Remove crossbar pins (5, Fig. 1) and retaining cap
screws (4). On JD672-A only, remove hydraulic tubes (8) before
removing rear stub shafts. Do not start engine at this
Retract lift arm pin (see Group 3460). Remove cross- timne. See Group 9016 before starting engine.
bar.

Litho in U.S.A.
34 Gradind Device JD670-A and JD672-A Motor Graders
3440-2 Grading Device Frames TM- 1188 (Dee-87)

I I \ Method #2:
Clean the mating surfaces with solvent to remove
any dirt, grease, oil, and paint. Also clean the cap
screws (32, Fig. 3) and holes. Cap screws must
be clean, dry, and free of all oil and grease before
installation.

Tighten the cap screws to 200 lb-h (271 N.m)


(27.6 kg-m).

Mark the position of each cap screw head using


center punch marks (1, Fig. 2).

Turn each cap screw an additional 180’ to final


torque position (4, Fig. 2).
l-Center Punch Marks 3-Saddle Ear
P-Cap Screw 4-Final Torque Position Tighten lift arm yoke retaining cap screws (18,
Fig. 3) to 117 + 21 lb-ft (158 + 28 N.m).
Fig. P-Torque Turn Method

l--Right Litt Arm to--Cap Screw (24 used) 19-Pin 27-Bushing (2 used)
2-Yoke (2 used) ll-Washer (27 used) 20-Boom Pivot Washer as--locking Crossbar
3-Bearing Cap (2 used) 12-indicator Plate 21-Ball Pin 29-Grease Fining (2 used)
4-Lock Washer (4 used) 13-Indicator 22-Cap Screw (4 used) 30-Grease Fitting (2 used)
I-Cap Screw (4 used) 14-Washer (2 used) 23-Lock Washer (4 used) Il-Grease Fitting (4 used)
6-Bushing (4 used) 15-Cap Screw (2 used) 24-Lett Litt Arm 32-Cap Screw (8 used)
7-Front Stub Shatt (2 used) 16-Retainer Cap (2 used) 25-Bushing (2 used) 33-Washer (8 used)
8-Main Pivot Shim (16 used) 17-Lock Washer (4 used) 26-Main Pivot Bushing 34-Front Saddle Ear (2 used)
g--Rear Stub Shatt (2 used) 18-Cap Screw (4 used) (4 used) 35-Shim (use as required)

Fig. 3-M Arm Assembly With Front Saddle Ears

Lifho in U.S.A.
JD670-A and JD672-A Motor Graders Grading Device
TM- 1188 (Jun-83) Grading Device Frames

l-Front Stub Shaft Shims


2-Rear Stub Shaft Shims

Fig. 3A-Lift Arms and Stub Shafts


Fig. 3C-Lift Arm and Locking Pin Housing
Install four shims under each front (1, Fig. 3A) and
With lift arms pushed against the front stub shafts
rear stub. shaft (2).
measure distance between the front surface of the lock-
ing pin housing and the machined surface on the rear
Measure the free play of the lift arms on the stub
side of the lift arms (Fig. 3C).
shafts.

Measurement must be between (0.75 and 3 mm)


Free play must be between (0.12 to 9.9 mm) 0.005 to
0.035 in. Add or deduct the required number of (0.75 0.030 and 0.120 in. If distance is greater than specified,
mm) 0.030 in. shims at the front stub shafts necessary remove the required number of (0.75 mm) 0.030 in.
shims from both rear stub shafts (2, Fig. 3A) and install
to obtain the specified travel.
them on the front stub shafts (1).

If distance is less than specified, remove the required


number of shims from the front stub shafts and add
them to the two rear stub shafts.

Fig. 36-Lift Arm and Main Frame

Swing lift arms under main frame (Fig. 38).

Litho in U.S.A
34 Grading Device JD670-A and JD672-A Motor Graders
3440-4 Grading Device Frames TM- 1188 (Jun-83)

Installation
Install indicator and indicator plate. Install hardware
retaining front and rear stub shafts to main frame.

Connect hydraulic tubes on main frame.

Attach crossbar to lift arms using side-shift arm pin


(19, Fig. 3) and ball pin (21).

Apply a heavy coat of John Deere Never-Seez lubri-


cant, or an equivalent, to the entire inside of center
saddle locking crossbar holes

Connect side-shift cylinder and lift cylinders as direct-


ed in Group 3460.
1 -Location of Locking P-Housing
Pin Shims Grease all fittings before resuming operation.

Fig. &Locking Pin

There are approximately four shims (1, Fig. 4) be-


tween the locking pin housing (2) and the main frame.
Add or deduct shims as necessary to make additional lift
arm to locking pin housing adjustments.

Litho in U.S.A.

--
JD670-A and JD672-A Motor Graders Grading Device 34
TM- 1188 (Dee-87) Grading Device Frames 3440-S

DRAFT FRAME

General Information Disconnect hoses from front of draft frame. Support


front of draft frame with blocks or moveable jacks.
The draft frame (1, Fig. 5) is attached to the main
frame in front by a ball retainer assembly and in the
Remove rotary manifold from draft frame. Block
rear by the blade lift cylinders. The rear of the draft
front of circle and front of draft frame. Remove cap
frame supports the circle and blade tilt assemblies.
screws attaching circle assembly to draft frame.
Removal
Remove circle drive gearbox as directed in Group
Side shift draft frame to one side to ease removal 3450.
of components. Lower blade to the ground and relieve
hydraulic pressure. Remove hardware from ball retainer. If necessary,
move draft frame, circle and blade assembly out and
Remove lift and side-shift cylinders as directed in away from unit.
Group 3460.
Repair
Refer to Fig. 5 during disassembly and assembly.
Replace parts as necessary.

2’59783N

1 --Draft Frame 4-Ball Retainer 7-Special Washer (6 used)


P-Cap Screw (10 used) 5-Draft Shim (6 used) 6-Ball Retainer
%-Lock Washer (10 used) I-Cap Screw (6 used) g--Grease Fitting

Fig. 5-Draft Frame


34 JD670-A and JD672-A Motor Graders Grading Device
3440-6 TM- 1188 (Dee-87) Grading Device Frames

Installation Try to rotate the ball retainer assembly by hand. If it


cannot be moved by hand, shims must be added.
Use the following procedure to determine ball
retainer shim pack (5, Fig. 5).
Add or remove shims till there is approximately
0.060 to 0.090 in. (1.5 to 2.3 mm) clearance.
While the draft frame is off the equipment frame,
temporarily assemble ball retainers (4 and 8, Fig. 5)
Install draft frame onto equipment frame using
onto draft frame using a shim pack of six.
shim pack determined above.

NOTE: Factory units and service parts have one


Lubricate ball retainer assembly with all purpose
piece shims (5, Fig. 5). To ease assembly of ball
grease before operating the unit.
retainer assembly, split the shims in half, with tin
snips, as shown in Fig. 5 if necessary.

Tighten cap screws to standard torque.

CIRCLE AND BLADE TILT ASSEMBLIES

General Information
The circle and blade tilt assemblies are used to
rotate the blade 360 degrees and tilt the blade 40
degrees to allow a variety of operations.

The circle is attached to the draft frame by four


supports. Shims and jack screws are provided for
adjustment.

Removal
Lower blade to the ground and relieve hydraulic
pressure.

Disconnect tilt cylinder as directed in Group 3460.

Support circle with blocks or jacks. T59764ri

l-Pin I-Cap Screw (8 used)


Remove cap screws attaching circle to draft frame 2-Circle 6-Rear Circle Support
and blade tilt assembly to moldboard. 3-Nut (6 used) lo--Washer (8 used)
4-Washer (12 used) ll-Nut (8 used)
L-Shim (Use as required) 12-Shim (Use as required)
Repair 6-Front Circle Support 13-Cap Screw
‘I-Bolt (6 used) 14-Lock Nut
Refer to Figs. 6 and 7 during disassembly and
assembly. Inspect bushings and pins for wear.
Replace parts as necessary. Fig. d-Circle

Litho in U.S.A.
Grading Device JD670-A and JD672-A Motor Graders 34
Grading Device Frames TM-l 188 (Dee-87) 3440-7

Circle Adjustment
NOTE: Install circle drive gearbox before adjusting
circle.

Position the circle as follows before you measure


and make any adjustments.
6
r

l-Blade Tilt Frame g-Bearing (4 used)


2-Cap Screw (6 used) ,lO-Cap Screw (8 used)
3-Lock Washer (6 used) 11-Bearing Cap (2 used)
4-Upper Retainer (2 used) 12-Grease Fitting
5-Shim (16 used) 13-Tilt Cylinder Pin
6-Lower Retainer (2 used) 14-Cap Screw
7-Lock Washer (12 used) 1%Lock Nut
8-Cap Screw (12 used) 16-Cylinder Bracket

Fig. 7-Blade Tilt Assembly l-O.12 to 0.32 in. (3 lo 8 mm) l--C-Clamp

Installation Fig. B-Position the Circle for Measurements

Position circle under draft frame.


1. Raise the blade and rotate it 90’ to main frame,
and so circle drive pinion tip aligns with root of
Attach blade tilt assembly to blade.
circle tooth as in Fig. 8.
Tighten moldboard retainer cap screws (2, Fig. 7)
2. Install a C-clamp (2, Fig. 8) to pull top of circle up
to 445 lb-f-t (603 N-m).
against draft frame front wear pads.
Connect tilt cylinder as directed in Group 3460.
3. Lower the blade to push top of circle (2, Fig. 6)
lightly against draft frame rear wear pads (10, Fig.
11).

4. Move the machine slightly forward with the blade


down to pull the circle back against the front
supports.

5. Before making measurements, check to see if the


circle top surface is against at least three wear
pads, and that the front supports are against the
circle.

Litho in U.S.A.
34 JD670-A and JD672-A Motor Graders Grading Device
3440-8 TM-1 188 (Dee-87) Grading Device Frames

Perform and record the following measurements SHIM CHART USING ONLY 0.036 in. (0.9 mm) SHIMS
before making any adjustment:
Shims
1. Check the clearance (1, Fig. 8) between tip’ of Measurement - inch (mm) Required

pinion and root of circle gear. If clearace is less 1.066 (27.08) to 1.209 (30.71) 1
than 0.12 in. (3 mm), the supports or the circle are 1.102 (27.99) to 1.136 (28.88) 2
worn excessively and must be replaced to prevent 1.138 (28.90) to 1.173 (29.8) 3
the circle from jamming. If the clearance is more 1.174 (29.82) to 1.209 (30.71) 4
than 0.32 in. (8 mm), check that the circle is tight 1.210 (30.73) to 1.245 (31.63) 5
against the front supports, and inspect the drive 1.246 (31.65) to 1.281 (36.54) 6
pinion for excessive wear. 1.282 (32.56) to 1.317 (33.46) 7
1.318 (33.48) to 1.353 (34.37) 8
1.354 (34.39) to 1.388 (35.29) 9
1.389 (35.31) to 1.425 (36.20) 10
1.426 (36.22) to 1.461 (37.11) 11
1.462 (37.13) to 1.497 (38.03) 12
1.498 (38.05) to 1.533 (38.94) 13
1.534 (38.96) to 1.569 (39.86) 14
1.570 (39.88) to 1.605 (40.77) 15
1.606 (40.79) to 1.641 (41.69) 16
1.642 (41.71) to 1.678 (42.62) 17

NOTE: Add to the lesser shim packs so they do not


differ from the thickest shim pack by more than two
shims.

SHIM CHARGE USING ONLY 0.060 in. (1.5 mm) SHIMS


Fig. 9-Measuring Distance from Bottom of Draft
Frame to Bottom of Circle Tooth
Shims
Measurement - inch (mm) Required
2. Measure the distance from bottom of draft frame
to bottom of circle tooth (see Fig. 9) on both sides 1.067 (27.10) to 1.126 (28.60) 1
of each support. 1.127 (28.62) to 1.186 (30.12) 2
1.187 (30.15) to 1.246 (31.65) 3
Using the longer distance measured at each 1.247 (31.67) to 1.306 (33.17) 4
support, find the number of shims required from 1.307 (33.20) to 1.366 (34.70) 5
the following charts and the note below the charts. 1.367 (34.72) to 1.426 (36.22) 6
Compare this number with the actual number of 1.427 (36.24) to 1.486 (37.74) 7
shims installed. 1.487 (37.77) to 1.546 (39.27) 8
1.547 (39.29) to 1.606 (40.79) 9
If the actual number of shims is different than the 1.607 (40.82) to 1.666 (42.32) 10
chart number, proceed with the vertical adjustment.
NOTE: Add to the lesser shim packs so they do not
differ from the thickest shim pack by more than one
shim.

Litho in U.S.A.
Grading Device JD670-A and JD672-A Motor Graders 34
Grading Device Frames TM- 1188 (Dee-87) 3440-g

USING BOTH 0.036 in. (0.6 mm) AND 0.060 in. (1.5 mm) SHIMS

If using a combination of 0.036 in. and 0.060 in.


shims, use the shim pack that is closest in thickness,
but still thicker than the minimum thickness found
from the equation below:

(depth measurement) -1.066 in. = minimum shim


(27.08 mm) pack
thickness
required

Example: T6238AN

1.198 in. - 1.066 in. = 0.132 in.


1 -Draft Frame 4-Cap Screw
(30.43 mm) (27.08 mm) (3.35 mm) a--Shims (as required) !&-Circle
a--front Circle Support 6-Vertical Clearance
1. Vertical Adjustment: 7-Front Wear Pad

To adjust the vertical clearance (6, Fig. 10) at the


Fig. IO-Circle Front Support Adjustment
front supports (3), loosen the cap screws (4). Add or
remove shims (2) as required by the shim chart and
the note below the chart.

To adjust the vertical clearance (3, Fig. 11) at the


rear supports (6), remove the two end cap screws
(2). Remove washers and reinstall the two cap screws
with nuts flush with end of cap screws. Remove the
middle cap screws.

A CAUTION: Be sure the two end cap screws


hold each rear support securely during
adjustment.

Add or remove shims (7, Fig. 11) as required by the


shim chart and the note below the chart.

Leave the rear support cap screws (2) loose for 1-Draft Frame B--Rear Circle Support
horizontal adjustment. 2-Cap Screw 7-Shims (as required)
3-Vertical Clearance 6-Stop Nut
4-Circle S-Jack Screws
B-Horizontal Clearance lo--Rear Wear Pad

Fig. 11 -Circle Rear Support Adjustment

2. Horizontal Adjustment:

The front supports (3, Fig. 10) must fit evenly and
tightly against the circle wear groove.

The horizontal clearance (5, Fig. 11) at both rear


supports (6) must add up to 0.03 to 0.06 in. (0.75 to
1.5 mm) total.
34 JD670-A and JD672-A Motor Graders Grading Device
3440-10 TM- 1188 (Dee-87) Grading Device Frames

To adjust horizontal clearance (5, Fig. 11) raise Put a thin coating of multi-purpose grease on the
the circle off the ground. Loosen the cap screws (2) top and bottom surfaces of the circle gear and on
slightly. Loosen the stop nuts (8). the inside surface of the circle wear area.

Turn the jack screws (9) equally against both rear Rotate the circle one revolution in each direction.
supports (6) until the rear supports are tight against If the circle binds at any point, determine if the
the circle wear groove. vertical or horizontal adjustment is too tight, and at
which support(s) the circle binds.
NOTE: The front supports must contact the circle
evely and tightly. If not, readjust the front supports If the horizontal adjustment causes the circle to
anad then tighten the cap screws (4, Fig. 10) to 670 bind, back off the jack screw(s) (9, Fig. 11) only
lb-ft (908 N#m). enough to allow the circle to rotate freely.

With jack screws (9, Fig. 11) tight against rear If vertical adjustment causes the circle to bind,
supports, back off the jack screws l/4 turn (90’) and add only enough shims (2, Fig. 10 or 7, Fig. 11) to the
tighten the stop nuts. Push the rear supports against support(s) that are too tight, so the circle can rotate
the jack screws and tighten the cap screws (2) to freely.
445 lb-ft (603 N.m).

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Grading Device 34
TM- 1188 (Jul- 79) Circle Gearbox 3450-l

Group 3450
CIRCLE GEARBOX
GENERAL INFORMATION
The circle drive gearbox (1, Fig. 1) transmits power
from the circle drive hydraulic motor through the worm
gear set to rotate the circle.

For information on the hydraulic motor, see Group


3460.

REMOVAL/REPAIR
Remove rear shoes on circle support and push circle
ahead so pinion is cleared during removal procedure.

Relieve hydraulic pressure.

Disconnect hydraulic lines from the motor. Remove


hardware (2, Fig. 1) attaching gearbox to draft frame. l-Gearbox l-Hydraulic Motor
Attaching Cap Screws
Remove gearbox and motor assembly.
Fig. I-Circle Drive Gearbox

Refer to Group 3460 for removal of hydraulic motor


Refer to Fig. 2 for disassembly and assembly. Re-
from gearbox.
place parts as necessary.

NOTE: To remove pinion shaft (20), remove gear-


box cover (5) and remove snap ring (7). Pinion shaft
may then be pulled from the bottom of the gearbox.

During assembly of gearbox hold thrust washer (19)


and spacer (21) in gear case while twisting worm into
position. Pin in spacer (21, Fig. 2) must fit into hole in
worm tooth.

Lubrication groove on motor adapter (13) should be


indexed down. q
,

Drive bushing (32) flush with oil seal (33) seat.


(Refer to Fig. 7, Group 3499.) I

Litho in U.S.A.
34 Grading Device JD670-A and JD672-A Motor Graders
3450-2 Grading Device Frames TM- 1188 (Jul- 79)

6-w
-
a

8
12 \ I”~ \
iiii -20

t-Cap Screw (12 used) 1 &-Gasket 19-Thrust Washer 27-Expansion Plug


P-Breather Vent 11 -Cap Screw (4 used) (2 used) 28-Nut (2 used)
3-Pipe Plug 12-Lock Washer (4 used) 2O-Pinion Shaft 29-Stud
4-Lock Washer (16 used) 13-Motor Adapter 21-Spacer with Pin 38-Spring Pin
6-Gearbox Cover M-Gasket 22-Worm Gear 31-Pipe Plug (2 used)
B-Bushing V&-Cap Screw (4 used) 23-Worm 32-Bushing
7-Snap Ring 16-Coupling 24-Gearbox 33-Oil Seal
8-GRing 17-Spring Pin 26-Lock Washer (4 used) 34-Worm and worm
g-Thrust Bearing (2 used) l&Bushing (2 used) 26-Gap Screw (3 used) gear matched set

fig. P-Circle Drive Gearbox

INSTALLATION
Use reverse of removal procedure to install circle
drive gearbox.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Grading Device 34
TM- 1188 (Mar-80) Hydraulic System 3460-l

Group 3460
HYDRAULIC SYSTEM
FUNCTION CONTROL VALVES
GENERAL INFORMATION The function control valves are a stack type control
valve assembly mounted in the control console (Fig. 1).

The control valve assembly is of the closed-center


design. The assembly consists of nine valve sections,
an end plate and a port plate held together by four tie
bolts.

l-Tie Bolt (4 used) 7-Blade Side-Shift


2-End Plate 8-Blade Rotation
d--Right-Hand Blade Lift g-Circle Side Shift
4-Left-Hand Blade Lift lo-Blade Tilt
5-Wheel Lean Ii-Front Mounted Equipment
8-Rear Steer 1 P-Port Plate

Fig. P-Control Valve Assembly

Refer to Fig. 2 for the function control valve sections.


For repair of wheel lean (5) and rear steer (6) valve
sections refer to Group 0960. The valve section for
front mounted equipment (11) is identical to the blade
l-Control Valve 2-Plug (3 used) lift sections (3 and 4) and is covered in this group.
3-Cap Screw (3 used)

Fig. l-Control Valve Assembly Location

Litho in U.S.A.
34 Grading De vice JD670-A and JD672-A Motor Graders
3460-2 Hvdraulic Svstem TM- 1188 (Mar-80)

The function control valves are four-way valves with Relieve pressure in hydraulic system by turning
double lockouts with the exception of the blade rotation steering wheel and operating brake pedals until no
valve. This valve section does not use lockouts. The response is felt. Due to lockouts in control valve as-
lockouts are of two types: a separate poppet, seat sembly, pressure in lines between cylinders and con-
assembly and plunger assembly or a plunger and trol valve cannot be relieved by operating control
popp.et assembly. levers. To relieve pressure slowly, crack fittings in lines
at control valve.
A detent mechanism is used in the blade lift sections
and front mounted equipment section for a float posi- NOTE: If motor grader is left outside in cold wea Nler
tion. All valve sections use lift checks except blade and then brought in to shop for repair, thermal lock may
rotation. take place. Thermal lock is caused by trapped oil
expanding in the lines between control valve and cyl-
Orifice plates are located in the top and bottom work inder. As oil expands due to temperature change, it
ports of the blade lift sections, circle sideshift section causes trapped oil pressure to rise above system
and the bottom work port of the front mounted equip- pressure. When this takes place it is impossible io
ment section. The orifice plates are installed with the operate function. To remedy this, crack a fitting be-
slotted side facing out. Each orifice plate is stamped tween cylinder and control valve affected.
with a number for identification.
Remove left-hand and right-hand control console
The inlet and outlet ports are in the port plate on the covers and front covers.
left-hand end of the valve assembly.
Disconnect battery ground strap and then remove
Refer to “Hydraulic Valves” in FOS Manual fuse block.
Ll HYDRAULICS for basic information on the

I 0
operation of control valves. Disconnect control linkage from valve spools.

Remove oil lines and cap.


REMOVAL

A
Loosen cap screws which hold the hydraulic line
CAUTION: Escaping fluid under pressure
clamps to allow the hydraulic lines to be shifted forward
can have sufficient force to penetrate the
in the main frame and away from the valve.
skin, causing serious personal injury. Before dis-
connecting lines, be sure to relieve all pressure.
Remove plugs (2, Fig. 1) from control console. Re-
Before applying pressure to system, be sure all
move the three valve mounting cap screws.
connections are tight and that lines, pipes and
hoses are not damaged. Fluid escaping from a very
Slide the valve assembly out the left side of control
small hole can be almost invisible. Use a piece of
console.
cardboard or wood, rather than hands to search for
leaks.

If injured by escaping fluid, see a doctor at once.


Serious infection or reaction can develop if proper
medical treatment is not administered immediate-
ly.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Grading Device 34
TM-1 188 (Dee-87) Hydraulic System 3460-3

REPAIR

Disassembly

T60224N

l-Dust Seal lo-spool Plug 18-Detent Screw 27-O-Ring


2-Machine Screw (2 used) 1 l-O-Ring Is-Cap, Detent Assembly 28-Plunger Assembly
3-Dust Seal Retainer 12-Valve Housing 20-Plug Assembly 29-Plunger and Poppet
4-Breather Washer 13-O-Ring 21-O-Ring (2 used) Assembly
B-Spool ‘l4-Bushing 22-Backup Washer (2 used) 30-O-Ring
g--Steel Ball 15-Washer 23-O-Ring (2 used) 31-Spring
7-Spring 16-Spool Centering 24-Spring 32-O-Ring
8-O-Ring Spring PS-Poppet 33-Backup Washer
g-O-Ring 17-Spool Washer 26-Seat Assembly 34-Plug Assembly

Fig. 3-Blade Lift and Front Mounted Equipment Control Valves

Refer to exploded views (Figs. 3 to 6) to disassem- Remove detent screw (18, Fig. 3) or spool screw
ble and assemble control valves. (18, Figs. 4 to 6) and spool centering spring (16, Fig.
3 or 17, Fig. 4, 5).
Remove the four tie bolts (1, Fig. 2) to separate the
valve assembly. Remove spool plug (lo), spring (7) and steel ball
(6).
Do not lose orifice plates when servicing valves.
Remove plug assembly (20 and 34, Figs. 3 to 5)
Remove machine screws (2, Figs. 3 to 6) dust seal and poppet (25, Figs. 3 and 4) (32, Fig. 5).
retainer (3) dust seal (1) and breather washer (4)
from valve housing (12). Use a small brass rod on head of plunger assembly
(28, Fig. 3) and carefully drive out plunger and poppet
Remove cap assembly (19) and pull spool assembly assembly (29). Then place rod on opposite end of
from valve housing (12). plunger assembly and carefully drive out plunger
assembly and seat assembly (26). For each valve
On valve section with detent mechanism pull cap section drive out plunger and poppet assembly first
off detent screw (18, Fig. 3). and then plunger assembly and seat assembly.

Push plunger assembly (28, Fig. 3) into valve so it


is against the plunger and poppet assembly (29).

NOTE: If plunger assembly cannot be pushed


against plunger and poppet assembly, pull the plunger
and poppet assembly out its end of valve. Then use a
small brass rod to drive plunger assembly and seat
out its end of valve.

Litho in U.S.A.
34 Grading De vice JD670-A and JD672-A Motor Graders
3460-4 Hydra u/k Sys tern TM- 1188 (J&78)

ir60225N

l-Dust Seal 18--spool Plug l8-Spool Screw 27-O-Ring


2-Machine Screw (2 used) 1 l-O-Ring lg--Cap Assembly 28-Plunger Assembly
3-Dust Seal Retainer 12-Valve Housing 28-Plug Assembly 29-Plunger and Poppet Assembly
4-Breather Washer 13-O-Ring 21-O-Ring (2 used) 38-O-Ring
5--SpOOl M-Bushing 22-Backup Washer (2 used) 31-Spring
8-steel Ball 15-Washer (2 used) 23-O-Ring (2 used) 32-O.Ring
7-Spring 18-Spool Spacer 24-Spring 33-Backup Washer
8-O-Ring 17-Spool Centering 28-Poppet 34-Plug Assembly
g-O-Ring Spring 28-Seat Assembly

fig. 4-Circle and Blade Side-Shift Control Valves

T60226N

l-Dust Seal lo-spool Plug 18-Spool Screw 27-O-Ring


P-Machine Screw (2 used) 11-O-Ring lg-Cap Assembly 28-Plunger and Poppet Assembly
3-Dust Seal Retainer la--Valve Housing PC&-Plug Assembly Pg-Plunger Assembly
4-Breather Washer 13-O-Ring 21-O-Ring (2 used) 38-O-Ring
!5-Spool 14--Bushing 22-Backup Washer (2 used) 31-Seat Assembly
8--Steel Ball 15-Washer (2 used) 23-O-Ring (2 used) 32-Poppet
7-Spring 18-Spool Spacer 24-Backup Washer 33-Spring
B-O-Ring 17-Spool Centering 25-O-Ring 34-Plug Assembly
g-O-Ring Spring %&Spring

fig. 5Blade Tilt Control Valve

Litho in U.S.A.
JD670-A and J/3672-A Motor Graders Grading Device 34
TM- 1188 (J&78) Hydraulic System 3460-S

560227N

l-Dust Seal S-Spool &O-Ring 12-Spool Centering


2--Machine Screw (2 used) 6-O-Ring g-Bushing Spring
3-Dust Seal Retainer 7-Valve Housing lo-Washer (2 used) 13-Spool Screw
4-Breather Washer 11 -Spool Spacer 14-Gap Assembly

Fig. d-Blade Rotation Control Valve

Inspect all parts for wear, scoring or breakage. Re- Spring (7, Figs. 3 to 5)
place as necessary. If spool or valve housing is dam- Free length.. . . . . . . . . . .0.597 in. (15.2 mm)
aged replace valve section. Test length . . . . . :. . . . .0.531 in. (13.5 mm)
compressed with 1.250 rf: 0.1 Ibs.)
Check that lockouts are free of all foreign material. (5.56t 0.44N) (0.57+ 0.05kg)

Check that breathers in cap assemblies are free of Spring (16, Fig. 3)
paint. Free length.. . . . . . . . . .1.717 in. (43.6 mm)
Test length . . . . . . . . 1 .I 55 in. (29.3 mm)
Check springs for fatigue. Replace as necessary. compressed with 22.5 ? 2.25 Ibs.)
(100 + 10 N) (10.2 + 1.02 kg)
Spring (24, Figs. 3 and 4) (33, Fig. 5)
Free length.. . . . . . . . .0.692 in. (17.6 mm) Spring (17, Figs. 4 and 5) (12, Fig. 6)
Test length . . . . . . . . .0.625 in. (15.9 mm) Free length.. . . . . . .1.595 in. (40.5 mm)
compressed with 0.75 + 0.1 Ibs. Test length . . . . .0.937 in. (23.8 mm)
(3.3+-0.4N) (0.34t 0.04kg) compressed with 25 + 2.5 Ibs.
(111 +- 11 N) (11 + 1.1 kg)
Spring (31, Figs. 3 and 4) (26, Fig. 5)
Free length.. . . . . . . . . . . . 0.939 (23.99 mm)
Test length . . . . . . . . . . 0.812 (20.6 mm)
compressed with 14.5 + 1.5 Ibs.
.
(64.5k 6.7N) (6.6+ 0.7kg)

Litho in U.S.A.
34 Grading De vice JD670-A and JD672-A Motor Graders
3460-6 Hydraulic Sysfem TM- 1188 (J&78)

Assembly
Install all new O-ring and backup washers dipped in
HY-GARD oil or its equivalent before assembly.

Refer to Figs. 3 to 5 and install lockouts in their


correct location.

Use John Deere Loctite Clean and Cure Primer to


clean the threads and John Deere Loctite Thread Lock
and Sealer (Medium Strength) or equivalent to coat the
threads before installing the following parts.

Tighten spool plug (10, Fig. 3 to 5) to spool (5), 5 to 8


lb-ft (7 to 11 Nm) (0.7 to 1 kg-m).

Tighten detent screw (18, Fig. 3) to spool 5 to 8 lb-ft frifice Plate


I-Special Washer
(7 to 11 Nm) (0.7 to 1 kg-m). (20 used) 0.0625 in. (1.59 mm)
2-O-Ring (20 used) (Stamped 340)
Tighten spool screw (18, Fig. 4 to 5) and (13, Fig. 6) 3-O-Ring (10 used) 7-Orifice Plate (2 used)
4-Orifice Plate (2 used) 0.0700 in. (1.98 mm)
to spool, 5 to 8 lb-ft (7 to 11 Nm) (0.7 to 1 kg-m).
0.1405 in. (3.56 mm) (Stamped 343)
(Stamped 367) 8-Orifice PIate (2 used)
Coat parts inside cap assembly (19, Figs. 3 to 6) and 5--Orifice Plate (2 used) 0.1130 in. (2.87 mm)
spool area under dust seal (1) with Lubriplate or its 0.0785 in. (1.99 mm) (Stamped 361)
equivalent. (Stamped 346) 9-Tie Bolt (4 used)
1 &Lock Was her (8 used)
11-Nut (8 used)
Tighten cap assembly (19) to valve housing, 50 to
55 lb-ft (68 to 75 Nm) (7 to 8 kg-m). Do not use Loctite Fig. 7-Orifice Plates and O-Ring Location
on these threads.
Install tie bolts (9) and tighten evenly to 20 to 25 lb-ft
When reassembling control valve assembly be sure (27 to 34 Nm) (3 to 4 kg-m)
to install special washers (1, Fig. 7) with O-rings (2)
and O-rings (3) between all sections. IMPORTANT: Tighten tie bolts evenly to 20 to 25
lb-ft (27 to 34 Nm) (3 to 4 kg-m). An improper
torque may distort valve bodies causing the valve
spools to stick or cause leakage between valve
sections.

Install orifice plates (4, 5, 6, 7 and 8) in correct work


ports with slot facing out.

NOTE: A number for identification is stamped on


each orifice plate.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Grading Device 34
TM- 1188 (Dee-87) Hydraulic System 3466-7

INSTALLATION
Mount control valve assembly to control console.
Install plugs in control console.

Connect control lever linkage.

Connect bottom tubes to their respective fittings


(Fig. 8) beginning with middle tubes. This offers
greater convenience when tightening connections.
Attach upper tubes in same manner.

Install fuse block and reconnect battery.

Start unit and check for oil leaks.

Install control console covers


l-Piston End, R.H. Litt lo-Plson End, R.H. Blade
Cylinder Side-Shin Cylinder
P-Rod End. R.H. Lift 1 l-Circle Rotation Right
Cylinder 12-Circle Rotation Lett
3-Piston End, L.H. Litt 13-Piston End, Circle
Cylinder Side-Shifl Cylinder
4-Rod End, L.H. Litt 14-Rod End, Circle
Cylinder Side-Shin Cylinder
J-Piston End, Wheel Lean 15-Piston End, Blade lilt
Cylinder Cylinder
B-Rod End, Wheel Lean 1 B-Rod End, Blade Tilt
Cylinder Cylinder
7-Rod End, L.H. Cylinder l7-Piston End, Front
Piston End, R.H. Mounting Equipment
Cylinder Rear Steer Cylinder
a--Rod End, R.H. Cylinder la--Rod End, Front Mounted
Piston End, L.H. Equipment Cylinder
Cylinder Rear Steer 19-Outlet
a--Rod End, L.H. Blade 20-Inlet
Side-Shift Cylinder

Fig. b-Control Valve Work Ports

Litho in U.S.A.
34 Grading Device JD670-A and JD672-A Motor Graders
3460-8 Hydraulic Sys tern TM- 1188 (Jul-78)

CIRCLE DRIVE MOTOR


GENERAL INFORMATION REMOVAL
Relieve pressure in hydraulic system by operating
the steering valve and brake valve with engine shut off.

Disconnect, mark and cap the hoses (2, Fig. 9) from


the motor.

Remove the four fastening cap screws (3) and slide


the motor out of the coupler inside the flange (4). The
coupler may come out with the motor.

REPAIR
Disassembly
Refer to Fig. IO during disassembly and assembly
for parts identification and correct location.

NOTE: Cleanliness is extremely important when


repairing the motor. Make sure the work area is clean.
l--Circle Drive Motor 4-Flange
Use a wire brush to remove the paint around the
2-Hose (2 used) 5-Circle Drive Gearbox exterior of the joints of metal to metal surfaces. Clean
3-Gap Screw (4 used) S-Connector (2 used) the entire motor to remove foreign material and debris.

Fig. g-circle Drive Motor Location


Place the motor in a vise; clamp across the front
mounting flange, not on the housing. Excess clamping
The circle drive motor (1, Fig. 9) is mounted on the pressure on the housing will cause distortion. When
circle drive gearbox (5) which is mounted on the draft clamping, always use some protective device such as
frame. pieces of hard rubber.

Although the motor is precision built, it is relatively Remove special cap screws (12) and seal washers
simple having only three moving parts: output shaft
(11).
with valve sleeve (1, Fig. lo), drive (5) and rotor in
geroter assembly (8). The motor is designed to deliver Remove end cap (10).
high torque at slow speed.
Remove geroter assembly (8) and spacer (9).
The output shaft, which is coupled to a worm gear in
the circle drive gearbox, drives the circle drive gear. Remove drive (5) and spacer plate (7).

Refer to “Hydraulic Motors” in FOS Manual


HYDRAULICS for basic information on the
operation of hydraulic motors.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Grading Device
TM- 1188 (Jul- 79) Hydraulic Sys tern

T60231N

l-Output Shaft 8-Geroter (Rotor and 13-Thrust Bearing 19-Internal Lock Washer
With Valve Sleeve Rotor Ring) 14-Bearing Race (4 used)
2-O-Ring g--Spacer l!i--O-Ring PO-Special Cap Screw
3-Plug 19-End Cap 16-Quad Seal (4 used)
4-Housing 1%Seal Washer (7 used) 17-Dust Seal 21-Circle Drive Gearbox
6-Drive 12-Special Cap Screw 18-Mounting Plate Coupler
6-Oil Seal (3 used) (7 used) 22-Pressure Passage Slot
7-Spacer Plate of Sleeve

Fig. 1O-CircleDrive Motor

Turn motor over and clamp across work ports, not Remove motor from vise. Place motor on clean flat
on the housing. Excessive clamping pressure on surface. Remove mounting plate (18, Fig. 10). I
housing causes distortion.
Remove output shaft with valve sleeve (1) from
1 Remove special cap screws (20, Fig. 10) and inter- housing.

1
nal lock washer (19). Force reauired to break loose cap

q
screws, approximately 25 to 33 lb-ft (34 to 45 Nm) (4 to Remove bearing race (14) and thrust bearing (13).
4.6 kg-m).
To remove plug (3), insert an Allen wrench through
NOTE: If force is excessive do not use an impact the work port opening and push it out.
wrench on Loctited cap screws. This may result in
rounded heads or broken sockets. Use a small flame
propane torch to heat a small area of housing directly
over cap screw. Gradually apply force’to cap screw as
beat is applied for 8 to 10 seconds. As soon as the cap
screws break loose, remove heat and remove cap
screws. Be careful not to overheat housing.

Litho in U.S.A.
34 Grading De vice JD670-A and JD672-A Motor Graders
3460-10 Hydraulic Sys tern TM- 1188 (Jut-79)

Check all mating surfaces. Replace any parts that NOTE: To help with the timing procedure for the
have scratches or burrs that could cause leakage or motor, a timing mark is machined on the valve sleeve
damage. Clean all metal parts in clean solvent. Blow end of output shaft.
dry with air. Do not wipe with a cloth or paper towel
because lint or other matter’ can get into the hydraulic Install thrust bearing (13, Fig. 10) and bearing race 1
system and cause damage. Check around the splined (14). Pull shaft partially out of housing, then push all
and chamfered area of the shaft .for burrs, nicks or three parts in housing together. Bearing race must
sharp edges that can damage the seals when reas- rotate freely when in position.
sembling the flange. Nicks or burrs may be removed
with a hard, smooth stone (such as an Arkansas Install mounting plate (18) with new seals and O-
stone). Do not try to file or grind these parts. ring. Install dust seal (17) with seal lips facing out.
Install quad seal (16) with seal lips facing motor. Lu-
Assembly bricate seals with petroleum jelly.

Use new seals when reassembling the motor. A seal


Apply three or four drops of John Deere Medium
kit is available for motor. Lubricate all seals and O-
Strength Loctite or equivalent at the top of the threads
rings with petroleum jelly.
in each of the 4 holes in housing and one drop to
threads of each cap screw.
Remove any, loose particles of cured Loctite from the
four tapped holes in the mounting plate end of housing.
Install cap screws (20) and internal lock washers
It is not necessary to remove the cured Loctite that is
(19) and tighten to 225 to 250 lb-in. (25 to 28 Nm) (2.6
securely bonded in the tapped holes. Wire brush the
to 2.9 kg-m).
cap screws (20, Fig. 10) threads to remove cured
Loctite and other debris. Discard any screws that have
NOTE: If primer is used allow Loctite to cure 10 to
damaged threads or corroded, damaged or rounded
15 minutes; without primer allow 6 hours before sub-
heads.
jecting the motor to high torque reversals.

Wash the cap screws and tapped holes in housing


Turn motor over and clamp in vise across mounting
with John Deere Loctite Clean and Cure Primer or its
plate.
equivalent.
Put a small amount of clean oil in output shaft with 1
Install plug (3) with O-ring (2) flush with housing.
valve sleeve.

I Apply a light coat of clean oil on the valve sleeve


area of output shaft (1) and carefully slide output shaft
with valve sleeve into housing.

IMPORTANT: Do not permit oil to get.into the


tapped holes.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Grading De vice 34
TM-I 188 (J&78) Hydraulic System 3460-11

install drive (4, Fig. 11) with timing mark on drive


tooth aligned with timing mark on output shaft.

Install new oil seal (6, Fig. 10) in housing groove.

Install spacer plate (7).

Install new oil seal (6) in groove in geroter assembly.

Install geroter with tip of rotor tooth aligned with


timing mark on drive (Fig, 11).

Turn the gerotor to line up the holes for cap screws.


Be careful not to disengage rotor from drive.’

Install spacer (9, Fig. 10).

Install new oil seal (6) in end cap, then carefully


place end cap on gerotor.

Install cap screws (12) and seal washers (11) in end


cap. Pre-tighten all cap screws to 15 to 40 lb-in (1.7 to
4.5 Nm) (0.17 to 0.46 kg-m). Check to make sure the
seals are seated properly in the grooves. Then tighten
cap screws to 175 to 200 lb-in. (20 to 23 Nm) (2.02 to
2.30 kg-m) in sequence shown in Fig. 12.

360232N

l-Forward Valving Slot 5-Geroter Assembly


l--Housing ~-Tip of Rotor Tooth
3-Spacer Plate T-liming Mark Drive
4-Drive 8-Timing Mark Shaft

Fig. 1 l-Motor Timing

!i'60242N

Fig. 1BCap Screw Torquing Sequence

Litho in U.S.A.
34 Grading De vice JD670-A and JD672-A Motor Graders
3460-12 Hydraulic Sys tern TM- 1188 (J&78)

INSTALLATION
Slide motor into flange and index splines on coupler
with the drive gearbox worm gear and the motor output
shaft.

Install cap screws (3, Fig. 9) and connect hoses (2).

Test blade rotation control to insure motor is rebuilt


correctly. If circle turns opposite to normal direction,
geroter is installed wrong.

To correct this problem remove end plate (IO, Fig.


10) and geroter (8). Move geroter one spiine tooth in
either direction on drive (5).

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Grading De vice 34
TM- 1188 (Jul- 78) Hydraulic System 3460-13

LIFT ARM LOCKING VALVE


GENERAL INFORMATION REPAIR

-13
e3

-14
a
&J-l5
b-16
643 -15

l-Return Hose
2-Lift Arm Locking
4-Fastening
6-Return
Cap Screws
Hose From P60233N
d
Valve Locking Pin
3-Center Mounting l-Cap Screw (2 used) E-O-Ring
2-90” Adjustable Elbow 9-Valve Body
Fig. 13-Lift Arm locking Valve Location (2 used) 1 &Spring Pin
3-O-Ring (2 used) 1 l-steel Ball
4-Center-Bonded 12-Plunger
The lift arm locking valve (Fig. 13) is a foot-operated
Mounting (2 used) 13-Boot
valve. The valve is located in the left underside of the 6-Washer (2 used) 14-Washer
operator’s platform. g-Jam Nut (2 used) 16-Snap Ring (2 used)
7-Plug M-O-Ring
REMOVAL
Fig. 14-Lift Arm Locking Valve
Lower blade to the ground.
Refer to Fig. 14 during disassembly and assembly of
Relieve pressure in hydraulic system by operating lift arm locking valve.
steering valve and brake valve with engine shut off.

Disconnect and cap hoses (1, 5, Fig. 13) from lift


arm locking valve.
Remove plug (7, Fig. 14) and pull plunger assembly
from valve body. q
,

Remove snap ring (15) and slide plunger (12) out of


Remove fastening cap screws (4) and remove valve. plug (7).

Remove 90” adjustable elbow (2) and remove ball


(11) and spring pin (10).

Inspect all parts and replace as necessary.

When assembling the valve, use new O-rings in all


locations.

Lifho in U.S.A.
34 Grading Device JD670-A and JD672-A Motor Graders
3460-14 Hydraulic Sys tern TM- 1188 (Jul-78)

INSTALLATION
If center mountings are replaced, install into support
with shoulder to the top side.

Position valve on unit and fasten with cap screws (1,


Fig. 14).

Connect hoses to valve.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Grading Device 34
TM- 1188 (Dee-87) Hydraulic System 3460-15

LIFT ARM LOCKING PIN


GENERAL INFORMATION Disconnect and cap hoses (4 and 6, Fig. 15) from
locking pin housing. Remove elbow from barrel.
Disconnect one end of the crossbar (1).

Disconnect battery and then remove wire from


locking pin switch (3).

Remove fastening cap screws (2) and remove


locking pin assembly. Note the number of shims
removed.

REPAIR
Refer to Fig. 16 and 16a during disassembly and
assembly of locking pin assembly.

Unscrew the housing (17, Fig. 16 or 11, Fig. 16a)


from the barrel (3, Fig. 16 or 16a).

Pull pin (12, Fig. 16 or 9, Fig. 16a) and piston from


barrel.
l-Crossbar 4-Hose
a--Cap Screw (6 used) S-Barrel
Remove retaining ring (7, Fig. 16) and slide piston
3-Locking Pin Switch 6-Hose
off of lift arm pin.
Fig, 15 Lift Arm Locking Pin
Inspect all parts and replace as necessary.
The lift arm locking pin is located on the underside
Measure the I.D. of the barrel (3, Fig. 16 or 16a), I.D.
of the main frame (Fig. 15).
of the locking pin housing (17, Fig. 16 or 11, Fig. 16a)
and O.D. of the locking pin (12, Fig. 16 or 9. Fig. 16a).
Lift arm locking pin will be engaged at all times
Use the following specifications.
that lift arm locking valve is not depressed. An
indicator light on dash panel will glow when pin is
Barrel I.D. (3, Fig. 16 or
disengaged.
Fig. 16a). . . . . . . . . . . . . . . . . . .2.998 + 0.002 in.
+ 0.002 in. (76.15 + 0.05 mm)
REMOVAL

A CAUTION: Be sure blade is on the ground


before removing locking pin.
Housing I.D. (17, Fig. 16 or
11, Fig. 16a) . , . . . . . . . . . . . . . .2.005 C 0.002 in.
(50.93 f 0.05 mm)
Hydraulically retract the locking pin using locking
pin valve. With the pin retracted turn the engine off. Pin O.D. (12,
Hold the valve in the retract position momentarily Fig. 16) . . . . . . . . . . . . . . . . .2.0000 f 0.0015 in.
and turn steering wheel back and forth to let the (50.8000 k 0.038 mm)
system pressure bleed off. Release the valve and pin
should stay in retracted position. Pin O.D. (9,
Fig. 16a). . . . . . . . . . . . . . . . 1.9996 - 2.0010 in.
(50.79 - 50.8254 mm)

Litho in U.S.A.
34 Grading Device JD670-A and JD672-A Motor Graders
3460-l 6 Hydraulic System TM-1 188 (Dee-87)

T59641N I

l-Adapter 8-Piston 14-Shim (as required)


2-O-Ring O-Seal 15-Locking Pin Switch
3-Barrel IO-Backup Ring (2 used) 18-Shim (as required)
4-Grease Fitting II-O-Ring (2 used) 17-Housing
5-Cap Screw 1 P-Pin 18-Cap Screw (8 Used)
B-Spacer 13--Rectangular Packing 19-Special Washer (8 used)
7-Retaining Ring

Fig. 764ocking f’ift-Serial No. ( -402698)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Grading Device 34
TM- 1188 (Dee-87) Hydraulic System 3460-17

T6723AB

l-Adapter 7-Backup Ring (2 used) 13-Shim (AR)


2-O-Ring 6-O-Ring (2 used) 14-Special Washer (6 used)
3-Barrel g--Pin 15-Cap Screw (6 used)
4-Grease Fitting 1 O-Rectangular Pacldng 16-Shim (AR)
S-Piston 1 l-Housing
g--Seal 12-Locking Pin Switch

Fig. l&-Locking Pin-Serial No. (402690- I

Litho in U.S.A.
34 Grading Device JD670-A and JD672-A Motor Graders
3460-18 Hydraulic System TM- 1188 (Dee-87)

Note the following when assembling the locking


pin.

When assembling use new seals and O-rings in


all locations.

Lubricate locking pin housing and lift arm pin with


John Deere Never Seez or its equivalent.

Install piston (8, Fig. 16 or 5, Fig. 16a) with O-ring,


backup ring and seal onto the locking pin (12, Fig. 16
or 9, Fig. 16a). Install piston with the large chamfer
pointing away from the locking pin housing (17, Fig.
16 or 11, Fig. 16a). Install retaining ring.

Add or deduct switch shims (16, Fig. 16 or 13, Fig.


16a) under the switch to cause switch to close when
locking pin is disengaged.

Tighten switch (15, Fig. 16 or 12, Fig. 16a) with 40


lb-ft (54.2 N-m) (6 kg-m).

Apply T43512 John Deere Loctite (Medium Strength) T59642N

or its equivalent to the threads of the barrel (3, Fig. 16


l-O-Ring Port Location l-Alternate Location
or 16a) and housing (17, Fig. 16 or 11, Fig. 16a).
Tig’hten barrel tight against housing. Back-off
Fig. 174ndex of O-Ring Port
minimum turns until 30 Y&IO0 index of O-ring port is
achieved (1, Fig. 17).
Connect the crossbar.
INSTALLATION
Apply John Deere Never-Seez or its equivalent to
Use the same amount of shims (14, Fig. 16 or 16, crossbar holes.
Fig. 16a) that were removed during removal.
Start up unit and engage and disengage pin. When
Position locking pin assembly with pin retracted in the pin is disengaged, it must clear the crossbar and
main frame and install cap screws. lift arms. With the lift arms pushed against the front
stub shaft, the distance from the end of the lockin pin
Connect hoses to barrel. housing to the milled pads on the lift arms should
measure approximately 0.090 in. (2 mm). If this
Connect electrical wires to switch. distance is greater than 0.120 in. (3 mm), add a shim.
If less than 0.060 in. (1.5 mm), deduct a shim.
Connect the battery.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Grading Device 34
TM- 1188 (Dee-87) Hydraulic System 3460-l 9

ROTARY MANIFOLD
GENERAL INFORMATION Disconnect, mark and cap lines on front and bottom
of rotary manifold

Remove rotary manifold from unit.

REPAIR
Refer to Fig. 19 during disassembly and assembly
of rotary manifold.

Scribe a mark on manifold body and spool to aid


in reassembly.

Remove the four cap screws (1) and retainer (3).

Press manifold spool (8) from manifold body (5).

Check manifold body and spool for damage.


Remove minor nicks and scratches with crocus cloth.

Measure O.D. of manifold spool and I.D. of manifold


body. Replace parts as necessary.

Fig. lb-Rotary Manifold Manifold Spool O.D. . . . . . . . . .3.6210 + 0.0015 in.


(91.97 + 0.04 mm)
The rotary manifold is mounted on the draft frame
(Fig. 18). Manifold Body I.D. . . . . . . . . . . .3.6260 + 0.0015 in.
(92.10 + 0.04 mm)
The manifold body remains stationary while the
manifold spool is turned by a bracket and rod Install washer (7) on manifold spool.
assembly that is attached to the spool and the circle
and blade assembly. Install seals (6) on manifold spool (8) after soaking
in oil.
The rotary manifold allows for 360” rotation of
circle and blade assembly. NOTE: One seal replaces two backup rings and
one O-ring packing.
REMOVAL
Install new felt washers (4) in manifold body after
Lower blade to the ground. soaking in oil.

Relieve pressure in hydraulic system by operating Coat the manifold spool and inside of manifold
steering valve, brake valve and control levers. Slowly body with oil. Install spool into manifold body being
crack fitting on rotary manifold to relieve any pressure careful not to damage seals.
trapped in lines due to lockouts in main control
valve. Position retainer on rotary manifold and install
lock washers (2) and cap screws (1).
Remove cover, bracket and rod assembly.

Litho in U.S.A.
34 Grading Device JD670-A and JD672-A Motor Graders
3460-20 Hydraulic System TM- 1188 (Dee-87)

l-Cap Screw (4 used) 4-Felt Washer (2 used) ‘I-Washer


P-Lock Washer (4 used) !&Manifold Body I-Manifold Spool
3--Retainer B-Seal (5 used)

Fig. 19-Rolary Manifold Assembly

INSTALLATION
Align marks made during removal and install rotary
manifold on the unit.

Connect hydraulic lines and hoses.

Install drive bracket.

Install cover.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Grading Device 34
TM- 1188 (Dee-87) Hydraulic System 3460-21

CROSSOVER RELIEF VALVE


GENERAL INFORMATION REMOVAL
Lower blade to the ground and remove all load
from lift cylinders.

Relieve pressure from hydraulic system by opera-


ting steering valve and brake valve with engine off.
Put blade lift control levers in float position to relieve
pressure in blade lift circuit.

Disconnect, mark and cap tubes and hoses.

Remove crossover relief valve.

REPAIR

l-From Head End 3-From Rod End


2-Crossover Relief 4-L.H. Lift Cylinder
Valve (2 used)

Fig. PO-Crossover Relief Valve


For Leff Blade Lift Cylinder
l-Special Plug (2 used) 5-Outer Spring
One crossover relief valve (2, Fig. 20) is located on 2-O-Ring (2 used) B-Inlet Guide
3-Washer (as required) 7-Steel Ball
each blade lift cylinder.
4-Inner Spring 8-Valve Housing

Crossover relief valves are used to reduce exces-


Fig. 2 7 -Crossover Relief Valve
sive load to blade lift cylinder when shifting circle
and raising blade. Excess pressure oil from rod end
Refer to Fig. 21 for disassembly and assembly of
of lift cylinder is allowed to bleed over to the return
crossover relief valve.
oil coming from head end of cylinder.

Check parts for wear or damage. Replace as


The ports on valve body marked “HE” are con-
necessary.
nected to the head end of cylinder and top work port
of blade lift valve sections. Ports marked “RE” are
connected to the rod end of lift cylinder and bottom
work port on blade lift valve sections.

Litho in U.S.A.
34 Grading Device JD670-A and JD672-A Motor Graders
3460-22 Hvdraulic Device TM-1 188 (Dee-87)

Check springs for fatigue. Replace as necessary. INSTALLATION

Inner Spring (4, Fig. 21)


Free length . . , . . . . . , . . . . . . 1.14 in. (29 mm)
Test length . . . . . . . . . . . . . 0.84 in. (21.9 mm)
compressed with 6.5 I!I 0.76 Ibs.
(28.9 31 3.4 N) (2.9 f 0.3 kg)

Outer Spring (5, Fig. 21)


Free length . . . . . . . . . . . . . . 1.20 in. (30.5 mm)
Test length . . . . . . . . . . . . . 1.00 in. (25.4 mm)
compressed with 42 & 4.2 Ibs.
(186.8 f 18.7 N) (19 f 1.9 kg)

T60237N

l-Cap Screw %-Washer


%-Washer 4-R.H. Lii Cylinder

Fig. 23-Crossover Relief Valve For Right


Fig. 22-Valve Housing Passage Blade Lifl Cylinder

Clean passage (Fig. 22) in valve housing. Install crossover relief valve to trunion of lift
cylinder. Be sure washer (3, Fig. 23) is between valve
and trunion.

Connect tubes and hoses. Head end of cylinder to


port in valve marked “HE” and rod end to port
marked “RE.”

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Grading Device 34
TM- 1188 (Dee-87) Hydraulic System 3460-23

CYLINDERS
GENERAL INFORMATION
The hydraulic cylinders used on the grader are
double-acting and use “V-packing type seals on
their pistons. Piston rods are heat treated, chrome
plated, and polished. Replaceable non-metallic wear
rings are used on piston to prevent scoring of the
cylinder barrels.

A groove is cut into the piston rod of blade side-


shift cylinder to identify rod that is pinned to piston.

NOTE: If scarifier and snowplow lift cylinder or


blade lift cylinder is replaced, a new cylinder with
cap seals will be furnished.

See “Hydraulic Cylinders” in FOS Manual-


l-l
ms HYDRAULICS for additional information on

I-J 0
cylinders.
l-Blade
L-Circle
Lift Cylinders
Side-Shift
rl-wacte Tilt Cylinder
C-Blade Shift Retainers
REMOVAL Cylinder (4 used)

A
F&Blade Side-Shift
CAUTION: Escaping fluid under pressure
Cylinder
can have sufficient force to penetrate the
skin, causing serious personal injury. Before dis-
Fig. 24-Blade and Circle Cylinders
connecting lines, be sure to relieve all pressure.
Before applying pressure to system, be sure all
Remove cylinder from unit.
connections are tight and that lines, pipes and hoses
are not damaged. Fluid escaping from a very small
Circle Side-Shift Cylinder
hole can be almost invisible. Use a piece of card-
(2, Fig. 24 and Fig. 26)
board or wood, rather than hands, to search for
suspected leaks. Lower blade.

If injured by escaping fluid, see a doctor at once. Relieve pressure in hydraulic system by operating
Serious infection or reaction can develop if proper steering valve and brake valve with engine shut off.
medical treatment is not administered immediately.
Due to lockouts in valve section pressure in circuit
Blade Lift Cylinders cannot be relieved by operating control lever. To
(1, Fig. 24 and Fig. 25) relieve pressure, slowly crack fittings at cylinder.

Lower blade.
Disconnect, mark and cap hoses from cylinder.

Relieve pressure in hydraulic system by operating


Remove cylinder from unit.
steering valve and brake valve with engine shut off.
Put blade lift control levers into float position to
relieve pressure in blade lift circuit.

Disconnect and cap lines from cylinder.

Litho in U.S.A.
34 Grading Device JD670-A and JD672-A Motor Graders
3460-24 Hvdraulic Svstem TM-l 188 (Dee-87)

Blade Tilt Cylinder Place blocks in front and in the rear of the blade to
(4, Fig. 24 and Fig. 27) prevent it from falling when removing blade from
circle.
Lower blade and retract blade tilt cylinder.
Remove top blade shift retainers (5, Fig. 24). Do not
Relieve pressure in hydraulic system by operating
lose shims.
steering valve and brake valve with engine off.
Disconnect and mark hoses from cylinder. Cap
Due to lockouts in valve section pressure in circuit
hoses with pipe caps so unit can be operated.
cannot be relieved by operating control lever. To
relieve pressure, slowly crack fittings at cylinder.
Lower circle so bottom blade shift retainers (5)
clear bottom blade side-shift rail. Back unit up for
Disconnect, mark and cap hoses from cylinder.
clearance to remove cylinder.

Remove cylinder from unit.


Remove cylinder retaining pins and slide cylinder
out of blade. Be careful so blade doesn’t fall.
Blade Side-Shift Cylinder
(3, Fig. 24 and Fig. 31)
Lower blade to the floor and extend blade tilt
cylinder.

Relieve pressure in hydraulic system by operating


steering valve and brake valve with engine shut off.
Due to lockouts in valve section pressure in circuit
cannot be relieved by operating control lever. To
relieve pressure, slowly crack fittings at cylinder.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Grading Device 34
TM-l 188 (Dee-87) Hydraulic System 3460-25

REPAIR

l--Barrel and Head I-Snap Ring 15-Piston Rod


l--stop Nut g-V-Packing 1 B--Shim
3-Wear Ring lo--Wear Ring ll-Rod End Cap
4-Piston 1 I-O-Ring 16-Cap Screw (2 used)
S-Seal 12-Backup Washer 1 O-Grease Fitting
6-O-Ring 13-Rod Guide 20-Set Screw
‘I-Piston 14-Wiper Seal Il-Backup Ring (2 used)

Fig. 25-Blade Lift Cylinder

Litho in U.S.A.
34 Grading Device JD670-A and JD672-A Motor Graders
3460-26 Hydraulic System TM-1 188 (Dee-87)
.

l-Cap Screw (2 used) g-Wear Ring 16-Wear Ring


P-Lock Washer (2 used) lo--Piston Retainer 17-O-Ring
3-Grease Fitting (2 used) 11 -V-Packing 16-Backup Washer
4-Ball Pivot Cap 12-O-Ring 1 g--Rod Guide
S-Ball Pivot Shim (as required) 13-Piston 20-Wiper Seal
B-Barrel and Head 14-Snap Ring Ol-Piston Rod
7-Set Screw 15-V-Packing 22-Cap Screw (2 used)
O-Stop Nut
Fig. 26-Circle Side-Shift Cylinder

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Grading Device 34
TM- Hydraulic System 3460-27
-_ 1188
_..... _ (Dee-87)

l-Grease Fitting ‘I-Piston Retainer 13-Wear Ring


Z-Bushing (2 used) E-Seal 14-O-Ring
3-Barrel and Head g-O-Ring 15-Backup Washer
4-Set Screw lo-Piston 16-Rod Guide
5-Stop Nut 1 l-Snap Ring 17-Wiper Seal
B-Wear Ring la-V-Packing 16-Bushing (2 used)
19-Piston Rod
to-Backup Ring (2 used)

Fig. 27-Blade Tilt Cylinder

Litho in U.S.A.
34 Grading Device JD670-A and JD672-A Motor Graders
3460-28 Hydraulic System TM- 1188 (Dee-87)

If cylinder packings have failed, some fragments of


the deteriorated parts may have entered the system.
Remove cylinder and flush hoses and tubes going to
control valve. Replace the filter.

Clamp the cylinder in a vise to prevent it from


turning. Remove set screw and rod guide. Use a
spanner wrench to loosen rod guide.

Remove piston rod, rod guide and piston from


barrel.

Clamp the rod end in a vise taking care to prevent


damage to the piston rod. Remove nut from end of
rod. Slide parts from end of rod.

Wash all parts thoroughly with diesel fuel and


inspect the following:
T34293N

1. Barrel, rod guide and rod for scoring, and O-


l-Snap Ring 4-Wear Ring
rings for surface damage.
P-O-Ring S-Wiper Seal
3-V-Packing B-Backup Washer
2. V-packings and wear rings for breaks, cuts or
embedded foreign material. Fig. 28-Cylinder Rod Guide Components

3. .Piston rod seal and wiper for wear or damage. Install new wiper seal (5, Fig. 28) in rod guide.
Remove sharp edges from piston rod with emery
cloth. Install new wear ring (4) in rod guide. Position
backup washer (6) and O-ring (2) on rod guide.
Repair kits are available for overhauling all cylin-
ders. Discard used parts and use all new parts Install the V-Packing (3) in rod guide with apex of
provided in kits when assembling cylinders. the “V” toward the wiper seal and secure with snap
ring (1).
Lubricate all O-rings, seals, and packings before
assembly. Slide rod guide assembly on piston red being
careful not to damage packing.
Coat rod guide and set screw threads with John
Deere Medium Strength Loctite or an equivalent
before installing in barrel.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Grading Device 34
TM- 1188 (Dee-87) Hvdraulic Svstem 3460-29

Installing Piston V-Packing V-packings are originally installed on the piston


with the apex of the V pointing away from the barrel
(Fig. 29). When replacing V-packings in the field this
procedure can be used if a suitable ring compressor
is available to compress packings when installed in
cylinders.

If a suitable compressor is not available, assemble


the packings with the apex of the V pointing toward
the barrel (Fig. 30). This eliminates scuffing that may
occur in assembly; however, the V-packing may
become torn if the cylinder has to be disassembled
in the future.

Position piston on piston rod. Install wear ring on


piston retainer. Position retainer on piston rod and
l-Piston Retainer 4-Nut secure with stop nut. Tighten stop nut for blade tilt
2-Wear Ring S-Cylinder Barrel cylinder to 600 to 700 lb-ft (813 to 949 N.m) (83 to 97
3-Piston kg-m).

Fig. 29-Original Installation of V- Packing Tighten stop nut for blade lift and circle side-shift
cylinders to 475 to 575 lb-ft (644 to 780 N.m) (66 to
0 79 kg-m).

I
Install piston rod assembly into barrel.

Secure piston rod assembly in barrel with rod


guide and tighten with 250 to 300 lb-f-t (339 to 407
N-m) (35 to 42 kg-m). Install set screw and tighten
after rod guide is tightened with 40 lb-in (4.5 N.m)
(0.46 kg-m).

INSTALLATION
Place the cylinder in position on the machine and
align the attaching holes. Insert pivot pins and secure
with cap screws. Connect the hydraulic lines, making
l-Piston Retainer 4-Nut
P-Wear Ring B-Cylinder Barrel sure they are connected to the same ends of the
3-Piston cylinder from which they were removed.

Fig. 30-Installation of V-Packing The ball and socket assemblies on the lift cylinder
Without Compressor rod ends and on the circle side-shift cylinders have
shims which may be removed to compensate for
wear.

Check the amount of looseness in these sockets


by lowering blade to the ground and operating the
cylinder back and forth without load.

DO NOT allow ball to bind in the socket.

After replacing the cylinder, operate the cylinder


several times to remove air from the system. Add oil
to bring it up to the proper level.

Litho in U.S.A.
34 Grading Device JD670-A and JD672-A Motor Graders
3460-30 Hydraulic System TM- 1188 (Dee-87)

Installing Piston Cap Seal IMPORTANT: For proper fit, the backup rings must
be installed with the radius toward seal expander.

3. Install backup rings (C) with radius toward seal


expander (6).

A-Piston C-Backup Rings (2 used)


B--Seal Expander D-Cap Seal

Fig. 31-Piston Cap Seal

NOTE: Use a cylinder repair kit when assembling


rebuildable cylinder. Before assembling, apply clean
hydraulic oil to all internal parts.

1. Install seal expander (B) on end of piston (A).

IMPORTANT: Cap seal must fit tight against seal


expander to prevent seal damage during assembly
into barrel.

2. Install cap seal (D) onto seal expander (B). If


necessary, shrink cap seal to its original size using a
ring compressor or hose clamp with shim stock.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Grading Device 34
TM- 1188 (Dee-87) Hydraulic System 3460-31

Blade Side-Shift Cylinder

l-Piston Rod (grooved) 6-Wear Ring (2 used) 11-Roll Pin


P-Wiper Seal (2 used) 7-V-Packing (2 used) 1 P-Piston
3-Rod Guide (2 used) I-Snap Ring (2 used) 13-Barrel
4-Backup Washer (2 used) g--Wear Ring (2 used) 14-Set Screw (2 used)
S-O-Ring (2 used) lo-Inner Seal 1 !&Piston Rod
1 g-Outer Seal

Fig. 32-Blade Side-Shift Cylinder

Litho in U.S.A.
34 Grading Device JD670-A and JD672-A Motor Graders
3460-32 Hydraulic System TM- 1188 (Dee-87)

If cylinder has failed, some fragments of the Assembly


deteriorated parts may have entered the system.
Repair kits are available for overhauling all cylin-
Remove cylinder and flush hoses and tubes from
ders. Discard used parts and use all new parts
cylinder to control valve. Replace the filter.
provided in kits when assembling cylinders.

Disassembly Lubricate all O-rings, seals, and packings before


Clamp the cylinder in a vise to prevent it from assembly.
turning. Remove set screws (14, Fig. 32) and rod
guides (3). Use a spanner wrench to loosen rod
guides.

Hold piston rod (1) and screw piston rod (15) out
of piston (12).

NOTE: Piston rod (7) has a groove cut in rod near


the rod eye.

Remove piston rod and rod guide (3) from barrel.

Remove piston rod (1) rod guide and piston from


barrel.

Clamp piston rod eye end in a vise taking care to


prevent damage to the piston rod. Drive roll pin (11)
out of piston (12) and screw piston rod out of piston.

Wash all parts thoroughly with diesel fuel and


1-Snap Ring 4-Wear Ring
inspect the following:
2-O-Ring B-Wiper Seal
3-V-Packing 6-Backup Washer
1. Barrel, rod guide and rod for scoring, and O-
rings for surface damage. Fig. 33-Cylinder Rod Guide Components

2. V-packings and wear rings for breaks, cuts or Install new wiper seal (5, Fig. 33) in rod guide.
embedded foreign material.
Install new wear ring (4) in rod guide. Position
3. Piston rod seal and wiper for wear or damage. backup washer (6) and O-ring (2) on rod guide.
Remove sharp edges from piston rod with emery
cloth. Install the V-packing (3) in rod guide with apex of
the V toward the wiper seal and secure with snap
ring (1).

Slip rod guide assembly on piston rod (1 and 15,


Fig. 32) being careful not to damage packing.

Coat rod guides and set screw threads with John


Deere Medium Strength Loctite or an equivalent
before installing in barrel.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Grading Device 34
TM- 1188 (Dee-87) Hydraulic System 3460-33

install new inner seal (10, Fig. 32) on piston (12). To obtain the proper clearance, remove cylinder
Install outer seal (16) over inner seal. and turn piston rod (15, Fig. 32) in or out as required.

Install new wear rings (9) on piston. NOTE: The clearance between the. retaining pin
and the outside edge of the piston rod pin hole is
Coat threads of piston rods with John Deere required to prevent piston rods from bending.
Medium Strength Loctite or its equivalent.
Drive unit ahead and raise circle to position lower
Screw piston rod (1) into piston (12). Align holes in blade shift retainers (5, Fig. 24) in place on lower
piston rod and piston and install roll pin (11). side-shift rail on blade.

Slide piston rod with rod guide and piston assembly Install upper blade shift retainers (5) and shims.
into barrel. Tighten rod guide with 250 to 300 lb-ft. Remove blocking from blade.
(339 to 407 N-m) (35 to 42 kg-m). Tighten set screw
with 40 lb-in. (4.5 N.m) (0.46 kg-m). Relieve pressure in hydraulic system by operating
steering valve and brake valve with engine shut off.
Slide piston rod (15, Fig. 32) with rod guide into
barrel. Hold piston rod (1) and screw piston rod (15) Carefully remove caps from hoses to relieve any
into piston (12). Turn piston rod seventeen 360” pressure.
turns into the piston. Tighten rod guide with 250 to
300 lb-ft (339 to 407 N.m) (35 to 42 kg-m). Tighten set Connect hoses to cylinder.
screw with 40 lb-in (4.5 N.m) (0.46 kg-m).
Operate the cylinders several times to remove air
NOTE: Allow two hours for Loctite to cure after from the system. Add oil to bring it up to the proper
assembling cylinder before using. level.

Installation
2
2

l”37991N

l-Clearance between retaining 2-Retaining Pins


pin and outside edge of 3-Blade Side-Shift
piston rod pin hole (0.25 Cylinder
in. [6.9 mm])

Fig. 34-Retaining Pins Installed in Cylinder

Install cylinder on blade and install retaining pins.


One of the retaining pins should be tight against the
outside edge of one of the piston rod pin holes and
the other retaining pin should have a clearance of
0.25 in. (6.9 mm) between the hole and the outside
edge of the piston rod pin hole. See Figure 34.

Litho in U.S.A.
34 Grading Device JD670-A and JD672-A Motor Graders
3460-34 Hydraulic System TM-1 188 (Dee-87)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Grading Device 34
TM- 1188 (Dee-87) Specifications and Special Tools 3499-I

Group 3499
SPECIFICATIONS AND SPECIAL TOOLS
GRADING DEVICE FRAMES
SPECIFICATIONS AND TORQUE VALUES

3- Distance between front surface


of casting on main frame (2,
Fig. 1) and back side of lift
arm (1). (With locking cross-
bar removed and lift arm swung
under main frame.) . . . . . . . . . . 0.38 to 0.44 in.
(10 to 11 mm)

Lift Arm Yoke Retaining


Cap Screw . . . . . . . . . . . . . . . . .117 +_ 21 lb-ft
(158 & 28 N.m)
Fig. l&it Arm Clearance
1 - Maximum vertical clearance
between wear pads and circle,
with circle resting on supports . . . . . . . 0.10 in.
(2.5 mm)
2 - Sum of horizontal clearances
between all circle supports
and circle . . . . . . . . . . . . . . . . . 0.03 to 0.06 in.
(0.75 to 1.5 mm)
3 - Draft frame-to-front
support cap screws . . . . . . . . . . . . . . 670 lb-ft
(908 N-m)
Draft frame-to-rear
support cap screws . _ . . . . _ . . . . . . . 445 lb-ft
(603 N.m)

Fig. P-Circle Clearance

1 - Clearance between tip of


drive pinion tooth and
root of circle tooth . . . . _ . . . . . 0.12 to 0.32 in.
(3 to 8 mm)

Fig. S-Circle Tooth ClearanCa

Litho in U.S.A.
34 Grading Device JD670-A and JD672-A Motor Graders
3499-2 Specifications and Special Tools TM- 1188 (Dee-87)

GRADING DEVICE FRAME-Continued


SPECIFICATIONS AND TORQUE VALUES-Continued

3 - Saddle Pin Housing


Clearance . . . . . . . . , . . . . . . . 0.09 + 0.03 in.
(2.3 = 0.8 mm)

T59859N I

l-Saddle Pin Housing P-Right Lift Arm

Fig. 4-Saddle Pin Housing Clearance

1 - Saddle Ear Cap Screw


Torque . . . . . . . . . . . . . . . . . 1665 f 166 lb-ft
(2330 k 132 N.m)
(229 f 23 kg-m)
or
1 - Saddle Ear Cap Screw
Torque . , . . . . . . . . . . . . . . . . . 200 + 20 lb-ft
(271 + 27 N.)
(27.6 + 2.7 kg-m)
plus 180° (l/2 turn)

Fig. g-front Saddle Ear Cap Screw

A - Moldboard Retainer Cap Screw


Torque . . . . . . . . . . . . . . . . . . . . . . 445 lb-ft
(603 N.m)

T672ZAD cf

Fig. 5a-Moldboard Retainer Cap Screw

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Grading De vice 34
TM- 1188 (J&78) Specifications and Special Tools 3499-3

CIRCLE GEARBOX
SPECIFICATIONS AND TORQUE VALUES

3 Installing Bushing. . Press bushing (1)


flush with seat (3)
of oil seal (2).

T59869N I J

l-Bushing 2-Oil Seal

Fig. 6-Installing Bushing

Litho in U.S.A.
34 Grading De vice JD670-A and JD672-A Motor Graders
3499-4 Specifications and Special Tools TM- 1188 (J&78)

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES

Blade Lift and Front Mounted Equipment 1 - Spring


Control Valves Free length . . . . . . ..~...~ 0.692 in. (17.6 mm)
Test length . . . . . . . . . . . . . . 0.625 in. (15.9 mm)
compressed with 0.75 t 0.1 Ibs.
(3.3 t 0.4 N) (0.34 + 0.04 kg)

2 - Spring
Free length . . . . . . . . . . . . . 0.939 in. (23.9 mm)
Test length . . . . . . . . . . . . 0.812 in. (20.6 mm)
compressed with 14.5 rt 1.5 Ibs.
T60292N (64.5 c 6.7 N) (6.6 rt 0.7 kg)

Fig. 7-8/&e Lift and Front Mounted Equipment 3 - Spring


Control Valves Free length . _. . . . . . . . .0.597 in. (15.2 mm)
Test length . . _. . . . . .0.531 in. (13.5 mm)
compressed with 1.250 r 0.1 tbs.
(5.56 k 0.44 N) (0.57 -?I 0.05 kg)

4 - Spring
Free length . . . . . . . . .1.717 in. (43.6 mm)
Test length . . . . . . . . . . 1.155 in. (29.3 mm)
compressed with 22.5 2 2.25 Ibs.
(100 & 10 N) (10.2 i 1.02 kg)

5 - Spool Plug (use Loctite). . . . . . 5 to 8 lb-ft


(7 to 11 Nm) (0.7 to 1 kg-m)

6 - Spool Screw (use Loctite) . _. _ 5 to 8 lb-ft


(7 to 11 Nm) (0.7 to 1 kg-m)

7 - Cap Assembly ... .. . . . . .50 to 55 lb-ft


(68 to 75 Nm) (7 to 8 kg-m)

Lifho in U.S.A.
JD670-A and JD672-A Motor Graders Grading De vice 34
TM- 1188 (J&78) Specifications and Special Tools 3499-5

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

Circle and Blade Side-Shift Control 1 - Spring


Valves Free length . . . . . . . .0.692 in. (17.6 mm)
Test length . . . .0.625 in. (15.9 mm)
compressed with 0.75 +- 0.1 Ibs.
(3.3 2 0.4 N) (0.34 r 0.04 kg)

2 - Spring
Free length . . _. .0.939 in. (23.9 mm)
Test length . . . . . . .0.812 in. (20.6 mm)
compressed with 14.5 * 1.5 tbs.
T60293N (64.5 k 6.7 N) (6.6 t 0.7 kg)

Fig. b-circle and Blade Side-Shift 3 - Spring


Control Valves
Free length 1.. . . . . . .0.597 in. (15.2 mm)
Test length . . _. . . . . . .0.531 in. (13.5 mm)
compressed with 1.250 ? 0.1 tbs.
(5.56 2 0.44 N) (0.57 t 0.05 kg)

4 - Spring
Free length . . .._ .1.595 in. (40.5 mm)
Test length . . . . . . . . .‘. .0.937 in. (23.8 mm)
compressed with 25 ?I 2.5 Ibs.
(111 ? 11 N) (11 ? 1 kg)

5 - Spool Plug (use Loctite). . . . . . . . :5 to 8 lb-ft


(7 to 11 Nm) (0.7 to 1 kg-m)

6 - Spool Screw (use Loctite) . . . . . 5 to 8 lb-ft


(7 to 11 Nm) (0.7 to 1 kg-m)

7 - Cap Assembly ... . . . . . . . . .50 to 55 lb-ft


(68 to 75 Nm) (7 to 8 kg-m)

Litho in U.S.A.
34 Grading De vice JD670-A and JD672-A Motor Graders
3499-6 Specifications and Special Tools TM- 1188 (J&78)

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

Blade Tilt Control Valve 1 - Spring


Free length . . . . . . . . . .0.939 in. (23.9 mm)
Test length . . . . . . . . . . .0.812 in. (20.6 mm)

Q lo& ($?$$g$ 2 _ ~~~~~ength, ,yy;;;;,yz

@jfJ$)Sg~ 0 Test length . : . . : : : : : : : : : : .0.625 in. (15.9 mm)


3 compressed with 0.75 + 0.1 tbs.
T60294N
(3.3 c 0.4 N) (0.34 t 0.04 kg)
Fig. 9-Blade Till Control Valve
3 - Spring
Free length . . . . . . . . . .0.597 in. (15.2 mm)
Test length . . . . . . . . . .0.531 in. (13.5 mm)
compressed with 1.250 i 0.1 Ibs.)
(5.56 + 0.44 N) (0.57 + 0.05 kg)

4 - Spring
Free length . . . . . . . . . . 1.595 in. (40.5 mm)
Test length . . ~. . . . . . . . . .0.937 in. (23.8 mm)
compressed with 25 t 2.5 Ibs.
(111 t 11 N) (11 + 1 kg)

5 - Spool Plug (use Loctite). . . . . 5 to 8 lb-ft


(7 to 11 Nm) (0.7 to 1 kg-m)

6 - Spool Screw (use Loctite) . . . . . . . 5 to 8 lb-ft


(7 to 11 Nm) (0.7 to 1 kg-m)

7 - Cap Assembly . . . . . . . . . . . . . . ,50 to 55 lb-ft


(68 to 75 Nm) (7 to 8 kg-m)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Grading De vice 34
TM-l 188 (Jul-781 SDecifications and SDecial Tools 3499-7

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

Blade Rotation Control Valve 1 - Spring


Free length . . . . . . . . .1.595 in. (40.5 mm)
Test length . . . .0.937 in. (23.8 mm)
compressed with 25 2 2.5 Ibs.
(111 + 11 N) (11 it 1 kg)
2- Spool Screw (use Loctite) . . . . . 5 to 8 lb-ft
(7 to 11 Nm) (0.7 to 1 kg-m)

3- Cap Assembly .. . . , . . .50 to 55 lb-ft


(68 to 75 Nm) (7 to 8 kg-m)
560295N

Fig. 7O-Blade Rotation Control Valve

Control Valve Assembly

1 - Orifice Plate . . . . . . . . . . . . . . . . Stamped 367


0.1405 in. (3.56 mm)

2- Orifice Plate . . . . . . . . . . . . . . Stamped 346


0.0785 in. (1.99 mm)

3 - Orifice Plate . . . . . . . . . . Stamped 340


0.0625 in. (1.59 mm)

4 - Orifice Plate . . . . . . . . . . . . . . . Stamped 361


0.1130 in. (2.87 mm)

5- Orifice Plate . . . . . . . . . . . . . . . . Stamped 343


0.0700 in. (1.98 mm)

6 - Tie Bolts . . . . . . . .20 to 25 lb-ft


@“to 34 k-t) (3 to 4 kg-m)
&
T60296N

Fig. I l-Orifice Plates and


Tie Bolts

Litho in U.S.A.
34 Grading De vice JD670-A and JD67.CA Motor Graders
Hydraulic Sysfem TM- 1188 (Jut-78)
3499-8

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

Circle Drive Motor To time motor, line up timing marks (2 and 3) with tip
of rotor tooth (1).

l'60297N

Fig. 12-Timing Motor

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Grading De vice 34
TM- 1188 (Jul-78) Specifications and Special Tools 3499-9

HYDRAULIC SYSTEM
TORQUE VALUES-Continued

1 - Cap Screws (use Loctite) . . . . 225 to 250 lb-in


(25 to 28 Nm) (2.6 to 2.9 kg-m)

2 - Cap Screws
Initial. . . . , . . 15 to 40 lb-in
(1.7 to 4.5 Nm) (0.17 to 0.46 kg-m)
Final (sequence Fig. 14) 175 to 200 lb-in
(20 to 23 Nm) (2.02 to 2.30 kg-m)

T60298N

Fig. 13-Circle Drive Motor Cap Screws

T60242N

Fig. 1CCap Screw Torque Sequence

Litho in U.S.A.
34 Grading Device JD670-A and JD672-A Motor Graders
3499-l 0 Specifications and Special Tools TM- 1188 (Jut-78)

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

Lift Arm Locking Pin 1 - Barrel I.D. . . . . . . . . . . . . . . . 2.998 + 0.002 in.


(76.82 + 0.05 mm)

2 - Pin O.D.. ......... .. 2.0000 & 0.0015 in.


(50.800 f 0.038 mm)

3 - Housing I.D. . . . . . . . . . . . 2.005 + 0.002 in.


(50.93 r 0.05 mm)
4 - Switch torque-. . . . . . . . . . . . . . . . . . . 40 lb-ft
(54.2 Nm) (5.5 kg-m)

5 - Clearance between locking pin housing


and milled pad on lift arm . . . . .0.06 to 0.12 in.
(1.5 to 3.0 mm)

V
‘59654N

Fig. 15-Locking Pin

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Grading De vice 34
TM- I 188 (J&78) Specifications and Special Tools 3499-11

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

Rotary Manifold

1 - Manifold body I.D. ... . 3.6260 + 0.0015 in.


(92.10 + 0.04 mm)

T38202N

Fig. l&Manifold Body

1 - Manifold spool O.D. ..... 3.6210 r 0.0015 in.


(91.97 + 0.04 mm)

T38203N
FIQ. 17-Manifold Spool

Litho in U.S.A.
34 Grading Device JD670-A and JD672-A Motor Graders
3499-12 Specifications and Special Tools TM- I 188 (J&78)

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

Crossover Relief Valve 1 - Inner Spring


Free length . . . . . . . . . . . . . . 1.14 in. (29 mm)
Test length . . . . . . . . . . . . . 0.84 in. (21.9 mm)
compressed with 6.5 f 0.76 Ibs.
(28.9 -c 3.4 N) (2.9 + 0.3 kg)

2 - Outer Spring
Free length .,“.......... 1.20 in. (30.5 mm)
Test length . . . . . . . . . . . . . 1.00 in. (25.4 mm)
compressed with 42 * 4.2 Ibs.
(186.8 r 18.7 N) (19 + 1.9 kg)

Fig. I&Crossover Relief Valve Springs

Blade Lift Cylinder


1 - Cylinder bore . . . . . 3.246 to 3.250 in.
(82.44 to 82.55 mm)

2 - Rod diameter .. ... 1.9985 to 2.0015 in.


(50.76 to 50.84 mm)

3 - Cylinder stroke . .. . . 44.88 + .12 in.


- (1 139.9 + 3 mm)
T38208N

Fig. 1943lade Lift Cylinder 4 - Rod guide torque.. . . . 250 to 300 lb-ft
(339 to 407 Nm)
(35 to 42 kg-m)

5 - Set screw torque . . . . . . . . . . . . . . . . 40 lb-in


(4.5 Nm)
(0.46 kg-m)

6 - Stop nut torque .... , . 475 to 575 lb-ft


(644 to 780 Nm)
(66 to 79 kg-m)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Grading De vice 34
TM- I 188 (Jul- 79) Specifications and Special Tools 3499-I 3

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

Circle Side-Shift Cylinder

3 1 - Cylinder bore . . . . . . . . . . . . 3.496 to 3.500 in.


(88.80 to 88.90 mm)

2- Rod diameter .. . . . 1.7485 to 1.7515 in.


(44.46 to 44.54 mm)

3 - Set screw torque . . . . . . . . . . . . . . . . . . . . 40 lb-in


T38207.V o !J (4.5 Nm)
(0.46 kg-m)
Fig. 20-Circle Side-Shift Cylinder

4 - Rod guide torque.. . . . . . 250 to 300 lb-ft


(339 to 407 Nm)
(35 to 42 kg-m)

5 - Cylinder stroke ... . . . . . 26.21 t 0.12 in.


(665.5 -+ 3.0 mm)

6 - Stop nut torque ... . . 475 to 575 lb-ft


(644 to 780 Nm)
(66 to 79 kg-m)

Blade Tilt Cylinder

1 - Cylinder bore . . . . , 3.996 to 4.000 in.


“i;&.50 to 101.60 mm)

2 - Rod diameter . . 1.7485 to 1.7515 in.


(44.41 to 44.49 mm)

3 - Set screw torque . . . . . . . . . . . . . . . . 40 lb-in

T38206N

Fig. Pl-Blade Tilt Cylinder


4 - Rod guide torque.. . .. .. 250 to 300 lb-ft
(339 to 407 Nm)
(35 to 42 kg-m)

5 - Cylinder stroke . . . . . . .6.89 +- 0.12 in.


(175.0 * 3.0 mm)

6 - Stop nut torque . . . 600 to 700 lb-ft


(813 to 949 Nm)
(83 to 97 kg-m)

Litho in U.S.A.
34 Grading Device JD670-A and JD672-A Motor Graders
3499-14 Specifications and Special Tools TM- 1188 (Jul- 79)

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

Blade Side-Shift Cylinder

1 - Cylinder bore . . .. . . 3.6854 to 3.6934 in.


(93.611 to 93.811 mm)

2 - Rod diameter . . . .. . 1.4930 to 1.4960 in.


(37.957 to 37.965 mm)

T38204N 4
J J 3 - Rod guide torque.. . . . . . . . . 250 to 300 lb-ft
'4
(339 to 407 Nm)
Fig. 22-Blade Side-Shift Cylinder (35 to 42 kg-m)

4- Set screw torque .. .. .40 lb-in


(4.5 Nm)
(0.46 kg-m)

5 - Cylinder stroke.. .. .. . .26.91 in.


(683.5 mm)

1 - Clearance between retaining


pin and piston rod pin hole
outside edge. .. .. . . . .0.25 in. (6.8 mm)

T38205N

Fig. 23-Blade Side-Shift Cylinder


f?etaining
PinClearance

GRADING DEVICE FRAMES


I
SPECIAL TOOLS

EZI
’ Convenience Tool
Tool Tool Number Use

D-051 25ST To tighten saddle ear cap


screws

T66329
Fig. 24-Torque Multiplier

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Ground Conditioning Tools 42
TM- 1188 (Jul-78) Teeth and Shanks. 4201-l

Section 42
GROUND CONDITIONING TOOLS
CONTENTS OF THIS SECTION

Page Page
GROUP 4201 - TEETH AND SHANKS GROUP 4260 - HYDRAULIC SYSTEM
Scarifier Front and Rear Mounted Equipment Valves
General Information .............. 4201-3 General Information . .. . 4260-l
Removal ........................ 4201-3 Removal .......... 4260-l
Repair .......................... . 4201-3 Repair ............ 4260-2
Installation. ...................... 4201-3 Installation. ........ b260-10
Ripper Cylinders
General Information .............. . 4201-4 General Information . 4260-l 1
Removal ........................ . 4201-4 Removal .......... 4260-l 1
Repair .......................... 4201-4 Repair ............ . 4260-l 2
Installation. ...................... . 4201-4 Installation. ........ 4260-l 5

GROUP 4215 - CONTROLS LINKAGE GROUP 4299 - SPECIFICATIONS AND


Scarifier SPECIAL TOOLS
General Information . . . .. . 4215-1 Specifications and Torque Values
Removal . .. . . . 4215-1 Hydraulic System .. . . . . 4299-l
Repair . . . . 4215-l Special Tools
Installation. . . . . . . 4215-1 Hydraulic System . . . .. . .. 4299-4

GROUP 4240 - FRAMES


Scarifier
General Information .. 4240-l
Removal . . .. . 4240-l
Repair . . 4240-l
Installation. . . . 4240-l
Ripper
General Information . .. 4240-4
Removal . .. . . 4240-4
Repair .. .. . 4240-5
Installation. ... . 4240-5

Litho in U.S.A.
42 Ground Conditioning Tools JD670-A and JD672-A Motor Graders
4201-2 Teeth and Shanks TM- I 188 (J&78]

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Ground Conditioning Toots 42
TM- 1188 (J&78) Teeth and Shanks 4201-3

Group 4201
TEETH AND SHANKS
SCARIFIER
General Information Replace worn tips by driving out groove pins with a
punch. Drive tip from the shank.
The scarifier is equipped with l-1 /4 x 4 inches (32 x
102 mm) shanks. Maximum depth is 12 inches (305
Install new tips by tapping onto the shank until tight.
mm) with alternate positions of IO inches (254 mm)
Insert groove pin in shank.
and 9.0 inches (229 mm) deep.
Installation
Five shanks and tip assemblies are furnished as
standard equipment. Up to nine shanks may be used.
The shanks may be stored upside down in the shank
holes when the scarifier is not in use.

See Group 9030 for adjustment of heavy-duty tooth


shanks.

Removal
Raise scarifier to position shanks off the ground.

A CAUTION: Whenever working under F@. PShank Lock

raised scarifier, chain or block to prevent


accidental lowering of scarifier beam. Insert tooth shanks from the underside of the scari-
fier frame. Secure the tooth shank in the desired posi-
Remove shank retainers or locks from shanks and tion by inserting the shank lock (Fig. 2) behind the tooth
pull shanks down and away from the scarifier frame. as shown.

Repair

P58767N

I-Shank Lock &-Tooth Shank


a-Tooth Tip 5-Shank Lock Spring
3-Groove Pin 6-Cap Screw and Lock
Was her

Fig. 1-Scarifier Shank

Litho-in U.S.A.
42 Ground Conditioning Tools JD670-A and JD672-A Motor Graders
4201-4 Teeth and Shanks TM- 1188 (Jul-78)

RIPPER

General Information Repair


Three teeth are furnished with the optional equip-
ment ripper-up to five may be used. Pins hold the
teeth in position with two positions possible.

A 14-inch (356 mm) working depth is available when


pin is in upper shank hole. The lower shank hole
position is intended to store shank for greater rear
clearance during non-ripping operations.

See Group 9030, for adjustment of teeth.

Removal
358768N
Raise ripper to position teeth off the ground.
l-Shank !&Cap Screw
If ripper teeth only are to be replaced, ripper shanks Z&Tooth Pin 6-Lock Washer
3-Ripper Tooth 7-Hex Nut
may be left in ripper beam.
4-Pin

A CAUTION: Whenever working under


raised ripper beam, chain or block to pre-
Fig. 3-Ripper Tooth

vent accidental lowering of ripper beam. Replace tooth tips by driving out tooth pin and
driving the tooth fromthe shank with a punch. Drive the
Remove pins and pull shanks down and away from new tooth on the shank and secure with tooth pin.
the ripper.
Installation
Insert the tooth shanks from the underside of the
ripper frame. Secure with pin in desired position.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Ground Conditioning Tools 42
TM- 1188 (J&78) Controls Linkage 4215-1

Group 4215
CONTROLS LINKAGE
GENERAL INFORMATION REMOVAL
The ripper control is an electric switch (2, Fig. 1). For
servicing of this switch refer to Group 1675.
Scarifier Valve Linkage
Unfasten coupler link (4, Fig. 2).
The scarifier control valve is located on the left side
of the nine section control valve (1, Fig. 1). It is ac- Remove cap screw (7), washer (6) and pin (5).
tivated by lever (3, Fig. 1) and linkage (Fig. 2).
Lift out lever assembly (2).

l--Bushing 5-Pin
2-Scarifier Lever 6-Washer
with Bushing 7-Gap Screw
3-Knob 8-Scarifier Control
4-Coupler Link Valve

Fig. PScarifier Linkage

REPAIR
Inspect parts and replace as necessary.

INSTALLATION
Slide pin (5, Fig. 2) through lever assembly (2).

Align pin (5) on control console and install washer


(6) and cap screw (7).

Install coupler link.

1-Scarifier Valve 3-Scarifier Lever


2-Ripper Control

Fig. i-Scarifier Control Valve

Litho in U.S.A.
42 Ground Conditioning Tools JD670-A and JD672-A Motor Graders
42152 Controls linkage TM- 1188 (Jul- 78)

bitho in U.S.A.
lJD670-A and JD672-A Motor Graders Ground Conditioning Tools 42
FM- 1188 (J&78) Frames 4240-l

Group 4240
FRAMES
GENERAL INFORMATION REMOVAL
There are two types of scarifiers available, a normal Lower scarifier to the ground. Support assembly with
service, Fig. 1, and a heavy duty, Fig. 2. Service a chain hoist.
procedures for both are covered.
Relieve hydraulic pressure in the lift cylinder by
operating auxiliary lever.

Remove cylinder pin, boom pin and upper link re-


taining hardware (See Fig. 1).

Fig. 1-Normal Service Scarifier

l-Boom Pin 2-Upper Link Retaining Hardware

Fig. P-Heavy Duty Scarifier

REPAIR
Refer to Fig. 3 during disassembly and assembly of
the normal service scarifier. Refer to Fig. 4 when
disassembling and assembling the heavy duty scari-
fier. Replace parts as necessary.

See Group 4201 for repair of shanks or teeth.

INSTALLATION
Use reverse of removal procedure to install scarifier.
Lubricate all fittings.

Litho in U.S.A.
42 Ground Conditioning Tools JD670-A and JD672-A Motor Graders
4240-2 Frames TM- 1188 (J&78)

T58387F

1-Scarifier 4-Washer 7-Lower Link


2-Pin 5-Boom .8-Gap Screw
3-Link 6-Cotter Pin 9-Lock Pin

Fig. 34Vormal Service Scarifier

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Ground Conditioning Tools 42
TM- 1188 (J&78) Frames 4240-3

T57720F

l-Left Mount 4-Pin 7-Lock Nut


a-Bushing !i-Scarifier 6-Grease Fitting
3-Arm 6-Cap Screw g+oom
10--Heavy-Duty Scarifier

Fig. 4-Heavy-Duty Scarifier

Litho in U.S.A.
42 Ground Conditioning Tools JD670-A and JD672-A Motor Graders
4240-4 Frames TM- 1188 (Jut-78)

RIPPER
General Information Leaving the linkage mount frame attached to the
grader also provides protection for the lower power unit
The ripper is used to operate in rocky and hard
during non-ripping periods also.
ground conditions. The ripper is used when surface
conditions are too severe for scarifier use.
For complete ripper removal, remove front pins of
upper link and lower linkage from linkage frame (see
Ripper functions are controlled by the auxiliary
Fig. 3). Remove hydraulic hoses with same cautions as
switch.
noted at left. Leave cylinder attached to ripper beam
and lower linkage.
Up to five tooth shanks may be inserted in two
different depth positions on the ripper frame. A sym-
metrical location of shanks should be used to balance
the draft loads on the grader.

A rear drawbar is provided on rear of ripper beam.

Removal
Lower ripper until tooth tips are resting on the
ground.

Support ripper with a chain hoist.

A CAUTION: Shut off the engine before dis-


connecting the hydraulic lines to the rip-
per. If the engine is left running the operator may
be sprayed with hot hydraulic oil. l-Upper Link Pins 2-Lower Linkage Pins

Fig. 3-Ripper Mounting Pins


Relieve all hydraulic system pressure before dis-
connecting hydraulic lines.
Carefully drive the grader from the ripper.

Disconnect the cylinder hoses from the ripper at the


Lower ripper beam and linkage to the ground.
rear valve and connect hoses together or cap ends and
plug valve ports.
Block or place floor jacks under linkage frame. Re-
move linkage frame to engine frame cap screws. Re-
The rear valve may be left on the grader.
move final drive housing to linkage frame cap screws.

If the rear valve is removed, plug hoses. Wire hoses


and wire harness to the motor grader so they do not
drag on the ground during operations.

For periods when the grader is operated without the


ripper, it is suggested to remove only the front pins on
both the upper and lower linkage and leave the linkage
mount frame attached to the grader. This procedure
shortens the removal and installation time and only the
hydraulic hoses between the rear valve and ripper
cylinder are disconnected.

bitho in U.S.A.
JD670-A and JD672-A Motor Graders Ground Conditioning Tools 42
TM- 1188 (Jul-78) Frames 4240-5

ReDair
.

l’59167N

l-Mounting Frame 6-Grease Fitting il-Lower Linkage


2-Washer ‘I-Cap Screw 12-Ripper
3-Gap Screw &Washer 13-Cap Screw
4-Washer g--Nut M-Pin
5-Cap Screw lo--Pin 15-Upper Link

Fig.4-Ripper

Installation The hose from the rod end of the cylinder connects
to port located on the right corner stamped “A’.
Support ripper in upright position with chain hoist.
The head end of the cylinder hose connects to the
Carefully back the motor grader to align the linkage. work port on the left side of the vehicle stamped “B”.

Attach upper links and lower linkage.

Grease all fittings before resuming operation.

Litho in U.S.A.
42 Ground Conditioning Tools JD670-A and JD672-A Motor Graders
4240-6 Frames TM- 1188 (J&78)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Ground Conditioning Tools 42
TM- 1188 (Dee-87) Hydraulic System 4260-l

Group 4260
HYDRAULIC SYSTEM
FRONT AND REAR MOUNTED EQUIPMENT
FRONT MOUNTED EQUIPMENT VALVE NOTE: Each poppet valve adjusting screw is set at
the factory to provide the cycle times shown in
The front mounted equipment valve is part of the
Group 9025. Do not turn screw out past flush with
function control valve stack. Refer to Group 3460 for
special plug.
general information, removal, repair, and installation
of this valve. The front mounted equipment valve is of
The poppet valve assemblies can be removed
the same construction as the blade lift valve.
individually from the valve housing for repair without
removing the valve housing from the unit.
REAR MOUNTED EQUIPMENT VALVE
Removal
General Information

A
CAUTION: Escaping fluid under pressure
The rear mounted equipment valve is located right
can have sufficient force to penetrate the
in front of the rear bumper.
skin, causing serious personal injury. Before dis-
connecting lines, be sure to relieve all pressure.
The valve contains one deluxe poppet valve to
Before applying pressure to system, be sure all
raise the rear mounted equipment and one standard
connections are tight and that lines, pipes and hoses
poppet valve to lower rear mounted equipment. The
are not damaged. Fluid escaping from a very small
deluxe poppet valve is in the bore next to the valve
hole can almost be invisible. Use a piece of card-
work ports.
board or wood, rather than hands to search for,
suspected leaks.
The difference between the standard and the deluxe
poppet valves is that the deluxe poppet valve has a
If injured by escaping fluid, see a doctor at once.
snubber sleeve and a load check poppet. The snubber
Serious infection or reaction can develop if proper
sleeve and load check poppet protect the hydraulic
medical treatment is not administered immediately.
system from pressures exceeding system pressure
when the ripper is under heavy load.
Lower rear mounted equipment.

The poppet valves are operated by electric


Relieve pressure in hydraulic system by operating
solenoids. The solenoids are energized by a switch
the steering valve, brake valve and ripper electric
located in the operator’s compartment.
controls with engine shut off and key switch on.

Each poppet valve has an adjusting screw located


NOTE: Valve assembly does not have to be removed
in the special plug section of the poppet valve assem-
from unit to remove poppet valve assemblies.
blies to reduce or speed up function speed. Turning
the adjusting screw in will slow the function down
Remove bumper housing cover panel and rear
and turning the adjusting screw out will speed the
bumper.
function up.
Disconnect, mark and cap hoses to valve. Remove
valve from unit

Litho in U.S.A.
42 Ground Conditioning Tools JD670-A and JD672-A Motor Graders
4260-2 Hydraulic System TM- 1188 (Jul-78)

Repair Remove special plug from the valve.

Remove valve cover.

Disconnect the solenoid spring from the electrical


wire.

lnsert a 3/16 in. Allen wrench into the hole (1, Fig. 1)
into the bottom of the poppet valve assembly and
unscrew poppet valve assembly from solenoid. Hold
solenoid by frame when unscrewing poppet valve.
Remove solenoid from valve.

Using Special Tool JD304 (see Special Tools in


l-Allen Wrench Hole 2-Special Plug Group 4299), drive poppet valve assembly out of valve
housing.
Fig. l-Special Plug Removed

Z58779N

l-standard Poppet Valve 6-Sealing Ring 14-Solenoid (2 used)


Assembly 7-Wiring Harness 16-Gasket
2-Deluxe Poppet Valve &Was her 1 Cover
Assembly g-Retainer Plate 17-Lock Washer (6 used)
3-Valve Body l&-Cap Screw (2 used) l&Cap Screw (6 used)
ATo Haad End of 11-O-Ring (2 used) 19-Nylon Block
Rear Mounted 12-Solenoid Valve Seat 2GNylon Screw (2 used)
Equipment Cylinder (2 used) Pi-Spring (2 used)
~--TO Rod End of Rear Mounted 13-Solenoid Valve Stem 22-Screw (2 used)
Equipment Cylinder (2 used)

Fig. P-Rear Mounted Equipment Valve

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Ground Conditioning Tools 42
TM- I 188 (Jul- 78) Hydraulic Sys tern 4260-3

Disassembly of Standard Poppet


Valve

NOTE: You must use special tool JD296 Retainer


Ring Crimping Tool to compress all retainer rings used
in valve assembly. Regular pliers should not be used
because they tend to burr ring surface, causing valve
failure.

Remove return seat (23, Fig. 5).

I-Valve Liner !%Spring


P-Valve Shaft GMetering Ring
3-Seal Retainer (2 used) 7-Return Poppet
4-O-Ring &Backup Rings (2 used)

Fig. 4-Valve Shaff Removed

l-Retaining Ring 3-Shim


a---Retainer 4-Pressure Poppet Pull valve shaft assembly out of valve liner.

Fig. 3-Pressure Poppet Removed Push down on the return poppet (7, Fig. 4) and
remove retaining ring (7, Fig. 5), return poppet (7, Fig.
Push down on the retainer (2, Fig. 3) and remove 4) and spring (5, Fig. 4) from valve shaft (2).
retaining ring (l), retainer (2), shims (3) and pressure
poppet (4). Replace the O-ring and backup washers inside the
return poppet before reassembling the valve poppet
NOTE: When removing the pressure poppet (4), the assembly.
O-ring and backup washers inside the pressure poppet
will be damaged because of the sharp edge on the To replace the backup rings (8, Fig. 4), O-ring (4)
retaining ring groove. Replace the O-ring and backup and seal retainers (3), remove t*he retaining rings (one
washers before reassembling the pressure poppet. on each side of seal retainer) and slide the parts off the
valve shaft. Replace retaining rings with new ones.

Litho in U.S.A.
42 Ground Conditioning Tools JD670-A and JD672-A Motor Graders
4260-4 Hvdraulic Svstem TM- 1188 (Jut-78)

T”58781N
l-Backup Ring g-Shim (as required) 17-Valve Shaft
2-O-Ring lO-Orifice Ring l8-Seal Retainer (2 used)
J-Adjusting Screw 1 l-Pressure Poppet W-Backup Ring (2 used)
4-Rectangular Packing 12-O-Ring (2 used) 28-O-Ring
!i-Special Plug 13-Backup Ring (3 used) Pl-Return Poppet
GSpring 14-Rectangular Packing 22-Metering Ring
7-Retaining Ring (4 used) 18-Valve Liner 23-Return Seat
8-Retainer 18-Rectangular Packing 24-Rectangular Packing
25--Spring

Fig. 5-Standard Poppet Valve Assembly

NOTE: /terns 7, 2, and 3, Fig. 6 are not service To disassemble the solenoid, unscrew the seat (6,
items. Fig. 6) and remove parts from solenoid.

Inspect the seat (6) and stem (5) seating areas for
nicks or scratches. Replace as necessary.

To check the spring (2), install the spring and


plunger (3) into the solenoid housing (1). Now press on
the plunger. It should take IO to 13 Ibs. (45 to 66 N)
(4.5 to 5.9 kg) of force to push plunger even with
outside edge of plunger bore. If it takes less force
replace solenoid assembly (4).
l-Solenoid Housing 4-Solenoid Assembly
2-Spring 8-Stem
3-Plunger 8-Seat

Fig. &Solenoid Assembly

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Ground Conditioning Tools 42
TM- 1188 (Mar-80) Hydraulic System 4260-5

Inspecting Standard Poppet Valve Assembling Standard Poppet Valve


Assembly
NOTE: Use new O-rings, packings, retaining rings
IMPORTANT: Inspect the seating surface on the and backup washers before reassembling the valve
pressure poppet (11, Fig. 5) and the valve liner (15) poppet. Dip O-rings and packing into oil before as-
for nicks and scratches. Replace parts if a nick or a sembling.
scratch is evident. Inspect the sealing surface of
the return seat (23) and the return poppet (21) for NOTE: You must use special fool JD-296 Reiainer
nicks and scratches. Replace parts if any nick or Ring Crimping Tool to compress all retainer rings used
scratch is evident. in v%ve a&&mbly. Reg&r pliers should nof be used
because they tend to burr ring surface, causing valve
Check spring (6, Fig. 5) failure.
Free length.. . . . . . . .1.55 in. (39.4 mm)
Test length . . 1.28 in. at 14 f 1.5 Ibs. force Install metering ring (5, Fig. 7) on return poppet.
(32.5 mm at 62 ? 7 N)
Position spring (25, Fig. 5) and return poppet (21) on
Check spring (25, Fig. 5) valve shaft (17). Push return poppet down and install
Free length.. . . . . . . . . . . .1.15 in. (29.2 mm) retaining ring (7).
Test length . . . . . 0.39 in. at 9.5 -c 2 Ibs. force
(10 mm at 42 + 9 N) Slide valve assembly into valve liner and install
pressure poppet (4, Fig. 3), shims (same amount as
removed) and retainer (2).

Install orifice ring (10, Fig. 5) on pressure poppet (4,


Fig. 3).

(23. Fig.
Install the return seat (23, Fia. 5) on the valve shaft.

l-Valve Liner 4-Return Seat


2-Orifice Ring 5-Metering Ring
3-Pressure Poppet GReturn Poppet

Fig. 7-Valve Poppet Seating Surfaces

Inspect the metering ring (5, Fig. 7) on the return


poppet (6), orifice ring (2) on the pressure poppet (3) Fig. &Refainer Flush with End of Valve Shaft
for wear grooves, nicks or broken edges. Replace as
necessary. Slide valve shaft toward return poppet end and
check to see if outside edge of retainer is flush with end
of valve shaft (end with the “hex.” hole). If it is not, add
or deduct shims as required. After obtaining the proper
shimming, remove one shim and install retaining ring
(1, Fig. 3).

Litho in U.S.A.
42 Ground Conditioning Tools JD670-A and JD672-A Motor Graders
4260-6 Hydraulic System TM- 1188 (Mar-80)

Check the gap between the valve liner and return Disassembly of Deluxe Poppet Valve
seat (Fig. 9) for a measurement of 0.010 to 0.030 in.
NOTE: You must use JD296 retainer ring crimping
(0.25 to 0.76 mm). If measurement is not within speci-
tool to compress all retainer rings used in valve as-
fication, readjust shim pack.
sembly. Regular pliers should not be used because
they tend to burr the surfacing of the ring, causing
This can be checked by inserting shims between
valve failure.
valve liner and return seat. If one but not two shims
slide in between liner and return seat, then gap is
Remove return seat (30, Fig. 13).
correct.

q
1 ‘” .\-.

l-Retaining Ring 3-Shim


2-Retainer 4-Pressure Poppet

Fig. 1O-Pressure Poppet Removed

Push down on the retainer (2, Fig. 10) and remove


retaining ring (l), retainer, shims (3) and pressure
wwet (4).

NOTE: When removing the pressure poppet (4) fhe


O-ring and backup washers inside the pressure poppet
will be damaged because of the sharp edge on the
retaining ring groove. Replace the O-ring and backup
washers before reassembling the pressure poppet.

Pull valve shaft assembly out of valve liner.

l-Proper Gap If snubber sleeve and load check poppet do not


come out with the shaft, make certain load check
Fig. B-Clearance Between Liner and Seal poppet is aligned with the opening in the snubber
sleeve and use brass drift to tap parts out.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Ground Conditioning Tools 42
TM- 1188 (J&78) Hydraulic System 4260-7

Remove load check poppet (1, Fig. 1 l), spring (2) Inspection of Deluxe Poppet Valve
and snubber sleeve (3) from deluxe poppet valve shaft
IMPORTANT: Inspect the seating surface on the
assembly.
pressure poppet (3, Fig. 12) and the valve liner (1)
for nicks and scratches. Replace parts if a nick or a
NOTE: When removing the load check poppet (I),
scratch is evident. Inspect the seating surface of
the O-ring and backup washers inside the poppet will
the return seat (4) and the return poppet (5) for
be damaged because of fhe sharp edge of the retain-
nicks and scratches.
ing ring groove. Replace the O-ring and backup
washers before reassembling the load check valve.
Inspect load check poppet for nicks and scratches.

Replace parts if any nick or scratch is evident.

Inspect the orifice ring (2) on the pressure poppet (3)


and the orifice ring (6) on the snubber sleeve (deluxe
model only) for wear grooves, nicks or broken edges.
Replace as necessary.

Insert snubber orifice ring (6, Fig. 13) into valve liner.
With feeler gauge, measure gap. It should be 0.004 to
0.012 in. (0.10 to 0.30 mm).

l-Load Check Poppet 7-Spring


2-Spring 8-Return Poppet
3-Snubber Sleeve g-Retaining Ring
4-Orifice Ring lO-Deluxe Poppet Valve
!&Seal Retainer Shaft Assembly
(2 used) 1 l-Backup Washers
6-O-Ring (2 used)

Fig. 17-Valve Shaft Assemblies

Push down on the return poppet (8) and remove


retaining ring (9), return poppet (8) and spring (7) from
valve shaft.
I-Valve Liner 5-Return Poppet
2-Orifice Ring 6-Orifice Ring
Replace the O-ring and backup washers inside the 3-Pressure Poppet 7-Snubber Sleeve
return poppet before reassembling the valve poppet 4-Return Seat
assembly.
Fig. 72-Poppet Valve Seating Surfaces

To replace the backup washers (1 i), O-ring (6) and


seal retainers (5), remove the retaining rings and slide
the parts off the valve shaft.

Refer to Standard Poppet Valve Disassembly for


repair and inspection of solenoid.

Litho in U.S.A.
42 Ground Conditioning Tools JD670-A and JD672-A Motor Graders
4260-8 Hydraulic Sys tern TM- 1 I88 (Jul-78)

l’58783N

l-Adjusting Screw O-Shim (as required) 17-O-Ring 26-GRing


2-Backup Ring 18-Orifice Ring 18--Rectangular Packing 2CValve Shaft
3-O-Ring 1 l-Pressure Poppet 19-Load Check 27-Spring
4-Rectangular Packing 12-Backup Ring (4 used) 28-Spring P&-Return Poppet
6--Special Plug 13-O-Ring (3 used) Pi-Snubber Sleeve 29-Metering Ring
6-Spring 14-Rectangular Packing 22-Snubber Orifice Ring 39-Return Seat
7-Retaining Ring (4 used) 1CValve Liner 23-Seal Retainer (2 used) 31-Rectangular
8-Retainer 16-Backup Ring (2 used) 24-Backup Ring (2 used) Packing

Fig. 13-Deluxe Poppet Valve Assembly

Check spring (6, Fig. 13)


Free length.. . . . . . . . . .1.55 in. (39.4 mm)
Test length . . . . . . . 1.28 in. at 14 + 1.5 lb.
(32.5 mm at 62 t 7 N) (32.5 mm at 6.3 + 0.7 kg)

Check spring (27, Fig. 13)


Free length. . . . . . . . .1.15 in. (29.2 mm)
Test length . . . . . .0.39 in. at 9.5 ? 2 lb.
(10 mm at 42 & 9 N) (10 mm at 4 I 0.9 kg)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Ground Conditioning Tools 42
TM- 1188 (Mar-80) Hydraulic System 4260-9

Assembly of Deluxe Poppet Valve Check the gap between the valve liner and return
seat (Fig. 15) for a measurement of 0.010 to 0.030 in.
NOTE: Replace O-rings, packings, retaining rings
(0.25 to 0.76 mm). If measurement is not within speci-
and backup washers before reassembling the valve
fication, readjust shim pack.
poppet. Dip O-rings and packings into oilbefore as-
sem b/y.
This can be checked by inserting shims between
valve liner and return seat. If one but not two shims
NOTE: Use special tool JD-296 Retaining Ring
slide in between liner and return seat, then gap is
Crimping Tool to compress all retainer rings used in the
correct.
valve assembly. Regular pliers should not be used
because they tend to burr ring surface, causing valve
failure.

Position spring (27, Fig. 13) and return poppet,(28)


on valve shaft. Push return poppet down and install
retaining ring (7).

Slide snubber sleeve (21), spring (20) and load


check poppet (19) on valve shaft.

Slide valve shaft assembly into valve liner and install


pressure poppet (11, Fig. 13), shims (9) (same amount
as removed) and retainer (8).

Install orifice ring (10) on pressure poppet.

Install the return seat (30) on the valve shaft.

l-Proper Gap

fig. 15Clearance Between Liner and Seat

F;g. WRetainer Flush with End of Valve Shaft

Slide valve shaft toward return poppet end and


check to see if outside edge of retainer is flush with end
of valve shaft (end with the “hex” hole). If it is not, add
or deduct shims as required. After obtaiiing the proper
shimming, remove one shim and install retaining ring
(7, Fig. 13).

Litho in U.S.A.
42 Ground Conditioning Tools JD670-A and JD672-A Motor Graders
4260-10 Hydraulic Sys tern TM- 1188 (Mar-80)

Installing Poppet Valve Assembly NOTE: Make sure the spring is not touching the
In Housing metal frame on the solenoid.

Coat the poppet valve and valve poppet bore in the


IMPORTANT: Adjust old or new solenoid by
housing with a light film of oil.
loosening nut on solenoid and turning adjusting
If troubleshooting indicates a possible problem in screw in until it bottoms out, then back out l/2 to
pilot area of valve, check orifice ring gap (10, Fig. 13 or 5/8 turn and tighten nut to 230 lb-in (26 Nm) (2.6
10, Fig. 5). To check orifice ring, remove orifice ring kg-m).
and place to a point just below the holes in the special
plug. Use feeler gauge and check orifice ring gap for a Install cover and gasket and tighten cap screws.
reading of 0.091 to 0.105 in. (2.3 to 2.7 mm).
Replacing Wire Harness
NOTE: When installing poppet valve assemblies by
using special tool, check to be sure return seat is tight Remove retainer plate (9, Fig. 2).
against housing.
Note location of black and white wires.
When installing special tool with valve on its side,
locate pressure poppet orifice ring to top of bore to Remove nylon screws and pull wire harness out of
prevent ends of ring from catching on end of tool.
valve.
Install poppet valve assembly into the housing as far
as it will go. Then with a twisting motion, carefully insert Install a new packing in the harness opening in the
special tool JD-340 into the housing. Drive in the valve housing.
special tool just hard enough to seat valve in top of the
bore. Do not use more force than is necessary as valve Install new wire harness in valve.
may be damaged.
Install washer and retainer plate (9, Fig. 2).
Remove special tool from valve housing.

Apply John Deere Loctite Thread Lock and Sealant, Fasten wire leads and solenoid springs to nylon
High Strength, or an equivalent to the threads of the block with nylon screws.
solenoid valve seat.
INSTALLATION
Install a 3/16 in. Allen wrench into the hole in the
valve shaft and screw the solenoid on the other end of Rear Mounted Equipment Valve
the valve shaft. Hold solenoid by frame while tighten- Install valve and tighten valve-to-retainer plate cap
ing. Tighten to 150 lb-in (17 Nm) (1.7 kg-m).
screws.
Install special plug and spring. Tighten plug with 90
lb-ft (122 Nm) (4 kg-m). Connect hoses and wire harness to the valve.

IMPORTANT: The hex. portion of the cap is Start up unit and check for leaks at the valve.
sealed with Loctite and has left-hand threads.
Tightening over the recommended 90 lb-ft (122 Install rear bumper and grille screen.
Nm) can break the Loctite seal or valve body and
cause problems in properly tightening the cap.

Fasten spring and electrical wire to nylon block


inside the valve.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Ground Conditioning Tools 42
TM- 1188 (Jul-78) Hydraulic S ys tern 4260-l 1

CYLINDERS
GENERAL INFORMATION
The hydraulic cylinders used on the grader are
double acting and use ‘V-packing type seals on their
pistons. Piston rods are heat treated, chrome plated,
and polished. Replaceable non-metallic wear rings are
used on piston to prevent scoring of the cylinder bar-
rels.

See “Hydraulic Cylinders” in FOS Manual -


HYDRAULICS for additional information on
cylinders.

REMOVAL

A CAUTION: Escaping fluid under pressure


can have sufficient force to penetrate the
skin, causing serious personal injury. Before dis-
connecting lines, be sure to relieve all pressure.
Before applying pressure to system, be sure all
connections are tight and that lines, pipes and
hoses are not damaged. Fluid escaping from a very
small hole can almost be invisible. Use a piece of
cardboard or wood, rather than hands, to search
for suspected leaks. l-Retaining Plate

Fig. 76-Front Mounted Equipment


If injured by escaping fluid, see a doctor at once.
Serious infection or reaction can develop if proper
Remove cover from front of main frame.
medical treatment is not administered immediate-
ly.
Disconnect, mark and cap hoses from cylinder.
Front Mounted Equipment
Remove pin retaining plate (1, Fig. 16) and drive pin
Lower front mounted equipment to the ground. from head end through holes on side of main frame.

Relieve pressure in hydraulic system by operating Remove pin from rod end and remove cylinder from
steering valve, brake valve with engine not running. unit.

Place front mounted valve control in float position.

Litho in U.S.A.
42 Ground Conditioning Tools JD670-A and JD672-A Motor Graders
4260-l 2 Hydraulic Sys tern TM- 1188 (J&78)

Rear Mounted Equipment Cylinder Lower rear mounted equipment to the ground.

Relieve pressure in hydraulic system by operating


steering valve, brake valve and rear mounted equip-
ment electric controls with key switch ON and engine
not running.

Disconnect, mark and cap hoses from cylinder.

Remove cap screws from retaining pins and remove


retaining pins from rod and head ends of cylinder.
Remove cylinder from unit.

REPAIR
If cylinder packings have failed, some fragments of
the deteriorated parts may have entered the system.
Replace the filter.

Fig. 17-Rear Mounted Equipment Cylinder

T58784N

l-Grease Fitting (2 used) 7-Piston Retainer 13-Wear Ring


a--Bushing (2 used) E-V-Packing 14-O-Ring
3-Barrel and Cap g-O-Ring lS-Backup Washer
4-Set Screw 1 O-Piston 1 S-Rod Guide
5-Stop Nut 1 l-Snap Ring l7-Wiper Seal
6-Wear Ring 12-V-Packing lB-Bushing (2 used)
19-Piston Rod

Fig. i&Rear Mounted Equipment Cylinder

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Ground Conditioning Tools 42
TM- 1188 (Jut-78) Hvdraulic Svstem 4260-13

T59362N

l-Cap Screw (2 used) g-Piston 17-Straight Grease Fitting


2-Lock Washer 1 O-Wear Ring l&O-Ring
3-Nut 1 l-O-Ring M-Backup Ring
4-Pin la-V-Packing PO-Rod Guide
5-Bushing (2 used) Xi-Piston 21-Wiper Seal
GBarrel with Head and Bushings 14-Snap Ring 22-Special Nut
7-Set Screw 15-V-Packing 23-Bushing
8-Lock Nut %-Wear Ring 24-Piston Rod
25-Pin

Fig. 19-Front Mounted Equipment Cylinder

Clamp the cylinder in a vise to prevent it from 2. V-packings and wear rings for breaks, cuts or
turning. Remove set screw and rod guide. Use a embedded foreign material.
spanner wrench to loosen rod guide.
3. Piston rod seal and wiper for wear or damage.
Remove piston rod, rod guide and piston from bar- Remove sharp edges from piston rod with emery cloth.
rel.
Repair kits are available for overhauling all cylin-
Clamp the rod end in a vise taking care to prevent ders. Discard used parts and use all new parts provid-
damage to the piston rod. Remove nut from end of rod. ed in kits when assembling cylinders.
Slide parts from end of rod.
Coat threads of rod guide and set screw with John
Wash all parts thoroughly with diesel fuel and in- Deere Loctite Sealant or an equivalent before installing
spect the following: in barrel.

1. Barrel, rod guide and rod for scoring, and O-rings


for surface damage.

Litho in U.S.A.
42 Ground Conditioning Tools JD670-A and JD672-A Motor Graders
4260-14 Hydraulic System TM- 1188 (J&78)

Lubricate all O-rings, seals, and packings before


assembly.

l-Piston Retainer 4-Nut


2-Wear Ring 5-Cylinder Barrel
3-Piston

Fig. 21-Original Installation of V-Packing

T34293N

l-Snap Ring 4-Wear Ring


2-O-Ring !&Wiper Seal
3-V-Packing S-Backup Washer

FIQ. PO-Cylinder Rod Guide Components

Install new wiper seal (5, Fig. 20) in rod guide.

Install new wear ring (4) in rod guide. Position


backup washer (6) and O-ring (2) on rod guide.

Install the packing (3) in rod guide with apex of the V


toward the wiper seal and secure with snap ring (1). l-Piston Retainer 4-Nut
2-Wear Ring 5-Cylinder Barrel
Slip rod guide assembly on piston rod being careful C&Piston

not to damage packing.


Fig. 224nstallation of V-Packing
Without Compressor
Installing Piston V-Packing
V-packings are originally installed on the piston with If a suitable compressor is not available, assemble
the apex of the V pointing away from the barrel (Fig. the packings with the apex of the V pointing toward the
21). When replacing V-packings in the field this pro- barrel (Fig. 22). This eliminates scuffing that may occur
cedure can be used if a suitable ring compressor is in assembly; however, the V-packing may become torn
available to compress packings when installed in cyl- if the cylinder has to be disassembled in the future.
inders.

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Ground Conditioning Tools 42
TM- 1188 (Jul-78) Hydraulic Sys tern 4260-l 5

Position piston on piston rod. Install wear ring on INSTALLATION


piston retainer. Position retainer on piston rod and
Place the cylinder in position on the machine and
secure with stop nut. Tighten stop nut with 600 to 700
align the attaching holes. Insert pivot pins and secure
lb-ft (814 to 949 Nm) (83 to 97 kg-m).
with cap screws. Connect the hydraulic lines, making
sure they are connected to the same ends of the
Install piston rod assembly into barrel.
cylinder from which they were removed.
Secure piston rod assembly in barrel with rod guide
After placing the cylinder, operate the cylinder sev-
and tighten with 250 to 300 lb-ft (339 to 407 Nm) (35 to
era1 times to remove air from the system. Add oil to the
41 kg-m). Install set screw in barrel of rear mounted
reservoir to bring it up to the proper level.
equipment cylinder and tighten after rod guide is tight-
ened to 40 lb-in. (4.5 Nm) (0.46 kg-m). -
Install covers.

Litho in U.S.A.
42 Ground Conditioning Tools JD670-A and JD672-A Motor Graders
4260-16 Hydraulic Sys tern TM- 1188 (J&78)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Ground Conditioning Tools 42
TM- 1188 (Jul-79) Specifications and Special Tools 4299-l

Group 4299
SPECIFICATIONS AND SPECIAL TOOLS
HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES

1 - Valve shaft to solenoid torque . . . . 150 lb-in.


(17 Nm)
(apply John Deere Loctite Thread Lock and Seal-
ant, High Strength, or an equivalent to the threads
of the solenoid valve seat prior to tightening).

2 - Special plug torque .. . . . . . . . . 90 lb-ft


(122 Nm)

Fig. 1-Valve Torques

1 - Shim until retainer is flush with end


of valve shaft and then remove one shim.

Fig. Z-Shimming Poppet Valve

Litho in U.S.A.
42 Ground Conditioning Tools JD670-A and JD672-A Motor Graders
4299-2 Specifications and Special Tools TM- 1188 (Jul- 79)

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued
1 _ Adjusting solenoid screw . Bottom
out adjusting screw and then back it out l/2 to 518
turn and tighten nut to 230 lb-in (26 Nm) (2.6
kg-m).

T41309N
Fig. 3-Poppet Valve Solenoid

Front Mounted Valve


1 - Detent Screw
Torque .. .. . .. . .. . . . 5 to 8 lb-ft
(6.8 to 10.8 Nm)
(0.7 to 1.0 kg-m)

2 - Cap Assembly
Torque . . . . . .. . .50 to 55 lb-ft
(67.8 to 74.6 Nm)
(7 to 8 kg-m)

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Ground Conditioning Tools 42
TM- 1188 (Jul-78) Specifications and Special Tools 4299-3

HYDRAULIC SYSTEM
SPECIFICATIONS AND TORQUE VALUES-Continued

Front Mounted Equipment Cylinder


1 - Cylinder bore . . . . . . . . 4.996 to 5.000 in.
(126.90 to 127.00 mm)

2 - Rod diameter . .. .. 1.9985 to 2.0015 in.


iiO.762 to 50.838 mm)

T38235N 3 - Rod guide torque.. ... . 250 to 300 lb-ft


Fig. CFront Mounted Equipment Cylinder (339 to 407 Nm)
(35 to 41 kg-m)

4 - Cylinder stroke.. . . . . . . . . . .13.31 i .12 in.


(338.0 t 3.0 mm)

5 - Stop nut torque . . _. . . . . . 600 to 700 lb-ft


(813 to 949 Nm)
(83 to 97 kg-m)

Rear Mounted Equipment Cylinder


1 - Cylinder bore . . . . . . . . . . . . . . 5.246 to 5.250 in.
(133.25 to 133.35 mm)

2 - Rod diameter . . . . . . . . . . . . 2.2485 to 2.2515 in.


(57.112 to 57.188 mm)

3 - Set screw torque . . . . , . . . . . . . . . . . . .40 lb-in


T38236N (4.5 Nm)
(0.46 kg-m)
Fig. B-Rear Mounted Equipment Cylinder

4 - Rod guide torque.. ... . . 250 to 300 lb-ft


(339 to 407 Nm)
(35 to 41 kg-m)

5 - Cylinder stroke.. ..... ... . .12.80 + 0.12 in.


(325.0 t 3.0 mm)

6 - Stop nut torque . .,...... . . 600 to 700 lb-ft


(813 to 949 Nm)
(83 to 97 kg-m)

Litho in U.S.A.
42 Ground Conditioning Tools JD670-A and JD672-A Motor Graders
4299-4 Specifications and Special Tools TM- 1188 (J&78)

HYDRAULIC SYSTEM
SPECI-AL TOOLS

Essential Tools

Tool Tool Number Use

JD304 To remove poppet valves


from housing

Fig. 7-Poppet Valve Removal Driver

JD296 To compress retaining rings

Fig. &Retaining Ring Compressor

JD340 To install poppet valves

Fig. O-Poppet Valve installation Tool

Litho in U.S.A.
JD670-A and JD672-A Motor Graders Ground Conditioning Tools 42
TM- 1188 (J&78) Specifications and Special Tools 4299 -5

HYDRAULIC SYSTEM
SPECIAL TOOLS-Continued

Convenience Tools

TOOI Tool Number Use

D-051 14ST Remove and install


rod guides
cylinder
1
q
-. m-e

Cl 788

Fig 1O-Spanner Wrench


(Adjustable from 4.5 to 6.25 inches)
(114 to 159 mm)

Litho in U.S.A.
42 Ground Conditioning Tools JD670-A and JD672-A Motor Graders
4299-6 Specifications and Special Tools TM- 1188 (J&78)

Litho in U.S.A.
,’
I

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